QSK-19 Troubleshooting 3666098 PDF

Troubleshooting
and Repair Manual

QUANTUM™ System K19
Series Engines
CopyrightR 1995 Bulletin No.

Cummins Engine Company, Inc. Printed 7/95
All rights reserved
Foreword
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 the WARNING 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 recommen-
dations 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. These
parts can be identified by the following trademarks:
g-01
Table of Contents
Section
Introduction.................................................................................................................................... i
Engine Identification ...................................................................................................................... E
Troubleshooting ............................................................................................................................. T
Section 0 - Complete Engine - Group 00....................................................................................... 0
Section 1 - Cylinder Block - Group 01 ........................................................................................... 1
Section 2 - Cylinder Head - Group 02............................................................................................ 2
Section 3 - Rocker Levers - Group 03............................................................................................ 3
Section 4 - Cam Followers/Tappets - Group 04 ............................................................................. 4
Section 5 - Fuel System - Group 05 .............................................................................................. 5
Section 6 - Injectors and Fuel Lines - Group 06 ........................................................................... 6
Section 7 - Lubricating Oil System - Group 07.............................................................................. 7
Section 8 - Cooling System - Group 08 ......................................................................................... 8
Section 9 - Drive Units - Group 09................................................................................................. 9
Section 10 - Air Intake System - Group 10 .................................................................................... 10
Section 11 - Exhaust System- Group 11 ........................................................................................ 11
Section 12 - Compressed Air System - Group 12 ......................................................................... 12
Section 13 - Electrical Equipment - Group 13............................................................................... 13
Section 14 - Engine Testing - Group 14......................................................................................... 14
Section 16 - Mounting Adaptations - Group 16............................................................................. 16
Component Manufacturers............................................................................................................. M
Specifications and Torque Values.................................................................................................. V
Index .............................................................................................................................................. X
Section i - Introduction
QSK19 - PRELIMINARY Page i-1
Section i - Introduction
Section Contents
Page
About the Manual................................................................................................................................................ i-2
Definition Of Terms ........................................................................................................................................... i-11
General Cleaning Instructions .......................................................................................................................... i-10
Glass or Plastic Bead Cleaning ...................................................................................................................... i-10
Solvent and Acid Cleaning .............................................................................................................................. i-10
Steam Cleaning .............................................................................................................................................. i-10
General Repair Instructions................................................................................................................................ i-9
Welding on a QUANTUM™ Fuel System Controlled Vehicle .............................................................................. i-9
General Safety Instructions................................................................................................................................ i-8
Important Safety Notice .................................................................................................................................... i-8
How to Use the Manual....................................................................................................................................... i-2
Illustrations ......................................................................................................................................................... i-7
Simbolos ............................................................................................................................................................ i-4
Symbole .............................................................................................................................................................. i-5
Symboles ........................................................................................................................................................... i-6
Symbols ............................................................................................................................................................. i-3
About the Manual Section i - Introduction
Page i-2 QSK19 - PRELIMINARY
About the Manual

This QUANTUM™ System K19 Series (QSK19) Troubleshooting and Repair Manual is intended to aid in determining
the cause of engine-related problems and to provide recommended repair procedures. The material in this manual
covers all QSK19 engines. The manual is divided into sections. Some sections contain reference numbers and
procedure numbers. The reference numbers provide general information, specifications, diagrams, and service
tools, where applicable. The procedure numbers describe specific repair procedures and are referred to in the
Troubleshooting Logic Charts.
How to Use the Manual

The manual is organized to provide an easy flow from problem identification to problem correction. A list of
troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Section.
Complete the following steps to locate and correct the problem:
(STEP 1.) Locate the symptom on the list.

Reference is made to the page number where the″Troubleshooting Logic Chart″ is found.
(STEP 2.) The left column of the ″Troubleshooting Logic Chart″ indicates a probable cause, starting at the
top with the simplest and easiest to repair, and continuing downward to the most difficult.
The right column provides a brief description of the corrective action with a procedure number
reference for the repair procedure.
(STEP 3.) Locate the probable cause in the left column, and then turn to the procedure referenced in the right
column.
The repair procedures are listed by system (cooling, lubricating oil, combustion air, compressed
air, fuel, electrical, and base engine components).
(STEP 4.) The Troubleshooting Logic Charts are based on the following assumptions:
1. The engine has been installed according to the manufacturer’s specifications.
2. The easiest repairs are done first.
3. ″Generic″ solutions to cover problems with the most common applications and Original
Equipment Manufacturer (OEM).
Section i - Introduction Symbols
Symbols
The following symbols have been used in this manual to help communicate the intent of the instructions. When
one of the symbols appears, it conveys the meaning defined below:
WARNING - Serious personal injury or extensive property damage can result if the warning
instructions are not followed.
CAUTION - Minor personal injury can result, or a part, an assembly, or the engine can be damaged
if the caution instructions are not followed.
Indicates a REMOVAL or DISASSEMBLY step.
Indicates an INSTALLATION or ASSEMBLY step.
INSPECTION is required.
CLEAN the part or assembly.
PERFORM a mechanical or time MEASUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE will be given.
TIGHTEN to a specific torque.
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual or another publication for additional information.
The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance
to lift the component.
Simbolos Section i - Introduction
Simbolos
Los sı́mbolos siguientes son usados en este manual para clarificar el proceso de las instrucciones. Cuando
aparece uno de estos sı́mbolos, su significado se especifica en la parte inferior.
ADVERTENCIA - Serios daños personales o daño a la propiedad puede resultar si las instruc-
ciones de Advertencia no se consideran.
PRECAUCION - Daños menores pueden resultar, o de piezas del conjunto o el motor puede
averiarse si las instrucciones de Precaución no se siguen.
Indica un paso de REMOCION o DESMONTAJE.
Indica un paso de INSTALACION o MONTAJE.
Se requiere INSPECCION.
LIMPIESE la pieza o el montaje.
EJECUTESE una MEDICION mecánica o del tiempo.
LUBRIQUESE la pieza o el montaje.
Indica que se dará una LLAVE DE TUERCAS o el TAMAÑO DE HERRAMIENTA.
APRIETESE hasta un par torsor especı́fico.
EJECUTESE una MEDICION eléctrica.
Para información adicional refiérase a otro emplazamiento de este manual o a otra publicación
anterior.
El componente pesa 23 kg [50 lb] o mas. Para evitar dano corporal empleen una cabria u obtengan
ayuda para elevar el componente.
Section i - Introduction Symbole
Symbole
In diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. Die
Symbole haben folgende Bedeutung:
WARNUNG - Wird die Warnung nicht beachtet, dann besteht erhöhte Unfall- und
Beschädigungsgefahr.
VORSICHT - Werden die Vorsichtsmassnahmen nicht beachtet, dann besteht Unfall- und
Beschädigungsgefahr.
AUSBAU bzw. ZERLEGEN.
EINBAU bzw. ZUSAMMENBAU.
INSPEKTION erforderlich.
Teil oder Baugruppe REINIGEN.
DIMENSION - oder ZEITMESSUNG.
Teil oder Baugruppe ÖLEN.
WERKZEUGGRÖSSE wird angegeben.
ANZUG auf vorgeschriebenes Drehmoment erforderlich.
Elektrische MESSUNG DURCHFÜHREN.
Weitere Informationen an anderer Stelle bzw. in anderen Handbüchern.
Das teil weigt 23 kg [50 lb] oder mehr. Zur vermeidung von koerperverletzung winde benutzen oder
hilfe beim heben des teils in anspruch nehmen.
Symboles Section i - Introduction
Symboles
Les symboles suivants sont utilisés dans ce manuel pour aider à communiquer le but des instructions. Quand l’un
de ces symboles apparaı̂t, il évoque le sens défini ci-dessous:
AVERTISSEMENT - De graves lésions corporelles ou des dommages matériels considérables

peuvent survenir si les instructions données sous les rubriques ″Avertissement″ ne sont pas
suivies.
ATTENTION - De petites lésions corporelles peuvent survenir, ou bien une pièce, un ensemble
ou le moteur peuvent être endommagés si les instructions données sous les rubriques ″Attention″
ne sont pas suivies.
Indique une opération de DEPOSE.
Indique une opération de MONTAGE.
L’INSPECTION est nécessaire.
NETTOYER la pièce ou l’ensemble.
EFFECTUER une MESURE mécanique ou de temps.
GRAISSER la pièce ou l’ensemble.
Indique qu’une DIMENSION DE CLE ou D’OUTIL sera donnée.
SERRER à un couple spécifique.
EFFECTUER une MESURE électrique.
Se reporter à un autre endroit dans ce manuel ou à une autre publication pour obtenir des
informations plus complètes.
Le composant pese 23 kg [50 lb] ou davantage. Pour eviter toute blessure, employer un appariel
de levage ou demander de l’aide pour le soulever.
Section i - Introduction Illustrations
Illustrations
The illustrations used in the ″Repair Sections″ of this
manual are intended to give an example of a problem,
and to show what to look for and where the problem can
be found. Some of the illustrations are ‘‘generic’’ and
might not look exactly like the engine or parts used in
your application. The illustrations can contain symbols
to indicate an action required, and an acceptable or not
acceptable condition.
The illustrations are intended to show repair or replace-

ment procedures. The illustration can differ from your
application, but the procedure given will be the same.
General Safety Instructions Section i - Introduction
General Safety Instructions

Important Safety Notice
WARNING
Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodily injury
or death.
Read and understand all of the safety precautions and warnings before performing any repair. This list contains
the general safety precautions that must be followed to provide personal safety. Special safety precautions are
included in the procedures when they apply.
• Make sure the work area surrounding the product is dry, well lit, ventilated; free from clutter, loose tools, parts,
ignition sources and hazardous substances. Be aware of hazardous conditions that can exist.
• Always wear protective glasses and protective shoes when working.
• Rotating parts can cause cuts, mutilation or strangulation.
• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.
Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a ‘‘Do Not Operate’’
tag in the operator’s compartment or on the controls.
• Use ONLY the proper engine barring techniques for manually rotating the crankshaft. Do not attempt to rotate
the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage,
or damage to the fan blade(s) causing premature fan failure.
• If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling system.
• Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
• Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are removed
or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes
pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.
• To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon)
lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied
and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere.
Federal law requires capture and recycling refrigerant.
• To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more.
Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct
capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting
hooks must not be side-loaded.
• Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact
with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case
of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY
CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH
OF CHILDREN.
• To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes,
and compartments.
• Always use tools that are in good condition. Make sure you understand how to use them before performing
any service work. Use ONLY genuine Cummins or Cummins ReconW replacement parts.
• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener
of lessor quality if replacements are necessary.
• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
Section i - Introduction General Repair Instructions
General Repair Instructions

This engine incorporates the latest diesel technology at the time it was manufactured; yet, it is designed to be
repaired using normal repair practices performed to quality standards.
• Cummins Engine Company, Inc. does not recommend or authorize any modifications or repairs to
engines or components except for those detailed in Cummins Service Information. In particular, un-
authorized repair to safety-related components can cause personal injury or death. Below is a partial
listing of components classified as safety-related:
Air Compressor
Air Controls
Air Shutoff Assemblies
Balance Weights
Cooling Fan
Fan Hub Assembly
Fan Mounting Bracket(s)
Fan Mounting Capscrews
Fan Hub Spindle
Flywheel
Flywheel Crankshaft Adapter
Flywheel Mounting Capscrews
Fuel Shutoff Assemblies
Fuel Supply Tubes
Lifting Brackets
Throttle Controls
Turbocharger Compressor Casing
Turbocharger Oil Drain Line(s)
Turbocharger Oil Supply Line(s)
Turbocharger Turbine Casing
Vibration Damper Mounting Capscrews
• Follow All Safety Instructions Noted in the Procedures.
- Follow the manufacturer’s recommendations for cleaning solvents and other substances used during the
repair of the engine. Some solvents and used engine oil have been identified by government agencies as
toxic or carcinogenic. Avoid excessive breathing, injestion and contact with such substances. Always use
good safety practices with tools and equipment.
• Provide A Clean Environment and Follow the Cleaning Instructions Specified in the Procedures
- The engine and its components must be kept clean during any repair. Contamination of the engine or
components will cause premature wear.
• Perform the Inspections Specified in the Procedures.
• Replace all Components or Assemblies Which are Damaged or Worn Beyond the Specifications
• Use Genuine Cummins New or ReConW Service Parts and Assemblies
- The assembly instructions have been written to use again as many components and assemblies as
possible. When it is necessary to replace a component or assembly, the procedure is based on the use
of new Cummins or Cummins ReConW components. All of the repair services described in this manual
are available from all Cummins Distributors and most Dealer locations.
• Follow The Specified Disassembly and Assembly Procedures to Avoid Damage to the Components.
Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins
Authorized Repair Location. Refer to Section L, Literature, for ordering instructions.
Welding on a QUANTUM™ Fuel System Controlled Vehicle
Caution: When welding on a vehicle controlled by a QUANTUM™ fuel system, to protect the ECM computer
circuits, the procedure below MUST be followed:
1. Remove both connectors going to the ECM.
2. Disconnect the negative (-) and positive (+) battery cables from the battery.
3. Do NOT connect the welder ground cable to any part of the QUANTUM™ fuel system.
General Cleaning Instructions Section i - Introduction
General Cleaning Instructions

Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the engine parts. Cummins Engine Company,
Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer’s instructions.
Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to
95 degrees Celsius [180 to 200 degrees Fahrenheit]. A cleaning tank that provides a constant mixing and
filtering of the cleaning solution will give the best results.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper
before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible,
steam clean the parts before putting them in the cleaning tank.
Warning: Acid is extremely dangerous, and can damage the machinery. Always provide a tank of strong
soda water as a neutralizing agent.
Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from
all of the capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound. The
rustproofing compound must be removed from the parts before installation on the engine.
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good
way to clean the oil drillings.
Warning: Wear protective clothing to prevent personal injury from the high pressure and extreme heat.
Do not steam clean the following parts:
1. Electrical Components
2. Wiring
3. Injectors
4. Fuel Pump
5. Belts and Hoses
6. Bearings
Glass or Plastic Bead Cleaning
Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The
cleaning process is controlled by the size of the glass or plastic beads, the operating pressure, and the
cleaning time.
Caution: Do not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead
cleaning on aluminum ring grooves. Small particles of glass or plastic will embed in the aluminum and
result in premature wear. Valves, turbocharger shafts, etc., can also be damaged. Follow the cleaning
directions listed in the procedures.
NOTE: Plastic bead blasting media, Part No. 3822735, can be used to clean aluminum ring grooves. Do not use
any bead blasting media on pin bores or aluminum skirts.
Follow the equipment manufacturer’s cleaning instructions. The following guidelines can be used to adapt to
manufacturer’s instructions:
1. Bead size: - Use U.S. size No. 16-20 for piston cleaning with plastic bead media, Part No. 3822735.
- Use U.S. size No. 70 for piston domes with glass media.
- Use U.S. size No. 60 for general purpose cleaning with glass media.
2. Operating Pressure: - Glass: Use 620 kPa [90 psi] for general purpose cleaning.
- Plastic: Use 270 kPa [40 psi] for piston cleaning.
3. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic
beads after cleaning. Rinse with hot water. Dry with compressed air.
4. Do not contaminate the wash tanks with glass or plastic beads.
Section i - Introduction Definition Of Terms
Definition Of Terms
A.C.: Alternating Current
ACT The wiring harness used to connect the actuators to the ECM
Harness:
AFC: Air Fuel Control; a device in the fuel pump that limits the fuel delivery until
there is sufficient intake manifold pressure to allow for complete combustion.
Alligator Clip: An electrical test clip attached to the end of a wire
API: American Petroleum Institute
ASTM: American Society of Testing and Materials
ATDC: After Top Dead Center; refers to the position of the piston or the crankshaft
rod journal. The piston is moving downward on the power stroke or intake
stroke.
BDC: Bottom Dead Center; refers to the position of the piston or the crankshaft rod
journal. The piston is at its lowest position in the cylinder.
BTDC: Before Top Dead Center; refers to the position of the piston or the crankshaft
rod journal. The piston is moving upward on the power stroke or exhaust
stroke.
C: Celsius
CAC: Charge Air Cooler
CARB: California Air Resources Board
C.I.D.: Cubic Inch Displacement
Circumferential Direction: In the direction of a circle in respect to the centerline of a round part or a
bore.
Cm: Centimeter
Concentricity: A measurement of the difference between the centers of either two or more
parts, or the bores in one part.
CPL: Control Parts List; this listing identifies the specific parts that must be in-
stalled on the engine to meet agency certification.
cSt: Centistokes
Cummins Sealant: This is a one part Room Temperature Vulcanizing (RTV) silicone rubber, ad-
hesive and sealant material having high heat and oil resistance, and low
compression set.
Some of the equivalent products are Marston Lubricants, Hylosil, Dow Corn-
ing, Silastic 732, Loctite Superflex, General Electric 1473, and General Elec-
tric 1470.
CVB: Control Valve Body
DCA: Diesel Coolant Additive
D.C.: Direct Current
Deutsch Connector: An electrical connector
Dye Penetrant Method: A method used to check for cracks in a part by using a dye penetrant and a
developer. Use Part No. 3375432 Crack Detection Kit, or equivalent.
End Clearance: The clearance in an assembly determined by pushing the shaft in an axial
direction one way, and then pushing the shaft the other way.
ECM: Electronic Control Module.
E.C.S.: Emission Control System
EPA: Environmental Protection Agency
Definition Of Terms Section i - Introduction
E.S.N.: Engine Serial Number

ESS: Engine Speed Sensor
F: Fahrenheit
ft-lb: Foot Pound
GPM: Gallons Per Minute
GVW: Gross Vehicle Weight
Hammer: A hand tool consisting of a hard steel head on a handle.
Hg: Mercury
HP: Horsepower
H20: Water
ID: Inside Diameter
in-lb: Inch Pound
kg: Kilograms
km: Kilometers
km/l: Kilometers per Liter
kPa: Kilopascal
l: Liter
Loctite 290: A single component, anaerobic, polyester resin, liquid sealant compound that
hardens between closely fitted metal surfaces producing a tough, hard bond
with good characteristics. An equivalent product is Perma-Lok HL 126.
Loctite 609: A single component anaerobic, liquid adhesive that meets or exceeds the re-
quirements of MIL-R-46082A (MR) TYPE 1.
Some of the equivalent products are Loctite 601 and Permabond HL 138.
Lubriplate 105: A mineral oil base grease with calcium soap (2 percent to 6 percent), and
zinc oxide (2 percent to 4 percent) additives.
m: Meter
Magnetic Particle Inspection: A method of checking for cracks in either steel or iron parts. This method
requires a Magnaflux machine, or an equivalent machine that imparts a mag-
netic field on the part being checked.
Mallet: A hand tool consisting of a soft head; either wood, plastic, lead, brass, or
rawhide on a handle.
MAX: Maximum allowed
MIN: Minimum allowed
Mini-Gen: Speed Sensor
mm: Millimeter
MPa: Megapascal
MPH: Miles Per Hour
MPQ: Miles Per Quart
N•m: Newton-meter
No.: Number
OD: Outside Diameter
OEM: Original Equipment Manufacturer
Section i - Introduction Definition Of Terms
OEM The wiring harness used to connect the ECM to the vehicle
Harness:
OS: Oversize
ppm: Parts Per Million
Protrusion: The difference in the height between two parts in the assembled state.
psi: Pounds Per Square Inch
PTO: Power Takeoff
REPTO: Rear Engine Power Takeoff
RPM: Revolutions Per Minute
S.A.E:. Society of Automotive Engineers
SCA: Supplemental Coolant Additive
SEN The wiring harness used to connect the engine system sensors to the ECM
Harness:
STD: Standard
TC: Torque Converter; used when referring to the torque converter cooler.
TDC: Top Dead Center; refers to the position of the piston or the crankshaft rod
journal. The piston is at its highest position in the cylinder. The rod journal is
pointing straight up toward the piston.
TIR: Total Indicator Reading; used when measuring the concentricity or the run
out. The TIR refers to the total movement of the needle on a dial indicator,
from the most negative reading to the most positive reading.
VOM: Volt Ohm Meter
VS: Variable Speed
VSS: Vehicle Speed Sensor
Water Pump Grease: A premium high temperature grease that will lubricate antifriction bearings
continually from minus 40 C [minus 40 F] to plus 150 C [plus 350 F].
Some of the greases meeting this requirement are Aeroshell No. 5, Chevron
SRI, Amoco Rykon Premium No. 2, Texaco Premium RB, and Shell Dolium
R.
Aeroshell No. 5 is not compatible with the other greases and must not be
mixed. Cummins Engine Company, Inc., uses Aeroshell No. 5 on new en-
gines and components.
Definition Of Terms Section i - Introduction
NOTES
Section E - Engine and Component Identification
QSK19 - PRELIMINARY Page E-1
Section E - Engine and Component Identification

Section Contents
Page
Engine Identification ......................................................................................................................................... E-2
Cummins Engine Nomenclature...................................................................................................................... E-2
Engine Dataplate ............................................................................................................................................ E-2
Fuel Pump Dataplate ...................................................................................................................................... E-2
External Engine Components ........................................................................................................................... E-6
General Specifications ...................................................................................................................................... E-3
Air Induction System....................................................................................................................................... E-4
Cooling System............................................................................................................................................... E-5
Electrical System ............................................................................................................................................ E-5
Exhaust System .............................................................................................................................................. E-5
Fuel System.................................................................................................................................................... E-5
General Engine Data....................................................................................................................................... E-4
Lubricating Oil System .................................................................................................................................... E-4
Engine Identification Section E - Engine and Component Identification
Page E-2 QSK19 - PRELIMINARY
Engine Identification
Cummins Engine Nomenclature
The model name provides the following data:
Q T A 19 – (750)
= Maximum Brake Horsepower

= Application Codes:
A = Agricultural
= Displacement in Litres C = Construction
= Engine is Aftercooled D = Generator Drive
= Engine is Turbocharged F = Fire Pump
G = Generator Set
= Series (Family of Engines)
L = Locomotive
M = Marine
P = Power Unit
R = Railcar
T = Tactical Military
Engine Dataplate
The engine dataplate shows specific information about
the engine. The engine serial number (E.S.N.) (1), Control
Parts List (CPL) (2), Model (3), and Horsepower and RPM
rating provide information for ordering parts and service
needs.
NOTE: The engine dataplate must not be changed unless
approved by Cummins Engine Company, Inc.
Fuel Pump Dataplate

The fuel pump dataplate is located on the top of the fuel
pump. It provides information for fuel pump calibration.
Section E - Engine and Component Identification General Specifications
General Specifications
Metric (U.S. Customary)
NOTE: Listed below are general specifications for this engine. Refer to each System Section for additional specifications.
Engine Speed ............................................ Refer to the fuel system calibration data for optional speed rating.
Displacement .................................................................................................................. 19 liters [1150 C.I.D.]
Bore and stroke ............................................................................ 158.75 mm x 158.75 mm [6.25 in x 6.25 in]
Engine Weight
Wet ................................................................................................................................. 2045 Kg [4504 lb]
Firing order ..................................................................................................................................... 1-5-3-6-2-4
Valve and injector settings:
Intake valve adjustment ................................................................................................. 0.36 mm [0.014 in]
Intake valve limits ................................................................................. 0.28 to 0.43 mm [0.011 to 0.017 in]
Exhaust valve adjustment .............................................................................................. 0.81 mm [0.032 in]
Exhaust valve limits ............................................................................. 0.74 to 0.89 mm [0.029 to 0.035 in]
Injector OBC Method adjustment (in engine) .................................................................. 19 N•m [165 in-lb]
Compression Ratio:
525 HP to 600 HP - Jacket Water Aftercooled ................................................................................... 17.0:1
600 HP to 750 HP - Low Temperature Aftercooled (LTA) .................................................................... 15.0:1
Crankshaft Rotation (viewed from the front of the engine) ................................................................. Clockwise
General Specifications Section E - Engine and Component Identification
General Engine Data
Cylinder location and Firing Order:

1-5-3-6-2-4
Intake and Exhaust Valve locations.
Air Induction System

Maximum Allowable Intake Restriction (at rated speed and load):
• With Clean Filter Element ...................................................................................................... 380 mm-H2O
[15 in-H2O]
• With Dirty Filter Element ....................................................................................................... 635 mm-H2O
[25 in-H2O]
Lubricating Oil System
Oil Pressure, Main Oil Rifle (15W40 oil at 107°C [225°F]):
• (Idle) RPM ................................................................................................................... 138 kPa to 483 kPa
[20 psi to 75 psi]
• (Rated) RPM ................................................................................................................ 345 kPa to 517 kPa
[50 psi to 75 psi]
Oil Temperature - Maximum ...................................................................................................... 120°C [250°F]
Oil Pan Capacity ................................................................................................................. Refer to Section V
Section E - Engine and Component Identification General Specifications
Cooling System
Coolant Capacity (Engine ONLY) ............................................................................................ 32.2 Liters
[34 U.S. Quarts]
Standard Thermostat Range .................................................................................................. 80°C to 90°C
[175°F to 195°F]
Coolant Pressure Cap (Minimum) ............................................................................................... 50 kPa [7 psi]
Coolant Temperature
Minimum .............................................................................................................................. 70°C [160°F]
Maximum (At Engine Outlet) ................................................................................................ 100°C [212°F]
Exhaust System
Back Pressure - Maximum (at rated speed and load) ........................................................ 75 mm-Hg [3 in-Hg]
Exhaust Pipe Size (Normally Acceptable Inside Diameter)
• All Ratings ........................................................................................................................ 152 mm [6 inch]
Fuel System
NOTE: For performance and fuel rate values, refer to the engine data sheet, or the fuel pump code for the particular
model involved.
Maximum Allowable Restriction to Pump (at rated power):
• With Clean Filter ....................................................................................................... 100 mm Hg [4 in Hg]
• With Dirty Filter ......................................................................................................... 178 mm Hg [7 in Hg]
Maximum Allowable Return Line Restriction
• With Check Valves .................................................................................................... 229 mm Hg [9 in Hg]
• Without Check Valves ............................................................................................. 330 mm Hg [13 in Hg]
Electrical System
Minimum Recommended Battery Capacity
System Voltage Ambient Temperatures

-18°C (0°F) 0°C (32°F)
Cold Reserve Cold Reserve
Cranking Capacity* Cranking Capacity*
Amperes Amperes Amperes Amperes
12 Volt** 1800 640 1280 480
24 Volt*** 900 320 640 240
* Note: The number of plates within a given battery size determines reserve capacity. Reserve capacity is the
length of time sustained cranking can occur.
** Note: Not recommended for QSK19 Engines.
*** Note: CCA ratings are based on two, 12 volt batteries in series.
Batteries (Specific Gravity)
External Engine Components Section E - Engine and Component Identification
External Engine Components

The illustrations show the locations of the major external engine components, the filters, and other service and
maintenance points. Some external components will be at different locations for different engine models.
Section E - Engine and Component Identification External Engine Components
External Engine Components Section E - Engine and Component Identification
NOTES
Section 0 - Complete Engine — Group 00
QSK19 - PRELIMINARY Page 0-1
Section 0 - Complete Engine — Group 00

Section Contents
Page
Complete Engine — General Information (000-000-999) .................................................................................. 0-2
Complete Engine — Tool Requirements — (022-001-500) ................................................................................ 0-3
Engine Installation (000-002)............................................................................................................................. 0-7
Install (000-002-026) ........................................................................................................................................ 0-7
Engine Removal (000-001) ................................................................................................................................. 0-4
Remove (000-001-002)..................................................................................................................................... 0-4
Complete Engine — General Information (000-000-999) Section 0 - Complete Engine — Group 00
Page 0-2 QSK19 - PRELIMINARY
Complete Engine — General Informa-

tion (000-000-999)
The procedures required to replace an engine will vary
with different engine models, the type of equipment, op-
tional equipment, and the shop facilities. Use the follow-
ing procedures as a guide.
NOTE: All replacement steps do not apply to all types of
equipment. Complete only the steps that apply to the equip-
ment involved. Use the equipment manufacturer’s recom-
mendations and precautions for removal of chassis parts to
gain access to the engine.
Section 0 - Complete Engine — Group 00 Complete Engine — Tool Requirements — (022-001-500)
Complete Engine — Tool Requirements — (022-001-500)
The following special tools are recommended to perform procedures in Section 00. The use of these
tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins
Authorized Repair Location.
Tool No. Tool Description Tool Illustration

Engine Lifting Fixture
Designed to lift an engine up to 3175 kg (7000 lb).
3822512
Engine Liftiing Hook

Designed to hook onto the lifting lugs of the cylinder heads to lift
the engine. Use with engine lifting fixture, Part No. 3822512
3823210
Engine Removal (000-001) Section 0 - Complete Engine — Group 00
Engine Removal (000-001)

Remove (000-001-002)
NOTE: Put a tag on all hoses, lines, linkage, and electrical
connections as they are removed to identify location and aid
during the installation process.
Warning: Always disconnect negative (-) cable first.

Disconnect the battery cables.
Drain the engine coolant.
Warning: Some state and federal agencies in the United

States of America have determined that used engine oil
can be carcinogenic and can cause reproductive toxicity.
Avoid inhalation of vapors, ingestion, and prolonged con-
tact with used engine oil. Always use the proper proce-
dures to dispose of the oil.
Drain the lubricating oil.
Disconnect the starter cable, engine ground straps, cab
or chassis to engine hoses, tubing, electrical wires and
hydraulic lines.
Disconnect the intake and exhaust system pipes.

Section 0 - Complete Engine — Group 00 Engine Removal (000-001)
Disconnect the driven units from the flywheel housing

and flywheel.
Disconnect the Electric Control Module (ECM) OEM wir-

ing harness. Refer to Procedure No. 019-031-002.
Warning: To prevent suffocation and frostbite, wear pro-

tective clothing and ONLY disconnect liquid refrigerant
(freon) lines in a well ventilated area. To protect the
environment, liquid refrigerant systems must be prop-
erly emptied and filled using equipment that prevents
the release of refrigerant gas (fluorocarbons) into the
atmosphere. Federal law requires capture and recycling
refrigerant.
Remove all chassis components necessary to remove the

engine from the equipment.
Engine Removal (000-001) Section 0 - Complete Engine — Group 00
NOTE: On applications when the rear engine mounts are

attached to the drive unit, it is sometimes necessary to
remove the engine and drive unit as an assembly.
Warning: The engine lifting equipment must be designed
to safely lift the engine and drive unit as an assembly.
Engine Weight (Wet): 2045 kg [4508 lb]
Refer to the equipment manufacturer’s specifications for
the weight of the drive unit. The Part No. 3822512 Lifting
Fixture is designed to lift a maximum of 3175 kg [7000 lb].
Use a properly rated hoist and lifting fixture to support the

weight of the engine. Remove the front and rear engine
support capscrews.
Use a properly rated hoist, engine lifting fixture, and two
Part No. 3823210 Lifting Hooks to remove the engine.
NOTE: If the drive unit is not removed, put a support under
the drive unit to prevent it from falling.
Warning: The oil sump or cover plate will not support

the weight of the engine. The engine will fall and per-
sonal injury can result.
Warning: Use a stand or skid that contacts the engine
mounts. The stand must hold the weight of the engine
and provide permanent support to prevent the engine
from falling.
Put the engine on the stand.
Cover all engine openings to prevent dirt and debris from

entering the engine.
Section 0 - Complete Engine — Group 00 Engine Installation (000-002)
Remove all remaining accessories and brackets that will

be used on the replacement engine.
Engine Installation (000-002)

Install (000-002-026)
Install all accessories and brackets that were removed
from the engine.
NOTE: On applications that the rear engine mounts are

attached to the drive unit, it is sometimes necessary to install
the engine and drive unit as an assembly.
Warning: The engine lifting equipment must be designed
to safely lift the engine and drive unit as an accessory.
Engine Weight (Wet): 2045 kg [4508 lb]
the weight of the drive unit. The Part No. 3822512 Lifting
Fixture is designed to lift a maximum of 3175 kg [7000 lb].
Use a properly rated hoist, engine lifting fixture, and two

Part No. 3823210 Lifting Hooks to install the engine.
Engine Installation (000-002) Section 0 - Complete Engine — Group 00
Align the engine in the chassis and tighten the engine

mounting capscrews. Refer to the equipment manufac-
turer’s torque specifications.
Connect all engine and chassis mounted accessories
that were removed.
NOTE: Be sure all lines, hoses, and tubes are in good con-
dition, properly routed, and fastened to prevent damage.
Connect the ECM OEM wiring harness. Refer to Proce-

dure No. 019-031-026.
Fill the engine with clean, 15W-40 lubricating oil.

Total Oil Capacity: Refer to Group 7 for system capacity.
NOTE: Refer to Specifications section to determine actual
capacity by oil pan part number.
NOTE: The engine must be prelubricated by pumping pres-
surized oil through the system prior to starting the engine.
NOTE: The lubricating oil system must be primed before

operating the engine after rebuild to avoid internal compo-
nent damage. Do not prime the system from the bypass filter
as the filter will be damaged.
Remove the large plug [1-12 inch UNF] from the oil cooler
housing.
Section 0 - Complete Engine — Group 00 Engine Installation (000-002)
Use a pump capable of supplying 205 kPa [30 psi] con-

tinuous pressure. Connect the pump to the front of the
engine oil cooler as shown.
Use a supply of clean oil. Turn the pump to the ON po-
sition. Check the engine oil pressure gauge. When the
gauge indicates oil pressure, begin monitoring the oil
level in the oil pan.
Fill the cooling system with 50 percent water, 50 percent

ethylene glycol base antifreeze, and Supplement coolant
additives (SCA) corrosion protection. Refer to the Speci-
fications section.
NOTE: Total Coolant Capacity (Engine Only): 30 Liter [32
U.S. Quart]
radiator and system capacity.
Complete a final inspection to be sure that all hoses,

wires, linkages, and components have been properly in-
stalled and tightened.
Operate the engine at low idle for 2 to 3 minutes.

Warning: Do not remove the radiator cap from a hot
engine. Hot steam can cause serious personal injury.
The engine coolant temperature must be below 70°C
[160°F].
Stop the engine and wait 5 to 7 minutes for the oil to drain
to the oil pan and check the oil and coolant levels again.
Engine Installation (000-002) Section 0 - Complete Engine — Group 00
Add oil or coolant to obtain the correct level if necessary.

Refer to the Section 18, Specifications section.
Operate the engine for 8-10 minutes to check for proper

operation, unusual noises, and coolant, fuel or lubricating
oil leaks.
Repair all leaks and component problems. Refer to the
appropriate procedures.
Section 1 — Cylinder Block — Group 01
QSK19 PRELIMINARY Page 1-1

Section Contents
Page
Accessory Drive Seal (001-003) ....................................................................................................................... 1-10
Install (001-003-026) ....................................................................................................................................... 1-11
Remove (001-003-002) ................................................................................................................................... 1-10
Alternator Drive Seal (001-001).......................................................................................................................... 1-7
Install (001-001-026)......................................................................................................................................... 1-8
Remove (001-001-002) ..................................................................................................................................... 1-7
Bearings, Connecting Rod (001-005)............................................................................................................... 1-14
Install (001-005-026) ...................................................................................................................................... 1-15
Remove (001-005-002) ................................................................................................................................... 1-14
Bearings, Thrust (001-007) .............................................................................................................................. 1-24
Inspect for Reuse (001-007-007)..................................................................................................................... 1-24
Install (001-007-026)....................................................................................................................................... 1-25
Remove (001-007-002) ................................................................................................................................... 1-24
Camshaft (001-008) .......................................................................................................................................... 1-25
Inspect (001-008-062) .................................................................................................................................... 1-33
Install (001-008-026) ...................................................................................................................................... 1-29
Remove (001-008-002) ................................................................................................................................... 1-25
Camshaft Bushings (001-010) .......................................................................................................................... 1-34
Inspect (001-010-062)..................................................................................................................................... 1-36
Install (001-010-026) ....................................................................................................................................... 1-35
Remove (001-010-002) ................................................................................................................................... 1-34
Camshaft Cover Plate (001-011) ....................................................................................................................... 1-36
Install (001-011-026) ....................................................................................................................................... 1-37
Remove (001-011-002).................................................................................................................................... 1-36
Camshaft Gear (Camshaft Installed) (001-012)................................................................................................ 1-37
Inspect (001-012-062)..................................................................................................................................... 1-39
Install (001-012-026)....................................................................................................................................... 1-38
Remove (001-012-002) ................................................................................................................................... 1-37
Camshaft Idler Gear (001-036)......................................................................................................................... 1-80
Install (001-036-026) ...................................................................................................................................... 1-80
Remove (001-036-002) ................................................................................................................................... 1-80
Camshaft Thrust Bearing (001-056) ............................................................................................................... 1-109
Inspect for Reuse (001-056-007) ................................................................................................................... 1-109
Connecting Rod (001-014) ............................................................................................................................... 1-40
Crankshaft (001-016) ........................................................................................................................................ 1-41
Initial Check (001-016-008)............................................................................................................................. 1-41
Crankshaft Gear, Front (Crankshaft Installed) (001-018) ................................................................................. 1-41
Inspect For Reuse (001-018-007).................................................................................................................... 1-42
Install (001-018-026)....................................................................................................................................... 1-42
Remove (001-018-002) ................................................................................................................................... 1-41
Crankshaft Seal, Front (001-023) ..................................................................................................................... 1-43
Clean (001-023-006)....................................................................................................................................... 1-44
Install (001-023-026) ...................................................................................................................................... 1-44
Remove (001-023-002) ................................................................................................................................... 1-43
Crankshaft Seal, Rear (001-024) ...................................................................................................................... 1-47
Clean (001-024-006)....................................................................................................................................... 1-47
Install (001-024-026) ...................................................................................................................................... 1-48
Remove (001-024-002) ................................................................................................................................... 1-47
Cylinder Block (001-026).................................................................................................................................. 1-50
Inspect for Reuse (001-026-007) .................................................................................................................... 1-50
Magnetic Crack Inspection (001-026-016)....................................................................................................... 1-50
Page 1-2 QSK19 PRELIMINARY
Page
Cylinder Block and Liner Seats (001-027) ....................................................................................................... 1-51
Measure (001-027-010)................................................................................................................................... 1-53
Preparatory (001-027-001) .............................................................................................................................. 1-51
Cylinder Block — Tool Requirements (022-001-501)......................................................................................... 1-3
Cylinder Liner (001-028) .................................................................................................................................. 1-55
Clean (001-028-006)....................................................................................................................................... 1-56
Install (001-028-026) ...................................................................................................................................... 1-58
Measure (001-028-010)................................................................................................................................... 1-57
Remove (001-028-002) ................................................................................................................................... 1-55
Gear Cover, Front (001-031) ............................................................................................................................. 1-67
Install (001-031-026)....................................................................................................................................... 1-73
Remove (001-031-002) ................................................................................................................................... 1-67
Gear Cover Spacer Plate (001-029).................................................................................................................. 1-61
Install (001-029-026) ...................................................................................................................................... 1-63
Remove (001-029-002) ................................................................................................................................... 1-61
Gear Train Backlash, Front (001-055) ............................................................................................................ 1-108
Measure (001-055-010) ................................................................................................................................. 1-108
Hydraulic Pump Idler Gear (001-039)............................................................................................................... 1-82
Install (001-039-026) ..................................................................................................................................... 1-82
Remove (001-039-002) ................................................................................................................................... 1-82
Main Bearings (001-006) .................................................................................................................................. 1-18
General Information (001-006-999) ................................................................................................................. 1-18
Install (001-006-026) ...................................................................................................................................... 1-20
Remove (001-006-002) ................................................................................................................................... 1-18
Piston (001-043) ............................................................................................................................................... 1-85
Clean (001-043-006)....................................................................................................................................... 1-85
Piston and Connecting Rod Assembly (001-054)............................................................................................ 1-98
Assemble, Articulated (001-054-025)............................................................................................................. 1-102
Disassemble (001-054-003) .......................................................................................................................... 1-101
Install (001-054-026)..................................................................................................................................... 1-103
Remove (001-054-002) ................................................................................................................................... 1-98
Piston Cooling Nozzles (001-046) .................................................................................................................... 1-88
Clean (001-046-006)....................................................................................................................................... 1-91
Install (001-046-026)....................................................................................................................................... 1-91
Remove (001-046-002) ................................................................................................................................... 1-88
Piston Rings (001-047)..................................................................................................................................... 1-93
Install (001-047-026) ...................................................................................................................................... 1-94
Measure (001-047-010)................................................................................................................................... 1-93
Vibration Damper, Single (001-052)................................................................................................................. 1-94
Eccentricity Check (001-052-064) ................................................................................................................... 1-97
Inspect for Reuse 001-052-007 ...................................................................................................................... 1-95
Install (001-052-026) ...................................................................................................................................... 1-96
Remove (001-052-002) ................................................................................................................................... 1-94
Wobble Check (001-052-065) ......................................................................................................................... 1-97
Water Pump Idler Gear (001-040) .................................................................................................................... 1-84
Install (001-040-026) ...................................................................................................................................... 1-84
Remove (001-040-002) ................................................................................................................................... 1-84
Section 1 — Cylinder Block — Group 01 Cylinder Block — Tool Requirements (022-001-501)
Cylinder Block — Tool Requirements (022-001-501)

Gauge Block
Measure cylinder liner protrusion.
ST-547
Puller
Remove the alternator and accessory drive pulleys.
ST-647
Dowel Pin Extractor

Remove dowel pins and crosshead guides.
ST-1134
Main Bearing Cap Pulley

Used to remove the main bearing caps from the cylinder block.
ST-1178
Drill Ream Fixture

Machine dowel hole to install oversize dowels in cylinder block
and flywheel housing. Use with a drill, reamer, and the appro-
ST-1232
priate drill/ream bushing set.
Piston Ring Expander

Designed to install piston rings on the piston without damaging
or distorting the rings.
ST-1269
Section 1 — Cylinder Block — Group 01 Cylinder Block — Tool Requirements (022-001-501)

Puller Assembly
Remove the crankshaft gear from the crankshaft. Use with Part
No. 3375835 Puller Jaw.
3375834
Universal Liner Puller

Remove cylinder liner from engine.
3376015
Gauge Block
Measure cylinder liner counterbore ledge angle.
3376220
Pulley Installation Tool

Install the alternator and accessory drive pulleys.
3376326
Lifting Hook
Attach a lifting fixture to the engine to allow the engine to be
lifted. This tool does not require a rocker lever cover with top
3376879
mounted breather to be removed.
Cummins Sealant
Used to prevent coolant or oil leaks. This is one part Room
Temperature Vulcanizing (RTV) silicone rubber, adhesive, and
3377132
sealant material having high heat and oil resistance, and low
compression rate.
Camshaft Bushing Tool Hydraulic Actuator Kit

Hydraulic ram provides the force to install/remove cam bushings
when used with installation/removal kit.
3823621
Camshaft Bushing Installation/Removal Kit

Used with the Part No. 3823621 Camshaft Bushing Hydraulic
Actuator Kit to remove the camshaft bushing.
3824842
Section 1 — Cylinder Block — Group 01 Alternator Drive Seal (001-001)
Alternator Drive Seal (001-001)

Remove (001-001-002)
Use a standard puller, Part No. ST-647, or equivalent.
Remove the alternator drive pulley. Refer to Procedure
009-029-002.
Remove the six, button hex head socket capscrews.
Use three [1/4-20 x 1 inch] capscrews to remove the seal

from the alternator drive shaft.
Install the three capscrews in the clinch nuts in the seal
case. Tighten the capscrews alternately and evenly to
remove the seal.
Remove the o-ring from the groove in the gear cover.

Alternator Drive Seal (001-001) Section 1 — Cylinder Block — Group 01
Install (001-001-026)
Install the o-ring in the groove in the gear cover.
Install the seal on the alternator drive shaft.
Use the seal installation tool that is supplied with the

service seal to push the seal on the alternator drive shaft.
Put the installation tool against the seal.
Use the pulley installation tool, Part No. 3376426, to push

the seal on the alternator drive shaft.
Position the pulley installer on the accessory drive shaft.
Section 1 — Cylinder Block — Group 01 Alternator Drive Seal (001-001)
Put the pulley installation housing on the pulley installer.
Align the three clinch nuts on the back of the seal carrier
flange with the three counterbores in the gear cover seal
mounting surface.
Use the tool to push the seal on the shaft until the seal
carrier flange contacts the gear cover.
Remove the pulley installation tool housing, seal instal-

lation tool, and pulley installer.
Accessory Drive Seal (001-003) Section 1 — Cylinder Block — Group 01
Install the six, button head hex socket capscrews. Tighten

the capscrews alternately and evenly.
Torque Value: 11 N•m [96 in-lb]
Install the alternator drive pulley. Refer to Procedure No.

009-029-026.
Accessory Drive Seal (001-003)

Remove (001-003-002)
Use a standard puller, Part No. ST-647, or equivalent.
Remove the accessory drive pulley. Refer to Procedure
009-004-002.
Remove the six, button hex head socket capscrews.

Section 1 — Cylinder Block — Group 01 Accessory Drive Seal (001-003)
Use three [1/4-20 x 1 inch] capscrews to remove the seal

from the accessory drive shaft.
Install the three capscrews in the clinch nuts in the seal
case. Tighten the capscrews alternately and evenly to
remove the seal.
Remove the o-ring from the groove in the gear cover.
Install (001-003-026)
Install the o-ring in the groove in the gear cover.
Install the seal on the accessory drive shaft.

Accessory Drive Seal (001-003) Section 1 — Cylinder Block — Group 01
Use the seal installation tool that is supplied with the

service seal to push the seal on the accessory drive shaft.
Put the installation tool against the seal.
Use the pulley installation tool, Part No. 3376426, to push

the seal on the accessory drive shaft.
Position the pulley installer on the accessory drive shaft.
Put the pulley installation housing on the pulley installer.
Align the three clinch nuts on the back of the seal carrier
flange with the three counterbores in the gear cover seal
mounting surface.
Section 1 — Cylinder Block — Group 01 Accessory Drive Seal (001-003)
Use the tool to push the seal on the shaft until the seal
carrier flange contacts the gear cover.
Remove the pulley installation tool housing, seal instal-

lation tool, and pulley installer.
Install the six, button head hex socket capscrews. Tighten

the capscrews alternately and evenly.
Install the accessory drive pulley. Refer to Procedure No.

009-004-026.
Bearings, Connecting Rod (001-005) Section 1 — Cylinder Block — Group 01
Bearings, Connecting Rod (001-005)

Remove (001-005-002)
Drain the oil, remove the oil sump and adapter cover.
Refer to Procedure 007-025-005.
Remove the oil suction tube. Discard the gasket.
Use the barring mechanism to rotate the engine. Rotate

the crankshaft to position a connecting rod at bottom
dead center (BDC).
The connecting rods must have the cylinder number

marked on both the rod and the cap on the side positioned
towards the camshaft. Check the rods for correct mark-
ings. Use a steel stamp and mark any rod that is not
correctly marked.
Loosen the capscrews until there is 6 mm [1/4 inch] of
clearance between the rod cap and the capscrew head.
Section 1 — Cylinder Block — Group 01 Bearings, Connecting Rod (001-005)
Use a mallet. Tap the connecting rod capscrews until the

connecting rod cap and rod separate. Remove the
capscrews and the cap.
Remove the lower rod bearing. Use a awl and mark the
bearing position in the tang area.
NOTE: Mark the bearing for future identification or for pos-
sible failure analysis.
Push the rods up enough to allow the upper bearing shells

to be removed. Remove the bearing shell and mark its
location.
Install (001-005-026)
NOTE: Used bearings must be installed in the same location
they were removed.
Lubricate the bearing shell with engine oil. Install the
upper bearing shell in the connecting rod with the tang of
the bearing in the slot of the rod.
Caution: Do not lubricate the back of the bearing shells.

Install the lower bearing shell in the rod cap. Be sure the
tang of the bearing shell is in the slot of the rod cap and
the end of the bearing is even with the surface of the rod
cap.
Bearings, Connecting Rod (001-005) Section 1 — Cylinder Block — Group 01
Use engine oil. Lubricate the connecting rod capscrews

and washers as shown.
Install the washers and capscrews in the rod caps.
Caution: The connecting rods and caps are not inter-

changeable. The rods and the caps are machines as an
assembly. Failure will result if the parts are mixed.
Caution: The cylinder number on the rod and cap must
be the same.
Caution: The side of the cap with the cylinder number
marking (bearing tang side) must be toward the cam-
shaft.
Install the connecting rod cap.
Tighten the capscrews alternately and evenly to pull the

cap over the dowel pins. Use the following steps to tighten
the capscrews.
Connecting Rod Cap Torque Values

N•m Step ft-lb
100 1 75
205 2 150
290 3 215
Loosen 4 Loosen
100 5 75
205 6 150
290 7 215
Check the side clearance between the rod and the crank-
shaft.
Minimum Side Clearance: 0.20 mm [0.008 inch]
Maximum Side Clearance: 0.35 mm [0.014 inch]
The rod must move freely from side-to-side.
Section 1 — Cylinder Block — Group 01 Bearings, Connecting Rod (001-005)
NOTE: Tighten the suction tube to the block capscrews (1)

before installing any support bracket capscrews.
NOTE: The suction tube shape can vary from the illustration.
All suction tubes attach to the block in the same manner.
Install the gasket, oil suction tube, washers, and
capscrews. Tighten the capscrews.
Torque Value (Capscrew): 60 N•m [45 ft-lb]
Caution: Do not pry or bend the suction tube to get the
support bracket capscrew holes to align.
Connect the support bracket to the adapter with the
capscrew (2). Tighten the capscrew (2).
Install the oil sump and related components. Refer to

Procedure No. 007-025-026.
Install new oil filter elements. Refer to Procedure No.

007-013-026.
Use clean, 15W-40 oil to fill the engine. Refer to Proce-

dure No. 007-025-028 for engine oil capacity.
Operate the engine to 70°C [160°F] coolant temperature.
Check for leaks.
Main Bearings (001-006) Section 1 — Cylinder Block — Group 01
Main Bearings (001-006)

General Information (001-006-999)
NOTE: The upper bearings contain an oil hole. The lower
bearings do not have an oil hole. Both bearings are marked
on the back side indicating location (UPPER or LOWER) and
size (STANDARD [STD] or OVERSIZE [OS]). The amount of
OS is indicated in [U.S. customary inches].
Use the same size bearing [STD, 0.010, 0.015, 0.020, or
0.030] that was removed.
The crankshaft will be stamped on the end of the No.1

counterweight to indicate if it has been ground undersize.
Thrust bearing size is stamped on a crankshaft counter-
weight adjacent to the thrust location.
NOTE: The location number (No.) of the main bearing caps,

beginning at the front, are No. 1 through No. 7.
The main bearings are two widths. The narrow main
bearings fit locations No. 1 and No. 7. The wide bearings
fit the remaining locations.
Remove (001-006-002)
NOTE: Before removing the main bearings, refer to General
Information, Procedure 001-006-999.
Warning: Some State and Federal agencies in the United
tact with used engine oil. Always use the proper envi-
ronmental procedures to dispose of the oil.
Drain the oil, remove the oil sump and adapter cover.
Refer to Procedure No. 007-025-005.
Section 1 — Cylinder Block — Group 01 Main Bearings (001-006)
Remove the oil suction tube. Discard the gasket.
Remove the oil pan adapter. Refer to Procedure

007-026-002.
Caution: Replace the bearings one pair at a time. Per-

sonal injury and damage to the crankshaft can result if
the crankshaft falls.
Caution: The caps must be pulled into position against
the block before the crankshaft is rotated. As bearings
are replaced, torque the cap to a minimum of 68 N•m [50
ft-lb] before turning the crankshaft.
The main bearings caps must be marked for position.
The last number on each bearing cap identifies the cap
location position in the block.
The block and main bearing cap identification numbers
must be identical.
Use a steel stamp and mark any cap that is not marked
correctly.
Loosen the main bearing cap capscrews until there is

approximately 13 mm [1/2-inch] between the capscrew
head and the cap. Use two pry bars to loosen the cap. Put
the pry bars in the notches at the sides of the caps.
Remove the cap and capscrews.
Remove the lower bearing. Use an awl and mark the

NOTE: Mark the bearing position for future identification or
for possible failure analysis.
NOTE: Refer to Thrust Bearings — Remove, Procedure
001-007-002, for removal instructions.
To remove the upper main bearing shell, use a tool similar

to the one shown and install it in the crankshaft main
bearing journal oil hole.
NOTE: Rotate the crankshaft so the tang (1) of the main
bearing shell rolls out of the block first.
Use the barring mechanism and slowly turn the crank-
shaft until the bearing shell is out of the block.
Clean the crankshaft journal.
Install (001-006-026)
NOTE: Used bearings must be installed in their original
location.
Install the upper main bearing shells using the same
method that was used for the removal of the shells.
Caution: The bearing tang (1) must fit into the slot (2) in
the bearing saddle.
Install the upper thrust bearing in the No. 6 bearing lo-
cation. Refer to Thrust Bearing — Install, Procedure No.
001-007-026.
NOTE: Before installing the thrust bearings, refer to General

Use a lint-free cloth. Clean the lower main bearings, the
lower thrust bearings, and the mounting surfaces.
NOTE: Do not lubricate the back of the main bearings.
Align the tang (1) in the bearing with the slot (2) in the main
bearing cap. Install the bearing. The end of the bearing
must be even with the main bearing cap mounting sur-
face.
Lubricate the bearing surface with engine oil.
Lubricate the capscrew head and threads with SAE EP

140W oil. Allow the excess oil to drip off of the capscrews
before installing in the block.
Install the capscrews in the cap.
Caution: The grooves in the thrust bearings must point
toward the crankshaft. The dowels that secure the bear-
ings must not protrude above the bearing.
Install the two thrust bearings on the No. 6 main bearing
cap.
Caution: The numbers on the main bearing caps must

be the same as the numbers on the block.
Check the number on the main bearing caps. The last
digit of each number (1 to 7), indicates the correct location.
Caution: Be sure the side of the cap and bearing with

the bearing locating tang is toward the tang in the block.
Lubricate the bearing surface with engine oil. The bearing
shells must be firmly seated in the cap and the correct
capscrew, washer combination in position. Install the main
bearing caps.
NOTE: Do not hit the main bearing caps with a hammer. The
bearing shells can fall out.
Caution: Do not rotate the crankshaft until all of the

main bearing caps are pulled to the block. Damage will
result if the bearings move out-of-location.
NOTE: Use your hands to install the capscrews.
Turn each capscrew until it touches the main bearing
caps.
NOTE: Do not use an impact wrench. The main bearing

shells can fall out.
Use both of the capscrews to pull the main bearing cap
into position.
Use two wrenches and tighten both capscrews at the
same time.
Check to be sure the No. 7 cap is even with the back of
the block.
Use the following steps and tighten the capscrews in the

sequence shown.
Main Bearing Capscrew Torque Values

N•m Step ft-lb
265 1 195
605 2 445
Loosen 3 Loosen
265 4 195
605 5 445
Turn the crankshaft. If the pistons have been removed,

use your hands. If the pistons have not been removed,
use the barring mechanism.
NOTE: The crankshaft will turn freely if the main bearings
are installed correctly.
Use a dial indicator and measure the crankshaft end

clearance.
Crankshaft End Clearance

mm in
0.10 MIN 0.004
0.41 MAX 0.016
If the clearance is not within specifications, check for
foreign material. Oversize thrust bearings are available to
adjust the end clearance.
NOTE: The upper and lower thrust bearing on the same
side of the main caps must be the same thickness.
Install the oil pan adapter. Refer to Procedure 007-026-026.
NOTE: Tighten the suction tube to block capscrews (1) be-

fore installing any support bracket capscrews.
Install the gasket, suction tube, washers, and capscrews
(1). Tighten the capscrews.
capscrew (2). Tighten the capscrew.
Torque Value: 35 N•m [25 ft-lb]

Procedure 007-025-026.
Install new oil filter elements. Refer to Procedure
007-013-026.
Bearings, Thrust (001-007) Section 1 — Cylinder Block — Group 01
Fill the engine with clean 15W-40 oil. Refer to Procedure

007-025-028 for engine oil capacity.
Check for leaks.
Bearings, Thrust (001-007)

Remove (001-007-002)
NOTE: Before removing the thrust bearings, refer to General
The No. 6 cap contains two thrust bearings. Remove and
mark them for position in the notched area.
Remove the two upper thrust bearings from the block at

the No. 6 location. Mark them for position.
NOTE: If necessary, slide the crankshaft to the front or to the
rear to allow the thrust bearings to be removed.
Inspect for Reuse (001-007-007)

Thrust bearings are available in three sizes: [STD, 0.010,
0.020] OS. The upper and lower thrust bearings must be
the same size. The front and rear can be different sizes.
Use the same size as those removed. The crankshaft will
be marked on a counterweight adjacent to the thrust
location if the thrust flange has been machined for over-
size thrust bearings.
Section 1 — Cylinder Block — Group 01 Camshaft (001-008)
Install (001-007-026)
NOTE: Before installing the thrust bearings, refer to General
Use engine oil. Lubricate the upper thrust bearings.
Caution: The grooves in the thrust bearings must point

toward the crankshaft.
Install the bearings in the No. 6 location.
NOTE: Move the crankshaft to the front or to the rear to so
the second thrust bearing to be installed.
Use a dial indicator and measure the crankshaft end

clearance.

mm in
0.10 MIN 0.004
0.41 MAX 0.016
foreign material. Oversize thrust bearings are available to
adjust the end clearance.
NOTE: The upper and lower thrust bearing on the same
side of the main caps must be the same thickness.
Camshaft (001-008)
Remove (001-008-002)
Remove the gear cover and all related components. Refer
to Procedure 001-031-003.
Camshaft (001-008) Section 1 — Cylinder Block — Group 01
Remove all of the cam follower assemblies. Refer to Pro-

cedure 004-001-002.
Remove one injector to allow timing to be checked. Refer

to Procedure 006-026-002. Begin with No. 3 cylinder.
Bar the engine by turning the crankshaft. Turn the engine

until the index marks on the crankshaft and camshaft
gears are in alignment with the marks on the crankshaft
idler gear.
Remove the camshaft idler gear. Refer to Procedure No.

001-036-002.
Remove the hydraulic pump idler gear if the engine is

equipped with this option. Refer to Procedure No.
001-039-002.
Remove the water pump idler gear. Refer to Procedure

No. 001-040-002.
Remove the camshaft gear. Refer to Procedure No.

001-012-002.
Remove the three capscrews, the thrust bearing plate,

camshaft key, and the thrust bearing.
Caution: Pilots must be used to prevent damage to the

camshaft and the bushings. Be sure the hooks do not
damage the camshaft bushings.
Use camshaft installation pilots, Part No. 3824843,
3824844, and 3814845. Put the pilots on the inner base
circle of the valve lobes for the last two cylinders.
Caution: This part weighs more than 23 kg [50 lbs]. To

avoid personal injury, use a hoist or get assistance to lift
the component.
Rotate the camshaft during removal so that one of the
pilots is always on the bottom part of the camshaft bushing.
Inspect the camshaft. Refer to Procedure No.

001-008-062.
Inspect the camshaft bushings. Refer to Procedure No.

001-010-062.
Install (001-008-026)
Install camshaft installation pilots, Part No. 3824843,
3824844, and 3824845 on the valve lobes of the cam-
shaft.
Use LubriplateW No. 105, or equivalent, to lubricate the
camshaft and camshaft bushings.
Caution: If the installation pilots are not available, use

caution to prevent the camshaft lobes from damaging
the bushings.
Install the camshaft. Turn the camshaft backward and
forward as it is being pushed. Keep the pilots turned
downward to support the camshaft.
NOTE: The camshaft thrust bearing has two bearings. Both

have a steel back with an aluminum overlay. An adhesive is
used to hold new bearings together. The bearings can sepa-
rate during engine operation. Do not use RTV to hold the
bearings together for assembly or the thickness may be too
great when the RTV cures. The thrust bearing must be
installed with the smooth surfaces against each other.
Use LubriplateW No. 105, or equivalent. Lubricate the
O.D. of the camshaft at the gear location.
Caution: The gear spacer plate gasket must not prevent
the thrust plate from being flat against the block. If nec-
essary, trim the gasket.
The grooves in the thrust plate must be positioned toward
the gear. Install the thrust plate.
Install the thrust bearing and the thrust bearing plate.

Install the three mounting capscrews.
Camshaft keys are available in different sizes (amount of

offset). The injection timing is controlled by:
• the selection of the camshaft key.
• the direction of the key offset when compared to the
camshaft gear rotation.
• the amount of offset.
Install the same part number key in the same orientation
as the key that was removed.
Caution: Wear protective clothing to prevent personal

injury from burns.
Caution: Do not exceed the specified time or the tem-
perature. Damage to the gear and the gear teeth will
result.
Caution: Do not attempt to install the gear without using
heat.
Use an oven and adjust the heat to 235°C [450°F]. Heat
the gear for a minimum of 1 hour, but no more than a
maximum of 6 hours. The I.D. of the gear will become
larger and will simplify the installation.

injury from burns.
NOTE: The timing mark on the camshaft gear must be
visible from the front of the gear after it is installed on the
camshaft.
Caution: Allow the gear to air cool slowly. Do not use
water or oil to reduce the cooling time. This will cause
the gear to crack.
Remove the gear from the oven. Install the gear on the
camshaft. The keyway in the gear must be aligned with
the key in the camshaft.
Install a C-clamp around the gear support plate and the

camshaft gear to hold the gear in position as it cools.
Remove the C-clamp after the gear has cooled to room
temperature.
Use a dial indicator and measure the camshaft end clear-

ance.
Camshaft End Clearance

mm in
0.15 MIN 0.006
0.33 MAX 0.013
foreign material or a piece of gasket between the thrust
plate and the block.
Install the camshaft idler gear. Refer to Procedure No.

001-036-002.
Install the hydraulic pump idler gear. Refer to Procedure

No. 001-039-026.
Install the water pump idler gear. Refer to Procedure No.

001-040-026.
Measure the gear train backlash. Refer to Procedure No.

001-055-010.
NOTE: The reason for installing only one cam follower as-
sembly at this time is to save time if the camshaft has to be
removed to adjust the injection timing.
Install the cam follower assembly on cylinder No. 3. Refer
to Procedure No. 004-001-026.
Measure the injection timing. Refer to Procedure No.

006-025-010.
Install the remaining cam follower assemblies and related

components. Refer to Procedure No. 004-001-026.
Install the gear cover and related components. Refer to

Inspect (001-008-062)
Use solvent and compressed air. Clean the camshaft.
After the camshaft has been cleaned, do not touch the

machined surfaces with bare hands. This will cause rust
to form. Lubricate the camshaft with clean 15W-40 oil
before handling.
Measure the seven camshaft bushing journals.
Camshaft Bushing Journal O.D.

mm in
82.42 MIN 3.245
82.47 MAX 3.247
Camshaft Bushings (001-010) Section 1 — Cylinder Block — Group 01
Visually inspect the camshaft lobes for cracks, scratches

or other damage.
Visually inspect the camshaft nose for fretting or burrs.

NOTE: If it is not possible to remove the fretting or burrs with
a fine crocus cloth, the camshaft must be replaced.
Measure the camshaft gear journal.
Camshaft Gear Journal O.D.

mm in
57.201 MIN 2.2520
57.215 MAX 2.2526
Camshaft Bushings (001-010)

Remove (001-010-002)
Use hydraulic actuator kit, Part No. 3823621, and cam-
shaft bushing installation/removal kit, Part No. 3824282,
to remove the camshaft bushings.
Section 1 — Cylinder Block — Group 01 Camshaft Bushings (001-010)
Remove the camshaft bushings.
Install (001-010-026)
Align the oil holes in the bushing with the oil drillings in
the block.
Caution: Clean the oil groove in the back of the cam-

shaft bushing to prevent contamination of the lubrica-
tion system.
Use the camshaft bushing driver assembly, Part No.
3376637, and the specified engine kit (mandrel). Install
the bushing until the edge of the groove on the back (O.D.)
is even with the edge of the block.
Clean the bushing O.D. Remove any metal shavings from
the oil groove.
Caution: Be sure that the front bushing is below the

surface of the block.
Install the bushing until the oil holes are aligned.
Camshaft Cover Plate (001-011) Section 1 — Cylinder Block — Group 01
There are three holes in each bushing. All holes must be

aligned except on the front bushing. There is no drilling
to align with the upper holes on the front bushing.
Use a 7 mm [1/4 inch] allen wrench. Check the alignment
of the bushing oil holes.
Inspect (001-010-062)
Clean and visually inspect the camshaft bores in the
block for reuse. Use an emery cloth to remove any burrs
and sharp edges from the bore. Measure the I.D.
Camshaft Bushing Bore in the Block

mm in
88.989 MIN 3.5035
89.015 MAX 3.5045
If the I.D. is not within specifications, install a repair
sleeve.
Visually inspect the amount of copper exposure on the

camshaft bushing. If it extends more than 180 degrees
around the bushing, the bushing must be replaced.
Measure the I.D.
Camshaft Bushing I.D.

mm in
82.550 MIN 3.2500
82.640 MAX 2.2535
If the bushing is not within specifications, the bushing
must be replaced.
Camshaft Cover Plate (001-011)

Remove (001-011-002)
Remove the three capscrews. Remove the camshaft cover.
Remove and discard the gasket.
Section 1 — Cylinder Block — Group 01 Camshaft Gear (Camshaft Installed) (001-012)
Install (001-011-026)
NOTE: The notch in the gasket and the cover must align with
the oil drainback hole.
Install the camshaft cover gasket and the cover. Install the
Camshaft Gear (Camshaft Installed)

(001-012)
Remove (001-012-002)
Use the Part No. ??????? Camshaft Gear Puller Kit to
remove the camshaft gear.
Attach the puller to the gear.
Remove the gear.
Remove the puller.

offset). The injection timing controlled by:
• The amount of offset.
Check and record the direction of the key offset when
compared to the camshaft gear rotation (same or oppo-
site).
Remove the key.
Remove the camshaft thrust bearing plate and thrust

bearing.
Camshaft Gear (Camshaft Installed) (001-012) Section 1 — Cylinder Block — Group 01
Install (001-012-026)
Use Lubriplate No. 105, or equivalent. Lubricate the O.D.
of the camshaft at the gear location.
The grooves in the thrust bearing must be positioned
toward the gear. Install the thrust bearing.
Caution: The gear spacer plate gasket must NOT pre-
vent the thrust plate from being flat against the block. If
necessary, trim the gasket.

used to hold new bearings together. The bearings can sepa-
rate during engine operation. Do not use RTV to hold the
installed with the smooth surfaces against each other.
Install the thrust bearing plate. Install the three mounting
capscrews.

offset). The injection timing is controlled by:
• the amount of offset.
Install the same part number key in the same orientation
as the key that was removed.

injury from burns.
result.
heat.
larger and will simplify installation.
Section 1 — Cylinder Block — Group 01 Camshaft Gear (Camshaft Installed) (001-012)

injury from burns.
Caution: Allow the gear to cool slowly. Do not use water
or oil to reduce the cooling time. This will cause the gear
to crack.
NOTE: The timing mark on the camshaft gear must be
camshaft.
Remove the gear from the oven and install it on the
camshaft. The keyway in the gear must be aligned with
the key in the camshaft.
Caution: Allow the gear to cool slowly. Do not use water

or oil to reduce the cooling time. This will cause the gear
to crack.
Install a C-clamp around the gear support plate and the
camshaft gear to hold the gear in position as it cools.
Remove the C-clamp after the gear has cooled to room
temperature (approximately 10 minutes).
Use a dial indicator and measure the camshaft end clear-

ance.
Camshaft End Clearance

mm in
0.15 MIN 0.006
0.33 MAX 0.013
If the clearance is too small, check for foreign material or
a piece of gasket between the thrust plate and the block.
Inspect (001-012-062)
Visually inspect the camshaft gear for cracks, chipped or
broken teeth.
Visually inspect the bore of the gear for fretting or burrs.
Connecting Rod (001-014) Section 1 — Cylinder Block — Group 01
Visually inspect the gear keyway for burrs.

Remove any burrs with fine crocus cloth.
Note: If the keyway is damaged or it is not possible to
remove the burrs with fine crocus cloth, the gear must be
replaced.
Measure the I.D. of the camshaft gear.
Camshaft Gear I.D.

mm in
57.124 MIN 2.2490
57.150 MAX 2.2500
The gear must be replaced if the I.D. is not within
specifications.
Connecting Rod (001-014)

Visually inspect the rod caps, connecting rod bearing
saddles, and capscrews for nicks, cracks, burrs, scratches
or fretting.
Visually inspect the bearing seating surface for nicks or

burrs. If it is not possible to remove any nicks or burrs with
a fine crocus cloth, the rod must be replaced.
Section 1 — Cylinder Block — Group 01 Crankshaft (001-016)
Crankshaft (001-016)
Initial Check (001-016-008)
Use a lint-free cloth. Clean the crankshaft journals, con-
necting rods, and main bearings. Check crankshaft jour-
nal for damage.
Crankshaft Gear, Front (Crankshaft

Installed) (001-018)
Remove (001-018-002)
NOTE: ONLY remove the gear when the crankshaft or the
gear is damaged.
Use a puller jaw, Part No. 3375835, and bridge assembly,
Part No. 3375834. Install the puller jaw and bridge as-
sembly on the gear.
Caution: Heat can be used to aid the removal of the gear.

Do NOT use a cutting torch. The high temperature of a
torch will damage the teeth of the gear.
Caution: Do not exceed 475 N•m [350 ft-lb] of torque
when turning the jackscrew.
Lubricate the puller jackscrew with engine oil. Hold the
pry bar and turn the jackscrew to remove the gear.
Remove the key.

Use a hone stone and polish the shaft O.D. Remove all
of the small scratches, burrs, and small grooves.
Crankshaft Gear, Front (Crankshaft Installed) (001-018) Section 1 — Cylinder Block — Group 01
Inspect For Reuse (001-018-007)

Clean and visually inspect the crankshaft for reuse. Mea-
sure the O.D.
Crankshaft O.D. (Gear Location)

mm in
111.25 MIN 4.380
111.28 MAX 4.381
Install (001-018-026)
Install the key.

injury from burns.
result.
heat.
larger and will simplify installation.

injury from burns.
Caution: Allow the gear to air cool slowly. Do not use
water or oil to reduce the cooling time. This will cause
the gear to crack.
NOTE: The timing mark on the crankshaft gear must be
crankshaft.
Lubricate the O.D. of the crankshaft with Lubriplate No.
105, or equivalent. Remove the gear from the oven and
install it on the crankshaft. The keyway in the gear must
be aligned with the key in the crankshaft.
Section 1 — Cylinder Block — Group 01 Crankshaft Seal, Front (001-023)
Crankshaft Seal, Front (001-023)

Remove (001-023-002)
Remove the fan and fan spacer(s). Refer to Procedure
No. 008-040-002).
Remove the fan belt. Refer to Procedure 008-002-002.
Remove the vibration damper and fan drive pulley. Refer

Remove the eight button head hex socket capscrews.

Crankshaft Seal, Front (001-023) Section 1 — Cylinder Block — Group 01
Use four [1/4-20 UNC x 1 inch] capscrews to remove the

seal from the crankshaft.
Install the capscrews into the clinch nuts in the seal case.
Tighten the capscrews alternately and evenly to remove
the seal.
Remove the o-ring from the gear cover.
Clean (001-023-006)
Use a clean cloth and safety solvent, Part No. 3823717,
or equivalent. Clean the crankshaft and seal mounting
area.
Install (001-023-026)
Install a new o-ring in the groove in the seal housing.
Section 1 — Cylinder Block — Group 01 Crankshaft Seal, Front (001-023)
Use hand pressure to push the seal on the crankshaft as

far as possible.
Align the four clinch nuts on the back of the seal carrier
flange with the counterbores in the gear cover mounting
surface.
Install the seal installation tool that is supplied with the

seal on the crankshaft.
Use three crankshaft adapter mounting capscrews.

Tighten the capscrews alternately and evenly in one-half
of a turn increments until the installation tool seats against
the nose of the crankshaft.
Remove the installation tool.

Crankshaft Seal, Front (001-023) Section 1 — Cylinder Block — Group 01
Install the eight, button head hex socket capscrews.

Tighten the capscrews alternately and evenly.
Install the vibration damper and fan drive pulley. Refer to

Install the fan belt. Refer to Procedure 008-002-026.
Install the fan spacer(s) and fan. Refer to Procedure No.

008-040-002.
Section 1 — Cylinder Block — Group 01 Crankshaft Seal, Rear (001-024)
Crankshaft Seal, Rear (001-024)

Remove (001-024-002)
Remove the transmission, clutch, and all related compo-
nents. Refer to the equipment manufacturer’s instruc-
tions. Remove the flywheel. Refer to Procedure No.
016-005-002.
Remove the seal mounting capscrews.
Use four [1/4-20 UNC x 1 inch] capscrews to remove the

seal from the crankshaft.
Install the capscrews in the welded nuts in the seal case.
Tighten the capscrews alternately and evenly to remove
the seal.
Clean (001-024-006)
Use a clean cloth and safety solvent, Part No. 3823717,
or equivalent. Clean the crankshaft and seal mounting
area.
Crankshaft Seal, Rear (001-024) Section 1 — Cylinder Block — Group 01
Install (001-024-026)
Install a new o-ring on the seal housing.
Use vegetable oil to lubricate the o-ring.
Use hand pressure to push the seal on the crankshaft as

far as possible.
Align the four clinch nuts on the back of the seal carrier
flange with the counterbores in the flywheel housing.
Attach the seal installation tool that is supplied with the

seal to the crankshaft, using three flywheel mounting
capscrews.
Section 1 — Cylinder Block — Group 01 Crankshaft Seal, Rear (001-024)
Align the installation tool with the pilot flange on the seal
carrier.
Tighten the three capscrews alternately and evenly in

one-half of a turn increments until the seal carrier seats
against the flywheel housing.
Remove the seal installation tool.
Install the seal mounting capscrews. Tighten the

capscrews.
Cylinder Block (001-026) Section 1 — Cylinder Block — Group 01
Install the flywheel. Refer to Procedure No. 016-005-026.

Install the transmission, clutch, and all related compo-
nents. Refer to the equipment manufacturer’s instructions.
Cylinder Block (001-026)

Warning: Naptha and methyl ethyl ketone are flammable
materials. Use caution to prevent personal injury. Follow
the manufacturer’s instructions. Do not use starting fluid.
Use a hydrocarbon solvent, such as naptha, methyl ethyl
ketone, trichorethane 1,1,1 (methyl chloroform), or
equivalent to clean the counterbore.
NOTE: The counterbore ledge must be clean and dry. The
sealant used in assembly will not dry if there is oil on the
ledge.
Pitting on the liner seat is not acceptable. This picture

illustrates an example of pitting in a damaged area.
This block requires counterbore machining before it can
be reused. Refer to the QSK19 Shop Manual.
Magnetic Crack Inspection (001-026-016)

Use a crack detection kit, Part No. 337532 or equivalent,
and check the counterbore ledge for cracks.
Hairline cracks on the counterbore seat are not detrimen-
tal.
Hairline cracks that remain after machining for an over-
size liner or salvage sleeve are acceptable.
Section 1 — Cylinder Block — Group 01 Cylinder Block and Liner Seats (001-027)
Open cracks require counterbore machining before evalu-

ating the counterbore ledge again.
If the cracks are closed after machining, the counterbore
is acceptable for reuse.
Capscrew Hole Cracks↔

Cracks that extend from the counterbore wall to the
capscrew hole are acceptable for reuse only if it does not
extend into threaded portion of hole.
Cracks that extend into threaded portion of the hole re-

quire repair with a blind end thread insert. Refer to the
Alternative Repair Manual.
Cylinder Block and Liner Seats

(001-027)
Preparatory (001-027-001)
Definition of numerical terms (call-outs):
1. Upper counterbore inside diameter
2. Counterbore depth
3. Lower counterbore inside diameter
4. Packing ring bore
5. Counterbore ledge
6. Counterbore radius
Cylinder Block and Liner Seats (001-027) Section 1 — Cylinder Block — Group 01

Measure the liner protrusion. Refer to Procedure 001-
028-008.
NOTE: If the protrusion is not correct, remove the liner. Refer
to Procedure 001-028-002. The protrusion can be adjusted
using shims, and machining the counterbore ledge. Refer to
the QSK19 Shop Manual.
Inspect the cylinder block to determine if an oversize or

a standard size head gasket is required.
NOTE: An oversize head gasket must be used on blocks that
have had 0.25 mm to 0.76 mm [0.010 inch to 0.030 inch]
material removed from the top surface of the block.
Use a scraper or a fibrous abrasive pad such as Scotch-

Brite 7477, or equivalent, and solvent. Clean the top deck
surface of the block. Do not allow any dirt into the cylinder.
The surface must be free of dirt, oil, and gasket material,
but does not have to look like new metal.
NOTE: Check the top surface of the block for wear. If fretting
damage is present in an area where a head gasket seal ring
or a grommet makes contact, the surface must be repaired.
Refer to the Alternative Repair Manual.
NOTE: Fretting damage in any other area is acceptable only
if it does not change the protrusion measurement of the
counterbore or liner.
Visually inspect the groove pins for damage. Use the

ST-1134 dowel pin extractor, or equivalent to remove the
pins.
Section 1 — Cylinder Block — Group 01 Cylinder Block and Liner Seats (001-027)
Measure (001-027-010)
NOTE: Be sure the micrometer contacts the flat surface of
the ledge. It must not touch the radius.
NOTE: If the counterbore depth does not meet specifica-
tions, a thicker or thinner seal ring may have been used in
a previous machining bore process. Measure and record the
measurement so that the liner protrusion can be determined.
Use a depth micrometer and measure the counterbore
depth at the four places shown.
Counter bore Depth
mm in
13.754 MIN 0.5415
13.805 MAX 0.5435
The four measurements must not vary more than 0.25
mm [0.001 inch]. If the measurements exceed the speci-
fications, the counterbore ledge must be machined. Re-
fer to the QSK19 Shop Manual.
NOTE: Be sure that the indicator does not contact the count-
erbore radius on a block that does not have a double un-
dercut.
Use a gauge block, Part No. ST-547. Measure the angle
of the counterbore ledge at four places on the counter-
bore circumference.
The measurement of the ledge depth must be as near to
the counterbore radius as possible, and as near to the
counterbore edge as possible.
The angle (12) of the counterbore ledge is acceptable

(OK) if the measurement that is near the counterbore
edge is the same or no more than 0.036 mm [0.0014 inch]
shorter than the measurement near the counterbore ra-
dius. If the measurement near the counterbore ledge is
longer than the measurement near the counterbore ra-
dius, the ledge must be machined. Refer to the QSK19
Shop Manual.
Cylinder Block and Liner Seats (001-027) Section 1 — Cylinder Block — Group 01
Measure the I.D. of the upper counterbore (1). The point

of measurement must be within 2.54 mm [0.100 inch]
from the top of the block.
Counterbore Diameter - UPPER Press Fit Diameter
mm in
188.16 MIN 7.408
188.21 MAX 7.410
The I.D. of the upper counterbore must be completely
round within 0.025 mm [0.001 inch]. If the measurement
is not within specification, check to see if the block can
be machined to use oversize liners.
NOTE: The upper counterbore must be no more than 0.076
mm [0.003 inch] larger than the cylinder liner flange.
NOTE: If the counterbore does not meet specifications, an
oversize liner may have been used in a previous machining
bore process. Measure and record the measurement so that
the proper press fit liner protrusion can be determined.
Measure the I.D. of the lower counterbore (3). The point

of measurement must be within 2.54 mm [0.100 inch]
from the top of the counterbore ledge.
Counterbore Diameter - LOWER Press Fit Diameter
mm in
180.09 MIN 7.090
180.14 MAX 7.092
The I.D. of the lower counterbore must be completely
round within 0.025 mm [0.001 inch].
NOTE: If the counterbore does not meet specifications, an
oversize liner may have been used in a previous machining
bore process. Measure and record the measurement so that
the proper press fit liner protrusion can be determined.
If the block is not within specifications, do not use the
block.
Check the chamfer at the top of the packing ring bore.

Excessive pitting must be repaired. Refer to the Alter-
native Repair Manual.
(4) Packing Ring Bore

mm in
177.34 MIN 6.982
177.39 MAX 6.984
Section 1 — Cylinder Block — Group 01 Cylinder Liner (001-028)
Cylinder Liner (001-028)

Remove (001-028-002)
Remove the cylinder head. Refer to Procedure
002-004-002.
Remove the piston and connecting rod. Refer to Proce-

dure 001-044-002.
Use the universal liner puller, Part No. 3376015.

Loosen the set screws (44). Turn the feet (45) of the puller
until the curved side turns away from the center as shown.
Move the holding pins (46) to the last hole as shown.
Install the tool in the cylinder liner. The puller feet must
not touch the top of the liner. The puller arms must be
positioned firmly on the bottom of the liner.
Cylinder Liner (001-028) Section 1 — Cylinder Block — Group 01
Turn the puller screw until the liner loosens in the block.
Remove the tool and the liner.
Clean (001-028-006)
Lubricate the inside of the liner with engine oil. Allow the
liner to soak for 5 to 10 minutes.
Caution: Do not use a cloth towel. Lint will cause severe

engine damage.
Use a lint-free cloth or towel and clean the inside of the
liner.
Repeat these three cleaning steps until the cleaning clorth
or towel shows no black or gray residue.

NOTE: The cross-hatching visible in the bore is the result of
the final honing process that establishes a surface finish to
retain an oil film for ring lubrication and sealing.
Inspect the inside of the liner. If the liner contains a heavily
polished area (the cross-hatching is not visible) the liner
must be replaced. Refer to Procedure 001-028-002.
Use a dial bore gauge. Measure the I.D. of the liner at the
top, the bottom, and the middle of the piston ring travel
area. Perform two measurements at each location. The
measurements must be 90 degrees apart.
Cylinder Liner I.D.

mm in
158.737 MIN 6.2495
158.877 MAX 6.2550
NOTE: The I.D. of a new cylinder liner can be 0.015 mm
[0.0006 inch] smaller than specifications because of the
LubriteW coating.
Visually inspect the crankshaft rod journals for damage.
Measure (001-028-010)
Caution: The clamps must touch the highest part of the
liner.
Use two cylinder liner clamps, Part No. 3376944, and two
cylinder head capscrews. Install the clamps and
Use a gauge block, Part No. 3376220, or equivalent.

Position the gauge block so the indicator needle will con-
tact the liner flange on the outside of the sealing bead as
shown.
Gently push the indicator needle down until it touches the
liner. Turn the gauge until the ‘‘0’’ is aligned with the head
of the dial. Repeat this step several times to be sure the
gauge is set to ‘‘0’’.
Raise the indicator and move the gauge block until the
indicator will touch the block surface.
Gently push the indicator down until it touches the block.
Read the indicator.
Cylinder Liner Protrusion

mm in
0.13 MIN 0.005
0.18 MAX 0.007
Read the liner protrusion in four places equally spaced on
the liner O.D. The measurements on each liner must not
vary more than 0.03mm [0.001 inch].
If the liner protrusion is not correct, the liner must be

removed. Refer to Procedure 001-028-002.
NOTE: Use shims to increae the protrusion. Machine the
counterbore ledge to decrease the protrusion. Refer to the
QSK19 Shop Manual.
Install (001-028-026)
Warning: Naptha and methyl ethyl ketone are flammable
materials. Use caution to prevent personal injury. Follow
the manufacturers instructions. Do not use starting fluid.
Use a hydrocarbon solvent, such as naptha, methyl ethyl
ketone, trichorethane 1,1,1 (methyl chloroform), or equiva-
lent to clean the counterbore.
Clean the bottom of the cylinder liner flange.
Caution: The cylinder liner flange must be clean and
dry. The sealant used in assembly will not dry if there is
oil on the ledge.
NOTE: The seal rings have three locating tabs on the I.D.
The tabs have an interference fit to the liner Lower Press Fit
(LPF) diameter to hold the seal ring in place during liner
installation.
Install the seal rings.
The seal ring must be straight on the liner upon instal-
lation. Use your fingers to push the seal ring near the tabs
to fit the seal ring down and over the LPF diameter during
installation.
This practice during installation of the seal ring will pre-
vent deformation that will result in the seal ring not fitting
squarely on the bottom of the liner flange.
Install the crevice seal. The beveled edge of the crevice

seal (2) must be positioned as shown.
NOTE: Some o-rings have a ‘‘D’’ shape cross section. This
type of o-ring must be installed with the flat side against the
cylinder liner.
Install o-rings in the position shown. Use the mold mark
on the o-ring to check if the o-ring is twisted.
(3) Black o-ring
(4) Red o-ring
Use vegetable oil to lubricate the I.D. of the packing ring

bores.
Use your hands to push the cylinder liners into the block.
Use liner installation tool, Part No. 3375422, or equiva-

lent. Install the bridge assembly and two cylinder head
Install the pusher plate in the liner. Be sure it is aligned
correctly in the liner. Turn the pusher screw until it touches
the plate.
Turn the pusher screw until the liner flange touches the
counterbore ledge. Do not use more than 65 N•m [50 ft-lb]
of torque. Remove the tool.
NOTE: New cylinder liners can be 0.005 mm to 0.015 mm

[0.0002 inch to 0.0006 inch] smaller than the minimum speci-
fications because of the LubriteW coating.
Use a dial bore gauge and measure the I.D. of the liner at
the top, bottom, and middle of the liner.
Perform two measurements at each location. The mea-
surements must be 90 degrees apart.
Cylinder Liner I.D. (New)

mm in
158.737 MIN 6.2495
158.775 MAX 6.2510
The I.D. must be no more than 0.076 mm [0.003 inch]
out-of-round at the top two measurements.
If the I.D. is more than 0.05 mm [0.002 inch] out-of-round
in the bottom measurement location, the liner must be
removed. Check for a twisted o-ring.
NOTE: A new bead of sealant must be applied if the liner is
removed and installed again.
Measure the liner protrusion. Refer to Procedure

001-028-008.
If the protrusion is not correct, the liner must be removed.
The protrusion can be adjusted using seal rings and/or
machining the counterbore ledge. Refer to the QSK19
Shop Manual.
Install the piston and connecting rod assemblies. Refer to

Section 1 — Cylinder Block — Group 01 Gear Cover Spacer Plate (001-029)
Install the cylinder head and related components. Refer

Gear Cover Spacer Plate (001-029)

Remove (001-029-002)
Remove the gear cover and all related components. Refer
Bar the engine by turning the crankshaft until the index

marks on the camshaft gear and the crankshaft gear are
in alignment.
Remove the hydraulic pump idler gear. Refer to Proce-

dure No. 001-039-002.
Gear Cover Spacer Plate (001-029) Section 1 — Cylinder Block — Group 01
Remove the water pump idler gear. Refer to Procedure

No. 001-040-002.
Remove the camshaft idler gear. Refer to Procedure No.

001-036-002.
Remove the camshaft gear. Refer to Procedure

001-012-002.
Remove the 14 mounting capscrews from the plate. Re-

move the plate and discard the gasket.
NOTE: Tag the special mounting capscrews for future
identification.

Clean and inspect the plate for reuse. Check for fretting
damage on both sides of the gasket surface. Replace the
plate if damaged.
Install (001-029-026)
Install the service gasket piece on top of the oil pan
adapter. Use a spray adhesive to hold it in position. Use
Cummins sealant, Part No. 3823494, at the joints.
Separate the gasket as shown. Discard the center tab

sections.
The diamond dowel (15) must be installed with the flat

surface turned toward the master dowel hole at the lower
right hand corner of the block. Guide studs (14) will aid
the installation.
Caution: Do not use gasket cement. Damage to the gas-

ket will result.
Use Cummins sealant, Part No. 3823494, or equivalent.
Apply a small amount to both sides of the gasket at the
butt joint. Install the gasket.
NOTE: Special capscrews are required to attach the spacer

plate and the gear housing. The capscrews have a captive,
cone-shaped washer to maintain torque. The capscrews for
the spacer plate are [1 inch].
Install the spacer plate and the 14 capscrews as shown.

Remove the guide studs.
NOTE: If the oil pan adapter is removed, spacer plate align-

ment must be checked. If the oil pan adapter is installed,
alignment does not require checking.
Use a gauge block, Part No. ST-547, or equivalent, and
measure the distance from the bottom of the block to the
bottom of the plate.
The bottom of the plate or housing must be within 0.05
mm [0.002 inch] of the bottom of the block.
Align the plate or housing with the bottom of the block if
necessary.
Use the sequence shown and tighten the capscrews.

Measure the plate or the housing to the block alignment
again to be sure it is within specifications.
Install the camshaft gear. Refer to Procedure No.

001-013-026.
Install the hydraulic pump idler gear. Refer to Procedure

No. 001-039-026.
Install the water pump idler gear. Refer to Procedure No.

001-040-026.
Install the camshaft idler. Refer to Procedure No.

001-036-026.
Use a dial indicator and measure the idler gear end clear-
ance.
Idler Gear End Clearance

mm in
0.10 MIN 0.004
0.36 MAX 0.014
NOTE: If the clearance is not within specifications, check for
foreign material between the parts, or check for proper lo-
cation of the thrust washers. Oversize thrust washers are
available.
If the camshaft gear was replaced, check the injection

timing. Machine tolerances can cause the timing to be out
of specifications. Refer to Procedure 006-025-010.
Install the gear cover and related components. Refer to

Section 1 — Cylinder Block — Group 01 Gear Cover, Front (001-031)
Gear Cover, Front (001-031)

Remove (001-031-002)
Disconnect the batteries and air starter to prevent acci-
dental starting. Refer to Procedure No. 013-009-002.
Open the draincock in the radiator bottom tank. Remove

the lower radiator hose if necessary. Drain the cooling
system. Refer to Procedure No. 008-009-005.
Remove the fan and fan spacer(s). Refer to Procedure

008-040-002.

Gear Cover, Front (001-031) Section 1 — Cylinder Block — Group 01
Remove the alternator belt and alternator. Refer to Pro-

cedure 013-001-002.
Remove the fan hub. Refer to Procedure No. 008-036-002.
Remove the fan hub idler. Refer to Procedure No.

008-029-002.
Remove the water pump. Refer to Procedure 08-062-002.

Remove the water pump drive. Refer to Procedure No.

009-029-002.
Remove the thermostat housing. Refer to Procedure No.

008-015-002.
Remove the vibration damper. Refer to Procedure No.

001-052-002.
Remove the alternator drive pulley. Refer to Procedure

009-029-002.

No. 009-004-002.
Remove the fuel pump. Refer to Procedure No.

005-016-002.
Remove the air compressor. Refer to Procedure No. 012-

014-002 for a single cylinder compressor, or Procedure
No. 012-015-002 for a two cylinder compressor.
Remove the accessory drive pulley and assembly. Refer

Remove the hydraulic pump drive.

NOTE: Some engines contain a cover plate instead of a
hydraulic pump drive assembly.
Remove the four capscrews.
Remove the hydraulic pump drive assembly. Remove and
discard the gasket.
NOTE: The master dowel must be removed before the one-

piece gear cover can be removed.
Use a [5/16-18 inch] capscrew or a threaded rod. Use an
old piston pin or a slide hammer (33). Remove the dowel.
NOTE: The front cover contains five capscrews on the bot-
tom and three capscrews on back.
Remove the capscrews.
NOTE: The gear cover has 24 capscrews in the front of the

cover.
Remove the gear cover. Remove and discard the gasket.

Measure the I.D. of the bushings. The bushings must be
replaced if not within specifications. Refer to the Q19
Shop Manual.
Bushing I.D.
mm in
Accessory Drive and Water Pump Drive (1):
39.75 MIN 1.565
39.90 MAX 1.571
Hydraulic Pump Drive (2):

38.13 MIN 1.501
38.25 MAX 1.506
Remove and check the barring mechanism.

Push the shaft in. Hold in position. Slide the worm gear
until the spring is compressed.
Use a screwdriver. Remove the retaining ring.
Remove the parts:

• Shaft
• Spring
• Worm gear
Remove the o-ring from the shaft. Discard the o-ring.
Use solvent to clean the parts. Flush the oil drillings. Dry
with compressed air.
Check the parts for damage.
Use vegetable oil to lubricate the o-ring. Install the o-ring

on the barring shaft.
Install the parts:
• Worm gear
• Spring
• Shaft
Install the retaining ring.

Rotate the shaft. Check for correct assembly.
Install (001-031-026)
NOTE: Trim the gasket to the correct width since the spacer
plate is already installed.
Install the service gasket piece on top of the oil pan
adapter. Use a spray adhesive to hold it in position. Use
Cummins sealant, Part No. 3823494, at the joints.
This illustration shows the capscrew length requirements

for the front cover.
NOTE: Do not tighten the capscrews until the master dowel

pin is installed.
The use of guide bolts will aid the assembly.
Install the front cover gasket, cover, and capscrews.
Put the clamping plate in position and begin the instal-

lation of the capscrew. The plate must remain loose until
the fan hub or the cover plate is installed.
Use a [5/16-8 x 3 inch] capscrew and a mallet.

Install the threaded master dowel. Drive the dowel in until
it touches the bottom of the hole in the block.
Tighten the mounting capscrews in the sequence shown.

NOTE: Sequence No.1, 2, and 3 capscrews are located at
the back of the spacer plate.
Install the five capscrews that attach to the bottom of the

oil pan adapter. Tighten the capscrews.
Install the hydraulic pump drive.

Using engine oil, lubricate the bushing in the cover.
Install the gasket, drive or cover, washers, and capscrews.
Tighten the capscrews.
Install the accessory drive assembly. Refer to Procedure

No. 009-001-026.
Install the accessory drive seal. Refer to Procedure No.

001-003-002.
Install the accessory drive pulley. Refer to Procedure No.

009-001-026.
Install the air compressor. Refer to Procedure No. 012-

014-026 for the single cylinder compressor, or Procedure
No. 012-015-026 for the two cylinder compressor.
Install the fuel pump. Refer to Procedure No. 005-016-026.
Install the water pump drive, Procedure No. 009-029-026.

Install the alternator drive seal. Refer to Procedure No.
001-001-026.
Install the alternator drive pulley. Refer to Procedure No.
009-029-026.
Install the front crankshaft seal. Refer to Procedure No.

001-023-026.
Install the vibration damper. Refer to Procedure No.

001-052-026.
Install the thermostat housing and support. Refer to Pro-

cedure No. 008-015-026.
Install the water pump drive. Refer to Procedure No.

009-029-026.
Install the water pump. Refer to Procedure No.

008-062-026.
Install the fan hub idler assembly. Refer to Procedure

008-029-026.
Install the fan hub. Refer to Procedure No. 008-036-026.
Install the alternator. Refer to Procedure No. 013-001-026.
Install the belt. Refer to Procedure No. 013-005-026.

Install the fan belt. Refer to Procedure No. 008-002-026.
Install the fan spacer(s) and fan. Tighten the capscrews.

Install new full flow oil filters. Refer to Procedure

007-013-026.
Connect the batteries or the starter.

Camshaft Idler Gear (001-036) Section 1 — Cylinder Block — Group 01
Fill the cooling system. Refer to Procedure 008-018-028.

Operate the engine to normal operating temperature.
Check for leaks.
Camshaft Idler Gear (001-036)

Remove (001-036-002)
Remove the front gear cover. Refer to Procedure No.
001-031-002.
Remove the five capscrews, the retaining ring, and the

front thrust bearing.
Remove the camshaft idler gear.
Remove the rear thrust bearing, the idler shaft, and the
thrust bearing wear sleeve.
Install (001-036-026)
NOTE: If the idler shaft ring dowel remained in the cylinder
block during disassembly, remove the dowel from the block
and install it into the idler shaft. The bore in the thrust
bearing wear plate and the O.D. of the dowel are designed
to provide a slight press fit to hold the wear plate in position
during installation of the idler assembly.
Section 1 — Cylinder Block — Group 01 Camshaft Idler Gear (001-036)
Caution: The grooves in the thrust washers must be

positioned toward the gear.
NOTE: The timing marks on the camshaft gear must be
visible when the gear is installed.
gear bushing, shaft, and the thrust washer.
Use engine oil. Lubricate the capscrews. Assemble the
parts as illustrated.
NOTE: The camshaft idler gear is the only idler gear that has
timing marks.
Align the "0" on the idler gear with the "0" on the crank-
shaft gear. Align the "X" on the camshaft gear with the "X"
on the idler gear.
Rotate the idler shaft as necessary to align the mounting

capscrew holes.
Use the capscrew to pull the shaft into the bore.
Use the following steps and tighten the capscrews in the
sequence shown.
Camshaft Idler Capscrew — Torque Value

N•m Step ft-lb
45 1 35
95 2 70
150 3 110
Use a dial indicator. Measure the idler gear end clear-

ance.
Camshaft Idler Gear — End Clearance

mm in
0.29 MIN 0.012
0.51 MAX 0.020
available.
Hydraulic Pump Idler Gear (001-039) Section 1 — Cylinder Block — Group 01
Install the front gear cover. Refer to Procedure No.

001-031-026.
Hydraulic Pump Idler Gear (001-039)

Remove (001-039-002)
001-031-002.
NOTE: The bolt-in idler shafts have a flange that require the
shaft, the idler gear, and the thrust washer to be removed as
an assembly.
Remove the capscrew from the idler gear.
NOTE: To remove the gear assembly, use two pry bars and
pry the gear and the shaft from the block.
Install (001-039-026)
Caution: Engines that contain a hydraulic pump must
have the oil holes in the hydraulic pump idler shaft as
shown. Idler gear bushing failure will result if the oil
holes are not aligned correctly.
Mark the flange to show oil hole orientation.
Section 1 — Cylinder Block — Group 01 Hydraulic Pump Idler Gear (001-039)

turned toward the gear.
Use engine oil. Lubricate the capscrew. Assemble the
parts as shown.
Caution: Engines that contain a hydraulic pump must

have the oil holes in the hydraulic pump idler shaft ori-
ented as shown. Idler gear bushing failure will result if
the oil holes are not aligned correctly.
Align the oil holes in the shaft to an angle 45 degrees to
the left of vertical.
Use the capscrew to pull the shaft into the bore. Tighten
the capscrew.
Caution: Engines that do not have a hydraulic pump

drive must have a plug installed in place of the idler shaft.
Low oil pressure will result if the plug is omitted.
Caution: The capscrew that is used for the lug must not
protrude beyond the block.
Use a [9/16-UNF-inch] capscrew, lock washer, and a plain
washer that is larger than the block bore. Tighten the
capscrews.
ance.
Hydraulic Pump Idler Gear — End Clearance

mm in
0.10 MIN 0.004
0.36 MAX 0.014
available.
Water Pump Idler Gear (001-040) Section 1 — Cylinder Block — Group 01

001-031-026.
Water Pump Idler Gear (001-040)

Remove (001-040-002)
001-031-002.
NOTE: The bolt-in idler shafts have a flange that require the
shaft, the idler gear, and the thrust washer to be removed as
an assembly.
Remove the capscrew from the idler gear.
NOTE: To remove the gear assembly, use two pry bars and
pry the gear and the shaft from the block.
Install (001-040-026)
turned toward the gear.
Use engine oil. Lubricate the capscrew. Assemble the
parts as shown.
Section 1 — Cylinder Block — Group 01 Piston (001-043)
Align the oil holes in the shaft to an angle 45 degrees to

the left of vertical.
Use the capscrew to pull the shaft into the bore. Tighten
the capscrews.
ance.
Water Pump — Idler Gear End Clearance

mm in
0.10 MIN 0.004
0.36 MAX 0.014
cation of the thrust washers. Oversize washers are available.

001-031-026.
Piston (001-043)
Clean (001-043-006)
Use a piston ring expander, Part No. ST-1269, or equiva-
lent. Remove the piston rings. Save the rings for possible
failure analysis.
Piston (001-043) Section 1 — Cylinder Block — Group 01
Warning: When using a steam cleaner, wear protective

clothing, and safety glasses or a face shield. Hot steam
can cause serious personal injury.
Use steam to clean the outer layers of carbon from the
piston surface. The bead blast method can be used to
clean the top of the piston. If this method is used, cover
the ring grooves and skirt securely.
NOTE: It is only necessary to remove the carbon buildup. It
is not necessary to make the crown appear new.
Caution: Do not contaminate the wash tank solution

with bead blast materials.
Use a kerosene emulsion based solvent. Do not use a
solvent that is higher than 9.5 pH. Do not use a solvent
that contains chlorinated hydrocarbons with cresol,
phenols, or cresylic components.
Allow the pistons to soak in the solvent a minimum of 30
minutes.
NOTE: For best results soak the pistons several hours or
overnight. Use a solvent that can be heated 90°C to 95°C
[180°F to 200°F]. Use a cleaning tank that will circulate and
filter the solvent.
Caution: Do not use the bead blast method to clean the

skirt. The piston skirt will be damaged by blast material
being embedded in the aluminum.
Caution: Do not use a metal bristle brush to clean the
pistons. Damage to the ring grooves will result.
Use a brush to clean the ring grooves. Walnut shell blast-
ing can be used on the piston crown.
Repeat the soaking and scrubbing process until the pis-
ton is thoroughly clean.
Use steam to rinse the solvent from the pistons. Dry the
pistons with compressed air.
Section 1 — Cylinder Block — Group 01 Piston (001-043)

Visually inspect the ring grooves. The pistons must be
replaced if there is a visible ridge in the back of the groove.
The piston must be replaced if a lip has formed on the
O.D. of the groove.
Use piston ring gauge, Part No. ST-560, and measure

both compression ring grooves.
The piston must be replaced if any measurement is not
within specification.
Use crack detection kit, Part No. 3375432, or equivalent.

Check for cracks on the top of the piston and in the piston
pin bore.
NOTE: The crack detection kit contains the cleaner, pen-
etrant, and developer necessary to check for cracks using
the dye penetrant method.
The piston must be replaced if there is a crack in the

piston bore skirt (1) or the sides (2).
Piston Cooling Nozzles (001-046) Section 1 — Cylinder Block — Group 01
Measure the oil ring groove. The piston must be replaced

if it is not within specification.
Piston Oil Ring Groove Width

mm in
4.788 MIN 0.1885
4.851 MAX 0.1910
Measure the piston pin bore inside diameter.
Articulated Piston Pin Bore I.D. (Crown)

mm in
60.960 MIN 2.4000
60.980 MAX 2.4008
Articulated Piston Bin Bore I.D. (Skirt)
mm in
60.951 MIN 2.3996
60.597 MAX 2.3999
Measure the piston pin outside diameter and length.
Piston Pin O.D.

mm in
60.929 MIN 2.3988
60.935 MAX 2.3990
Piston Pin Length
mm in
132.59 MIN 5.220
132.85 MAX 5.230
Piston Cooling Nozzles (001-046)

Remove (001-046-002)
Caution: Do not attempt to remove the piston cooling
nozzle when the piston is at BOTTOM DEAD CENTER
(BDC). The nozzle will be damaged and can result in
piston failure.
Section 1 — Cylinder Block — Group 01 Piston Cooling Nozzles (001-046)

014-002 for a single cylinder compressor, and Procedure
No. 012-015-002 for a twin cylinder air compressor.
Remove the electronic fuel control valve assembly. Refer

Remove the lubricating oil filters. Refer to Procedure No.

007-013-002.
To prevent damage to the piston cooling nozzles during

removal, use the valve set marks and the sequence chart
to identify those nozzles that can be removed at each
index mark on the accessory drive pulley.
One complete crankshaft revolution is required to remove
all of the nozzles.
Rotate the engine barring device until the "A" mark on the
pulley is aligned with the mark that is cast on the acces-
sory drive seal boss.
Remove the piston cooling nozzle on cylinders No. 1 and

No 6.
Remove the piston cooling nozzle mounting capscrew.
Use a slide hammer with a [3/8 x 16 inch] thread to
remove the nozzle.
After removing the nozzle from cylinders No. 1 and No.

6, rotate the engine barring device and align the next
valve set mark with the mark cast on the gear cover.
Using the chart illustrated, remove the appropriate piston

cooling nozzles.
Repeat the process to remove the remaining piston cool-
ing nozzles.
Section 1 — Cylinder Block — Group 01 Piston Cooling Nozzles (001-046)
Clean (001-046-006)
Use solvent to clean the piston cooling nozzles. Dry with
compressed air.
Blow out the oil passages with compressed air.

Caution: Any damage to the piston cooling nozzle can
result in major engine damage.
Visually inspect the piston cooling nozzles for cracks or
damage.
Visually inspect the screws for damaged or mutilated
threads.
Replace any parts that are damaged.
Install (001-046-026)
Use vegetable oil. Lubricate the new o-ring. Do not soak
the new o-rings in engine oil.
Caution: Any damage to the piston cooling nozzle can
result in major engine damage.
Install the o-rings in the groove of the piston cooling
nozzle that is the least distance to the flange. Install the
piston ring type (steel) seal ring in the groove that is the
most distance from the flange.
Align one of the valve set marks with the mark cast in the
accessory drive seal boss.
Refer to the sequence chart illustrated to identify the two
piston cooling nozzles that can be installed.
Caution: Do not use the capscrew to pull the nozzle into

the cylinder block. Nozzles and o-ring damage or exter-
nal oil leaks can result.
Install the two piston cooling nozzles. Use only your hand
to push the nozzle into the bore until the flange touches
the block. Install and tighten the capscrew.
Rotate the barring device and align the next valve set
mark with the mark cast into the gear cover.
Install the appropriate piston cooling nozzles following

the illustrated sequence chart.
Repeat the process to install the remaining piston cooling
nozzles.

014-026 for the single cylinder compressor, and Proce-
dure No. 012-015-026 for the twin cylinder compressor.
Section 1 — Cylinder Block — Group 01 Piston Rings (001-047)
Install the electronic fuel control valve assembly. Refer to

Install the lubricating oil filters. Refer to Procedure No.

007-013-002.
Piston Rings (001-047)

Measure (001-047-010)
To check the ring gap, install the piston ring in the cylinder
liner that will be used. Use the top part of the piston to
position the ring in the liner correctly.
Use a feeler gauge to check the ring gap. The ring must
be replaced if it does not meet the following specifica-
tions.
Piston Ring Gap

Top Intermediate Oil
MIN 0.63 mm 0.63 mm 0.38 mm
[0.025 in] [0.025 in] [0.015 in]
MAX 1.02 mm 1.02 mm 0.74 mm
[0.040 in] [0.040 in] [0.029 in]
Vibration Damper, Single (001-052) Section 1 — Cylinder Block — Group 01
Install (001-047-026)
NOTE: Do not install the piston rings until the pistons are
installed on the rods.
NOTE: The piston rings are marked with the part number.
The shipping package is marked with the location.
The part number on the ring must be positioned toward the
top of the piston.
Use a ring expander, Part No. ST-1269, or equivalent and
install the piston rings.
NOTE: Do not align the gap of a ring with the piston pin bore.
NOTE: The gap in the oil ring expander must be turned 180
degrees opposite the gap on the oil ring.
Rotate the rings until the gaps are positioned as shown.
Vibration Damper, Single (001-052)

Remove (001-052-002)
Caution: This assembly weighs more than 23 kg. [50 lb].

To avoid personal injury, use a hoist or get personal
assistance to lift the component.
Remove one capscrew and install a [3/4-16x5 inch] guide
stud (32).
Caution: Do not pry or hammer on the vibration damper.
Damage will result.
Remove the remaining capscrews, damper and pulley.
Remove the guide stud (32).
NOTE: Engines that do not have a belt driven fan hub have
an adapter instead of the pulley.
Section 1 — Cylinder Block — Group 01 Vibration Damper, Single (001-052)
Remove the pulley from the damper.
Inspect for Reuse 001-052-007

NOTE: Vibration dampers have a limited service life. The
damper must be replaced after 576,000 km, [360,000 miles],
or 15,000 hours of service.
NOTE: Do not repair or balance a viscous damper in the
field.
Clean and inspect the damper for reuse. Inspect for cracks
on the mounting flange. Inspect for dents or bulges on the
housing.
If the damper is damaged, it must be replaced.
Use a paint solvent and fine crocus cloth. Remove the

paint from the front and back of the housing at the four
areas shown.
Measure no less than 3 mm [1/8 inch] from the O.D. to be
sure that the measurement is on a flat surface.
Measure the thickness at four places. If the measure-
ments vary more than 0.25 mm [0.010 inch], or if the
thickness exceeds 42.24 mm [1.663 inch], the damper
must be replaced.
NOTE: The following illustrates the procedure to check the

damper for fluid leakage.
Step One: Use the crack detection kit, Part No. 3375434,
or equivalent and spray the rolled lip of the damper.
NOTE: The crack detection kit, Part No. 3375434, contains
the necessary cleaner, penetrant, and developer to check for
cracks using the dye penetrant method.
Vibration Damper, Single (001-052) Section 1 — Cylinder Block — Group 01

injury from burns.
Step Two: Use an oven with the temperature adjusted to
93°C [200°F].
Put the damper in the oven with the rolled lip down. Heat
the damper for two hours.

injury from burns.
Remove the damper and check for leakage around the lip.
If there is any leakage the damper must be replaced.
Install (001-052-026)
Install the vibration damper on the crankshaft pulley or
adapter. Install the six washers and capscrews. Tighten
the capscrews.
Install the guide stud (3) in the crankshaft.

Install the damper assembly. The pilot must be aligned
with the crankshaft correctly. Install the washers and
capscrews. Tighten the capscrews to the values indicated
below.
Capscrew Torque Values

N•m Step ft-lb
230 1 170
445 2 330
Section 1 — Cylinder Block — Group 01 Vibration Damper, Single (001-052)
Eccentricity Check (001-052-064)

Use a dial indicator and adjust it as shown to measure
radial alignment of the vibration damper. Turn the crank-
shaft 360 degrees and record the TIR.
Maximum Eccentricity
mm in
1.02 Viscous damper 0.040

If the measurement is not within specifications, be sure
the damper pilot is aligned correctly.
Wobble Check (001-052-065)

NOTE: The crankshaft end clearance must be pushed or
pulled in the same direction each time a measurement is
taken.
Put the indicator 13 mm [1/2 inch] from the O.D. to mea-
sure the damper wobble. Turn the crankshaft 360 degrees
and record the TIR.
Maximum Wobble
mm in
1.02 Viscous damper 0.040
NOTE: When the dial indicator is positioned more than 13

mm [1/2 inch] from the O.D., the specification is different.
To determine the specification,
• measure the distance from the center of the crank-
shaft to the point the indicator tip touches the damper,
• multiply the distance by 0.18 mm [0.007 inch] when
the damper is rubber; 0.15 mm [0.006 inch] when
the damper is viscous, to obtain the maximum TIR.
If the measurement is not within specifications, check for
foreign material between the crankshaft and the adapter
(or pulley), and between the adapter (or pulley) and the
damper.
Install the fan belt and related components. Refer to Pro-

cedure 008-002-026.
Piston and Connecting Rod Assembly (001-054) Section 1 — Cylinder Block — Group 01
Piston and Connecting Rod Assembly

(001-054)
Remove (001-054-002)
Remove the cylinder head. Refer to Procedure No.
002-004-002.
Remove the piston cooling nozzles. Refer to Procedure

No. 001-046-002.
Drain the oil. Remove the oil sump and adapter cover.
Remove the capscrew from the mounting clamp.

Remove the two capscrews from the mounting flange.
Remove the oil pan suction tube. Remove and discard the
gasket.
Section 1 — Cylinder Block — Group 01 Piston and Connecting Rod Assembly (001-054)
Protect the push rod galleys, and coolant and oil pas-
sages from contamination.
Caution: Do not use abrasive paper to remove the car-

bon deposits. Small particles of abrasive paper will cause
severe engine damage.
Use a scraper or a similar blunt-edged tool to loosen the
carbon deposits.
Caution: Use extreme care to be sure that no abrasive

cleaners or materials are used in the piston ring travel
area.
Remove the remaining carbon with a nylon abrasive pad,
Scotch-Brite 7448, or equivalent, and solvent. The carbon
must be removed, but the surface does not have to ap-
pear like new metal.
Warning: Wear eye protection to prevent serious eye

damage during this operation.
An alternative method to remove the carbon ridge is to
use a high quality steel wire wheel installed in a drill.
NOTE: Do not use a steel wire wheel of inferior quality
because the wire wheel will lose steel bristles during op-
eration, and cause additional contamination.
Do not use a steel wire wheel in the piston travel area.

Operate the wire wheel in a circular motion to remove the
deposits.
Use the barring mechanism to rotate the engine. Rotate

the crankshaft to position the connecting rod at bottom
dead center (BDC).
Connecting rods must have the cylinder number marked

on both the rod and the cap on the side positioned toward
the camshaft. Check the rods for correct markings. Use
a steel stamp and mark any rod is not correctly marked.
Loosen the capscrews until there is 6 mm [1/4 inch] of
clearance between the rod cap and the capscrew head.
Use a mallet. Tap the connecting rod capscrews until the

connecting rod cap and rod separate. Remove the
capscrews and the cap.
Remove the lower rod bearing. Use a awl and mark the
NOTE: Mark the bearing for future identification or for pos-
sible failure analysis.
Use two connecting rod guide pins, Part No. 3375098, or

equivalent. Install the guide pins in the connecting rod.
Push the piston and connecting rod up until the piston
rings are above the cylinder liner.
Caution: Put the piston and rod assembly in a rack to

prevent damage.
Remove the piston and rod assembly.
Remove the upper connecting rod bearing. Use an awl
and mark the bearing position in the tang area.
Disassemble (001-054-003)
Use internal snap ring pliers. Remove the snap rings from
both sides of the piston.
Caution: To prevent personal injury and damage to the

piston, do not drop the piston while removing the piston
pin.
When the piston pin is removed from an articulated pis-
ton, the skirt will separate from the crown.
The skirts and crowns are interchangeable. It is recom-
mended that these parts be kept together for possible
failure analysis.
Clean and inspect the pistons. Refer to Procedure

001-043-006.
Assemble, Articulated (001-054-025)

Clean and check the pistons for reuse. Refer to Procedure
No. 001-043-007.
Install a new snap ring in one piston pin bore of each

piston skirt.
Position the skirt over the piston crown.
NOTE: It is not necessary to heat the articulated pistons
before assembly. The piston is slip-fit.
Caution: Do not use a hammer to install the piston pin.

The piston can distort, causing it to seize in the liner.
Use engine oil. Lubricate the piston pin and connecting
rod bushing.
Align the pin bore of the rod with the pin bore of the piston
skirt and crown, and install the piston pin.
The snap ring must be seated completely in the piston

groove to prevent engine damage during engine opera-
tion.
Install a new snap ring in the piston pin bore.
Install (001-054-026)
Use a lint-free cloth. Clean the connecting rod and the
bearing shells.
Install the rod bearing. Be sure the tang is positioned as
shown. The end of the bearing must be even with the cap
mounting surface.
Caution: Do not lubricate the back side of the bearing
shells.
Use engine oil. Lubricate the bearing surface. The bear-
ings must be installed in their original location if new
bearings are not used.
NOTE: All of the rod bearings are identical.
Install two connecting rod guide pins, Part No. 3375098,

in the rod.
The guide pins will aid the assembly and protect the
crankshaft.
Caution: The connecting rods and caps are not inter-

changeable. The rods and the caps are machined as an
assembly. Failure will result if they are mixed.
Install the lower bearing shell in the rod cap. Be sure the
tang of the bearing shell is in the slot of the cap and the
end of the bearing is even with the cap surface.
Use engine oil. Lubricate the connecting rod capscrews

and washers as shown. Install the washers and capscrews
in the caps.
Lubricate the cylinder liner with engine oil. The entire

bore must be lubricated.
Immerse the piston in engine oil until the rings are covered.
Allow the excess oil to drip off of the assembly.
Check to be sure the ring gap position is still correct.

Caution: Be sure the rings fit correctly in the piston

rings.
Use a piston ring compressor, Part No. 3375342, or equiva-
lent. Install the ring compressor on the piston.
NOTE: The ring compressor has a tapered bore. The small
end of the taper must be positioned toward the piston skirt.

be the same.
Caution: The side of the rod with the cylinder number
(bearing tang side) must be toward the camshaft.
Rotate the crankshaft until the journal for the rod being
installed is at bottom dead center (BDC).
NOTE: If the engine has a crankshaft with bolt-on counter-
weights, the journal must be at ‘‘TDC’’ top dead center.
Install the rod and piston until the ring compressor touches
the block. Align the rod with the crankshaft journal.
Hold the ring compressor firmly against the block. Use a
wooden hammer handle to push the piston into the liner.
Push the piston into the bore until the rod bearing con-
tacts the crankshaft journal. Remove the guide pins.

be the same.
Caution: The side of the cap with the cylinder number
marking (bearing tang side) must be toward the cam-
shaft.
Install the connecting rod cap.
Tighten the capscrews alternately and evenly to pull the
cap over the dowel pins. Use the following steps to tighten
the capscrews.
Connecting Rod Cap Torque Values
N•m Step ft-lb
100 1 75
205 2 150
290 3 215
Loosen 4 Loosen
100 5 100
205 6 150
290 7 215
Check the side clearance between the rod and the

crankshaft.
The rod must move freely from side-to-side.
Connecting Rod and Crankshaft Side Clearance

mm in
0.20 MIN 0.008
0.35 MAX 0.014
NOTE: Tighten the suction tube to the block capscrews (1)

before installing any support bracket capscrews.
Install the gasket, oil suction tube, washers, and
capscrew (2). Tighten the capscrews.
Torque Value: 35 N•m [25-lb]

Replace the cylinder head and related components. Re-

fer to Procedure 002-004-002.
Install the piston cooling nozzles. Refer to Procedure No.

001-046-026.
Install new oil filter elements. Refer to Procedure

007-013-002.
Gear Train Backlash, Front (001-055) Section 1 — Cylinder Block — Group 01

No. 007-025-028 for engine oil capacity.
Operate the engine to 70°C [160°F] coolant temperature
and check for leaks.
Gear Train Backlash, Front (001-055)

Measure (001-055-010)
NOTE: This check must be performed after the gear cover
is removed. If the cover is not already removed, refer to
Caution: The adjacent (engaging) gear must not turn as
the gear being measured is turned.
Position a dial indicator so the tip is contacting the surface
of the gear tooth as shown. Do not allow the mating gear
to turn.
Rotate the gear being measured clockwise. Position the
indicator to "0". Now rotate the gear counterclockwise
and read the indicator.
Gear Train Backlash

mm in
0.07 MIN 0.003
0.30 MAX 0.012
The backlash on the oil pump can be adjusted by rotating

the pump body.
Section 1 — Cylinder Block — Group 01 Camshaft Thrust Bearing (001-056)
Camshaft Thrust Bearing (001-056)

Visually inspect the thrust bearing for damage. Measure
the thickness.
Camshaft Thrust Bearing Thickness

mm in
9.12 MIN 0.359
9.44 MAX 0.372
used to hold new bearings together. The bearings can seper-
ate during engine operation. Do not use RTV to hold the
installed with the smooth sides against each other.
Section 2 — Cylinder Head — Group 02
Section 2 — Cylinder Head — Group 02

Section Contents
Page
Cylinder Head - General Information (002-999-999) ......................................................................................... 2-2
Cylinder Head - Specifications (018-001-502) ................................................................................................... 2-3
Cylinder Head - Tool Requirements (022-001-502)............................................................................................ 2-4
Cylinder Head (002-004) .................................................................................................................................... 2-5
Clean (002-004-006) ........................................................................................................................................ 2-8
Inspect for Reuse (002-004-007) ...................................................................................................................... 2-9
Install (002-004-026) ...................................................................................................................................... 2-12
Pressure Test (002-004-013)............................................................................................................................. 2-9
Remove (002-004-002)..................................................................................................................................... 2-5
Cylinder Head Gasket (002-021) ...................................................................................................................... 2-17
Leak Test (002-021-014) ................................................................................................................................. 2-17
Cylinder Head Valve (002-0020)....................................................................................................................... 2-16
Remove (002-020-002)................................................................................................................................... 2-16
Cylinder Head - General Information (002-999-999) Section 2 — Cylinder Head — Group 02
Cylinder Head - General Information

(002-999-999)
The QSK19 uses a torque-turn method for torquing all
cylinder head capscrews. This method provides better
control of the load on the capscrews.
The QSK19 utilizes a stemless crosshead design. This

design does not require adjustment.
The QSK19 cylinder head gasket has been altered due to
changes to the shape of the push tube hole. The grom-
mets have been built into the gasket.
Section 2 — Cylinder Head — Group 02 Cylinder Head - Specifications (018-001-502)
Cylinder Head - Specifications (018-001-502)

Cylinder Head:
Maximum Allowable Crack Length: ......................................................................6 mm [0.25 in]
Maximum Allowable Valve Depth:.................................................................. .0.51 mm [0.020 in]
Cylinder Head Capscrews:
Step 1 ................................................................................................. .205 N•m [150 ft-lb]
Step 2 ................................................................................................. .300 N•m [220 ft-lb]
Step 3...................................................................................................Rotate 90 Degrees
Rocker Lever Cover Capscrews: ........................................................................45 N•m [35 ft-lb]
Fuel Manifold Capscrews: ............................................................................. .9.5 N•m [85 in-lb]
Section 2 — Cylinder Head — Group 02 Cylinder Head (002-004)
Cylinder Head (002-004)

Remove (002-004-002)
Caution: Always disconnect negative terminal first.
Disconnect the batteries or air supply to the air starter to
prevent accidental engine starting.
Warning: Allow the engine to cool before draining to

avoid burns from hot liquid.
Open the draincock on the bottom of the radiator and
remove the lower radiator hose to drain the cooling system.
Remove the turbocharger. Refer to Procedure No.

010-033-002.
Remove the exhaust manifold. Refer to Procedure No.

011-007-002 for an engine with a dry manifold.
Cylinder Head (002-004) Section 2 — Cylinder Head — Group 02
Remove the fuel tubes. Refer to Procedure No.

006-024-002.
Remove the aftercooler. Refer to Procedure No.

010-002-002.
Remove the fuel manifolds. Discard the 18 o-rings.
Remove the rocker lever cover. Refer to Procedure No.

003-011-002.
Remove the rocker levers. Refer to Procedure No.

003-009-002.
Remove the valve push rods, the injector push rod, and
the crossheads.
Remove the coolant thermostat housing support. Refer to

Remove the gear cover clamping plate.

Remove the rocker lever housing. Refer to Procedure No.

003-013-002.
Remove the injector. Refer to Procedure No. 006-026-002.
Caution: This component weighs 23 kg [50 lb] or more.

To avoid personal injury, use a hoist or get assistance to
lift the component.
Remove the six capscrews and the cylinder head. Re-
move and discard the gasket.
Clean (002-004-006)
Warning: To avoid personal injury, read and follow sol-
vent manufacturer’s safety instructions.
Clean the heads with solvent. Check for broken springs
or other damage.

Check for cracks on the combustion surface.
NOTE: If a crack around the injector bore exceeds the maxi-
mum length, the cylinder head must be replaced.
Maximum Allowable Crack Length: 6 mm [1/4-inch]
NOTE: Both ends of a crack between the valve must be
visible. If one end of a crack extends into the valve seat bore
(behind the valve seat), the condition of the cylinder is ques-
tionable. To be sure that the cylinder head is reusable, re-
move the valve and valve seat.
Use a gauge block head, Part No. 3376220, or equivalent.

Measure the valve head depth.
NOTE: If the valve depth exceeds the maximum, the cylinder
head must be rebuilt.
Maximum Allowable Valve Depth: 0.51 mm [0.020 inch]
To measure injector protrusion, refer to Procedure No.

006-028-010.
Pressure Test (002-004-013)

Remove the valves. Refer to Procedure No. 002-020-002.
Use a hydrostatic tester, Part No. ST-1012, with water test

adapter plate, Part No. 3375070, to test the cylinder head.
Remove one of the two plugs from the pressure regulator.

Install the pressure gauge in the regulator.
Turn the adjusting knob on the regulator counterclock-
wise as far as it will turn.
Install the pressure regulator between the air supply and

the quick disconnect fitting.
NOTE: The arrow on the top of the pressure regulator must
point in the direction of the air flow (toward the quick dis-
connect fitting).
Use adapter plate (4), Part No. 3375070, and o-ring (5),
Part No. 3375071, to test the head.
With the head as shown, assemble the adapter plates.

The guide pins on the lower plate (5) must go in the water
passages. The o-ring on the upper plate (4) creates a seal
on the upper water passage. The other end of the plate
goes into the injector bore.
Put the clamping assembly (1) over the head and adapt-
ers. The guide pins on the clamp must go into the holes
in the lower adapter plate.
Tighten the clamp on the head. Connect the wire hose to
the upper adapter fitting.
Attach the lifting arm to the clamp assembly with the lock
pins.
NOTE: One mounting location on each piece is color coded
red.
Adjust the air pressure. Lower the head into a tank of

water. Bubbles will indicate an air leak.
Air Pressure: 552 kPa [80 psi]
If the cylinder head leaks, it must be repaired or replaced.
Install (002-004-026)
NOTE: The word TOP stamped on top of the head gasket
must be visible after the gasket is installed.
Install the gasket.
Install the cylinder head. It must slide easily over the

groove pins.
Lubricate the capscrew head and threads with SAE EP
140W oil. Allow excess oil to drip off of the capscrews
before installing in the block.
Install the capscrews.
NOTE: When using torque plus angle, the tolerance on the

90 degree angle of rotation is one to two flats (90° ± 30°).
If the capscrew is rotated beyond two flats, do not loosen the
capscrew. The clamp load is still acceptable, however, ro-
tating the capscrew beyond two flats causes additional stretch
and reduces the life of the capscrew. With proper torquing,
the capscrew can typically be reused for the life of the
engine.
After all capscrews on one head have been torqued to 300
N•m [220 ft-lb], they must be rotated in the tightening
direction an additional 90 degrees. Rotate the capscrew
until the mark on the cylinder head is between the next
two marks joined by an arc (more than one flat and less
than two flats).
The markings on the head of the flange head capscrews

serve as an aid during installation. After torquing the
capscrew to 300 N•m [220 ft-lb], mark the cylinder head
adjacent to one of the two single marks on the capscrew
head.
Tighten the capscrews using the following steps and in

the sequence shown.
Torque Value: Step 1 - 68 N•m [50 ft-lb]
Step 2 - 205 N•m [150 ft-lb]
Step 3 - 300 N•m [220 ft-lb]
Step 4 - Rotate 90 Degrees
Install the rocker lever housings, push rods, and

crossheads. Refer to Procedure No. 003-013-026.
Install the injectors. Refer to Procedure No. 006-026-026.
Install the rocker levers. Refer to Procedure No.

003-009-026.
Adjust the valves and injectors. Refer to Procedure No.

003-006.
NOTE: Do not use gasket cement. It will prevent the gasket

from sealing properly.
Install the rocker lever cover, gasket, and capscrews.
Install the gear cover clamping plate. Tighten the

capscrews.
Install the coolant thermostat housing support. Refer to

Install the fuel tubes. Refer to Procedure No. 006-024-

026.
Install the fuel manifolds.
Use vegetable oil to lubricate the o-rings. Install the o-rings
in the fuel manifold.
Install the manifold, washers, and capscrews. Begin tight-
ening at the center of the manifold and work toward the
outer edges. Tighten the capscrews.
Torque Value: 9.5 N•m [85 in-lb]
Install the aftercooler. Refer to Procedure No. 010-002-026.
Install the exhaust manifold. Refer to Procedure No.

011-007-026.
Install the turbocharger. Refer to Procedure No.

010-033-026.
Cylinder Head Valve (002-0020) Section 2 — Cylinder Head — Group 02
Caution: To avoid arcing, connect negative-terminal last.

Connect the batteries or air starter supply line.
Fill the cooling system. Refer to Procedure No. 008-066-

028.
Operate the engine and check for leaks.
Operating Coolant Temperature (Minimum):
71°C [160°F]
Cylinder Head Valve (002-0020)

Remove (002-020-002)
Caution: The valve springs are under compression. Use
caution when using the valve spring compressor. Per-
Use a valve spring compressor, Part No. ST-448, or Part
No. 3375960, or equivalent. Valve spring stand, Part No.
ST-1022, and the compressor plate, Part No. 3375043,
can be used to compress all four springs at the same time.
Mark the valve for location prior to removal. The intake
and exhaust valves are different. The practice will help
with future installation identification.
Compress the valve spring and remove the following parts.
1. Valve collets
2. Valve spring retainer
3. Valve spring
4. Valve rotator
5. Valve
6. Valve stem seal
Discard the collets.
Section 2 — Cylinder Head — Group 02 Cylinder Head Gasket (002-021)
Install the seal driver (6) on the valve guide. Push the seal
(7) over the seal driver and on the valve guide. Push the
seal down on the guide until the lower spring is in the
groove on the guide.
NOTE: The QSK19 and L10/M11 engines can use the same
valve stem driver.
Remove the seal driver.
Install the valves.
Install (002-020-026)
Caution: The valve springs are under compression. Use
caution when using the valve spring compressor. Per-
Use a valve spring compressor, Part No. ST-448, or Part
No. 3375960, or equivalent. Valve spring stand Part No.
ST-1022 and the compressor plate, Part No. 3375043,
can be used to compress all four springs at the same time.
Install the following parts.
• (5) Valve
• (4) Valve rotator
• (3) Valve spring
Compress the valve spring and install the following parts.
• Valve spring retainer
• New valve collets
Cylinder Head Gasket (002-021)

Leak Test (002-021-014)
Use steam or high pressure water. Clean the exterior of
the engine.
Cylinder Head Gasket (002-021) Section 2 — Cylinder Head — Group 02
Operate the engine at low idle.

Check for oil or coolant leaks between the cylinder head
and the engine block.
Listen for a chirping sound between the cylinder head and

engine block. A chirping sound indicates a combustion
leak.
If a leak is found, remove the cylinder head and all related

components. Refer to Procedure No. 002-004-002.
Pressure check the cooling system to be sure the leak

was at the head gasket and not at the liner counterbore.
Refer to Procedure No. 001-026-016 for coolant leaks at
the counterbore.
Section 2 — Cylinder Head — Group 02 Cylinder Head Gasket (002-021)
Install the cylinder head and all related components. Re-

fer to Procedure No. 002-004-026.
Cylinder Head Gasket (002-021) Section 2 — Cylinder Head — Group 02
NOTES
Section 3 — Rocker Lever — Group 03
Section 3 — Rocker Lever — Group 03

Section Contents
Page
Overhead Set (Outer Base Circle) ..................................................................................................................... 3-5
Adjust (003-006-029)........................................................................................................................................ 3-5
Determine the Cylinder in Position for Valve Set.......................................................................................... 3-5
Worksheet (003-006-056) ................................................................................................................................. 3-9
Rocker Lever Assembly (003-009) ................................................................................................................... 3-10
Install (003-009-026)....................................................................................................................................... 3-11
Remove (003-009-002) ................................................................................................................................... 3-10
Rocker Lever Cover (003-011) .......................................................................................................................... 3-12
Inspect for Reuse (003-011-007) ..................................................................................................................... 3-13
Install (003-011-026) ....................................................................................................................................... 3-13
Remove (003-011-002) ................................................................................................................................... 3-12
Rocker Lever Housing (003-013)...................................................................................................................... 3-14
Install (003-013-026) ...................................................................................................................................... 3-16
Remove (003-013-002) ................................................................................................................................... 3-14
Rocker Lever — General Information (003-999-999) ......................................................................................... 3-2
Rocker Lever — Specifications (018-003-201)................................................................................................... 3-3
Rocker Lever — Tool Requirements (022-001-503) ........................................................................................... 3-4
Rocker Lever — General Information (003-999-999) Section 3 — Rocker Lever — Group 03
Rocker Lever — General Information

(003-999-999)
The QUANTUM System K19 utilizes the Outer Base Circle
(OBC) overhead set procedure.
NOTE: The OBC procedure requires the use of an accurate
inch-pound torque wrench. Torque wrench kit, Part No.
3824783, is available. A dial-type torque wrench with a range
from 0 to 35 N•m [0 to 300 in-lb] is required. The torque
wrench needs to be checked on a routine bases for proper
calibration. Use of a clicker-type torque wrench is not
recommended.
The QSK19 valve rocker lever incorporates a ball and

socket to minimize crosshead wear and reduce tipping of
the valves.
Section 3 — Rocker Lever — Group 03 Rocker Lever — Specifications (018-003-201)
Rocker Lever — Specifications (018-003-201)

Adjusting Screw Lock Nut:
With Torque Wrench Adapter, Part No. ST-669 .....................................................................45 N•m [35 ft-lb]
Without Adapter ...................................................................................................................60 N•m [45 ft-lb]
Air Crossover Capscrews .......................................................................................................45 N•m [35 ft-lb]
Air Crossover Hose Clamp .................................................................................................... 8 N•m [75 in-lb]
Injector Lever Adjusting Screw
Initial Torque......................................................................................................................20 N•m [175 in-lb]
(Loosen adjusting screw at least 1 revolution.)
Subsequent Torque............................................................................................................19 N•m [165 in-lb]
Rocker Lever Bushing Bore I.D.:
Minimum.......................................................................................................................47.66 mm [1.8763 in]
Maximum ......................................................................................................................47.73 mm [1.8793 in]
Rocker Lever Cover Capscrews..............................................................................................45 N•m [35 ft-lb]
Rocker Lever Housing Capscrews ...........................................................................................8 N•m [70 ft-lb]
Rocker Lever Shaft Capscrews...........................................................................................225 N•m [165 ft-lb]
Rocker Lever Assembly Capscrews .......................................................................................45 N•m [35 ft-lb]
Valve Adjustment (Initial Set):
Exhaust ............................................................................................................................0.81 mm [0.032 in]
Intake................................................................................................................................0.36 mm [0.014 in]
Reset Limits:
Exhaust ........................................................................................................................0.029 mm [0.0350 in]
Intake.............................................................................................................................0.011 mm [0.0170 in]
Section 3 — Rocker Lever — Group 03 Overhead Set (Outer Base Circle)
Overhead Set (Outer Base Circle)

Adjust (003-006-029)
Shut the engine OFF. Remove the rocker lever cover and
all related components. Refer to Procedure No.
003-011-002.
NOTE: The barring device shaft turns approximately two

revolutions before the engine begins to turn. The device will
not turn the engine opposite the direction of normal rotation.
Push the shaft in and turn the barring device counter-
clockwise until the "A" mark on the pulley is aligned with
the mark that is cast into the boss for the accessory drive
seal on the front gear cover.
Determine the Cylinder in Position for Valve Set

The valves will be adjusted on the cylinder that has all the
valves closed. Use the table to determine the cylinders for
valve position.
If the rocker lever assemblies have been removed, use

this step to determine the cylinder to be set.
NOTE: All adjusting screws must be loose on all cylinders,
and the push rod must remain in alignment.
NOTE: Perform this step on both cylinders to be checked.
Hold both rocker levers against the crossheads. Turn the
adjusting screws until they touch the push rods. Turn the
lock nuts until they touch the levers.
NOTE: The push rods will be the same height above the top
of the rocker lever housing on the cylinder ready for valve
adjustment.
Overhead Set (Outer Base Circle) Section 3 — Rocker Lever — Group 03
If the rocker levers have not been removed, wiggle the

valve rocker levers on the two cylinders in question. Set
the valves on the cylinder where both levers feel loose.
Use the chart to determine the injector that is ready to

adjust.
NOTE: Adjustment can begin on any valve set mark.
In our example, assume the A mark is aligned and the
push rod heights indicate that the valves on cylinder No.
6 are closed (ready to set). The chart shows the valves on
No. 2 are ready to adjust. The chart shows the injector on
cylinder No. 3 is ready to adjust.
After the adjustment, bar the engine to the B set mark.
Adjust the valves on cylinder No. 4 and adjust the injector
on cylinder No. 6.
Valves
Valve Adjustment (Initial Set)

Reference
Point mm in
A 0.81 Exhaust 0.032
B 0.36 Intake 0.014
NOTE: Be sure the feeler gauge is under the center of the

ball and socket, or the socket can crack, resulting in an
incorrect adjustment.
Select a feeler gauge for the correct valve lash specifi-
cation. Insert the gauge (2) between the rocker lever
socket and the crosshead.
Two different methods for establishing valve lash clear-

ance are described below. Either method can be used.
The torque wrench method has proven to be the most
consistent.
• Torque Wrench Method: Use Part No. 3376592,
Inch Pound Torque Wrench. Tighten the adjusting
screw to 0.68 N•m [6 in-lb] torque.
• Feel Method: Use a nut driver and turn the adjust-
ing screw only until the lever touches the feeler
gauge.
Torque Wrench Method ↔

Hold the torque wrench in a position that allows you to
look in a direct line at the dial. This is to be sure the dial
will read accurately.
Be sure the parts are in alignment and squeeze the oil out
of the valve and the injector train while tightening the
adjusting screw.
After loosening the adjusting screw at least 1 revolution,
tighten the adjusting screw again.
Feel Method ↔
NOTE: The feeler gauge must slide backward and forward
with only a slight drag.
NOTE: The adjusting screw must not turn when the lock nut
is tightened.
• With Torque Wrench Adapter, Part No. ST-669 (1):
— Torque Value: 45 N•m [35 ft-lb]
• Without Adapter:
Attempt to insert a feeler gauge that is 0.03 mm [0.001 in]
thicker. The valve lash is not correct when the thicker
gauge will fit.
Repeat the adjustment process until the clearance is
correct on both the intake and the exhaust valves.
Overhead Set (Outer Base Circle) Section 3 — Rocker Lever — Group 03
Injectors
Use a dial-type torque wrench to tighten the injector rocker
lever adjusting screw. If the screw chatters during setting,
repair the screw and lever as required.
Hold the torque wrench in a position that allows you to
look in a direct line at the dial. This is to be sure the dial
will be read accurately.
Be sure the parts are in alignment and squeeze the oil out
of the valve and injector train, while tightening the ad-
justing screw.
Loosen the adjusting screw at least 1 revolution.
Tighten the adjusting screw again.
The torque wrench must be calibrated, have a resolution
of 0.28 N•m [2.5 in-lb], and have a range of 17 to 23 N•m
[150 to 200 in-lb]. Do not use a clicker-type torque wrench.
Hold the adjusting screw in this position. The adjusting

screw must not turn when the lock nut is tightened.
Tighten the lock nut to the following values:
• With Torque Wrench Adapter, Part No. ST-689:
• Without Adapter:
Overhead Check (Outer Base Circle) (003-006)

Worksheet (003-006-056)
1. Engine firing order 1-5-3-6-2-4.
2. Cylinders are numbered from the front gear cover end of the engine.
3. Two crankshaft revolutions are required to adjust all of the valves and the injectors.
4. One pair of valves and one injector are adjusted at each pulley index mark before rotating the engine to the next
index mark.
5. The valves and the injectors on the same cylinder are not adjusted at the same mark.
6. Each cylinder has three rocker levers. The lever nearest to the front of the engine is the exhaust lever.
The following chart is useful for recording values.
Inspection Report for Valve Lash and Injector Travel

VS Mark Injector
and Crosshead Torque
Work Se- Valves to Reset (OK/ Cylinder Adjust-
quence Be Set Intake Exhaust (Y/N) Reset) No. ment Reset(Y/N)
A-5 4
B-3 1
C-6 5
A-2 3
B-4 6
C-1 2
Customer:
Location:
Unit No. Hours: Date:
Job No.:
Engine Model No.: Engine Serial No.:
Type of Inspection (Failure, Routine, Complaint):
Inspection Notes:
This page can be copied for your convenience.

Rocker Lever Assembly (003-009) Section 3 — Rocker Lever — Group 03
Rocker Lever Assembly (003-009)

Remove (003-009-002)
Remove the rocker lever covers. Refer to Procedure No.
003-011-002.
NOTE: Do not allow the rocker levers to fall off the shaft
during removal.
Remove the rocker lever assemblies.

Remove the capscrews and hardened washers. Pull the
shaft out of the rocker levers.
Clean and inspect the parts for damage.
Inspect the shaft for damage or roughness.

Section 3 — Rocker Lever — Group 03 Rocker Lever Assembly (003-009)
Inspect the socket for wear on both the injector and valve
sockets. Inspect the crosshead pad for wear.
Check the bushing wear. Measure the I.D. of the bushing.
Bushing Bore I.D.

mm in
47.66 MIN 1.876
47.73 MAX 1.879
Lubricate the shaft with engine oil.

NOTE: The oil drillings in the shaft must be in alignment with
the oil drillings in the levers.
Slide the levers on the shaft in the sequence shown.
1. Exhaust lever
2. Injector lever
3. Intake lever
Install the washers and capscrews.
Install (003-009-026)
NOTE: Be sure the ring dowel that aligns the rocker shaft is
installed in the housing.
NOTE: Be sure the adjusting screws are loose.
Position the rocker lever assembly on the housing. Install
the capscrews 2 or 3 revolutions.
Align the push rod sockets with the adjusting screws.
Rocker Lever Cover (003-011) Section 3 — Rocker Lever — Group 03

003-006-029.
Install the rocker lever covers and related parts. Refer to

Rocker Lever Cover (003-011)

Remove (003-011-002)
Remove the four mounting capscrews at the top of the air
crossover. Loosen the four capscrews at the bottom of the
air crossover until there is clearance between the washer
and the crossover.
Remove the air crossover hose clamps and slide the hose
down the turbocharger outlet. Remove the air crossover.
Caution: The rocker lever cover gasket has a thin, metal

core. Handle with care to avoid personal injury.
NOTE: Crankcase breathers can be mounted in any cylinder
location. Record the number of breathers and their correct
location, before mounting.
Remove the rocker lever cover and discard the gasket.
Section 3 — Rocker Lever — Group 03 Rocker Lever Cover (003-011)

Use a solvent that will not harm aluminum. Clean the
rocker lever cover.
Inspect the cover for cracks.
Install (003-011-026)
Caution: Do not use gasket cement. Gasket cement will
prevent the gasket from sealing properly.
Install each gasket, rocker lever cover, and capscrews.
Tighten all the capscrews.
Install the hose and the two clamps on the crossover.

Install the air crossover.
Slide the hose down over the turbocharger. Position the
clamps.
Install the gasket and capscrews.
Use the sequence illustrated. Tighten capscrews and

clamps.
Torque Value (Clamp): 8 N•m [75 in-lb]
Rocker Lever Housing (003-013) Section 3 — Rocker Lever — Group 03
Rocker Lever Housing (003-013)

Remove (003-013-002)
Drain the cooling system. Open the draincock and re-
move the lower radiator hose to drain the cooling system.
Use the water tube driver, Part No. ST-1319 (20). Use a
hammer. Drive the water tube towards the front of the
engine until the back part of the tube clears the rocker
lever housing as shown.
Remove the rocker lever covers. Refer to Procedure No.

003-011-002.
Remove the rocker lever assembly. Refer to Procedure

No. 003-009-002.
Section 3 — Rocker Lever — Group 03 Rocker Lever Housing (003-013)
Remove the valve push rods, injector push rod, and

crossheads.
Remove the seven mounting capscrews and the rocker

lever housing.
Caution: The rocker lever housing gasket has a thin,

metal core. Handle with care to avoid personal injury.
Use pliers. Remove and discard the gasket.

Remove the parts:
1. Water transfer tube
2. O-rings
Discard the o-rings.
Use steam or solvent. Clean the parts.
Inspect the parts for damage. If the ring dowel (4) is

damaged, it must be replaced. Use a blind hole puller
contained in light duty puller kit, Part No. 3375784, or
equivalent, to remove the dowel ring.
Use the dye penetrant method. Inspect the housing for
cracks. If the housing is cracked, it must be replaced.
Install (003-013-026)
Use vegetable oil. Lubricate the o-rings (2). Install the
o-rings.
Install the water transfer tube (1).
NOTE: The gasket and housing must be aligned correctly

with the dowel pins.
Install the gasket and the housing.
Install the seven capscrews.
Use the sequence shown to tighten the capscrews.

Section 3 — Rocker Lever — Group 03 Rocker Lever Housing (003-013)
NOTE: The push rods must be seated correctly in the cam

followers.
NOTE: The injector push rods are thicker in the middle. The
valve push rods are the same for both intake and exhaust.
Use engine oil. Lubricate the sockets in the cam followers.
Install the push rods.

003-009-026.
Install each gasket, rocker lever cover, and capscrews.

Use water tube driver, Part No. ST-1319, and a hammer.

Drive the water tube into the adjacent housing until the
water tube is approximately centered.

028.
Operate the engine to 70°C [160°F] minimum coolant
temperature and check for leaks.
Section 4 — Cam Follower — Group 04
Section 4 — Cam Follower — Group 04

Section Contents
Page
Cam Follower - Specifications (018-001-201) .................................................................................................... 4-2
Cam Follower Assembly (004-001) .................................................................................................................... 4-3
Install (004-001-026) ........................................................................................................................................ 4-5
Remove (004-001-002)..................................................................................................................................... 4-3
Cam Follower — General Information (003-999-999) ........................................................................................ 4-2
Push Rods (004-014).......................................................................................................................................... 4-7
Install (004-014-026) ........................................................................................................................................ 4-8
Remove (004-014-002)..................................................................................................................................... 4-7
Cam Follower — General Information (003-999-999) Section 4 — Cam Follower — Group 04
Cam Follower — General Information

(003-999-999)
Warning: The cam follower mounting capscrews are spe-
cial 12-point flange heads. Failure will result if standard
capscrews are used.
The QUANTUM System K19 utilizes a one-piece cam
follower cover with a FoametW gasket. FoametW is a
resilient foam on a steel carrier. Do not use sealant on this
type gasket. These gaskets must be installed dry.
QSK19 cam followers are not rebuildable in the field.

Liquid nitrogen is required to shrink the pin sufficiently to
slide through the bores in the lever.
Section 4 — Cam Follower — Group 04 Cam Follower - Specifications (018-001-201)
Cam Follower - Specifications (018-001-201)

Cam Follower Roller Clearance:
Side Clearance ............................................................................... 0.23 mm MIN [0.009 in]
0.64 mm MAX [0.025 in]
Pin Clearance .............................................................................. .0.076 mm MIN [0.0030 in]
0.112 mm MAX [0.0044 in]
Cam Follower Capscrew Mounting Torque:
Step 1 ................................................................................................... 55 N•m [40 ft-lb]
Step 2 ...................................................................................................110 N•m [80 ft-lb]
Step 3 ................................................................................................ .165 N•m [120 ft-lb]
Cam Follower Cover Capscrew: .......................................................................25 N•m [20 ft-lb]
Cam Follower Assembly (004-001) Section 4 — Cam Follower — Group 04
Cam Follower Assembly (004-001)

Remove (004-001-002)
003-011-002.

003-009-002.
NOTE: It is a good service practice to mark the push rods so

they can be installed in their original position.
Remove the push rods.
NOTE: Do not remove the cam follower cover until other

parts, such as the wiring harness, fuel tubing, and the crank-
case vent hose (21) are removed.Refer to Procedure No.
006-024-002.
Remove the cam follower cover. Remove and discard the
gasket.
Section 4 — Cam Follower — Group 04 Cam Follower Assembly (004-001)
Remove the cam follower assembly. Pull straight out until

the shaft is off the ring dowels.

Clean and inspect the cam follower assembly for reuse.
The shaft must rotate easily. If resistance is apparent,

disassemble and check for burrs on the shaft.
Inspect the cam follower for reuse. The cam follower lever
assembly must be replaced if damaged.
Cam Follower Assembly (004-001) Section 4 — Cam Follower — Group 04
The roller must rotate easily. Check the clearance of the

roller.
Cam Follower Roller Clearance

Reference mm in
Point
(1) 0.23 MIN 0.009
0.64 MAX 0.025
(2) 0.076 MIN 0.0030
0.112 MAX 0.0044
NOTE: If the clearances do not meet specifications, the cam
follower lever assembly must be replaced.
Install (004-001-026)
NOTE: Service replacement cam followers are coated with
a heavy preservative to prevent rust. This preservative must
be removed completely with solvent before the parts are
installed on the engine.
Caution: The cam follower mounting capscrews are spe-
cial. Shaft failure will result if standard capscrews are
used.
Use engine oil. Lubricate the camshaft and cam followers.
Install the cam follower assembly. The shaft must fit on
both ring dowels.
Install the capscrews.
Cam Follower Capscrew Mounting Torque

Step N•m ft-lb
Step 1 55 40
Step 2 110 80
Step 3 165 120
NOTE: A FoametW gasket must be used on the QSK19 cam

follower cover. FoametW is a resilient foam on a steel carrier.
Do not use sealant on this type of gasket. These gaskets
must be installed dry.
Install the gasket, cover, and capscrews. Tighten the
capscrews.
Section 4 — Cam Follower — Group 04 Cam Follower Assembly (004-001)

followers.

003-009-026.
Adjust the overhead (OBC). Refer to Procedure No.

003-006-029.
Install the rocker lever cover and all related parts. Refer
Push Rods (004-014) Section 4 — Cam Follower — Group 04
Push Rods (004-014)

Remove (004-014-002)
003-011-002.

003-009-002.
NOTE: It is a good service practice to mark the push rods so

they can be installed in their original position.
Remove the push rods.

Clean and inspect the push rods. Inspect to be sure the
rod is straight. View the rod while rolling it across a level
service.
Section 4 — Cam Follower — Group 04 Push Rods (004-014)
Inspect both ends of the push rods for wear or damage.

NOTE: The cam follower socket must be replaced if the push
rod is worn or damaged in the area where it contacts the
socket. Replace both the rocker lever adjusting screw and
the push rod if the socket surface in the rod or on the
adjusting screw is damaged.
NOTE: A loose socket end collar on a solid push rod is
acceptable for reuse as long as the collar is not in danger
of separating from the rod.
Install (004-014-026)
followers.

003-009-026.
Adjust the overhead (OBC). Refer to Procedure No.

003-006-029.
Push Rods (004-014) Section 4 — Cam Follower — Group 04
Install the rocker lever covers and all related parts. Refer
Section 5 — Fuel System — Group 05
Section 5 — Fuel System — Group 05

Section Contents
Page
Electronic Fuel Control Valve Assembly (005-053) ......................................................................................... 5-19
Install (005-053-026) ...................................................................................................................................... 5-21
Remove (005-053-002)................................................................................................................................... 5-19
Fuel Consumption (005-010) ............................................................................................................................ 5-10
Initial Check (005-010-001) ............................................................................................................................. 5-10
Test (005-010-012) .......................................................................................................................................... 5-10
Fuel Pump (005-016) ........................................................................................................................................ 5-11
Install (005-016-026) ...................................................................................................................................... 5-14
Pressure Test (005-016-013) ........................................................................................................................... 5-12
Prime (005-016-050) ...................................................................................................................................... 5-15
Remove (005-016-002) ................................................................................................................................... 5-11
Fuel Shutoff Valve (005-043)............................................................................................................................ 5-16
Install (005-043-026) ...................................................................................................................................... 5-18
Remove (005-043-002)................................................................................................................................... 5-16
Fuel System — General Information (005-999-999) .......................................................................................... 5-2
Fuel System Flow Diagrams (200-001-202) ....................................................................................................... 5-4
Fuel System — Service Tools (022-001-505)..................................................................................................... 5-5
Fuel System — Specifications (018-001-202).................................................................................................... 5-6
Installation Recommendations (005-999-248) ................................................................................................... 5-7
Fuel System — General Information (005-999-999) Section 5 — Fuel System — Group 05
Fuel System — General Information

(005-999-999)
The QUANTUMW fuel system is used on the QUANTUM
System K19 engine.
The QUANTUMW fuel system uses a PT type fuel pump

to supply a linear gear pump pressure from 60 psi at 600
RPM to 280 psi at 2100 RPM to the electronic fuel control
valve assembly.
The QUANTUMW fuel pump throttle shaft is locked in the

full closed position.
There is no mechanical throttle on the QUANTUMW fuel
pump.
The QUANTUMW fuel pump does not contain an AFC

valve. The pump only has an AFC cover plate.
Section 5 — Fuel System — Group 05 Fuel System — General Information (005-999-999)
The electronic fuel control valve assembly is located on

the fuel pump side of the engine.
The electronic fuel control valve assembly includes:
• timing and rail pressure sensors
• timing and rail actuators
• fuel shutoff valve
• ambient air pressure sensor
• fuel inlet and outlet connections
Fuel System Flow Diagrams (200-001-202) Section 5 — Fuel System — Group 05
Fuel System Flow Diagrams (200-001-202)

Section 5 — Fuel System — Group 05 Fuel System — Service Tools (022-001-505)
Fuel System — Service Tools (022-001-505)

Fitting
Connects gauges when measuring various fuel pressures.
ST-435-7
Gauge
Used to measure the fuel pump pressure from 0 to 2758 kPa [0
to 400 psi].
3375884
Fuel Pump/Air Compressor Wrench

Used to reach nuts when removing or installing the fuel pump or
air compressor.
3376845
Digital Multimeter
Check resistance of fuel shutoff solenoid.
3377161
Lubricant DS-ES
Dielectric lithium grease used to lubricate the pins in the elec-
trical connectors.
3822934
QD Contact Cleaner
A non-petroleum cleaner used to clean electrical connections.
3824510
Fuel System — Specifications (018-001-202) Section 5 — Fuel System — Group 05
Fuel System — Specifications (018-001-202)

Basic Application Requirements
Engine Idle Speed ........................................................................................................... 600 to 1400 RPM
Fuel Inlet Maximum Restriction:
Clean Fuel Filter .................................................................................................. 100 mm Hg [4.0 in-Hg]
Dirty Fuel Filter ................................................................................................... 203 mm Hg [8.0 in-Hg]
Fuel Drain Line Maximum Restriction:
Without Check Valves ............................................................................................ 229 mm Hg [9 in-Hg]
With Check Valves ............................................................................................... 330 mm Hg [13 in-Hg]
Fuel Check Valve Between Fuel Pump and Cylinder Head (Integral to Fuel Pump):
Opening Pressure .............................................................................................. 21 to 35 kPa [3 to 5 psi]
Engine Minimum Cranking Speed ................................................................................................ 150 RPM
Fuel Check Valve in Fuel Drain Line:
Opening Pressure .................................................................................. 13 to 25 mm Hg [1/4 to 1/2 psi]
Derate Engine Fuel Rate for High Altitude ...................... 4% per 300 M [1000 ft] above 3600 m [12,000 ft]
Derate Engine Fuel Rate for Hot Weather ................. 2% per 11°C Above 38°C [1% per 10° above 100°F]
Shutoff Valve Solenoid Coil Resistance in Ohms 24VDC ................................................................. 28 - 32
Engine Minimum Cranking Speed ................................................................................................ 150 RPM
Fuel Pump Cranking Pressure — Minimum: .................................................... 172 kp [25 psi] @ 150 RPM
Fuel Pump Pressure — Minimum:
1500 RPM: ................................................................................................................... 1448 kp [210 psi]
1800 RPM: .................................................................................................................. 1655 kp [240 psi]
2100 RPM: ................................................................................................................... 1861 kp [270 psi]
2350 RPM: .................................................................................................................. 1999 kp [290 psi]
Section 5 — Fuel System — Group 05 Fuel System — Specifications (018-001-202)
Installation Recommendations (005-999-248)

Installation Publications
Publications are available to provide fuel system instal-
lation recommendations approved by Cummins Engine
Company, Inc.
• Parts and Service Publications can be purchased
from:
Literature Control Service
10003 Bunsen Way
P. O. Box 99085
Louisville, KY 40299
• Contact the nearest Cummins authorized repair lo-
cation for engine fuel system specifications and re-
quirements provided on the ‘‘Engine Data Sheet’’
for your specific engine and application.
Overhead Tank Installation Requirements

Warning: If a fuel line shutoff valve is not installed, the
overhead tank can drain when the fuel filter is changed,
causing an extreme fire hazard.
Cummins Engine Company, Inc. recommends a ball-type
valve and not a gate-type valve.
Install a fuel shutoff valve between the filter and the fuel
tank.
Install a check valve in the fuel drain line when the maxi-
mum fuel level in the fuel tank is even or above the fuel
drain that is in the cylinder head. Install the valve with the
fuel flow arrow toward the fuel tank.
Fuel System — Specifications (018-001-202) Section 5 — Fuel System — Group 05
The QUANTUMW fuel pump contains an integral check

valve in the fuel pump outlet. An additional check valve
is not required when the maximum fuel level is above the
injector drain, or when the fuel filters are lower than the
fuel tank.
Section 5 — Fuel System — Group 05 Fuel System — Specifications (018-001-202)
Fuel Oil Recommendations

Cummins diesel engines have been developed to take advantage of the high energy content and generally lower
cost of No. 2 diesel fuels. A Cummins diesel engine will also operate satisfactorily on No. 1 fuels or other fuels
within the following specifications.
Fuel Oil Recommended Properties:
Viscosity 1.3 to 5.8 CentiStoke (1.3 to 5.8 mm2 per second) at 40°C [104°F].
(ASTM D-445)
Cetane Number 40 minimum except in cold weather or in service with prolonged low loads,
(ASTM D-613) a higher cetane number is desirable.
Sulfur content Not to exceed 0.5 mass percent.

(ASTM D-129 or 1552)
Water and Sediment Not to exceed 0.5 volume percent.

(ASTM D-1796)
Carbon Residue Not to exceed 0.25% by weight on 10% residue.

(Ransbottom ASTM D-524
or D-189)
Flash Point 52°C [125°F] minimum. Certain marine registries requires higher flash points.
(ASTM D-93)
Density -1 to 6°C [30 to 42°F] A.P.I. at 16°C [60°F] (0.816 to 0.876 Sp. Gr.)
(ASTM D-287)
Cloud Point 5.6°C [10°F] below lowest temperature expected to operate.

(ASTM D-97)
Active Sulfur-Copper Not to exceed No. 2 rating after 3 hours at 50°C [122°F].
Strip-Corrosion
(ASTM D-130)
Ash Not to exceed 0.02% by weight.

(ASTM D-482)
Distillation The distillation curve should be smooth and continuous. At least 90% of
(ASTM D-86) the fuel should evaporate at less than 360°C [680°F]. All of the fuel should
evaporate at less than 385°C [725°F].
Fuel Consumption (005-010) Section 5 — Fuel System — Group 05
Fuel Consumption (005-010)

Refer to the fuel consumption check lists sheets in the
back of this section.
The most accurate method to check the fuel consumption
is to weigh the fuel used.
Install a remote fuel tank (1) with enough capacity to run

80 kilometers [50 miles] or 1 hour.
Fill the fuel tank. Weigh the tank with the fuel. The weight
of No. 2 diesel fuel is nominally 0.844 kg per liter [7.03
pounds per gallon].
NOTE: Use a scale capable of measuring within 0.045 kg
[0.1 lb] to weigh the fuel tank.
Test (005-010-012)
Off-Highway↔
Measure the time with a stopwatch.
After one hour of operation, weigh the fuel remaining, and

compute the fuel used in liters [gallons] as required.
Compute the fuel consumption. Fuel used divided by the
time equals the fuel consumption rate.
Section 5 — Fuel System — Group 05 Fuel Pump (005-016)
Fuel Pump (005-016)

Remove (005-016-002)
Warning: Always disconnect the negative (-) cable first
to prevent arcing.
Disconnect the battery cables.
Warning: Fuel is flammable. Do not allow cigarettes,

flames, sparks, arching switches or equipment, pilot
lights, or other ignition sources near the fuel system.
Clean the fuel pump and the surrounding area.
Disconnect the fuel inlet hose (1). Disconnect the elec-

tronic fuel control valve supply hose (2).
Remove the four mounting capscrews, and the fuel pump.

Remove the jaw coupling spider (23). Remove and dis-
card the gasket.
Fuel Pump (005-016) Section 5 — Fuel System — Group 05

Clean the fuel pump, and the air compressor or acces-
sory drive mounting surfaces.
Inspect the mounting surfaces for damage.
Visually inspect the spider coupling for damage.

Engine Cranking↔
Use a quick disconnect fitting, Part No. ST-437-7, and a
0-205 kPa [0-400 psi] pressure gauge, Part No. 3375884,
or equivalent.
Connect the gauge to the quick disconnect fitting at the
fuel pump.
Crank the engine and measure the fuel pressure.

Minimum Cranking Speed: 150 RPM
Minimum Fuel Pressure @ 150 RPM: 172 kp [25 psi]
Engine Operating↔
Use a quick disconnect fitting, Part No. ST-435-7, and a
0-2758 kPa [0-400 psi] pressure gauge, Part No. 3375884,
or equivalent.
Start the engine and operate at high idle speed.
Minimum Fuel Pressure

Engine High Idle kPa psi
Speed
1500 RPM 1450 210
1800 RPM 1650 240
2100 RPM 1860 270
2350 RPM 2000 290
NOTE: Fuel pressure will not change significantly with en-

gine load.
If the fuel pump pressure is not within specifications,

check the fuel pump on a fuel pump test stand.
If the fuel pump pressure is within specifications when

checked on a fuel pump test stand, then check the in-
jector o-rings for damage. Refer to Procedure No.
006-026-007.
Fuel Pump (005-016) Section 5 — Fuel System — Group 05
Install (005-016-026)
All QSK19 engines use a white nylon or light green fuel
pump drive coupling.
Install the fuel pump drive coupling (23), gasket, fuel
pump, and four capscrews. Tighten the capscrews.
Check for the proper installation of the o-rings in both

locations.
Install the fuel pump inlet hose and the fuel supply hose.
Tighten the hose (1).
Tighten the hose (2).
Warning: Always connect the negative cable last to pre-

vent arcing.
Connect the battery cables.
Operate the engine to normal operating temperature and

check for leaks.
Prime (005-016-050)
NOTE: This procedure is normally only required when the
fuel pump has been changed, the fuel filters are dry, or the
fuel system has been drained.
To reduce engine cranking time, depress the quick dis-
connect fitting at the fuel pump outlet until fuel is present
while cranking the engine.

flames, sparks, arcing switches or equipment, pilot lights
or other ignition sources near the fuel system.
Prime the fuel supply pump to reduce engine cranking
time.
NOTE: If the fuel supply pump is dirty, clean the outside of
the pump near the fuel inlet and outlet.
Loosen the fuel line at the top of the fuel pump while the
engine is cranking. If no fuel comes out of the connection,
the pump must be primed.
Remove the fuel inlet hose. Fill the gear pump with clean
engine oil.
Fuel Shutoff Valve (005-043) Section 5 — Fuel System — Group 05
Install the fuel inlet hose to the gear pump.

Fuel Shutoff Valve (005-043)

Remove (005-043-002)
Remove the Electric Control Module (ECM). Refer to Pro-
cedure No. 019-031-002.
Clean the fuel shutoff valve and surrounding area.
Use a [3/8-inch] wrench. Remove the nut holding the

electrical connection of the fuel shutoff valve coil. Re-
move the connection.
Section 5 — Fuel System — Group 05 Fuel Shutoff Valve (005-043)
Remove the four capscrews. Remove the coil housing

and the fuel shield. Discard the o-ring.
Remove the spring washer, valve disc, actuator disc, and
actuator spacer from the valve housing. Discard the o-ring.

Use mineral spirits. Clean all of the parts except the coil
assembly.
NOTE: Do not get solvent on the coil. Clean the coil with a
dry cloth. Use a 200 grit emery cloth and a flat surface to
polish the coil surface.
Visually check the valve disc, valve seat, and actuator
disc for dirt, metal parts, bonding separation, corrosion,
cracks, or wear. Replace if necessary.
Use a wire brush to clean any corrosion from the coil

terminal.
Check the coil assembly with an ohm meter. Replace the

coil if it is not between 28 and 32 ohms resistance.
NOTE: If the coil assembly shows 0 ohms, there is an elec-
trical short in the coil.
Fuel Shutoff Valve (005-043) Section 5 — Fuel System — Group 05
Tighten the nut that holds the electrical connection post

on the fuel shutoff valve coil.
Install (005-043-026)
Assemble the shutoff valve as shown. Install these parts
as follows.
Install a new o-ring (6) between the spacer (7) and the
electronic control valve body (8).
Install the spacer (7) o-ring groove toward the coil. Install
the actuator disc (5) with the cup side toward the coil.
Install the spring washer (3) with the cup side toward the
coil.
Align the actuator disc (5), spacer (7), and valve disc (4)
on the electronic control valve body (8). Install a new
o-ring (6).
Put the spring washer (3) on the valve disc (4), with the
cavity side positioned upward, in a position around the
valve locator.
NOTE: The coil must be orientated with the electrical con-
nection post on the bottom.
Install the fuel shield (2) and coil (1) on the front cover (8).
Install a new o-ring and tighten the capscrews.
Install the electrical connection of the fuel shutoff valve.

Install the nut on the threaded post of the coil.
Use two [3/8-inch] wrenches. Hold the post of the nut
firmly while tightening the connection nut.
Section 5 — Fuel System — Group 05 Electronic Fuel Control Valve Assembly (005-053)
Install the ECM. Refer to Procedure No. 019-031-026.
Electronic Fuel Control Valve Assem-

bly (005-053)
Remove (005-053-002)
Loosen the two hose clamps. Remove the crankcase vent
hose.
Remove the ECM. Refer to Procedure No. 019-031-002.
Clean the control valve body and the surrounding area.

Electronic Fuel Control Valve Assembly (005-053) Section 5 — Fuel System — Group 05
Disconnect the fuel supply hose (1), timing pressure line

(2), and rail pressure line (3), at the control valve body.
NOTE: It is a good service practice to label parts during

removal. Identification of the connections at time of removal
with a label will aid the installation process.
Label the electrical connections to the actuators, fuel
pressure sensors, and ambient air pressure sensor.
Disconnect the actuators and pressure sensor

connections.
Use a [3/8-inch] wrench. Remove the nut holding the

electrical connection of the fuel shutoff valve coil. Re-
move the connection.
Remove the four capscrews. Move the wire harness and

brackets away from the control valve body to gain access.
Remove the control valve body assembly.
Install (005-053-026)
Install the four capscrews to secure the control valve body
assembly and the wire harness and brackets.
Tighten the nut that holds the electrical connection post

on the fuel shutoff valve coil.
Install the electrical connection on the fuel shutoff valve.

Install the nut on the threaded post of the coil.
Use two [3/8-inch] wrenches. Hold the post of the nut
firmly while tightening the connection nut.
Inspect the actuator and pressure sensor connections for

dirt and debris.
Use dielectric lithium grease, Part No. 3822934, and QDW
contact cleaner, Part No. 3824510. Clean and lubricate
the connections and actuator if cleaning is required.
NOTE: If the electrical connections were not labeled for

identification purposes during disassembly, verify the types
of connections on the wiring diagram.
Connect the actuator and pressure sensor connections.
Connect the fuel supply hose (1), the timing rail pressure
line (2), and the metering rail pressure lines (3) to the
control valve body.
Tighten the fuel supply hose (1).
Tighten the timing pressure (2) and rail pressure lines (3).
Install the ECM. Refer to Procedure No. 019-031-026.

Install the crankcase vent hose. Tighten the hose clamps.

NOTES
Section 6 — Injectors and Fuel Lines — Group 06
Section 6 — Injectors and Fuel Lines — Group 06

Section Contents
Page
Air-In-Fuel (006-003) .......................................................................................................................................... 6-9
General Information (006-003-999)................................................................................................................... 6-9
Test (006-003-012) ........................................................................................................................................... 6-9
Fuel Drain Line Restriction (006-012) .............................................................................................................. 6-11
Measure (006-012-010) ................................................................................................................................... 6-11
Fuel Drain Lines (006-013)............................................................................................................................... 6-12
Install (006-013-026) ...................................................................................................................................... 6-14
Remove (006-013-002) ................................................................................................................................... 6-12
Fuel Filter (006-015) ......................................................................................................................................... 6-14
Install (006-015-026) ...................................................................................................................................... 6-15
Remove (006-015-002) ................................................................................................................................... 6-14
Fuel Inlet Restriction (006-020) ....................................................................................................................... 6-15
Measure (006-020-010) .................................................................................................................................. 6-15
Fuel Manifold (006-022) ................................................................................................................................... 6-16
Install (006-022-026) ...................................................................................................................................... 6-19
Remove (006-022-002)................................................................................................................................... 6-16
Fuel Supply Lines (006-024) ............................................................................................................................ 6-21
Install (006-024-026) ...................................................................................................................................... 6-24
Remove (006-024-002) ................................................................................................................................... 6-21
Injector and Fuel Lines — QUANTUMW Injector............................................................................................... 6-5
Injectors (006-026) ........................................................................................................................................... 6-26
Calibrate (006-026-030).................................................................................................................................. 6-26
Install (006-026-026) ...................................................................................................................................... 6-29
Remove (006-026-002)................................................................................................................................... 6-26
Injectors and Fuel Lines (006-999).................................................................................................................... 6-2
General Information (006-999-999)................................................................................................................... 6-2
Injectors and Fuel Lines — Flow Diagram (200-001-202) ................................................................................. 6-4
Injectors and Fuel Lines — Required Service Tools (022-001-505).................................................................. 6-7
Injectors and Fuel Lines — Specifications (018-001-202)................................................................................. 6-6
Injectors and Fuel Lines (006-999) Section 6 — Injectors and Fuel Lines — Group 06
Page 6-2 QSK19
Injectors and Fuel Lines (006-999)

The QUANTUMW System K19 (QSK19) uses a QUAN-
TUMW fuel system that requires a split fuel manifold and
three fuel circuits. The three circuits are rail (1), timing (2),
and drain (3).
Fuel is delivered to the fuel blocks (4) at the front and rear
of the engine from the electronic control valve assembly.
The QSK19 uses flat o-ring fittings, except the fuel filter
inlet and the fuel drain connection that are 37 degree flare
fittings.
1. Tube nut
2. Tube flare (flat)
3. O-ring
4. Fitting
Hold the o-rings in position during assembly using Lubri-

plateW 105, or equivalent.
Section 6 — Injectors and Fuel Lines — Group 06 Injectors and Fuel Lines (006-999)
QSK19 Page 6-3

flames, sparks, arcing switches or equipment, pilot lights,
Caution: If LubriplateW is not used, the o-ring can fall
out or get pinched during assembly and cause a fuel
leak.
Injectors and Fuel Lines — Flow Diagram (200-001-202) Section 6 — Injectors and Fuel Lines — Group 06
Page 6-4 QSK19
Injectors and Fuel Lines — Flow Diagram (200-001-202)

Section 6 — Injectors and Fuel Lines — Group 06 Injector and Fuel Lines — QUANTUMW Injector
QSK19 Page 6-5
Injector and Fuel Lines — QUANTUMW Injector

Injectors and Fuel Lines — Specifications (018-001-202) Section 6 — Injectors and Fuel Lines — Group 06
Page 6-6 QSK19
Injectors and Fuel Lines — Specifications (018-001-202)

Fuel Drain Line (Engine-to-Fuel Tank): ................................................................................... 75 N•m [55-ft-lb]
Fuel Drain Lines: (Tubes): ...................................................................................................... 47 N•m [35 ft-lb]
Fuel Drain Restriction (Maximum) at High Idle:
• Without Check Valve: ............................................................................................. 330 mm-Hg [13 in-Hg]
• With Check Valve: ................................................................................................... 229 mm-Hg [ 9 in-Hg]
Fuel Inlet Restriction (Maximum):
• With Clean Fuel Filters: ............................................................................................. 102 mm-Hg [4 in-Hg]
• With Dirty Fuel Filters: .............................................................................................. 203 mm-Hg [8 in-Hg]
Fuel Manifold End Plugs:
• Size [1/2-Inch]: ........................................................................................................... 20.5 N•m [180 in-lb]
• Size [3/8-Inch]: .............................................................................................................. 7.0 N•m [ 60 in-lb]
Fuel Connection Block: ...................................................................................................... 10.2 N•m [90 in-lb]
Fuel Manifold Capscrews-To- Cylinder Head: ......................................................................... 10 N•m [85 in-lb]
Injector Hold-Down Capscrews: ............................................................................................. 54 N•m [40 ft-lb]
Fuel Tube Clamps: ................................................................................................................. 27 N•m [20 ft-lb]
Fuel Inlet Line (To Fuel Pump): .............................................................................................. 88 N•m [65 ft-lb]
Fuel Inlet Line (Fuel Tank-to-Fuel Filter]: ............................................................................... 115 N•m [85 ft-lb]
Fuel Rail Supply Lines (Tubes): .............................................................................................. 27 N•m [20 ft-lb]
Fuel Control Supply Line (Fuel Pump-To-Control Valve Body): ................................................ 61 N•m [45 ft-lb]
Fuel Timing Supply Line: ....................................................................................................... 27 N•m [20 ft-lb]
Section 6 — Injectors and Fuel Lines — Group 06 Air-In-Fuel (006-003)
QSK19 Page 6-9
Air-In-Fuel (006-003)
flames, sparks, arcing switches or equipment, pilot lights
There are two good methods to check for air in the fuel.
• Sight Glass Method
• Gear Pump Drain Method
Test (006-003-012)
Sight Glass Method
Remove the fuel inlet line.
Install a sight glass in the line.
Operate the engine at high idle with no load.
NOTE: A small air leak will have a "milky" appearance.
NOTE: A large air leak will look like bubbles in the fuel.
If an air leak is found, perform the following.

• Tighten the hose connections and the fuel filter.
• Check the drop tube in the fuel tank for damage.
• Check o-rings for damage.
Continue to test until no air bubbles are visible.

Remove the sight glass.
Tighten the fuel inlet hose.
Air-In-Fuel (006-003) Section 6 — Injectors and Fuel Lines — Group 06
Page 6-10 QSK19
Gear Pump Drain Method

To perform a pressure side air in fuel test, use the fol-
lowing items.
• Quick Disconnect Fitting, Part No. 3376859
• High Pressure Hose
• Pressure Valve (Capable of 2758 kPa [400 psi])
• Clean Tubing
• Clean Container
Connect the equipment to the quick-connect fitting at the

fuel pump outlet.
Put the end of the clear hose in the clean container.
Operate the engine at high idle with no load. Slowly open

the valve until a steady stream of fuel is visible.
Put the end of the hose below the surface of the fuel.
If there is an air leak, bubbles will be visible.
Section 6 — Injectors and Fuel Lines — Group 06 Fuel Drain Line Restriction (006-012)
QSK19 Page 6-11
If an air leak is found, perform the following.

• Tighten the hose connections on the fuel filter.
• Check the drop tube in the fuel tank for damage.
• Check the o-rings for damage.
Continue to test and look for air leaks until there are no
bubbles visible.
Remove the test equipment.
Fuel Drain Line Restriction (006-012)

Measure (006-012-010)
Remove the fuel drain line. Install the pressure gauge,
Part No. ST-1273-1, or equivalent, and adapter, Part No.
???????.
If the engine has a drain side check valve, install the

adapter between the fuel drain line and the check valve.
Fuel Drain Lines (006-013) Section 6 — Injectors and Fuel Lines — Group 06
Page 6-12 QSK19
Start and operate the engine at high idle, no load.
Maximum Drain Line Restriction

mm-Hg in-Hg
Without Check Valve 330 13
With Check Valve 228 9
If the fuel drain line restriction is above specifications,

inspect the fuel drain line. Refer to Procedure No.
006-011-007.
Remove the gauge. Install the fuel drain line.

Tighten the fuel line.
Fuel Drain Lines (006-013)

Remove (006-013-002)
Engine-To-Fuel Tank
Remove the fuel drain hose from the engine.
Section 6 — Injectors and Fuel Lines — Group 06 Fuel Drain Lines (006-013)
QSK19 Page 6-13
Fuel Drain Line

NOTE: The procedure for the fuel drain line is the same as
the rail and timing lines. Refer to Procedure No. 006-046-002.

Engine-To-Fuel Tank
Visually inspect the inside of the hose.
• The inner lining of the hose can separate from the
center hose section.
• A separation of flap can cause a restriction in the
fuel flow.
Visually inspect for any pinches in the hose that would
obstruct the flow.
Be sure the hose does not have pinches or loops that

would obstruct the flow.
Fuel Drain Line

The procedure for Inspect for Reuse is the same as the
rail and timing lines. Refer to Procedure No. 006-046-007.
Fuel Filter (006-015) Section 6 — Injectors and Fuel Lines — Group 06
Page 6-14 QSK19
Install (006-013-026)
Engine-To-Fuel Tank
Install and tighten the drain hose.
Fuel Drain Line

The procedure for installation of the fuel drain line is the
same as the rail and timing lines except for the torque
value. Refer to Procedure No. 006-046-026.
Fuel Filter (006-015)

Remove (006-015-002)
flames, sparks, arcing switches or equipment, pilot lights,
Close the fuel line shutoff valve before changing the fuel
filters or the overhead tank can drain causing a fuel leak.
Remove the fuel filter with filter wrench, Part No. 3376807.
Remove the thread adapter sealing ring (1).

Use a clean, lint-free towel to clean the surface of the filter
head gasket.
Section 6 — Injectors and Fuel Lines — Group 06 Fuel Inlet Restriction (006-020)
QSK19 Page 6-15
Install (006-015-026)
Install a new thread adapter sealing ring supplied with the
new filter.
A fuel-water separator or fuel filter, and water separator
combination must be installed.
Apply a light coating of clean engine oil to the surface of
the filter gasket.
Fill the filter with clean fuel.
Install the filter on the filter head. Turn the filter until the
gasket touches the surface of the filter head.
Tighten the filter an additional 1/2 to 3/4 of a turn after the
gasket touches the filter head surface.
Open the fuel line shutoff valve and check for leaks.
Fuel Inlet Restriction (006-020)

Measure (006-020-010)
Use a quick-connect fitting, Part No. 3376859, and a
vacuum gauge, Part No. ST-434-12, or equivalent. Con-
nect the gauge to the quick-connect fitting on the fuel
pump inlet fitting.
Start and operate the engine at high idle, no load.
Maximum Fuel Inlet Restriction

mm-Hg in-Hg
With Clean Filters 102 4
With Dirty Filters 203 8
Fuel Manifold (006-022) Section 6 — Injectors and Fuel Lines — Group 06
Page 6-16 QSK19
If the restriction is above specifications,

• change the fuel filters. Refer to Procedure No. 006-
015.
• inspect the fuel lines. Refer to Procedure No.
006-019-007.
Fuel Manifold (006-022)

Remove (006-022-002)
Remove the engine wiring harness and brackets. Refer to
On engines equipped with an air compressor, remove the

air inlet connection hose and gasket. Discard the gasket.
Remove the fuel supply tubes. Refer to Procedure No.

006-024-002.
Section 6 — Injectors and Fuel Lines — Group 06 Fuel Manifold (006-022)
QSK19 Page 6-17
Drain the cooling system. Refer to Procedure No.

008-018-005.
Remove the aftercooler assembly. Refer to Procedure

No. 010-002-002.
Remove the 12 capscrews. Remove the front fuel mani-

fold. Discard the o-rings.
Repeat this process for the removal of the rear fuel
manifold.

Remove the four fuel connection block capscrews. Re-
move the fuel connection block. Discard the o-rings.
Page 6-18 QSK19
NOTE: The illustration shows the fuel manifold turned up-

side down. The small hole is on the bottom of the fuel
manifold.
Remove the six plugs at the ends of the manifold. Discard
the o-ring if damaged or enlarged.
Use solvent. Clean the manifold. Use compressed air to

clean all of the drillings.
Be sure all the drillings are clean and open.
Check the manifold for cracks in the fuel passages.

The manifold must be replaced if damaged.
Use clean, engine oil. Lubricate the o-rings.

Install the plugs. Apply torque to the plugs.
Torque Value (1): 20 N•m [180 in-lb]
Torque Value (2): 7 N•m [60 in-lb]
Section 6 — Injectors and Fuel Lines — Group 06 Fuel Manifold (006-022)
QSK19 Page 6-19
Use LubriplateW to secure the o-rings in position.

Install the fuel connection block and the three new o-rings.
Install (006-022-026)
Use LubriplateW 105, or equivalent, to position and se-
cure the o-rings. Install the o-rings.
Install the front fuel manifold. Use the sequence illus-

trated to tighten the 12 capscrews.
Repeat this process for the installation of the rear fuel
manifold.
Install the aftercooler assembly. Refer to Procedure No.

010-002-026.
Page 6-20 QSK19
Install the fuel supply tubes. Refer to Procedure No.

006-024-026.
On engines equipped with an air compressor, install the

air inlet connection, connection hose, and new gasket.
Fill the cooling system. Refer to Procedure No.

008-018-028.
Install the engine wiring harness and brackets. Refer to

Section 6 — Injectors and Fuel Lines — Group 06 Fuel Supply Lines (006-024)
QSK19 Page 6-21
Fuel Supply Lines (006-024)

Remove (006-024-002)
Fuel Tank-To-Fuel Filter
Remove the fuel inlet line.
Fuel Rail Supply Line

Fuel Timing Supply Line
Remove as much of the engine wire harness and brackets
as necessary to gain access to the fuel tubes. Refer to
On engines with an air compressor, remove the air inlet

connection. Discard the connection hose and the gasket.
Remove the fuel tube clamps.
NOTE: Use two wrenches to remove the fuel tubes and

hoses.
Support the mating fittings with a wrench. Loosen the fuel
tube nuts with the other wrench.
Remove the fuel tubes and hoses.
Fuel Supply Lines (006-024) Section 6 — Injectors and Fuel Lines — Group 06
Page 6-22 QSK19
Fuel Control Supply Line

Remove the fuel control supply hose. Discard the o-ring.
Fuel Inlet Line

Remove the hose between the fuel filter head outlet and
the fuel pump inlet fitting. Discard the o-rings.

fuel flow.
Visually inspect for any pinches in the hose that would
obstruct the flow.
Be sure the hose does not have pinches or loops that
would obstruct the flow.

Fuel Timing and Supply Line
Use compressed air. Flush the lines and remove any
loose dirt particles.
QSK19 Page 6-23
Visually inspect the fuel line for cracks that can cause a
loss of pressure.
Visually inspect the fuel line for sharp bends that can
cause a restriction in pressure.
Fuel Control Supply Line

Visually inspect the hose for pinched areas that prevent
the proper flow, or frayed mesh. The hose must be re-
placed if damaged.
Use compressed air. Flush the lines and remove any

loose dirt particles.
Fuel Inlet Line

fuel flow.
Visually inspect for bends in the line that can restrict the
fuel flow.
Fuel Supply Lines (006-024) Section 6 — Injectors and Fuel Lines — Group 06
Page 6-24 QSK19
Install (006-024-026)
Install and tighten the fuel inlet line.

Fuel Timing Supply Line
Loosely assemble the fuel tubes and clamps.
NOTE: It is a good service practice to use two wrenches

when tightening the fuel fittings.
Support the fitting. Use a crowfoot wrench and a torque
wrench. Tighten the fuel tube nut.
Tighten the fuel tube clamps.

QSK19 Page 6-25
On engines equipped with an air compressor, install the

air compressor air inlet connection with a new hose and
gasket.
Torque Value (Flange Capscrew): 4 N•m [35 in-lb]
Install the engine harness and the brackets. Refer to

Fuel Control Supply Lines

Install new o-rings. Be sure the o-ring is installed properly.
Install and tighten the fuel control valve supply hose.

Injectors (006-026) Section 6 — Injectors and Fuel Lines — Group 06
Page 6-26 QSK19
Fuel Inlet Line

Install a new o-ring. Check for proper o-ring installation.
Install the hose at the fuel pump inlet and fuel filter head
outlet fitting. Tighten the hose.
Injectors (006-026)
Calibrate (006-026-030)
Refer to the QSK19 Operation and Maintenance Manual
for the injector calibration interval.
NOTE: This procedure requires special equipment and must
be done at a Cummins Authorized Repair Location.
Remove (006-026-002)
003-011-002.
Section 6 — Injectors and Fuel Lines — Group 06 Injectors (006-026)
QSK19 Page 6-27
Remove the rocker lever assembly. Refer to Procedure

No. 003-009-002.
NOTE: The hold-down clamp can not be removed until the

injector is removed.
Remove the injector hold-down capscrew. Remove the
injector and clamp.
Use injector puller, Part No. 3823579, to remove HPIW
injectors. Insert the pin of the tool in the hole provided in
the body of the injector. The hole faces the front of the
engine.
If the injector puller mentioned above is not available,
carefully use a pry bar. Pry upward on the injector against
the cylinder head.

Remove the sealing ring (1) and note the cylinder loca-
tion.
NOTE: Sealing rings are available in different thickness
sizes to adjust the injector protrusion.
Remove the o-rings (2, 3, 4, and 5).

Use a lint free cloth. Clean the exterior of the injector.
Carefully check the area where the sealing ring touches
the injector.
NOTE: The four new o-rings must be installed and oriented
correctly on the injector. Identify the o-rings to install them
in the correct grooves.
Page 6-28 QSK19
O-ring (2) is brown and is smaller in diameter than the

other three.
O-ring (3) is black.
O-ring (4) is brown and is larger in diameter than (2), but
has a smaller cross section than the o-ring (5).
O-ring (5) is brown and is the largest in diameter and cross
section.
NOTE: Do not lubricate the o-rings until the injector is ready

for installation in the cylinder head.
Install four new o-rings on the injector. Do not twist the
o-rings.
Install the proper size sealing ring (1).
Filter Screen↔
NOTE: Use solvent when cleaning the filters. The screens
must be thoroughly dry before installation.
Check the rail (6) and timing (7) filter screens for debris,
tears, or punctures. Replace the filter screens if damaged
or dirty.
Check the rail (6) and timing (7) filter for proper installa-
tion.
Screens must be securely snapped into correct position.
QSK19 Page 6-29
Use a small screwdriver. Remove the filter screen. Gently

pry up on the connector clip.
Wrap the filter screen around the inlet groove.
Apply pressure on the filter screen connector clip. A prop-

erly secured connector will create a single, snapping
sound.
Install (006-026-026)
Use clean, 15W-40 oil. Lubricate the o-rings.
Page 6-30 QSK19
Install the hold-down clamp on the side of the injector.
Install the injector and hold-down clamp in the cylinder

head.
Use injector installation tool, Part No. 3824830, to set the
injector in the bore.
The slide hammer will make a dull sound when the in-
jector is seated properly.
NOTE: If the injector installation tool, Part No. 3824830, is
not available, use a 40 mm [1 9/16-inch] socket with an
extension and a rubber mallet to install the injector.
Use clean, engine oil. Lubricate the injector hold-down

capscrew.
Install the injector hold-down capscrew.
Install the rocker lever assembly. Refer to Procedure No.

003-009-026.
QSK19 Page 6-31

003-006-029.
Install the rocker lever cover. Refer to Procedure No.

003-011-026.
Page 6-32 QSK19
NOTES
Section 7 — Lubricating Oil System — Group 07

Section Contents
Page
Cylinder Smokes (Blue Smoke) (007-050) ....................................................................................................... 7-47
Fluorescent Dye Tracer (007-050-054) ............................................................................................................ 7-47
Lubricating Oil Contamination......................................................................................................................... 7-38
Fluorescent Dye Tracer Test (007-044-054) ..................................................................................................... 7-39
Oil Diluted with Fuel .................................................................................................................................. 7-39
Pressure Test (007-044-013) ........................................................................................................................... 7-39
Oil Diluted with Coolant............................................................................................................................. 7-39
Lubricating Oil Cooler (007-003)........................................................................................................................ 7-9
Pressure Differential Test (007-003-063) ........................................................................................................... 7-9
Lubricating Oil Cooler Cover (007-045)............................................................................................................ 7-41
Install (007-045-026)....................................................................................................................................... 7-43
Remove (007-045-002) ................................................................................................................................... 7-41
Lubricating Oil Cooler Element........................................................................................................................ 7-10
Install (007-007-026) ....................................................................................................................................... 7-11
Pressure Test (007-007-013) ........................................................................................................................... 7-10
Remove (007-007-002).................................................................................................................................... 7-10
Lubricating Oil Cooler Housing ....................................................................................................................... 7-45
Install (007-046-026)....................................................................................................................................... 7-46
Remove (007-046-002) ................................................................................................................................... 7-45
Lubricating Oil Dipstick (007-009).................................................................................................................... 7-11
Calibrate (007-009-030) .................................................................................................................................. 7-11
Lubricating Oil Dipstick Tube (007-011) ........................................................................................................... 7-12
Install (007-011-026) ....................................................................................................................................... 7-12
Remove (007-011-002).................................................................................................................................... 7-12
Lubricating Oil Filter (007-013) ........................................................................................................................ 7-13
Inspect (007-013-062)..................................................................................................................................... 7-13
Pressure Differential Test (007-013-063) ......................................................................................................... 7-15
Remove (007-013-002) ................................................................................................................................... 7-13
Lubricating Oil Filter Head (007-015)............................................................................................................... 7-16
Install (007-015-026)....................................................................................................................................... 7-17
Remove (007-015-002) ................................................................................................................................... 7-16
Lubricating Oil Filter Head Adapter (007-018) ................................................................................................. 7-17
Install (007-018-026)....................................................................................................................................... 7-18
Remove (007-018-002) ................................................................................................................................... 7-17
Lubricating Oil Leaks (007-024) ....................................................................................................................... 7-18
Fluorescent Dye Tracer (007-024-054) ............................................................................................................ 7-19
Inspect (007-024-062) .................................................................................................................................... 7-18
Lubricating Oil Pan (007-025)........................................................................................................................... 7-21
Fill (007-025-028) ........................................................................................................................................... 7-23
Install (007-025-026)....................................................................................................................................... 7-22
Remove (007-025-002) ................................................................................................................................... 7-21
Lubricating Oil Pan Adapter (007-026)............................................................................................................. 7-24
Install (007-026-026)....................................................................................................................................... 7-26
Remove (007-026-002) ................................................................................................................................... 7-24
Page
Lubricating Oil Pan Adapter Cover Plate (007-027) ......................................................................................... 7-30
Install (007-027-026)....................................................................................................................................... 7-31
Remove (007-027-002) ................................................................................................................................... 7-30
Lubricating Oil Pressure Gauge (007-028)....................................................................................................... 7-32
Lubricating Oil Pressure Regulator (Main Rifle) (007-029).............................................................................. 7-32
Install (007-029-026)....................................................................................................................................... 7-34
Remove (007-029-002) ................................................................................................................................... 7-32
Lubricating Oil Pump (007-031) ....................................................................................................................... 7-34
Install (007-031-026)....................................................................................................................................... 7-36
Remove (007-031-002) ................................................................................................................................... 7-34
Lubricating Oil System - Flow Diagrams (200-002-047) .................................................................................... 7-4
Lubricating Oil System - General Information (007-999-999)............................................................................ 7-3
Lubricating Oil System - Specifications (018-001-203) .................................................................................... 7-7
Lubricating Oil System - Tool Requirements (022-001-507) .............................................................................. 7-8
Lubricating Oil Temperature Gauge (007-038)................................................................................................. 7-37
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil System - General Information (007-999-999)
Lubricating Oil System - General

Information (007-999-999)
dures to dispose of the used oil.
Caution: The use of low viscosity oil, such as 10W or

10W-30, can be used to aid in starting the engine and in
providing sufficient oil flow at ambient temperatures be-
low -5°C [23°F]. Continuous use of low viscosity oil can
decrease engine life due to wear.
A used oil analysis can help diagnose internal damage

and determine if it was caused by one of the following:
• Intake air filter malfunction
• Coolant leaks
• Oil diluted with fuel
• Metal particles causing wear
NOTE: Do not disassemble an engine for repair based only
on the results of an oil analysis. Inspect the oil filter also. If
the filter shows evidence of internal damage, find the source
of the problem and repair the damage. Refer to the appro-
priate section(s) based on the oil filter inspection.
Lubricating Oil System - Flow Diagrams (200-002-047) Section 7 — Lubricating Oil System — Group 07
Lubricating Oil System - Flow Diagrams (200-002-047)

Section 7 — Lubricating Oil System — Group 07 Lubricating Oil System - Flow Diagrams (200-002-047)
Lubricating Oil System - Flow Diagrams

Lubricating Oil System - Flow Diagrams (200-002-047) Section 7 — Lubricating Oil System — Group 07
Lubricating Oil System - Flow Diagrams

Section 7 — Lubricating Oil System — Group 07 Lubricating Oil System - Specifications (018-001-203)
Lubricating Oil System - Specifications (018-001-203)

Oil Pressure (With 15W-40 oil at 107°C [225°F])
At Idle (Minimum Allowable) ......................................................................................................... 138 kPa [20 psi]
At No Load Governed Speed .................................................................................... 345 to 483 kPa [50 to 70 psi]
Oil Filter Capacity

Bypass Filter (Spin-On) ............................................................................................... 2.8 Liter [0.75 U.S. Gallon]
Full-Flow Filter (Spin-On) ............................................................................................. 3.5 Liter [0.93 U.S. Gallon]
Oil Pan Capacity (Liter) [U.S. Gallon]

Oil Pan Part No. High Low High Low
3024391 72 61 [19] [16]
3086096 61 49 [16] [13]
3086097 61 49 [16] [13]
3086233 61 49 [16] [13]
NOTE: When the rear gear train option is specified, add 7.6 liter [2 U.S. gallon] to the oil pan capacity listed above.
Lubricating Oil System - Tool Requirements (022-001-507) Section 7 — Lubricating Oil System — Group 07
Lubricating Oil System - Tool Requirements (022-001-507)

Oil Filter Wrench
Remove spin-on oil filter.
3375049
Pressure Regulator Removal Tool

Remove retaining ring from lubricating oil pump regulator (on
engine).
3375055
Valve Spring Tester

Measure spring force at a given spring height.
3375182
Filter Cutter
Open spin-on full-flow filter for inspection.
3376579
Fluorescent Tracer
Add to oil. Use with black light to find oil leaks.
3376891
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Cooler (007-003)
Lubricating Oil Cooler (007-003)

Pressure Differential Test (007-003-063)
Use a differential pressure gauge or one pressure gauge
with two oil hoses and two valves to eliminate gauge error.
Minimum Gauge Capacity: 517 kPa [75 psi]
Install each hose into the [1-12 UNF inch] plugged hole
at each end of the oil cooler housing.
Operate the engine at rated RPM until the oil temperature

is at least 65°C [150°F].
Close valve No. 1 and open valve No. 2. Read the oil
pressure after the oil coolers.
Lubricating Oil Cooler Element (007-007) Section 7 — Lubricating Oil System — Group 07
Open valve No. 1 and close valve No. 2. Read the pres-
sure of the oil being supplied to the oil coolers.
Compare the difference between the two pressures. If the
difference is more than 138 kPa [20 psi], replace the oil
cooler elements. Refer to Procedure No. 007-007-002.
Lubricating Oil Cooler Element

(007-007)
Remove (007-007-002)
Remove the oil cooler cover. Refer to Procedure No.
007-045-002.
NOTE: There is little clearance between the capscrews and

the block on some engines. If necessary, use a drift and a
mallet to tap the loosened capscrews from the oil cooler
housing.
Remove the eight capscrews and the two oil cooler ele-
ments. Remove and discard the gaskets.

Discard the cores if debris from a failure is found in the
oil filters.
Use solvent that will not harm copper. Clean the ele-
ments.
Pressure test the cores to check for leaks.
NOTE: Heating the water in the tank to 50°C [120°F] will
improve the test results.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Dipstick (007-009)
Install (007-007-026)
NOTE: Remove the plastic shipping plugs from the new oil
cooler elements.
Install the gaskets, oil cooler elements, and capscrews.
NOTE: The cores must not touch the cylinder block. Grind
off enough block material to allow clearance if necessary. Do
not allow grinding to contaminate the block.
Install the oil cooler cover. Refer to Procedure No.

007-003-026.
Lubricating Oil Dipstick (007-009)

Calibrate (007-009-030)
NOTE: This procedure must begin with the oil pan drained,
and the vehicle on a level surface.
Install the dipstick in the dipstick tube housing.
Use the correct volume of clean, 15W-40 oil. Fill the oil
pan to the specified LOW or L oil level. Refer to Lubri-
cating Oil System — Specifications, for the correct engine
oil capacity for the application.
Caution: Use care when marking the dipstick, or the

dipstick will break if the scribe mark is too deep.
Remove the dipstick and scribe a mark across the stick
at the oil level. Label the mark with a L to indicate the LOW
oil level.
If a new, blank dipstick is being used, cut the dipstick
approximately 38 mm [1.5 inch] below the LOW or L oil
level mark.
Lubricating Oil Dipstick Tube (007-011) Section 7 — Lubricating Oil System — Group 07
Wipe the excess oil from the dipstick and install it in the
dipstick tube housing.
Use the correct volume of oil to fill the oil pan to the
specified HIGH or H oil level. Refer to Lubricating Oil
System Specification for engine oil capacity.
Remove the dipstick and scribe a mark across the stick

at the oil level. Label the mark with a H to indicate the
HIGH oil level.
Lubricating Oil Dipstick Tube (007-011)

Remove (007-011-002)
Remove the dipstick and dipstick tube.
Install (007-011-026)
NOTE: The dipstick tube and fuel filter mounting locations
vary depending on the application of the engine.
Install the dipstick tube. Tighten the nut 3/4-turn to 1 turn
after contact with the ferrule.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Filter (007-013)
Lubricating Oil Filter (007-013)

Remove (007-013-002)
The external appearance of the full-flow (1) and the com-
bination (2) filters is the same. The accompanying picture
identifies the difference between the two filters.
NOTE: The full-flow filter contains [1 1/2-16 inch] threads.
The bypass filter contains [1 3/8-16 inch] threads.
A combination oil filter is used on some engines. The

upper section of the filter contains the full-flow filter ele-
ment while the lower section contain the bypass element.
NOTE: The following illustrations show the full-flow

combinatin oil filter. Use the same procedure when changing
the remote bypass oil filters.
Use an oil filter wrench, Part No. 3375049, or equivalent.
Remove the full-flow oil filters.
Discard the filters if they are not needed for a failure
analysis.
Inspect (007-013-062)
Caution: Carefully cut the full-flow oil filter open. The
filter element spring is under compression and can cause
personal injury.
Lubricating Oil Filter (007-013) Section 7 — Lubricating Oil System — Group 07
Use Part No. 3376579 Tube Cutter to open the full-flow oil
filter.
Inspect the filter element for evidence of moisture or
metal particles.
Metal Probable Source

Copper Bearings and Bushings
Chromium Piston Rings
Iron Cylinder Liners
Lead Bearing Overlay Material
Aluminum Piston Wear or Scuffing
Discard the old filters.
Install (007-013-026)
Clean the head surface of the new oil filter.
Use engine oil to lubricate the gasket surface of the filters.
Fill the filters with clean, 15W-40 oil. Install the filters on
the oil filter head.
NOTE: Mechanical overtightening can distort the threads or
damage the filter element seal.
Turn the filter until the seal contacts the head. Turn an
additional 3/4-turn to 1 turn.
Operate the engine at rated RPM until the oil temperature

is at least 65°C [150°F]. Check for leaks.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Filter (007-013)
Pressure Differential Test (007-013-063)

Use a differential pressure gauge, or one pressure gauge
with two oil hoses and two valves to eliminate gauge error.
Connect one hose in the [1-5/16-12] SAE plug hole at the

bottom of the nose.
This reading will indicate oil pressure before the oil goes
through the filters.
Connect the other hose in the [1/2-20] SAE plug hole (2),
or the plugs on the top.
This reading will indicate the oil pressure after the oil goes
through the filters.
Operate the engine at rated RPM and normal operating

temperature.
Open the valve to read the pressure after the filter first.
Then close the valve and open the other valve to read the
oil pressure before the filter.
Lubricating Oil Filter Head (007-015) Section 7 — Lubricating Oil System — Group 07
If the difference in pressure is more than 103 kPa [15 psi],

replace the filters.
If the difference in pressure using clean oil filters is more
than 69 kPa [10 psi], an oil filter with excessive restriction
is being used. Replace the oil filters.
Lubricating Oil Filter Head (007-015)

Remove (007-015-002)
tact with used engine oil. Always follow the proper pro-
cedures to dispose the used oil.
Discard the filters if they are not needed for failure
analysis.
Remove the six capscrews and the filter head assembly.


Use solvent to clean the filter head.
Visually inspect the part for cracks or other damage.
Refer to the QSK19 Shop Manual to replace the piston
cooling valve or the oil filter bypass valve.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Filter Head Adapter (007-018)
Install (007-015-026)
Install the gasket, filter head and six capscrews. Tighten
the capscrews.
Install new full-flow oil filters. Refer to Procedure No.

007-012-026 or 007-013-026.
Fill the engine with clean, 15W-40 oil. Refer to Procedure

No. 007-027-028 for engine oil capacity.
check for leaks.
Lubricating Oil Filter Head Adapter

(007-018)
Remove (007-018-002)
NOTE: Oil filter heads that use the combination oil filter have
an adapter for the filter.
Remove the oil filters. Discard the filter if it is not required
for failure analysis.
Lubricating Oil Leaks (007-024) Section 7 — Lubricating Oil System — Group 07
Remove the four capscrews. Remove the filter head

adapter. Remove and discard the o-rings.

Use solvent to clean the adapter.
Visually inspect for cracks or other damage.
Install (007-018-026)
Lubricate the o-ring (1) and install in the filter head before
the adapter.
Lubricate the o-ring (2) and install in the adapter.
Install the adapter (3) and spring (4). Install the capscrews.
Lubricating Oil Leaks (007-024)

Inspect (007-024-062)
Use a steam cleaner or a high pressure washer to clean
the engine.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Leaks (007-024)
Operate the engine until the coolant temperature reaches

80°C [180°F]. Inspect the exterior of the engine for leak-
ing gaskets, seals, o-rings, pipe plugs, or fittings.
NOTE: Before replacing any gaskets, check that the
capscrews are tightened to the correct torque values. Refer
to the Specifications, Section 18, for the capscrew torque
listings.
Check for a loose, broken, or missing oil dipstick tube,

dipstick, or oil filler cap.
Check the engine crankcase breather elements and hose

for restriction.
If not restricted, check blowby. Refer to Procedure 014-
005-012. High blowby can cause gasket and seal leakage.
Fluorescent Dye Tracer (007-024-054)

Add one unit of Part No. 3376891 Fluorescent Tracer to
each 38 liters [10 U.S. gallons] of engine lubricating oil.
Refer to the specifications in this Section for oil pan ca-
pacity.
Operate the engine at low idle for 10 minutes.
Lubricating Oil Leaks (007-024) Section 7 — Lubricating Oil System — Group 07
Shut the engine OFF.
Use a high intensity black light to inspect for oil leakage.

Fuel will glow a yellow color.
If an oil leak into the coolant is suspected, check the

coolant.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pan (007-025)
Lubricating Oil Pan (007-025)

Remove (007-025-002)
Warning: Hot oil can cause serious personal injury. Drain
the oil when the oil temperature is approximately 60°C
[140°F].
Remove the oil drain plug from the bottom of the oil sump.
Drain the oil. Tighten the drain plug.
Remove the 28 capscrews. Remove the oil pan. Remove

and discard the gasket.

Use solvent that will not harm aluminum. Clean the oil
pan.
Lubricating Oil Pan (007-025) Section 7 — Lubricating Oil System — Group 07
Install (007-025-026)
Caution: Gasket cement will prevent the gasket from
sealing properly.
NOTE: Use a contact adhesive such as 3M Spray 77 or 3M
4693 to hold the gasket in position.
Install the gaskets and oil pan.
Use the sequence shown to install the capscrews. Tighten

the capscrews.

007-012-026 or 007-013-026.

No. 007-027-028 for the oil capacity of the engine.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pan (007-025)
Fill (007-025-028)
Install the oil drain plug and tighten the plug.
Add the specified amount of clean, 15W-40 oil to fill the
oil pan.
Oil Pan Capacity
(Liters) [U.S. Gallon]
Oil Pan Part No. High Low High Low
3024391 72 61 [19] [16]
3086096 61 49 [16] [13]
3086097 61 49 [16] [13]
3086233 61 49 [16] [13]
NOTE: If the engine contains a rear gear train, add 7.6 liter
[2 U.S. gallon] to the values listed in the table above, to bring
the oil level to the HIGH or H mark.
Check the oil level on the dipstick. The level must be to
the HIGH or H mark.

check for oil leaks.
Shut the engine OFF and wait 10 minutes for the oil to
drain back to the oil pan.
Check the oil level. Add oil as necessary to bring the level
up to the H or HIGH mark on the dipstick.
Lubricating Oil Pan Adapter (007-026) Section 7 — Lubricating Oil System — Group 07
Lubricating Oil Pan Adapter (007-026)

Remove (007-026-002)
Remove the oil pan and oil pan adapter cover.
Refer to Procedure No. 007-027-002 or 007-025-002.
Remove the three capscrews from the suction tube. Re-

move the oil pan suction tube. Remove and discard the
gasket.
Disconnect the breather vent from the hand hole cover.
Remove the turbocharger oil drain hose from the oil pan
adapter.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pan Adapter (007-026)
Remove the dipstick and dipstick tube.
Warning: The engine must be supported securely be-

fore removing the front engine support to avoid serious
personal injury.
Remove the front engine support bracket. Refer to Pro-
cedure No. 016-002-002.

Discard the filters if they are not needed for failure
analysis.
Remove the two [7/16-14 inch] capscrews, and the five

[3/8-16 inch] capscrews from the flywheel housing.
Caution: The component weighs 23 kg [50 lb] or more.

lift the component.
Remove all of the capscrews and the pan adapter. Re-
move and discard the gasket, the two rectangle seals (41),
and the seven bolt seals (42) from the adapter.

parts.
Install (007-026-026)
4693 to hold the bolt seals in position.
Install the four bolt seals on the oil pan adapter.
The two rectangular seals have an adhesive on one side.
Remove the protective paper strips from the seals. Install
the seals on the oil pan adapter.

sealing properly.
NOTE: use a contact adhesive such as 3M Spray 77 or 3M
Install the gasket. Make sure the gasket touches the rect-
angular seals.
Use Cummins sealant, Part No. 3377132, or equivalent.

Apply the sealant as shown.
Caution: The component weighs 23 kg [50 lb] or more.

lift the component.
NOTE: Be sure the seals remain in position when the adapter
is installed.
Lift the adapter up against the block surface, and then
move it back against the flywheel housing. Hand tighten
four capscrews to hold the adapter in position.
NOTE: The four capscrews shown must be tightened alter-

nately and evenly to be sure the adapter is pulled evenly to
the block and flywheel housing.
Install the four washers and capscrews as shown. Push
the adapter towards the block and flywheel housing while
tightening the capscrews.
Use the following steps while tightening the oil pan adapter
capscrews.
2 - 25 N•m [20 ft-lb]
3 - 40 N•m [30 ft-lb]
4 - 45 N•m [35 ft-lb]
Install the three capscrews and tighten them in the se-

quence shown. Use the steps and torque values below
when tightening the capscrews.
2 - 40 N•m [30 ft-lb]
3 - 45 N•m [35 ft-lb]
NOTE: Capscrews No. 24 through 28 thread into the front

cover on engines.
Install the remaining [3/8-inch] washers and capscrews.
Install the two [7/16-inch] washers and capscrews shown.

Install the [9/16-inch] washer and capscrew. Tighten the

capscrew.
Install the front engine support. Refer to Procedure No.

016-002-026.
NOTE: The dipstick tube mounting location depends on the

application.
Install the dipstick tube mounting. Tighten the nut 3/4-
turn to 1 turn after contact with the ferrule.
Caution: These parts are a safety-related item. The parts

must be clamped correctly to prevent fretting.
Install the oil drain hose for the turbocharger as shown.
Tighten the hose swivel nut.
Connect the breather vent hose to the hand hole cover.

Tighten the hose clamps.
Install the gasket, oil pan suction tube, and capscrews.

Tighten the two suction tube connector capscrews.
Tighten the clamp capscrew.
Lubricating Oil Pan Adapter Cover Plate (007-027) Section 7 — Lubricating Oil System — Group 07
Install the oil pan, Procedure No. 007-025-026, and the oil
pan adapter cover, Procedure No. 007-027-026.

007-012-026 or Procedure No. 007-013-026.

No. 007-027-028.
check for leaks.
Lubricating Oil Pan Adapter Cover

Plate (007-027)
Remove (007-027-002)
Drain the lubricating oil. Refer to Procedure No.
007-025-005.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pan Adapter Cover Plate (007-027)
Remove the 18 capscrews. Remove the cover plate. Re-

move and discard the gasket.

Use solvent that will not harm aluminum. Clean the parts.
Install (007-027-026)
sealing properly.
Install the gasket and oil pan adapter cover.
Use the sequence shown to tighten the capscrews.

Lubricating Oil Pressure Gauge (007-028) Section 7 — Lubricating Oil System — Group 07

007-012-026.
No. 007-025-028.
Lubricating Oil Pressure Gauge

(007-028)
Inspect the following for defects:
• electrical wiring that is broken;
• sending unit malfunction;
• plumbing that is loose or broken;
Use a reference gauge of known accuracy to verify the

reading of the suspect gauge.
Connect the line from the master gauge at location (1). If
this location is not accessible, remove one of the three
plugs in the lubricating oil filter head (2).
Operate the engine. Compare the pressure reading of the
master gauge and the suspect gauge.
The sending unit must be replaced if it is defective.
Lubricating Oil Pressure Regulator

(Main Rifle) (007-029)
Remove (007-029-002)
NOTE: The oil pump does not need to be removed.
007-037-005.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pressure Regulator (Main Rifle) (007-029)
Remove the oil pan or the oil pan adapter cover located
at the front of the engine. Remove and discard the gasket.
Refer to Procedure No. 007-025-002 for removal of the oil
pan, or Procedure No. 007-026-002 for removal of the oil
pan adapter.
Use pressure regulator removal tool, Part No. 3375055, to

hold the retainer in position during the removal of the snap
ring.
The pressure regulator tool will fit over the No. 1 con-
necting rod. Rotate the crankshaft backward slightly to
push the regulator spring inward to release the tension of
the retaining spring.
Use internal snap ring pliers to remove the snap ring.
Remove the pressure regulator assembly.

Clean and inspect the parts for reuse.
Put the plunger in the bore and move it to check for free
movement. If the bore is damaged, the pump must be
replaced. If the plunger is damaged, it must be replaced.
Check the free length of the spring. The free length is

approximately 95 mm [3.75 inch].
Use a valve spring tester, Part No. 3375182, or equivalent.
Measure the spring force (7) at the working height (6).
(6) Working Height: 63.88 mm [2.515 inch]
(7) Spring Force: 322 N MIN [72.3 lb]
344 N MAX [77.3 lb]
Lubricating Oil Pump (007-031) Section 7 — Lubricating Oil System — Group 07
Install (007-029-026)
Use engine oil to lubricate the regulator plunger and bore.
Install the plunger (5), spring, and retainer (4).
Use pressure regulator removal tool, Part No. 3375055, to
compress the spring. Use internal snap ring pliers to
install the snap ring in the housing groove.
Install the oil pan or the oil pan adapter cover. Refer to
Procedure No. 007-025-026 for the oil pan, or Procedure
No. 007-026-026 for the oil pan adapter cover.

007-012-026.
No. 007-025-028.
Lubricating Oil Pump (007-031)

Remove (007-031-002)
007-037-005.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pump (007-031)

001-031-002.
Remove the three capscrews from the oil pump mounting

flange.
Use a pry bar and gently pry the oil pump out of the engine
block.
Remove and discard the two o-rings and the seal ring
from the pump.

Clean and inspect the oil pump for reuse. Rotate the drive
gear slowly and check the pump gears for damage.
Measure the oil pump end clearance.
Oil Pump End Clearance

mm in
0.1016 MIN 0.004
0.2286 MAX 0.009
Lubricating Oil Pump (007-031) Section 7 — Lubricating Oil System — Group 07
Use solvent to flush the lubricating oil pump.

Inspect the gears of the oil pump for damage. If the part
is damaged, it must be rebuilt or replaced.
Install (007-031-026)
NOTE: Apply a light coat of grease to the seal ring to hold
it in place during assembly.
Install the o-rings and the seal ring on the pump.
Use vegetable oil to lubricate the o-rings and the bore in
the block.
Install the pump and the capscrews. Tighten the
capscrews.
Be sure the seal ring at the back of the pump is positioned

correctly.
Look up into the block between the No. 1 and No. 2 main
bearing caps. The seal must be visible in the space
between the rear of the pump and the block.
Check the oil pump gear backlash. Refer to Procedure

No. 001-055-010. Adjust the backlash if necessary by
loosening the mounting capscrews and rotating the pump.
Lubricating Oil Pump Gear Backlash

mm in
0.0760 MIN 0.003
0.3050 MAX 0.012
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Temperature Gauge (007-038)
Install the front cover and remaining components. Refer

Lubricating Oil Temperature Gauge

(007-038)
Drain the oil from the oil pan. Refer to Procedure No.
007-037-005.
Remove one of the pipe plugs on either side of the oil pan.
Install a reference gauge of known accuracy to verify the
reading of the suspect gauge.
Minimum Gauge Capacity: 150°C [300°F]
Fill the engine with oil. Refer to Procedure No. 007-025-

028.
Operate the engine. Compare the temperature reading of
the master gauge and the suspect gauge.
Lubricating Oil Contamination (007-044) Section 7 — Lubricating Oil System — Group 07
If the suspect gauge does not read the same temperature

as the reference gauge, check the following for defects.
• Electrical wiring
• Sending unit
Replace the defective parts.
Drain the oil from the oil pan. Refer to Procedure No.
007-037-005.
Remove the reference gauge. Tighten the pipe plug to
specification.

028.
Operate the engine to normal operating temperature.
Check for leaks.
Lubricating Oil Contamination

(007-044)
A used oil analysis can help diagnose internal damage
and determine if it was caused by one of the following:
• Oil diluted with coolant
• Oil diluted with fuel
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Contamination (007-044)

Oil Diluted with Coolant
Fluorescent Dye Tracer Test (007-044-054)

Oil Diluted with Fuel
NOTE: This test is not effective on a cold engines, less than
21°D [70°F] coolant temperature, or with a loose overhead
setting.
Install an isolated fuel supply tank to the inlet and drain
lines. Add fluorescent tracer, Part No. 3376891, to the fuel
supply tank.
Remove the valve cover mounting capscrews, but do not

remove the valve covers.
Start the engine and operate it at high idle for 30 seconds.

Let the engine go to low idle.
Complete the next step within 5 minutes.
Lubricating Oil Contamination (007-044) Section 7 — Lubricating Oil System — Group 07
While the engine is operating at low idle, remove the valve

covers.
Use a black light to find fuel leaks from inside or around

the injector. Refer to the black light operating instructions.
NOTE: Injectors normally have a small amount of fuel
leakage.
If there is excess leakage around the outside of the in-

jector, check the top o-ring for damage.
Remove the injector and replace all three o-rings. Refer
If there is excess leakage from inside the injector, replace

the injector. Refer to Procedure No. 006-026-062.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Cooler Cover (007-045)
Lubricating Oil Cooler Cover (007-045)

Remove (007-045-002)
Open the draincock on the bottom of the radiator and
remove the lower radiator hose to drain the cooling sys-
tem. Refer to Procedure No. 008-018-005.
Open the draincock on the oil cooler housing and on the

water pump. Close the draincock after the coolant is
drained.
Remove the turbocharger oil drain hose. Remove the

turbocharger coolant supply hose.
Remove the water bypass tube clamp (9). Loosen both

hose clamps. Remove the water bypass tube.
Lubricating Oil Cooler Cover (007-045) Section 7 — Lubricating Oil System — Group 07
Disconnect the aftercooler supply hose from the water

pump outlet connection.
Remove the water pump outlet connection assembly.

Remove the water transfer tube from the water connec-
tion. Remove and discard the two o-rings (13) and the
gasket.
Remove all of the capscrews, the oil cooler cover, and

gasket.
Discard the gasket.

Clean and inspect the cover for reuse. Check the alumi-
num covers for corrosion.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Cooler Cover (007-045)
Install (007-045-026)
Install the oil cooler cover and new gasket. Use several
capscrews to secure the cover in position, but do not
tighten the capscrews.
Install the capscrews as shown.
Tighten the capscrews to the values specified and in the

sequence shown.
Use vegetable oil. Lubricate the o-rings (13).

Install the transfer tube in the water pump outlet connec-
tion.
Install the water pump outlet connection, gasket, and
capscrews.
Lubricating Oil Cooler Cover (007-045) Section 7 — Lubricating Oil System — Group 07
Connect the aftercooler supply hose to the water pump

outlet connection. Tighten the clamps.
Use vegetable oil. Lubricate the o-ring on the bypass

tube. Install the bypass tube.
NOTE: The raised lip on the retainer (9) must point toward
the thermostat housing.
Install the retainer (9) and capscrew.
Tighten the capscrew and the hose clamps.
Capscrew Torque Value: 45 N•m [35 ft-lb]
Hose Clamp Torque Value: 6 N•m [50 in-lb]
Install the oil drain hose on the turbocharger. Tighten the

hose swivel nut.
Connect the coolant supply hose to the turbocharger.

028.
check for leaks.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Cooler Housing (007-046)
Lubricating Oil Cooler Housing

(007-046)
Remove (007-046-002)
Remove the oil cooler cover, Procedure No. 007-045-002,
or the torque converter, Procedure No. 008-065-002.
Remove the water pump. Refer to Procedure No.

008-062-002.
NOTE: If the starting motor is located on the right side of the

engine, it must be removed.
Remove the starting motor capscrews, the starter, spacer
and gaskets. Discard the gaskets.
NOTE: Some engines do not contain spacers and gaskets.
Remove the capscrews and oil cooler housing. Remove

and discard the gaskets.
Lubricating Oil Cooler Housing (007-046) Section 7 — Lubricating Oil System — Group 07

Clean and inspect the housing. Check the aluminum
housings for corrosion.
Install (007-046-026)
Install two guide studs. Put the gasket and housing into
position.
Caution: Do not tighten the capscrews until the oil cooler

cover or torque converter cooler cover is installed.
Install the capscrews as shown.
Caution: The two capscrew holes marked "X" align with
cylinder head capscrews. The cylinder head capscrews
will be damaged if the cooler housing capscrews are too
long.
Oil Cooler Capscrew Lengths

Illustration Callout No. Without Oil Filter [Inch]
(1) [1-1/4]
(2) [1-3/4]
(3) [1-5/8]
(4) [1-3/4]
(5) [1-5/8]
Section 7 — Lubricating Oil System — Group 07 Cylinder Smokes (Blue Smoke) (007-050)
NOTE: Starting motor spacers are not on all engines.

NOTE: The wet type flywheel housing requires gaskets for
starting motor installation.
Install any spacer or gaskets. Install the starting motor
and capscrews.
Starting Motor Torque Values

Flywheel Housing N•m ft-lb
Cast Iron 215 160
Aluminum 195 145
Install the water pump. Refer to Procedure No.

008-062-026.
Install the oil cooler cover, Procedure No. 007-003-026, or

the torque converter cooler, Procedure No. 007-043-026.
Cylinder Smokes (Blue Smoke)

(007-050)
Caution: This assembly weighs more than 23 kg [50 lb].
To avoid personal injury, use a hoist assistance to lift the
component.
To check for single cylinder oil comsumption, remove the
exhaust manifold. Refer to Procedure No. 011-007-002.
Cylinder Smokes (Blue Smoke) (007-050) Section 7 — Lubricating Oil System — Group 07
Add one unit of Part No. 3376891 Florescent Tracer to

each 38 liters [10.0 U.S. gallons] of engine oil.
Idle the engine for 5-10 minutes or until normal operating
temperature is reached to allow the dye to circulate through
the lubricating system.
Use a high intensity blacklight. Inspect the exhaust ports.

A yellow glow indicates a fuel leak. A dark blue glow
indicates an oil leak.
Look for excessive blue smoke coming out of the faulty

cylinder.
Check the cylinder heads. Refer to Procedure No.

002-004-007.
Section 7 — Lubricating Oil System — Group 07 Cylinder Smokes (Blue Smoke) (007-050)
Check the pistons and rings. Refer to Procedure No.

001-054-002.
Cylinder Smokes (Blue Smoke) (007-050) Section 7 — Lubricating Oil System — Group 07
NOTES
Section 8 — Cooling System — Group 08

Section Contents
Page
Belt, Cooling Fan Drive (008-002).................................................................................................................... 8-15
Adjust (008-002-029)...................................................................................................................................... 8-16
Install (008-002-026) ...................................................................................................................................... 8-16
Remove (008-002-002)................................................................................................................................... 8-15
Coolant Filter (008-006) ................................................................................................................................... 8-17
Install (008-006-026) ...................................................................................................................................... 8-17
Remove (008-006-002)................................................................................................................................... 8-17
Coolant Temperature Gauge (008-004)............................................................................................................ 8-17
Initial Check (008-004-008) ............................................................................................................................ 8-17
Coolant Thermostat (008-013) ......................................................................................................................... 8-18
Install (008-013-026) ...................................................................................................................................... 8-25
Leak Test (008-013-014) ................................................................................................................................. 8-23
Remove (008-013-002) ................................................................................................................................... 8-18
Test (008-013-012).......................................................................................................................................... 8-21
Coolant Thermostat Housing Support (008-015) ............................................................................................ 8-28
Install (008-015-026) ...................................................................................................................................... 8-30
Remove (008-015-002) ................................................................................................................................... 8-28
Coolant Thermostat Seal (008-016) ................................................................................................................. 8-34
Install (008-016-026) ...................................................................................................................................... 8-35
Remove (008-016-002) ................................................................................................................................... 8-34
Coolant Vent Lines (008-017)........................................................................................................................... 8-35
Cooling System (008-018)................................................................................................................................ 8-37
Drain (008-018-005) ....................................................................................................................................... 8-37
Fill (008-018-028) ........................................................................................................................................... 8-43
Flush (008-018-009) ....................................................................................................................................... 8-38
Pressure Test (008-018-013) ........................................................................................................................... 8-40
Cooling System Diagnostics (008-020) ........................................................................................................... 8-50
Pressure Test (008-020-013)........................................................................................................................... 8-50
Cooling System — Air or Combustion Gas (008-019)..................................................................................... 8-45
Test (008-019-012).......................................................................................................................................... 8-45
Cooling System — Flow Diagrams (200-003-204) ............................................................................................. 8-8
Jacket Water-Aftercooled ................................................................................................................................. 8-9
LTA ................................................................................................................................................................ 8-10
LTA Torque Converter ..................................................................................................................................... 8-11
Cooling System — General Information (008-999-999)..................................................................................... 8-3
FleetguardW Products for Cummins Engines ................................................................................................... 8-5
Cooling System — Required Tools (022-001-508) ........................................................................................... 8-13
Cooling System — Specifications (018-001-204) ............................................................................................ 8-12
Cooling System Service Requirements (008-022) ........................................................................................... 8-51
General Information (008-022-999) ................................................................................................................ 8-51
Fan, Cooling (008-040)..................................................................................................................................... 8-56
Initial Check (008-040-001) ............................................................................................................................ 8-56
Install (008-040-026) ...................................................................................................................................... 8-57
Remove (008-040-002)................................................................................................................................... 8-56
Rotation Check (008-040-052)........................................................................................................................ 8-58
Fan Drive Ilder Arm Assembly (008-029)......................................................................................................... 8-52
Install (008-029-026) ...................................................................................................................................... 8-54
Remove (008-029-002)................................................................................................................................... 8-52
Page
Fan Hub, Belt Driven (008-036)........................................................................................................................ 8-54
Install (008-036-026) ...................................................................................................................................... 8-55
Remove (008-036-002)................................................................................................................................... 8-54
Radiator (008-042)............................................................................................................................................ 8-59
Initial Check (008-042-008) ............................................................................................................................ 8-60
Test (008-042-012) ......................................................................................................................................... 8-59
Radiator Hose, Lower (008-045) ...................................................................................................................... 8-62
Install (008-045-026) ...................................................................................................................................... 8-62
Remove (008-045-002)................................................................................................................................... 8-62
Radiator Hose, Upper (008-046) ...................................................................................................................... 8-63
Install (008-046-026) ...................................................................................................................................... 8-64
Remove (008-046-002)................................................................................................................................... 8-63
Radiator Pressure Cap (008-047)..................................................................................................................... 8-66
Pressure Test (008-047-013)........................................................................................................................... 8-66
Radiator Shroud (008-048)............................................................................................................................... 8-66
Radiator Top Tank (008-051) ............................................................................................................................ 8-66
Leak Test (008-051-014) ................................................................................................................................. 8-66
Supplemental Coolant Additive (SCA) (008-060)............................................................................................. 8-67
Torque Converter Cooler (008-065) ................................................................................................................. 8-74
Install (008-065-026) ...................................................................................................................................... 8-77
Pressure Test (008-065-013)........................................................................................................................... 8-76
Remove (008-065-002)................................................................................................................................... 8-74
Water Pump (008-062) ..................................................................................................................................... 8-68
Inspect (008-062-062) .................................................................................................................................... 8-70
Install (008-062-026)....................................................................................................................................... 8-71
Remove (008-062-002)................................................................................................................................... 8-68
Section 8 — Cooling System — Group 08 Cooling System — General Information (008-999-999)
Cooling System — General Information

(008-999-999)
The primary function of the cooling system is to remove
unused heat energy, created by the combustion process,
from the engine. The excess heat energy that is not
removed by the cooling system is carried away by exhaust
gases and radiation into the atmosphere.
The accompanying chart illustrates the jacket water-

cooled coolant flow through the engine. For more details,
refer to the coolant flow charts in Procedure No. 008-
018-047.
A. Engine Cylinder Head
B. Thermostat Housing
C. Radiator
D. Pump
E. Aftercooler
F. Oil Cooler
G. Engine Block
The accompanying chart illustrates the LTA coolant flow

through the engine. For more details, refer to the coolant
flow charts in Procedure No. 008-018-047.
A. Water Pump
B. Base Engine
C. Thermostat, Engine
D. Radiator, Engine
E. LTA Thermostat
F. LTA Radiator
G. Aftercooler
Cooling System — General Information (008-999-999) Section 8 — Cooling System — Group 08
The following publications, available through Cummins

Distributors or Cummins Dealers, provide cooling system
installation recommendations and specifications approved
by Cummins Engine Company, Inc.
• Automotive Installation Recommendations (Cooling
System), Bulletin No. 3382413.
• Construction, Mining, Logging, and Agriculture In-
stallation Recommendations (Cooling System), Bul-
letin No. 3382171.
• Data Sheets for Construction, Mining, Logging, and
Agriculture, Bulletin No. 3381194; for Generator Drive
and Generator Set, Bulletin No. 3381174; for Auto-
motive, Bulletin No. 3381237.
• Operation of Diesel Engines in Cold Climates, Bul-
letin No. 33790009.
• Generator Drive and Generator Set Installation Rec-
ommendations (Cooling System), Bulletin No.
3382395.
• Coolant Maintenance, Bulletin No. 3666101.
NOTE: Refer to Section L for literature ordering information.
FleetguardW Products for Cummins Engines

Diesel engines require special chemical treatment of the cooling system, or liner pitting leading to engine failure
will result.
During the mid-Eighties, antifreeze manufacturers revised antifreeze formulations to protect new aluminum ra-
diators in automobiles. The high levels of silicates in these revised formulations combined with the silicates in
Supplemental Coolant Additives (SCAs) used in diesels caused gel to plug diesel radiators and diesel water pump
seals to fail. This led Cummins and other diesel engine manufacturers to caution against over-treatment with SCAs.
Customers responded by trying to maintain the minimum acceptable amount of SCA in the cooling system.
Silicone hoses are being used much more widely. These hoses have excellent chemical resistance, but are prone
to cold water leaks at fittings unless special precautions are used. This results in dilution of the SCA level,
sometimes below an acceptable level.
Many new drivers and mechanics do not understand that topping off radiators when cold and losing major amounts
of coolant will dilute the SCA level so low that just changing the coolant filter will not replace the lost SCA.
The DCA4 test kit was introduced for monitoring the SCA level. The service recommendations on this kit are based
on the assumption that coolant filters would be changed at every oil drain. However, some customers use the test
kit to determine when to change coolant filters, and as a result, operate with very little margin for sudden coolant
loss.
Many of the engine changes that have been made to increase durability and fuel economy and decrease emissions
have increased liner excitation, making it more important that sufficient SCA be maintained in the cooling system.
Now, with low silicate DCA4 and low silicate antifreeze meeting ASTM specification D4985 widely available for
diesel engines, silica gel is rarely a problem. Improved water pump seals now live with fairly high levels of DCA4.
Now, it is more appropriate to be concerned about under-concentration of SCAs rather than over-concentration.
These changes in maintenance requirements will provide a greater margin for dilution and will make it easier to
maintain the proper chemical treatment and avoid liner pitting failures.
DCA4 Service Requirements
The following requirements apply when coolant filter service intervals are between 16,000 Km [10,000 Mi] or 250
Hours and 40,000 Km [25,000 Mi] or 625 Hours. Other maintenance practices can require different precharge or
service amounts of DCA4 to maintain the DCA4 concentration in an acceptable range.
When the coolant is replaced, the cooling system must be precharged. Add 1 pint of DCA4 liquid (5 units) for each
4 gallons of coolant (1.2 units per gallon). In addition, a service coolant filter containing 1 unit of DCA4 for each
4 gallons of coolant must be installed. This will result in a total precharge of approximately 1.5 DCA4 units per
gallon of coolant.
• The service coolant filter must be replaced at every oil drain, resulting in the level of DCA4 increasing over
time. This is normal and desirable until the level reaches 3 units per gallon. When the level is above 3 units
per gallon, the coolant filter need not be replaced until the level drops below 3 units per gallon when tested
at every subsequent oil drain interval.
• Coolant should be tested a minimum of twice a year. When excessive coolant loss occurs and coolant is
replaced, dilution of the DCA4 chemical results. If excessive coolant loss is suspected, coolant needs to be
tested at every oil drain and liquid DCA4 added to make up for the chemical lost due to dilution. Low levels
of DCA4 will result in liner pitting failure. Testing need not be used to maintain only minimum DCA4 levels.
• The following action is required after testing coolant at the coolant filter service interval for DCA4 concentration.
Cooling System — General Information (008-999-999) Section 8 — Cooling System — Group 08
Below 1.2 Units Per Gallon:

• Replace the service filter and add 1 pint of DCA4 liquid (5 units) for each 4 gallons of coolant (1.2 units per
gallon of coolant).
1.2 to 3 Units Per Gallon:
• Continue to replace the service coolant filter at each oil drain interval.
Above 3 Units Per Gallon:
• Do not replace the service filter until the SCA level falls below 3 units per gallon when tested at every
subsequent oil drain interval.
FleetguardW Part No. Cummins Part No. DCA4 Units

Table 1: DCA4 Spin-on Coolant Filters
WF-2070 3318157 2
WF-2071 3315116 4
WF-2072 3318201 6
WF-2073 3315115 8
WF-2074 3316053 12
WF-2075 3318318 15
WF-2076 3318319 23
Table 2: FleetguardW Part No. Quantity DCA4 Units

DCA60L 1 Pint 5
DCA65L 0.5 Gal 20
DCA75L 5 Gal 200
DCA80L 55 Gal 2200
Table 3: RESTORE Heavy-Duty Cooling System Cleaner

CC2610 1 gallon
CC2611 5 gallons
CC2612 55 gallons
Instructions for Using FleetguardW Test Kit, Part No. CC2602, to Test for DCA4
Coolant testing is recommended at least every 6 months. It is also recommended when:
• coolant loss between service intervals exceeds 20 percent of system capacity.
• water pump seal leakage is apparent.
• anytime the coolant condition is unknown or corrosion is apparent with the cooling system.
Coolant testing and monitoring are useful tools for tracking and controlling coolant condition and performance. The
two methods available for testing coolants include field test kits and portable refractometers and coolant analysis
programs. Cumins recommends FleetguardW CC2602 3-WayW test kit and CC2800 refractometer for on-site
testing, and the FleetguardW CC2700 Monitor C program for laboratory testing. The CC2602 field test kit is
appropriate for testing nitrite-molybdate formulations such as FleetguardW DCA4, as well as nitrite formulations
such as FleetguardW DCA (Fleetcool). The CC2700 Monitor C program can evaluate most new or used coolant
formulations.
Field test kits offer the benefit of on-site measurements and are designed to approximate SCA levels. Some test
kits also incorporate freeze point protection measurements. FleetguardW CC2602 test strips contain a test patch
for measuring this parameter. When required, freeze point can be more accurately determined with on-site
refractometer readings such as FleetguardW, Part No. CC2800.
When using FleetguardW CC2602 test kit, it is important to follow the simple instructions provided in the kit. Coolant
must be collected from the radiator or block drain, but never from the surge tank or coolant recovery bottle. Each
test trip contained in the kit has three test patches and can be dipped directly into the coolant. No other chemical
dilution is required. Each test patch has a specific function. One test patch measure Nitrites (NO1), another
measure Molybdates (MoO4), and another measures freeze point protection. Because the kit measures nitrites
and molybdates separately, it can reliably measure both FleetguardW SCA formulations. DCA (Fleetcool) utilizes
Nitrites while DCA4 utilizes a Nitrite-Molybdate formulation. Cummins preference for a Nitrite-Molybdate formu-
lation for pitting protection is explained in Attachment 1.
Coolant analysis programs are performed in laboratories and offer additional useful information, but require mailing
coolant samples to the laboratory.
Cooling System — Flow Diagrams (200-003-204) Section 8 — Cooling System — Group 08
Cooling System — Flow Diagrams (200-003-204)

Section 8 — Cooling System — Group 08 Cooling System — Flow Diagrams (200-003-204)

Jacket Water-Aftercooled
Cooling System — Flow Diagrams (200-003-204) Section 8 — Cooling System — Group 08

LTA
Section 8 — Cooling System — Group 08 Cooling System — Flow Diagrams (200-003-204)
Cooling System — Flow Diagram (200-003-204)

LTA Torque Converter
16. Torque Converter Oil Inlet

17. Torque Converter Oil Outlet
Cooling System — Specifications (018-001-204) Section 8 — Cooling System — Group 08
Cooling System — Specifications (018-001-204)

QSK19C Metric U.S.
Coolant Capacity (Engine Only) 26 Liter [28 U.S. Quart]
Standard Modulating Thermostat Range 80°C-90°C [175°F — 195°F]
Maximum Coolant Pressure (Exclusive of Pressure Cap) 241 kPa [35 psi]
Maximum Allowable Top Tank Temperature 100°C [212°F]
Minimum Recommended Top Tank Temperature 70°C [160°F]
Maximum Allowable Deaeration Time 25 Minutes 25 Minutes
Minimum Allowable Drawdown or 20% of System Ca- 11 Liter [12 U.S. Quart]
pacity (whichever is greater)
Minimum Allowable Pressure Cap 50 kPa [ 7 psi]

Cooling System — Required Tools (022-001-508) Section 8 — Cooling System — Group 08

Digital Optical Tachometer
Used to measure RPM of a viscous fan.
3377462
Section 8 — Cooling System — Group 08 Belt, Cooling Fan Drive (008-002)
Belt, Cooling Fan Drive (008-002)

Remove (008-002-002)
Remove the fan and fan spacers. Refer to Procedure No.
008-040-062.
Caution: The fan belt idler is under tension. Do not allow

your hands to get between the idler and the belt, or the
fan hub. Personal injury can result.
Loosen nuts (1) and (2). Turn nut (1) counterclockwise to
end of threaded rod to relieve tension on the belt.
Remove the fan belt.

Inspect the belt for:
• Cracks
• Glazing
• Tears or cuts
Belt, Cooling Fan Drive (008-002) Section 8 — Cooling System — Group 08
Install (008-002-026)
NOTE: The fan belt has 21 grooves. The fan hub and crank-
shaft pulleys have 22 grooves. Install the belt in the grooves
toward the front of the engine. The remaining groove that is
not used is to be toward the radiator.
Install the belt.
Adjust (008-002-029)
Loosen nut (2) to end of threads. Pull belt tensioner with
your hand until the idler pulley contacts the fan belt.
Tighten nut (1) finger-tight. Use a wrench and tighten nut
(1) an additional nine revolutions.
Apply torque to nut (2).
Install the fan and fan spacers. Refer to Procedure No.

008-040-026.
NOTE: If the belt was not replaced, it is not necessary to

perform this step (belt removed and installed as part of
another repair).
Operate the engine for 10 minutes at high idle. Reset the
belt tension.
After this procedure, it is not necessary to tension the belt
again until the belt is replaced.
Section 8 — Cooling System — Group 08 Coolant Temperature Gauge (008-004)
Coolant Temperature Gauge (008-004)

Check for a blown fuse.
Check the wiring from the gauge to the sending unit for
broken connection(s).
Use a temperature gauge of known accuracy to check the

existing gauge.
Replace a faulty gauge.
Coolant Filter (008-006)

Remove (008-006-002)
Turn the valve on the filter head to the OFF position.
Remove the coolant filter.
Install (008-006-026)
Use engine oil and lubricate the seal on the filter.
NOTE: Do not allow oil to get in the filter. It will adversely
affect the DCA.
Coolant Thermostat (008-013) Section 8 — Cooling System — Group 08
Install the coolant filter. Turn the filter until the seal touches
the filter head. Turn an addition 1/2 to 3/4 of a turn after
contact.
Turn the valve to the ON position.
Coolant Thermostat (008-013)

Remove (008-013-002)
Conventional Aftercooling
008-018-005)
Remove both upper radiator hoses from the thermostat

housing.
Remove the vent lines from the top of the thermostat
housing.
Section 8 — Cooling System — Group 08 Coolant Thermostat (008-013)
NOTE: If the engine is equipped with an air compressor,

remove the air compresor coolant return tube.
Remove bypass tube clip (9). Loosen both hose clamps.
Remove the bypass tube.
Remove the nine long capscrews.

Remove the thermostat housing. Remove and discard the
gasket.
Remove the thermostats. Remove the seals. Refer to

LTA
008-018-005).
Remove both of the upper engine radiator hoses from the

thermostat housing.
Remove both of the upper LTA radiator hoses from the
thermostat housing.
Remove both of the vent lines from the top of the ther-
mostat housing.
Remove the aftercooler water return tube clip. Loosen

both hose clamps (2). Remove the aftercooler coolant
water return tube (1).
Remove the bypass tube clip (9). Loosen both hose

clamps. Remove the bypass tube.
Remove the nine long capscrews (1). Remove the ther-

mostat housing (2). Remove and discard the gasket (3).
Remove both of the engine thermostats (1). Remove the

LTA thermostat (2). Remove the seals (3).

LTA
Visually inspect the thermostat for damage.
Test (008-013-012)
Suspend the thermostat and a 100°C [212°F] thermom-
eter in a container of water.
NOTE: Do not allow the thermostat or thermometer to touch
the container.
Heat the water and check the thermostat as follows.
The nominal operating temperature is stamped on the

thermostat.
• Thermostat must begin to open within 2°C [3°F] of
nominal temperature.
• Thermostat must be fully open at 12°C [22°F] above
The fully open distance between the thermostat flange
and housing is 9.525 mm [0.3750-inch].
Remove the container from the heat. Check to see if the

thermostat returns to the CLOSED position.
LTA
Suspend the thermostat and a 100°C [212°F] thermom-
eter in a container of water.
NOTE: Do not allow the thermostat or thermometer to touch
the container.
Heat the water and check the thermostat as follows.
The nominal operating temperature is stamped on the

thermostat.
• Thermostat must begin to open within 2°C [3°F] of
• Thermostat must be fully open at 12°C [22°F] above
The fully open distance between the thermostat flange
and housing is 7.87 mm [0.310-inch].
Remove the container from the heat. Check to see if the

thermostat returns to the CLOSED position.
Leak Test (008-013-014)

The engine thermostat and thermostat seal must operate
properly in order for the engine to operate in the most
efficient heat range. Overheating or overcooling will
shorten engine life.
NOTE: With a LTA thermostat, the intake air temperature is
monitored by the electronic system and will generate a fault
code when the intake air temperature exceeds the maximum
temperature limits.
Engine Coolant Temperature Below Normal↔

Warning: Complete this test with the engine coolant
temperature below 50°C [120°F]. Hot steam can cause
serious personal injury.
NOTE: If the engine being tested has LTA, leave the LTA
radiator hoses connected to the thermostat housing.
Remove the upper engine radiator hoses from the ther-
mostat housing.
Install two hoses of the same size on the thermostat

housing outlets long enough to reach a remote dry con-
tainer.
Install and tighten hose clamps on the housing outlets.
Put the end of the hoses in two dry containers.
Operate the engine at rated RPM for 1 minute.

Shut the engine OFF, and measure the amount of coolant
collected in each container.
The amount of coolant collected must not be more than
100 cc [3.3 fl-oz].
If more than 100 cc [3.3 fl-oz] of coolant is collected, the

thermostat or the thermostat seal is leaking.
Remove the thermostat and test operation as describes
in Procedure No. 008-013-002.
Engine Coolant Temperature Above Normal↔

Restrict the radiator air flow. Operate the engine until the
coolant temperature rises to 90-93°C [195-200°F].
Record the temperature of the coolant outlet hoses. An

increase in temperature indicates the thermostats have
started to open.
Use a contact pyrometer (shown) or install a temperature
gauge in the desired locations prior to operating the
engine.
Record the temperature of the radiator bottom tank or

coolant out tube.
If the difference in temperature is more than 8°C [15°F],

either the thermostats are not fully open or the radiator
core is plugged.
To replace the thermostats, refer to Procedure No. 008-
013-002. To check the radiator, refer to Procedure No.
008-042-008.
Install (008-013-026)
Install the thermostat seals. Refer to Procedure No. 008-
016-026.
Install the thermostat by pushing on the outer rim.
Install a new gasket. Install the thermostat housing and


Torque Value (Hose Clamp): 6 N•m [50 in-lb]
Install the two upper radiator hoses. Tighten the hoses

clamps.
Install the vent lines.
install the air compressor coolant return tube.

028.
Check for leaks.
LTA
Install the thermostat seal. Refer to Procedure No. 008-
016-026.
Install the thermostat by pushing on the outer rim.
Install a new gasket. Install the thermostat housing and


Install the aftercooler water return tube (1). Install the tube
clip and capscrew (2).
Tighten the hose clamps and capscrew.
Install both vent lines to the top of the thermostat housing.

Install both upper LTA hoses. Tighten the hose clamps.
Install both upper engine radiator hoses. Tighten the hose
clamps.

028.
Check for leaks.
Coolant Thermostat Housing Support (008-015) Section 8 — Cooling System — Group 08
Coolant Thermostat Housing Support

(008-015)
Remove (008-015-002)
008-018-005.
Remove both upper radiator hoses from the thermostat

housing.
Remove the bypass tube clip (9). Loosen both hose
clamps. Remove the bypass tube.
Remove the aftercooler coolant return tube and gasket

(7), hose (8), and vent hose (6) from the thermostat hous-
ing support.
Disconnect the coolant temperature wire.
Remove the aftercooler water supply tube clip (7). Loosen

the hose clamps. Remove the support bracket (34).
Remove the tube (31). Remove and discard the o-ring.
Section 8 — Cooling System — Group 08 Coolant Thermostat Housing Support (008-015)
Disconnect the air compressor water outlet tube from the

thermostat housing.
Remove the four mounting capscrews and the thermostat
housing assembly.
Remove the water transfer tube. Remove and discard the
two o-rings (19).
LTA
008-018-005.
Remove both of the upper radiator hoses from the ther-

mostat housing.
Remove both of the upper LTA radiator hoses from the
thermostat housing.
Remove both of the vent hoses from the thermostat
housing.
Remove the bypass tube clamp (9). Loosen both hose

clamps. Remove the bypass tube, hose, and water
connection.
Remove the water inlet and outlet tube clips (7). Loosen
the hose clamps. Remove the aftercooler water tube sup-
port bracket (34).
Remove the aftercooler water tubes. Remove and discard
the o-rings.
Disconnect the coolant temperature sensor wire (17).
Remove the aftercooler water supply tube clip (7). Loosen

the hose clamps. Remove the support bracket (34).
Remove the tube (31). Remove and discard the o-ring.
Remove the four mounting capscrews (11). Remove the

thermostat housing assembly (29).
Remove the water transfer tube. Remove and discard the
two o-rings.
Install (008-015-026)
Install the o-rings (19) on the water transfer tube.
Use vegetable oil. Lubricate the o-rings. Install the tube
in the bore of the rocker lever housing.
Align the bore in the thermostat housing support with the
transfer tube. Push the support into position.
NOTE: The outside capscrew holds a clip for the aftercooler

water inlet tube.
Install the four lockwashers and capscrews. Tighten the
capscrews.
Use vegetable oil to lubricate the o-ring. Install a new

o-ring on the aftercooler water supply tube (31).
Install the tube in the bore of the thermostat housing.
Install the retainer clip (7) and capscrew. Tighten the
capscrew.
Attach the support clip to the bracket (34).
Connect the aftercooler coolant return tube (7) and hose(s)

to the aftercooler. Install the gasket and return tube
Install the vent hose (6).
Connect the coolant temperature sensor wire.
install the air compressor coolant return tube.

Install the retainer (9) and capscrew. Tighten the capscrew.
Install the two upper radiator hoses. Tighten the hose

clamps.
Install the vent lines.

028.
LTA
Install the o-rings (19) on the water transfer tube.
Use vegetable oil. Lubricate the o-rings. Install the tube
in the bore of the rocker lever housing.
Align the bore in the thermostat housing support with the
transfer tube. Push the support into position.
NOTE: The outside capscrew holds a clip for the aftercooler

water inlet tube.
Install the four lockwashers and capscrews. Tighten the
capscrews.

Install the retainer (9) and capscrew. Tighten the capscrew.
Use vegetable oil to lubricate the o-ring. Install a new

o-ring on the aftercooler water supply tube (31).
Install the tube in the bore of the thermostat housing.
Install the retainer clip (7) and capscrew. Tighten the
capscrew.
Attach the support clip to the bracket (34).
Use vegetable oil to lubricate the new o-rings. Install the

o-rings on the aftercooler water inlet and outlet.
Install the tubes. Install the retainer clips and capscrews.
Attach the support clips to the bracket.
Connect the coolant temperature sensor wire.
Install both of the radiator vent lines. Install the upper LTA
radiator hose. Tighten the clamps.
Install both of the upper engine radiator hoses. Tighten
the clamps.
Coolant Thermostat Seal (008-016) Section 8 — Cooling System — Group 08

028.
Check for leaks.
Coolant Thermostat Seal (008-016)

Remove (008-016-002)
Remove the thermostats. Refer to Procedure No.
008-013-002.
Caution: Do not damage the thermostat housing when

removing the thermostat seals.
NOTE: The thermostat housing has a machined counter-
bore to locate the seals.
Use a rolling head pry bar. Position the pry bar tip under
the top flange of the seal and pry upward. Remove the
seals from the housing.
Use a Snap-OnW pry bar, Part No. 1650 or equivalent.
Remove the engine thermostat seals.
LTA
Remove the engine thermostats (1). Refer to Procedure
No. 008-013-002.
Remove the LTA thermostat (2). Refer to Procedure No.
008-013-002.
Section 8 — Cooling System — Group 08 Coolant Vent Lines (008-017)
Caution: Do not damage the thermostat housing when

removing the thermostat seals.
NOTE: The thermostat housing has a machined counter-
bore to locate the seals.
Use a rolling head pry bar. Position the pry bar tip under
the top flange of the seal and pry upward. Remove the
seals from the housing.
Use a Snap-OnW pry bar, Part No. 1250 or equivalent.
Position the pry tip under the top flange of the seal and
pry upward. Remove the LTA thermostat seals.
Install (008-016-026)
LTA
NOTE: The seal must be installed with the part number
positioned upward.
Use a mallet and a mandrel, or a socket with a diameter
the same as the diameter of the seal case. Install the
seals. Be sure the seals seat in the bottom of the
counterbore.
Coolant Vent Lines (008-017)

The cooling system must be designed to allow the air to
escape while filling the radiator.
The aftercooler vent line is routed from the aftercooler

outlet tube to the top of the thermostat housing (6).
Coolant Vent Lines (008-017) Section 8 — Cooling System — Group 08
A second vent line is routed from the top of the thermostat

housing to the radiator top tank expansion space above
the water level.
Caution: Do not route the FILL or vent line in a manner

that will allow air to be trapped in the system.
• Route the vent line away from the makeup or FILL
line.
• The vent line must have a continuous rise to prevent
air lock and inadequate venting.
LTA
The cooling system must be designed to allow the air to
escape while filling the radiator.
The engine vent line (1) and the aftercooler vent line (2)
is routed from the top of the thermostat housing to the
radiator above the water level.
Section 8 — Cooling System — Group 08 Cooling System (008-018)
Caution: Do not route the FILL or vent line in a manner

that will allow air to be trapped in the system.
• Route the vent line away from the makeup or FILL
line.
• The vent line must have a continuous rise to prevent
air lock and inadequate venting.
Cooling System (008-018)

Drain (008-018-005)
Warning: Wait until the coolant temperature is below
50°C [120°F] before removing the coolant system pres-
sure cap. Failure to do so can cause personal injury from
heated coolant spray.
Remove the radiator cap after the engine is cool.
Position the vehicle on level ground. Open the draincock

at the bottom of the radiator. Remove the lower radiator
hose. Drain the cooling system.
LTA
Position the vehicle on level ground. Drain the coolant.
The LTA cooling system is drained by removing a pipe
plug (5) and opening a valve (4) located in the coolant
plumbing connecting, connecting the bottom tank of the
main engine and LTA radiator cores.
Cooling System (008-018) Section 8 — Cooling System — Group 08
NOTE: On some radiators, the plumbing that connects the

bottom tank of the engine and the LTA radiator are incorpo-
rated internally. With this design, there will be two drain
locations on the radiator bottom tank.
The plumbing between the radiator cores is designed to
only allow coolant to flow from the main engine core (2)
to the LTA core (3) during the fill procedures. To prevent
coolant flow in the opposite direction during engine op-
eration, a swing valve (1) must be included in the plumb-
ing. The arrow on the swing valve must point toward the
LTA core.
Draining the cooling system at the main engine radiator
core by removing the hose (6) or the pipe (7) will not allow
the LTA core to drain due to the swing valve.
Flush (008-018-009)
Warning: Wait until the coolant temperature is below
50°C [120°F] before removing the coolant system pres-
sure cap. Failure to do so can cause personal injury from
NOTE: The performance of RESTOREW is dependent on

time, temperature, and concentration levels. An extremely
scaled or flow restricted system, for example, can require
higher concentrations of cleaners, higher temperatures, or
longer cleaning time. RESTOREW can be safely used up to
twice the recommended concentration levels. Extremely
scaled or fouled systems can require more than one cleaning.
Drain the cooling system. Refer to Procedure No. 008-

018-005 and Procedure No. 008-018-006.
Do not remove the coolant filters.
Caution: Fleetguard RESTOREW contains no antifreeze.

Do not allow the cooling system to freeze during the
cleaning operation.
Immediately add 3.8 liters [1 U.S. gallon] of Fleetguard
RESTOREW, or equivalent, for each 38 to 57 liters [10
U.S. gallon] of cooling system capacity, and fill the system
with plain water.
Turn the heater temperature switch to HIGH to allow maxi-
mum coolant flow through the heater core. The blower
does not have to be ON.
Operate the engine at a coolant temperature of at least

85°C [185°F] for 1 to 1-1/2 hours.
Shut the engine OFF and drain the cooling system. Refer
to Procedure No. 008-018-005 and Procedure No.
008-018-005.
Fill the cooling system with clean water. Refer to Proce-

dure No. 008-018-028.
Operate the engine at high idle for 5 minutes with the

coolant temperature above 85°C [185°F].
Shut the engine OFF, and drain the cooling system. Refer
to Procedure No. 008-018-005 and Procedure No. 008-
018-005.
NOTE: If the water drained is still dirty, the system must be
flushed again until the water is clean.
Install a new coolant filter and fill the cooling system with
a fresh mixture of 50 percent low silicate antifreeze and
50 percent water. Refer to Procedure No. 008-006-026.
NOTE: Use additional DCA4 to bring the coolant to the
correct DCA4 concentration level. Refer to the specifications
in this Section.
Install the pressure cap. Operate the engine until the

coolant reaches a temperature of 70°C [160°F], and check
for coolant leaks.

Internal
Check the oil cooler housing for coolant leakage. Remove
the plugs from the cooler housing and check for coolant.
If coolant is present, replace the oil cooler cores. Refer to

If the oil cooler cores are not leaking, drain the oil. Refer
to Procedure No. 007-007-002. Check for coolant in the
oil.
If the oil does not contain coolant, check the aftercooler.
If the oil contains coolant, remove the oil pan and adapter
cover. Refer to Procedure No. 007-026-002 and Proce-
dure No. 007-027-002.
Check for leakage on the inside and outside of the cyl-

inder liner.
Replace all cylinder liners that are leaking. Refer to Pro-
cedure No. 001-028-026.
If the cylinder liners are not leaking, check the aftercooler
element.
Disconnect the aftercooler coolant hoses. Plug one hose

and apply air pressure to the other hose.
If the air pressure decreases, replace the aftercooler el-
ement. Refer to Procedure No. 010-008-026.
If the aftercooler element is not leaking, check the cyl-

inder heads.
Remove the aftercooler housing. Refer to Procedure No.
010-002-002.
Check the intake ports for coolant. To replace the cylinder

head, refer to Procedure No. 002-004-026.
Remove the test equipment. Remove the plug from the

overflow tube.
Replace the pressure cap.
External
Warning: Wait until the temperature is below 50°C
[120°F] before removing the coolant system pressure
cap. Failure to do so can cause personal injury from
To confirm and locate external coolant leaks, it is not
necessary to warm the engine.
Check the coolant level and fill if necessary.

NOTE: Add heavy duty coolant. Refer to Procedure No.
008-018-028, for instructions.
To confirm and locate external coolant leaks that occur
during normal engine operation, complete this test while
the engine is warm.
If the radiator is equipped with a pressure relief valve,

install a plug in the overflow tube (1).
Caution: Do not apply more than 140 kPa [20 psi] air
pressure to the cooling system. Excessive air pressure
can damage the water pump seal.
Install the pressure tester on the radiator fill neck or surge
tank (if equipped). Apply maximum air pressure.
Maximum Air Pressure: 140 kPa [20 psi]
Maintain the air pressure for a minimum of 5 minutes.

Check for leaks. Any leaks must be repaired.
Remove the pressure test equipment and the plug from
the pressure relief valve overflow tube (if equipped).
Replace the coolant system pressure cap.
Fill (008-018-028)
LTA
Close the radiator draincocks.
Install the lower radiator hose(s). Tighten the hose clamps.
Use a mixture of 50 percent ethylene or propylene glycol

antifreeze and 50 percent water to fill the cooling system.
NOTE: Use the correct units of DCA4 to obtain the correct
cooling system protection. Refer to Procedure No.
008-022-028.
Fill the cooling system with coolant to the bottom of the

fill neck in the radiator fill (or expansion) tank.
Replace the radiator or fill cap.

Operate the engine until the coolant reaches a tempera-
ture of 70°C [160°F]. Check for leaks.
Warning: Check the coolant level only when the engine

is stopped. Wait until the temperature is below 50°C
[120°F] before removing the pressure cap. Failure to do
so can cause personal injury from heated coolant spray.
Shut the engine OFF and allow it to cool.
Section 8 — Cooling System — Group 08 Cooling System — Air or Combustion Gas (008-019)
Cooling System — Air or Combustion

Gas (008-019)
Test (008-019-012)
Warning: Wait until the temperature is below 50°C
[120°F] before removing the coolant system pressure
cap. Failure to do so can cause personal injury from
Allow the engine to cool. Remove the radiator cap.
NOTE: The pressure cap must make a tight seal.

Install a radiator pressure cap that has had the spring and
pressure relief valve removed.
Attach a rubber hose to the radiator overflow connection.
Put the free end of the hose in a container of water.
Operate the engine at rated RPM until it reaches a tem-

perature of 80°C [180°F] with the thermostat open.
Check for a continuous flow of air bubbles from the hose
in the water container.
A continuous flow of air bubbles indicates:

• an air compressor cylinder head leak. Inspect the air
compressor head and gasket. Refer to Procedure
No. 012-007.
Cooling System — Air or Combustion Gas (008-019) Section 8 — Cooling System — Group 08
• A cylinder head combustion gas leak. Inspect the

cylinder head and gasket for damage. Refer to Pro-
cedure No. 002-004-021.
• Incorrect cylinder liner protrusion. Refer to Proce-
dure No. 001-028-007.
• Cracked or broken cylinder liners. Refer to Proce-
dure No. 001-028-007.
If no air is in the system, do the following.

Install the correct radiator pressure cap.
Operate the engine to a temperature of 80°C [180°F], and
check for coolant leaks.
Air Compressor
Caution: The air compressor discharge must be discon-
nected at the compressor. This will allow the compressor
to discharge air to the atmosphere to prevent the com-
pressor from overheating during this test.
Caution: Do not operate the engine over 5 minutes with
the components isolated from the cooling system. Com-
ponent damage can result.
Disconnect and plug the coolant supply and coolant drain

lines.
Repeat the test. If no air is found in the cooling system
with the air compressor isolated, replace the air com-
pressor head gasket. Refer to Procedure No. 009-006-008.
Cylinder Head and Cylinder Liner

A cracked or defective cylinder head will pressurize the
cooling system and force the coolant out the overflow
tube.
Check the cylinder head gasket. The part must be re-
placed if defective. Refer to Procedure No. 002-004-008,
or Procedure No. 002-021-008.
A cracked or porous cylinder liner will pressurize the

cooling system and force coolant out the overflow tube.
Check the cylinder liner. The liner must be replaced if
defective. Refer to Procedure No. 001-028-002.
To determine the cylinder liner that is leaking, perform the

following:
• Remove the water pump. Refer to Procedure No.
008-062-002.
• Remove the drive shaft.
• Install the water pump without the drive shaft.
NOTE: Drain part of the coolant so the coolant level will be

level with the water manifold tubes.
Slide the water manifold tubes into the rocker lever
housing.
Cooling System — Air or Combustion Gas (008-019) Section 8 — Cooling System — Group 08
Operate the engine at low idle for a maximum of 4 min-

utes. Check inside the water passage of each rocker lever
housing for air bubbles. Air bubbles in the coolant indi-
cate a porous or cracked cylinder liner.
A defective cylinder liner must be replaced. Refer to
Install the water tubes and water pump drive shaft.
Sight Glass Method

Put a clear PyrexW tube in the water connection between
the engine radiator and the thermostat housing.
NOTE: If desired, put the PyrexW tube in the vent line be-
tween the thermostat housing and the radiator.
Caution: Use wire lace to cover the tube and hose. Per-
sonal injury can result if the PyrexW tube separates from
the hoses.
Operate the engine at 75 percent of rated RPM until it

reaches an operating temperature of 80°C [180°F].
Check for a continuous flow of air bubbles in the hose.
A continuous flow of air bubbles indicates excessive air

in the system. Continue to operate the engine for 25
minutes.
If the flow of bubbles does not stop, check for the fol-
lowing:
• an air compressor cylinder head leak. Inspect the air
compressor head and gasket. Refer to Procedure
No. 008-019-012.
• a cylinder head combustion gas leak. Inspect the
cylinder head and gasket for damage. Refer to Pro-
cedure No. 008-019-012.
• incorrect cylinder liner protrusion. Refer to Proce-
dure No. 008-019-012.
• Cracked or broken cylinder liners. Refer to Proce-
dure No. 008-019-012.
If no air is found in the system, or if the flow of bubbles

stops within 25 minutes, do the following:
Install the correct radiator pressure cap.
Operate the engine until it reaches a temperature of 70°C
[160°F], and check for coolant leaks.
Cooling System Diagnostics (008-020) Section 8 — Cooling System — Group 08
Cooling System Diagnostics (008-020)

Use a pressure gauge with a minimum capacity of 275
kPa [40 psi]. Measure the coolant pressure at the water
manifold (1).
Operate the engine until the coolant temperature reaches
80°C [180°F].
NOTE: The thermostats must be open.
Operate the engine at rated RPM. Compare the pressure

readings to the following specifications.
Minimum Coolant Pressure-At-Water Manifold

Engine RPM kPa psi
1800 75 11
1900 82 12
2100 89 13
Maximum Coolant Pressure (Cap Removed):

241 kPa [35 psi]
If the above measurement location is not accessible,

install the gauge in the oil cooler housing.
Minimum Coolant Pressure-At-Oil Cooler Housing

Engine RPM kPa psi
1800 103 15
1900 117 17
2100 131 19
Maximum Coolant Pressure (Cap Removed):

241 kPa [35psi]
If coolant pressure is high, check the thermostat or ra-

diator for a restriction. Refer to Procedure No.
008-042-007.
Section 8 — Cooling System — Group 08 Cooling System Service Requirements (008-022)
If the coolant pressure is low, install a gauge (with a

maximum capacity of 69 kPa [10 psi] at the water pump
inlet.
Operate the engine at rated RPM. If the gauge reads more

than 35 kPa [5 psi], check the radiator. Refer to Procedure
No. 008-042-008.
Cooling System Service Requirements

(008-022)
Water↔
Always use good quality soft water in the coolant mixture.
Water added to the cooling system must meet the speci-
fications given in the accompanying chart.
Antifreeze↔
Caution: Antifreeze overconcentration reduces freeze
protection. Do not use more than 68 percent antifreeze
or overheating can result. A mixture of 50 percent anti-
freeze and 50 percent water is sufficient for freeze pro-
tection to -37°C [-34°F]
NOTE: Use ethylene propylene glycol antifreeze year-round
to provide freeze point and boil-over protection.
Caution: Do not use a high silicate antifreeze. A silicate-
gel (hydro-gel) formation can occur when a cooling sys-
tem contains an overconcentration of high silicate anti-
freeze and, or supplemental coolant additives. Engine
damage will result.
Fan Drive Ilder Arm Assembly (008-029) Section 8 — Cooling System — Group 08
Sealing Additives↔
• Do not use sealing additives in the cooling system.
using sealing additives will cause the following prob-
lems:
• buildup in coolant low flow areas,
• clogged coolant filters, and
• plugged radiator,
Soluable Oils↔
Do not use soluble oils in the cooling system. The use of
soluble oil will:
• allow cylinder liner pitting,
• corrode brass and copper,
• damage heat transfer surfaces, and
• damage seals and hoses.
Coolant Additives and Filters↔

Supplemental coolant additives, DCA4 or equivalent, are
required to protect the cooling system from fouling, solder
blooming, liner pitting, and general corrosion. The cool-
ant filter is required to protect the cooling system from
abrasive material, debris, and precipitated coolant
additives.
Fan Drive Ilder Arm Assembly (008-

029)
Remove (008-029-002)
Remove the fan belt. Refer to Procedure No. 008-002-002.
Section 8 — Cooling System — Group 08 Fan Drive Ilder Arm Assembly (008-029)
Caution: The belt tensioner and the pivot arm assembly

will rotate during removal. Personal injury can result. To
avoid personal injury, use a hoist or get personal assis-
tance to lift the component.
Remove the belt adjusting nut (1) from the tensioner
assembly.
Remove the three capscrews (2) from the pivot arm as-
sembly.
Remove the pivot arm and the belt tensioner as an
assembly.
Remove the belt tensioner from the idler arm assembly.

Inspect the idler pulley. Rotate the pulley to check for
rough bearings. Check the bearing end clearance.
Bearing End Clearance

mm in
0.08 MIN 0.003
0.25 MAX 0.010
Inspect the grease seal for damage.
Inspect the belt tensioner assembly for cracks or exces-

sive wear. The part must be replaced if worn.
Fan Hub, Belt Driven (008-036) Section 8 — Cooling System — Group 08
Install (008-029-026)
Install the belt tensioner on the idler arm. Tighten the
capscrews.
Install the idler arm assembly and capscrews (2). Tighten

the capscrews.
Install the belt tensioning nut (1). Do not tighten the nut.
Fan Hub, Belt Driven (008-036)

Remove (008-036-002)
Remove the fan. Refer to Procedure No. 008-040-002.
Remove the fan belt. Refer to Procedure No. 008-002-002.
Section 8 — Cooling System — Group 08 Fan Hub, Belt Driven (008-036)

To avoid personal injury, use a hoise or get personal
assistance.
Remove the eight nuts and washers, and the fan hub.

Clean and inspect the fan hub for reuse. Rotate the pulley
to check for rough or damaged bearings.
Check bearing end clearance.
Bearing End Clearance

mm in
0.03 MIN 0.001
0.25 MAX 0.010
Inspect the grease seals for damage.
Install (008-036-026)
Install the fan hub, the eight washers and nuts. Tighten
the fan hub nuts.

Install the fan. Refer to Procedure No. 008-040-026.
Fan, Cooling (008-040) Section 8 — Cooling System — Group 08
Fan, Cooling (008-040)

Visually check the fan for cracked, bent, or broken blades.
Warning: Do not straighten a bent fan blade, or continue

to use a damaged fan. A bent or damaged fan blade can
fail during operation and cause serious personal injury
or property damage.
Remove (008-040-002)
Disconnect the batteries or air supply line to the air starter
to prevent accidental engine starting.
Caution: Do not pry or pull on the fan. The fan blades

can be damaged.
Section 8 — Cooling System — Group 08 Fan, Cooling (008-040)
Remove the fan and spacer.
Install (008-040-026)
Caution: Replace the original equipment fan with a fan
of the identical part number. Cummins Engine Company,
Inc. must approve any fan changes.
Install the fan and applicable spacer.

Tighten the mounting capscrews.
Connect the batteries or air starter supply line.

Fan, Cooling (008-040) Section 8 — Cooling System — Group 08
Rotation Check (008-040-052)

Use an optical tachometer, Part No. 3377462, or a strobe
light to measure the fan RPM.
Mark a spot on the fan so the fan RPM can be measured.

Mark another spot on the vibration damper or accessory
drive pulley to measure engine RPM.
NOTE: When using Cummins optical tachometer, use a piece
of reflective tape, Part No. 3377464, to mark the spot.
Measure the diameter of the fan belt pulley to determine

the drive ratio.
Belt Driven Fan

Fan Pulley Diameter Fan RPM
239 mm [9.4 in] .85 x engine RPM
NOTE: The fan center distance is the distance between the
center of the fan hub and the center of the crankshaft.
Operate the engine. Read and compare the fan RPM to

the engine RPM. Compare the fan RPM to the
specification.
Section 8 — Cooling System — Group 08 Radiator (008-042)
If the fan RPM is not correct, check the belt tension. Refer
Radiator (008-042)
Test (008-042-012)
Obstruction↔
Use a pressure gauge designed to measure 0-100 kPa
[0-15 psi]. Install a valve on each side of the gauge.
Install one line into the water pump inlet connection and
the other into the thermostat return line of on top of the
radiator core.
Bleed the air from the gauge lines.
Restrict the radiator air flow. Operate the engine until the
coolant temperature reaches 88-90°C [190-195°F].
Radiator (008-042) Section 8 — Cooling System — Group 08
Operate the engine at rated RPM. Close valve No. 1 and

open valve No. 2. Record the pressure at the top of the
radiator.
Close valve No. 2 and open valve No. 1. Record the

pressure at the water pump inlet.
Compare the two pressure readings. If they differ by more
than 35 kPa [5 psi], the radiator core or piping is
obstructed.

Caution: Wear appropriate eye protection and face pro-
tection when using compressed air. Improper use can
cause bodily injury from flying debris and dirt.
Visually check for plugged radiator fins.
Use compressed air to blow out the dirt and debris. Blow
the compressed air opposit the direction of the fan air
flow.
Visually check for bent or broken fins. Visually check for

radiator core and gasket leaks.
If the radiator must be replaced, refer to the manufac-
turer’s replacement procedures.
Section 8 — Cooling System — Group 08 Radiator (008-042)
Warning: If a liquid refrigerant system must be removed

before removing the radiator, wear eye and face protec-
tion. Wrap a cloth around the fittings before removal.
Liquid refrigerant can cause serious eye and skin injury.
For environmental protection, federal regulations require
that freon be recycled, and not vented into the atmosphere.
Reverse Flow
NOTE: This test must be performed with the cooling system
completely full and the coolant at ambient temperature.
Operate the engine at medium to high idle. Since the
thermostats are closed, coolant flow is through the by-
pass line (1) and the engine (2).
As the engine is warming up, use your hands or a contact

pyrometer to check the temperature of the radiator top
and bottom tanks.
If the bottom tank begins to warm to the touch and the top
tank remains cold, the radiator has reverse flow. Refer to
the manufacturer’s instructions for repair procedures.
Check the piping to be sure it is the correct size and
routed per specifications. Refer to the appropriate Instal-
lation Recommendation Bulletin.
Radiator Hose, Lower (008-045) Section 8 — Cooling System — Group 08
Radiator Hose, Lower (008-045)

Remove (008-045-002)
008-018-005.
Disconnect the lower radiator hose from the water pump

inlet. Disconnect the lower radiator hose from the radiator
bottom tank. Remove the lower radiator hose.

Caution: Do not bend or deform the hoses during in-
spection. This can cause the hoses to crack.
Check all hoses for cracks, cuts, or collapsing.
NOTE: The silicone engine coolant hose will exhibit swelling
due to the elasticity of the hose.
Install (008-045-026)
Install the lower radiator hose to the water pump inlet.
Tighten the clamps.
Torque Value (Worm Clamp): 5.6 N•m [50 in-lb]
Torque Value (T-Bolt Clamp): 8 N•m [70 in-lb]
Install the lower radiator hose to the radiator bottom tank.
Tighten the clamps.
Torque Value (Worm Clamp): 5.6 N•m [50 in-lb]
Section 8 — Cooling System — Group 08 Radiator Hose, Upper (008-046)

028.
Check for leaks.
Radiator Hose, Upper (008-046)

Remove (008-046-002)
008-018-005.
Remove the upper radiator hoses from the thermostat

housing.
Remove the upper radiator hoses from the top tank of the
radiator.
Radiator Hose, Upper (008-046) Section 8 — Cooling System — Group 08
LTA
Remove the LTA hoses from the thermostat housing.
Remove the LTA radiator hoses from the top tank of the
radiator.

Caution: Do not bend or deform the hoses during in-
spection. This can cause the hoses to crack.
Inspect all hoses for cracks, cuts, or collapsing.
NOTE: The silicone engine coolant hose will exhibit swelling
due to the elasticity of the hose.
Install (008-046-026)
Install the upper radiator hoses to the thermostat housing.
Tighten the clamps.
Torque Value (Worm Clamp): 5 N•m [50 in-lb]
Section 8 — Cooling System — Group 08 Radiator Hose, Upper (008-046)
Install the upper radiator hoses to the top tank of the

radiator. Tighten the clamps.
LTA
Install the upper LTA radiator hoses to the thermostat
housing. Tighten the clamps.
Install the LTA radiator hoses to the top tank of the radiator.
Tighten the clamps.

028.
Operation the engine to 70°C [160°F] coolant tempera-
ture. Check for leaks.
Radiator Pressure Cap (008-047) Section 8 — Cooling System — Group 08
Radiator Pressure Cap (008-047)

Visually inspect the rubber seal of the pressure cap for
damage.
Visually inspect the radiator fill neck for cracks or other
damage.
Refer to the radiator manufacturer’s instructions if the fill
neck is damaged.
NOTE: Be sure the correct radiator cap is being used. The
pressure rating must be 48 kPa [7psi] or greater.

Pressure test the radiator cap.
The pressure cap must seal within 14 kPa [2 psi] of the
value printed on the cap, or it must be replaced.
Radiator Shroud (008-048)

Inspect the fan shroud for the correct fan clearance. Refer
to the vehicle manufacturer’s specifications and the ap-
propriate Installation Recommendations Bulletin.
Visually inspect the shroud for cracks, air leaks, or other
damage. Replace the part if damaged. Refer to the manu-
facturer’s instructions.
Radiator Top Tank (008-051)

Leak Test (008-051-014)
008-018-005.
Section 8 — Cooling System — Group 08 Supplemental Coolant Additive (SCA) (008-060)
Plug the radiator fill line outlet.

Fill the top tank within 50 mm [2 inch] of the top with water.
If the level drops and leakage is observed from the
draincock and the lower radiator outlet, the baffle is leak-
ing. The radiator must be repaired or replaced.
Supplemental Coolant Additive (SCA)

(008-060)
Supplemental coolant additives, or equivalent, are used
to prevent the buildup of corrosion and scale deposits in
the cooling system.
Caution: Inadequate concentration of coolant additives

can result in major corrosive damage to cooling system
components. Overconcentration can cause the forma-
tion of gelatin (gel) that can cause restrictions and plug-
ging.
The DCA4 concentration must not fall below 1.5 units per
3.8 liters [1 U.S. gallon], or exceed 3 units per 3.8 liters
[1 U.S. gallon].
NOTE: DCA4 is compatible with all permanent-type anti-

freeze except Methoxy Propanol. If Methoxy Propanol anti-
freeze is used, reduce the amount of DCA4 by one-third. This
will prevent inhibitor loss due to precipitation, caused by
chemical incompatibility.
Water Pump (008-062) Section 8 — Cooling System — Group 08
When changing the coolant, the initial DCA4, or equiva-

lent concentration, must be between 1.5 and 3 units per
3.8 liters [1 U.S. gallon] of coolant (initial charge).
NOTE: The cooling system must be clean before adding
DCA4, or equivalent. Refer to Procedure No. 008-018-006).
If coolant is added between drain intervals, additional

DCA4, or equivalent, will be required.
Check the coolant just before changing the coolant filter.
Use only coolant test kit, Fleetguard, Part No. 3300846S,
to check the coolant additive concentration when DCA4
is used. Refer to instructions in the Specifications section
of this manual.
Use the correct Fleetguard coolant filter to maintain the

correct DCA4 concentration in the system. Refer to the
Specifications section of this manual.
Maintain the correct concentration by changing the main-
tenance coolant filter at each oil drain interval.
Water Pump (008-062)

Remove (008-062-002)
Disconnect the batteries or air supply line to the air starter
to prevent accidental engine starting.
008-018-005.
Section 8 — Cooling System — Group 08 Water Pump (008-062)
Open the draincock on the oil cooler housing and on the

water pump.
Remove the coolant filter.
Remove the bypass tube clamp (9). Loosen both hose

clamps. Remove the bypass tube, hose, and water
connection.


Remove the water transfer tube from the water connec-
tion. Remove and discard the two o-rings (13) and the
gasket.
Disconnect the lower radiator hose from the water pump

inlet.
Remove the capscrew from the water pump support

bracket. Remove the three capscrews and the nut from
the water pump mounting flange.
Remove the water pump and the gasket. Discard the
gasket.
Remove the drive shaft (14).
Remove the water inlet connection and gasket (1). Re-

move the support bracket (2).
Inspect (008-062-062)
Rotate the shaft and inspect for rough or damaged
bearings.
Inspect the drive shaft for wear. If the drive shaft splines
are worn, check the female splines in the pump and in the
water pump drive.
Use a feeler gauge and measure the impeller-to-pump

body clearance.
Impeller Vane-To-Body Clearance

mm in
0.58 MIN 0.023
0.86 MAX 0.034
Install (008-062-026)
Install the inlet connection (1), gasket, and capscrews.
NOTE: Do not tighten the support bracket until the water
pump is assembled to the engine. Use a heavy, plain washer
on the capscrew that attaches through the slotted hole.
Install the support bracket (2).
NOTE: Failure of the water pump drive shaft will result when
the wrong shaft is installed.
Use shaft (1) with cast iron impeller pumps. Use shaft (2)
with phenolic (plastic) impeller pumps.
NOTE: Install the shaft with the oil hole at the side of the shaft
towards the water pump.
Use engine oil and lubricate the drive shaft (14). Install the
shaft in the splined hole in the water pump drive.
NOTE: Do not tighten the capscrews and nut until the sup-
port bracket is aligned with the cylinder block.
Install the gasket and water pump. Install three capscrew
and nut. Tighten the capscrews and nut.
The support bracket must be flat against the water pump

and the cylinder block. Align the bracket before tightening
the capscrews.
Install the capscrew through the bracket. Tighten the
capscrew.
Check the alignment between the support bracket and
the water pump. Loosen the capscrew and adjust if nec-
essary.
Tighten the capscrews holding the support bracket to the
water pump.
Connect the lower radiator hose. Tighten the clamps.

Use vegetable oil and lubricate the o-rings (13).

tion.

Install the bypass connection gasket. Tighten the

capscrews.
Use vegetable oil and lubricate the o-ring on the bypass
Install the retainer (9) and capscrew. Tighten the capscrew
and the hose clamps.
Torque Value (Hose Clamps): 6 N•m [50 in-lb]
Replace the coolant filter. Refer to Procedure No. 008-

006-006.
Close the draincock on the water pump and oil cooler
housing.

028.
Torque Converter Cooler (008-065) Section 8 — Cooling System — Group 08
Torque Converter Cooler (008-065)

Remove (008-065-002)
008-018-005.
Open the draincocks on the water pump and oil cooler

housing.
Close the draincock(s) after all of the coolant is removed.
Remove the turbocharger oil drain hose. Remove the

turbocharger coolant supply hose.
Remove the water bypass tube clamp (9). Loosen both

hose clamps. Remove the bypass tube and discard the
o-ring.
Section 8 — Cooling System — Group 08 Torque Converter Cooler (008-065)


Remove the water transfer tube from the water outlet
connection. Remove and discard the two o-rings (13) and
the gasket.
Remove the oil supply (1) and oil return (2) hoses from the
torque converter cooler.
Remove the torque converter cooler cover mounting

capscrews. The cover must be pried from the housing
because of the tight fit between the cover and the o-rings
on the elements.

lift the component.
Use two [3/8-16x12-inch] guide studs to support the hous-
ing while the capscrews are being removed.
Remove the remaining capscrews, the torque converter
cooler housing, and the gasket. Discard the gasket.
Remove the torque converter cooler element mounting

nuts. Remove the elements. Remove and discard the
o-rings.

parts.
Visually inspect the parts for cracks or other damage.

NOTE: Heating the water in the tank to 50°C [120°] will
improve the test results.
Pressure test the elements to check for leaks.
Install (008-065-026)
Install the elements. Tighten the self-locking nuts.
Use new o-rings. Lubricate the o-rings with vegetable oil.
Install the o-rings on the cooler elements.

lift the component.
Use two [3/8-16x12-inch] guide studs to support the hous-
ing during installation.
Install the gasket and housing.
Install the capscrews in the bottom row of holes on the
housing. These capscrews are all 101.6 mm [4-inch] long.
NOTE: The length and location of all the capscrews on the

torque converter cooler and cover are shown. Be sure the
capscrews are the correct length.
Do not tighten any of the capscrews until all of them have
been installed.
NOTE: Be sure the capscrews are the correct length.

Use vegetable oil to lubricate the o-rings on the cooler
elements and the bores in the cover.
Install the gasket and cover. Push the cover over the
o-rings until the cover is against the housing.
Install the remaining capscrews.
NOTE: The capscrews have different torque values. The

torque values depend on the manufacturing material of the
oil cooler housing.
Tighten the capscrews in the sequence shown.
Use vegetable oil. Lubricate the o-rings (13).

tion.

Use vegetable oil. Lubricate the o-ring on the water by-

pass tube.
Install the bypass tube.
Install the retainer (9) and capscrew. Tighten the capscrew
and hose clamps.
Torque Value (Clamp): 5.6 N•m [50 in-lb]
Connect the torque converter oil hoses to the torque

converter cooler.
Caution: These parts are a safety-related item. Be sure

the parts are clamped correctly to prevent fretting.
Install the turbocharger oil drain tube. Tighten the
capscrews.
Connect the coolant supply hose to the turbocharger.

028.
Check for leaks.
NOTES
Section 9 — Drive Units — Group 09
Section 9 — Drive Units — Group 09

Section Contents
Page
Accessory Drive (009-001) ................................................................................................................................. 9-6
Clean (009-001-006) ........................................................................................................................................ 9-7
Install (009-001-026) ........................................................................................................................................ 9-8
Remove (009-001-002)..................................................................................................................................... 9-6
Accessory Drive Pulley (009-004) .................................................................................................................... 9-10
Install (009-004-026)....................................................................................................................................... 9-11
Remove (009-004-002) ................................................................................................................................... 9-10
Drive Units — General Information (009-999-999) ............................................................................................ 9-2
Drive Units — Specifications............................................................................................................................. 9-3
Drive Units — Tool Requirements (022-001-509) .............................................................................................. 9-5
Water Pump Drive (009-029) ............................................................................................................................ 9-12
Install (009-029-026) ...................................................................................................................................... 9-14
Remove (009-029-002)................................................................................................................................... 9-12
Drive Units — General Information (009-999-999) Section 9 — Drive Units — Group 09
Drive Units — General Information (009-999-999)

Accessory Drive
The housing is manufactured of aluminum. The aluminum housing does not contain a bushing, and does not
require thrust washers.
Caution: Installation of an air compressor on a fuel pump drive housing will result in failure due to the
lack of lubrication.
The housings are available in two designs, with and without provisions for mounting an air compressor. Those
without air compressors do not have provisions for a compressor oil pressure and drain-back. The fuel pump drive
has provisions for a lovejoy coupling. The compressor drive has provisions for a splined sleeve-type coupling. The
procedures are identical for both of the designs.
The fuel pump/compressor drive gear has stamped marks. The stamped marks must be aligned properly with the
camshaft idler gear so that the accessory drive pulley is installed correctly.
The retainer capscrew on the compressor drive (splined half-coupling) is special. It has a drilling in it that provides
lubrications of the splined coupling. The retainer capscrew on the fuel pump drive (lovejoy half-coupling) does not
have an oil drilling.
Section 9 — Drive Units — Group 09 Drive Units — Specifications (018-001-201)
Drive Units — Specifications

(018-001-201)
Accessory Drive Shaft Journal — O.D.

Reference mm in
Point
(1) 34.963 MIN 1.3765
34.976 MAX 1.3770
(2) 39.664 MIN 1.5615
39.674 MAX 1.5620
(3) 33.300 MIN 1.3110
33.330 MAX 1.3120
(4) 25.476 MIN 1.0030
25.489 MAX 1.0035
Accessory Drive — End Clearance

mm in
0.05 MIN 0.002
0.30 MAX 0.012
Accessory Drive Shaft Bore — I.D.

mm in
33.43 MIN 1.316
33.50 MAX 1.319
Splined Coupling — I.D.

mm in
25.400 MIN 1.0000
25.425 MAX 1.0010
Lovejoy Coupling — I.D.

mm in
25.425 MIN 1.0010
25.438 MAX 1.0015
Accessory Drive Pulley Bore — I.D.

mm in
34.912 MIN 1.3745
34.938 MAX 1.3755
Drive Units — Specifications (018-001-201) Section 9 — Drive Units — Group 09
Accessory Drive Thrust Bearing — Thickness

mm in
2.36 MIN 0.093
2.41 MAX 0.095
Acessory Drive Housing — Depth

mm in
45.54 MIN 1.793
45.67 MAX 1.798
Water Pump Drive — End Clearance

mm in
0.23 MIN 0.009
0.33 MAX 0.013
Accessory Drive Housing Capscrew [3/8-Inch]: ........................................................... 45 N•m [35 ft-lb]

Accessory Drive Housing Capscrew [1/2-Inch]: ......................................................... 100 N•m [75 ft-lb]
Accessory Drive Housing Straight Thread O-Ring Plug: ............................................... 8 N•m [75 in-lb]
Section 9 — Drive Units — Group 09 Drive Units — Tool Requirements (022-001-509)
Drive Units — Tool Requirements (022-001-509)

Gear Puller
Used to remove the drive pulleys and impellers.
ST-647
Oil Seal Remover/Installer

Used to remove small bushings, oil seals, and bearings.
ST-1311
Pulley Installation Tool

Used to install drive pulleys.
3376326
Coupling Puller
Used to remove accessory drive coupling.
3376663
Accessory Drive (009-001) Section 9 — Drive Units — Group 09
Accessory Drive (009-001)

Remove (009-001-002)
NOTE: If an air compressor is not mounted on the engine,
it will not be necessary to drain the cooling system.
NOTE: Drain the cooling system. Refer to Procedure No.
008-018-005.

005-016-002.

014-002 for single cylinder compressor, or Procedure No.
012-015-002 for two cylinder compressor.

No. 009-004-002.
Section 9 — Drive Units — Group 09 Accessory Drive (009-001)
Caution: The woodruff key must be removed before re-

moving the accessory drive assembly. Damage to the
bushing can result.
Remove the four capscrews and the nut (31). Remove the
accessory drive assembly.
Remove the oil slinger (30).
Clean (009-001-006)
Use solvent. Clean the parts. Dry with compressed air.

Caution: The accessory drive support is different if the
engine is equipped with an air compressor. The support
used with an air compressor has a drilling to supply
engine oil to the compressor. The support used with only
a fuel pump does not have the oil drilling. If a support
without the drilling is used with a compressor, the com-
pressor will fail from lack of lubrication.
Clean and inspect the accessory drive for reuse. Inspect
the end clearance.
Accessory Drive — End Clearance

mm in
0.05 MIN 0.002
0.30 MAX 0.012
Inspect the teeth of the gear for damage.
Accessory Drive (009-001) Section 9 — Drive Units — Group 09
Inspect the coupling washer. It must be positioned tightly

between the coupling and the shaft. If the washer is not
tight, the drive must be replaced or rebuild.
Install (009-001-026)
Remove the two straight threaded o-ring plugs from the
timing holes in the front cover.
Check the index mark alignment.
Caution: Do not use the "A" on the camshaft idler gear

for the accessory drive alignment unless the "X" marks
on the camshaft and the camshaft idler gears are aligned
and centered in the upper timing plug hole. If the "X"
marks are not visible in the upper hole, rotate the engine
until the "X" marks on the camshaft gear and camshaft
idler gear are aligned and centered in the upper timing
plug hole.
NOTE: Install the accessory drive so that the "A" on the
accessory drive gear is centered in the lower timing plug
hole.
Caution: If the accessory drive housing is aluminum,

plain washers must be installed on the capscrews.
Install the gasket, capscrews, and nut. Tighten the
capscrews.
Section 9 — Drive Units — Group 09 Accessory Drive (009-001)
Install the straight threaded o-ring plugs. Tighten the o-ring

plugs.
Install the oil slinger (4). Install the accessory drive pulley
alignment key (5).

001-001-026.
Install the tool adapter (7). Install the accessory drive
pulley. Refer to Procedure No. 009-004-026.

014-026 for a single cylinder compressor, or Procedure
No. 012-015-026 for a two cylinder compressor.
Accessory Drive Pulley (009-004) Section 9 — Drive Units — Group 09
Install the fuel pump and related components. Refer to


028.
Operate the engine to 70°C [160°F]. Check for leaks.
Accessory Drive Pulley (009-004)

Remove (009-004-002)
Caution: Use a capscrew in the shaft to prevent damage
to the shaft threads.
Install a [7/16-20 X 1 inch] capscrew in the shaft.
Use a standard puller, Part No. ST647, or equivalent (28).
Remove the accessory drive pulley.
Use a brass drift and remove the woodruff key (29) from
the shaft. Remove the capscrew (27) from the shaft.

Visually inspect the pulley for cracks, wear in the belt
grooves, or other damage.
Section 9 — Drive Units — Group 09 Accessory Drive Pulley (009-004)
Clean the mating surface and pulley bore. Inspect each

area for damage.
Install (009-004-026)
Install the woodruff key.
Caution: Do not use a hammer to drive the pulley into

position. Damage to the thrust bearing will result.
Use a pulley installation tool kit, Part No. 3376326. Insert
the appropriate adapter (7) in the pusher.
NOTE: Do not lubricate. The lips on the seal and the seal
surface on the pulley wear sleeve must be clean and dry.
Lubricate the shaft O.D. and the pulley I.D. with engine oil.
Align the keyway in the pulley with the key in the shaft.
Use the tool to push the pulley on the shaft until it touches
the step on the shaft.
Water Pump Drive (009-029) Section 9 — Drive Units — Group 09
Water Pump Drive (009-029)

Remove (009-029-002)
Remove the water pump. Refer to Procedure No.
008-062-002.
Loosen the adjusting link and the alternator mounting.

Caution: The lower jam nut is a left-hand thread.
Loosen both of the jam nuts. Turn the adjusting screw to
relieve the belt tension. Remove the alternator belt.
Remove the plastic plug at the end of the shaft.

Insert the adapter, Part No. 3376089, in the shaft to pre-
vent damage. The adapter is included with the pulley
installation tool, Part No. 3376326.
NOTE: If the adapter is not available, a [3/4-16 inch] capscrew
with a head ground smaller than the pulley I.D. can be used.
Put the puller on the pulley. Remove the pulley. Remove

the adapter.
Section 9 — Drive Units — Group 09 Water Pump Drive (009-029)
Remove the water pump drive assembly. Remove and

discard the gasket.
NOTE: If necessary, tap on the end of the shaft with a mallet.
Remove the alternator drive oil seal. Refer to Procedure

No. 001-001-002.

Measure the water pump drive end clearance.
Water Pump Drive End Clearance

mm in
0.23 MIN 0.009
0.33 MAX 0.013
If the end clearance is not within specifications, replace
or rebuild the assembly.
NOTE: Oversize thrust bearings are available to adjust the
end clearance.
Inspect the water pump drive bushing in the front cover

for excessive wear or damage.
Inspect the alternator drive pulley for reuse. Refer to Pro-

cedure No. 009-010-008.
Inspect the water pump for reuse. Refer to Procedure No.
008-062-062.
Install (009-029-026)
Install the gasket. Install the water pump drive assembly.
The drive will be secured in position by the stud.

001-001-026.
Caution: Do not use a hammer to drive the pulley into
position. The thrust washers will be damaged.
Use the pulley installation kit, Part No. 3376326, or equiva-
lent. Install the correct adapter in the pusher.
Install the pulley on the shaft. The pulley must touch the
step on the shaft. Remove the tool and adapter.
Install the plastic plug that protects the threads.

Remove the capscrew from the water pump drive.
Section 9 — Drive Units — Group 09 Water Pump Drive (009-029)
Install the alternator belt. Refer to Procedure No.

013-005-026.
Install the water pump and related parts. Refer to Proce-

dure No. 008-062-026.
NOTES
Section 10 — Air Intake System — Group 10
Section 10 — Air Intake System — Group 10

Section Contents
Page
Aftercooler Assembly (010-002)....................................................................................................................... 10-6
Inspect for Reuse (010-002-007) ..................................................................................................................... 10-8
Install (010-002-026) ....................................................................................................................................... 10-8
Remove (010-002-002) ................................................................................................................................... 10-6
Aftercooler Element (010-008) ........................................................................................................................ 10-11
Install (010-008-026) ..................................................................................................................................... 10-13
Pressure Test (010-008-013) ......................................................................................................................... 10-12
Remove (010-008-002) .................................................................................................................................. 10-11
Air Intake Information — General Information (010-999-999).......................................................................... 10-2
Air Intake System - Specifications (018-001-205)............................................................................................ 10-4
Air Intake System - Tool Requirements (022-001-510)..................................................................................... 10-5
Air Intake System — Flow Diagrams (010-200-281)......................................................................................... 10-3
Air Leaks, Air Intake System (010-024) .......................................................................................................... 10-15
Boost Pressure (010-057) ............................................................................................................................... 10-30
Measure (010-057-010) ................................................................................................................................. 10-30
Intake Air Restriction (010-031)...................................................................................................................... 10-17
Measure (010-031-010) ................................................................................................................................. 10-17
Turbocharger Axial Clearance (010-038) ........................................................................................................ 10-24
Measure (010-038-010) ................................................................................................................................. 10-24
Turbocharger Blade Damage (010-039) .......................................................................................................... 10-24
Turbocharger Compressor Seal Leaks (010-040) ........................................................................................... 10-25
Inspect (010-040-062) ................................................................................................................................... 10-25
Turbocharger Radial Bearing Clearance (010-047) ........................................................................................ 10-27
Measure (010-047-010) ................................................................................................................................. 10-27
Turbocharger Turbine Seal Leaks (010-049) ................................................................................................... 10-28
Fluorescent Dye Tracer (010-049-054)........................................................................................................... 10-28
Turbocharger (Water-Cooled) (010-037) ......................................................................................................... 10-18
Check for Correct Component (010-037-048) ................................................................................................ 10-23
Install (010-037-026) ..................................................................................................................................... 10-20
Remove (010-037-002).................................................................................................................................. 10-18
Air Intake Information — General Information (010-999-999) Section 10 — Air Intake System — Group 10
Air Intake Information — General

The combustion air system consists of air intake system,
turbocharger (A), exhaust system (B), air crossover (C),
and aftercooler assembly (D).
The turbocharger uses exhaust gas energy to turn the

turbine wheel. This turbine wheel drives a compressor
impeller that provides pressurized air to the engine for
combustion
Section 10 — Air Intake System — Group 10 Air Intake System — Flow Diagrams (010-200-281)
Air Intake System — Flow Diagrams (010-200-281)

Air Intake System - Specifications (018-001-205) Section 10 — Air Intake System — Group 10
Air Intake System - Specifications (018-001-205)

Air Induction System:
Maximum Intake Restriction (Clean Air Filter Element): ................................ 380 mm H2O [15.0 in-H2O]
Maximum Intake Restriction (Dirty Air Filter Element): ................................. 635 mm H2O [25.0 in-H2O]
Exhaust System:
Maximum Back Pressure: ....................................................................................... 75 mm Hg [3.0 in-Hg]
Normal Exhaust Pipe Diameter: ...................................................................................... 152 mm [6 inch]
Section 10 — Air Intake System — Group 10 Air Intake System - Tool Requirements (022-001-510)
Air Intake System - Tool Requirements (022-001-510)

Manometer
Used to measure water restriction.
ST-1111-3
Dial depth gauge

This gauge is used to check for proper nozzle ring crush or end
clearance checks on turbochargers.
ST-537
Aftercooler Assembly (010-002) Section 10 — Air Intake System — Group 10
Aftercooler Assembly (010-002)

Remove (010-002-002)
008-018-005.

and the crossover.
Loosen the two hose clamps and remove the outlet hose
(8).
Loosen the two hose clamps and remove the inlet hose.
Section 10 — Air Intake System — Group 10 Aftercooler Assembly (010-002)
Remove the air compressor air inlet connection. Remove

and discard the hose.
Loosen the fuel tubing nuts at the fuel junction block on
the fuel manifold. Remove the fuel tubing mounting clamp
and the fuel tubes.
Refer to Procedure No. 006-013-002 or 006-024-002.

To avoid personal injury, use a hoist or get personal
assistance to lift the component.
For removal of wiring harness, refer to Procedure No.
019-043-002.
For removal of the intake manifold pressure sensor, refer
For removal of the intake manifold air temperature sensor,
refer to Procedure No. 019-059-002.
Remove two mounting capscrews. Install two [3/8-16 inch]
guide studs.
Use a hoist, two tee handles, and a lifting sling. Attach the
tee handles, sling, and hoist. Raise the hoist until there
is tension on the sling.
Remove the remaining capscrews and the aftercooler
assembly. Remove and discard the gaskets.
Remove and discard the aftercooler bolt seals from the

aftercooler housing.

Clean and inspect the aftercooler for reuse. Look into the
cylinder head ports and into the aftercooler for indications
of coolant leakage. Refer to Procedure No. 008-018-013.
Install (010-002-026)
Install the bolt seals in the aftercooler housing.

lift the component.
NOTE: Use guide studs long enough to protrude beyond the
installed part.
Install 12 guide studs in the upper row of capscrew holes
in the cylinder heads.
Install the gaskets on the studs with the raised bead on
the gasket toward the cylinder head.
For the installation of the wiring harness, refer to Proce-
dure No. 019-043-026.
For the installation of the intake manifold pressure sensor,
refer to Procedure No. 019-061-026.
For the installation of the intake manifold air temperature
sensor, refer to the Procedure No. 019-059-026.
Section 10 — Air Intake System — Group 10 Aftercooler Assembly (010-002)
Install the aftercooler and the bottom row of capscrews.

Tighten the capscrews only enough to hold the part.
Remove the guide studs and install the top row of
capscrews.
Use the sequence shown, and the steps and values in-
dicated below to tighten the capscrews.
Intake Manifold Torque Sequence

N•m Step ft-lb
25 1 20
45 2 35
Install the parts for the air compressor air inlet connec-
tion. Install the capscrew and the clamp.
Torque Value (Capscrew): 45 N•m [35 in-lb]
Install the fuel tubing. Refer to Procedure No. 006-013-
002 or 006-024-002.
Connect the inlet hose. Tighten the clamps.

Connect the water outlet hose. Tighten the clamps.

Install the hose and two hose clamps on the air crossover
tube.
Install the air crossover. Slide the hose down the turbo-
charger and over the outlet. Install the gasket and
capscrews.
Use the sequence illustrated. Tighten the capscrews.

Tighten the clamps.
Fill the Cooling System

Operate the engine to coolant temperature. Check for
leaks.
Operating Coolant Temperature: 71°C [160°F]
Section 10 — Air Intake System — Group 10 Aftercooler Element (010-008)
Aftercooler Element (010-008)

Remove (010-008-002)
008-018-005.

and the crossover.
Loosen the two hose clamps. Remove the outlet hose (8).
Loosen the two hose clamps and remove the inlet hose.
Aftercooler Element (010-008) Section 10 — Air Intake System — Group 10
Remove the capscrews, seal retainer (3), gaskets (4), and

seals (5). Discard the seals and gaskets.
Remove the aftercooler cover capscrews and cover.
Remove the element and gaskets.

Use a hose plugged with a pipe plug. Plug one water tube
as shown. Attach and air line and gauge to the remaining
tube.
Apply air pressure and check for leaks.
NOTE: Heating the tank water to 50°C [120°F] will improve
the test results.
Section 10 — Air Intake System — Group 10 Aftercooler Element (010-008)
Install (010-008-026)
Install the element and two gaskets.
Install the cover and aftercooler cover capscrews.

Do not tighten the capscrews until the inlet and outlet
seals are installed.
Use engine oil. Lubricate the seal (5). Install the seal on
the retainer (3).
Use engine oil. Lubricate the O.D. of the water bosses on
the aftercooler element.
Slide the gasket (4) on the water bosses. Slide the seal
and the retainer on the tube. Install the capscrews.
Tighten and torque the 24 cover capscrews in the steps

and values listed below.
Aftercooler Cover Torque Sequence

N•m Step ft-lb
35 1 25
50 2 35
Aftercooler Element (010-008) Section 10 — Air Intake System — Group 10
Connect the water inlet hose. Tighten the clamps.

Connect the water outlet hose. Tighten the clamps.

tube.
Install the air crossover. Slide the hose down and over the
turbocharger outlet. Install the gasket and capscrews.
Tighten the capscrews. Use the sequence shown.

Tighten the clamp.
Section 10 — Air Intake System — Group 10 Air Leaks, Air Intake System (010-024)
Fill Cooling System

Operate the engine to coolant temperature. Check for
leaks.
Air Leaks, Air Intake System (010-024)

Caution: The engine air intake must be filtered to pre-
vent dirt and debris from entering the engine. If intake air
piping is damaged or loose, unfiltered air will enter the
engine and cause premature wear.
Visually inspect the system for damaged or loose intake
piping.
Replace damaged pipes and tighten loose clamps.
NOTE: Stall speed is not full power.

Operate the engine at rated RPM and load.
Listen for a high pitch noise from the turbocharger.
This type of noise can be caused by an air leak from the

following:
Turbocharger-To-Aftercooler Air Supply Hose
Inspect the hose for damage. Tighten the hose clamps.
Air Leaks, Air Intake System (010-024) Section 10 — Air Intake System — Group 10
Air Crossover-To-Aftercooler Connection Leak

Replace the air crossover gaskets. Refer to Procedure
No. 010-019-026.
Turbocharger-To-Exhaust Manifold Gasket Leak

Replace the gasket. Refer to Procedure No. 010-043-026.
Turbine Housing Sealing Surface Leak

Tighten the HX82 nuts.
If an air leak is still present, replace the turbocharger.
Compressor Housing Sealing Surface Air Leak

Tighten the V-band HX82 clamp.
If an air leak is still present, remove and replace the
turbocharger. Refer to Procedure No. 010-033-026.
Section 10 — Air Intake System — Group 10 Intake Air Restriction (010-031)
Intake Air Restriction (010-031)

Measure (010-031-010)
Install a vacuum gauge or water manometer in the intake
piping between the turbocharger and the air filter. The
gauge must have a capacity of 1270 mm H2O [50 inch
H2O].
The gauge adapter (or fitting) must be installed at a 90

degree angle to the air flow in a straight section of pipe.
The adapter location must be at least one pipe diameter
before the turbocharger.
The adapter must not extend through the wall of the air
intake tubing.
If the adapter must be located in a curved section of
tubing, locate it on the flat side of the curve, not in the
radius.
Operate the engine at full throttle and rated RPM with

maximum load. Record the reading of the gauge or ma-
nometer.
NOTE: Restriction must not exceed 635 mm H2O [25 inch
H2O].
Maximum Operating Air Restriction:

635 mm H2O [25 inch H2O]
NOTE: Stall speed is not full power. Operate the engine at
rated RPM and load.
If the restriction exceeds specifications, do the following:

Replace or clean the air filter element. Refer to the equip-
ment manufacturer’s instructions.
Turbocharger (Water-Cooled) (010-037) Section 10 — Air Intake System — Group 10
Visually inspect the intake air piping for damage. Refer to

the equipment manufacturer’s instructions.
NOTE: If no damage is visible, check the size and routing
of the intake air piping. Refer to the Installation Recommen-
dations Bulletin.
Turbocharger (Water-Cooled) (010-037)

Remove (010-037-002)
NOTE: This procedure applies to a turbocharger with a water-
cooled bearing housing.
Remove the intake and exhaust pipes from the
turbocharger.

008-018-005.
Section 10 — Air Intake System — Group 10 Turbocharger (Water-Cooled) (010-037)

and the crossover.
Disconnect the oil drain hose and the oil supply hose from
the turbocharger.
Disconnect the coolant supply hose and the coolant re-

turn hose from the turbocharger.
Remove the mounting capscrews, nuts, and the turbo-

charger. Remove and discard the gasket.
Install (010-037-026)
Holset turbocharger(s) are used on the QSK19 engine.
Refer to the data tag on the turbocharger to determine the
model.
NOTE: The name is also cast on the housing of a
turbocharger.
NOTE: All turbocharger fittings are the flat face o-ring type
fittings. Be sure the o-ring is in place before attaching the
hose(s) to the fittings.
The Holset turbocharger uses a [9/16-18 UNF], straight
thread, o-ring type oil supply fitting.
Apply an antiseize compound to the mounting capscrews.

Install the gasket. The word OUT must be positioned
toward the turbocharger.
Install the turbocharger, washers, and nuts. Tighten the
capscrews.
Position the turbocharger drain tube. The drain tube must

be within 35 degrees of vertical. Turn the bearing housing
to align the tube, if necessary.
NOTE: The turbocharger uses standard nuts to attach the
bearing housing to the turbine housing.
Adjust the Through-Stud Style.

Bend the lockplate off the stud nuts. Remove the nuts.
Rotate the bearing housing. Align the drain tube and the
capscrew holes.
Install the lockplates and nuts. Tighten the nuts.

Bend the lockplate tabs over the nuts.
Caution: These parts are a safety-related item. Be sure

the parts are clamped correctly to prevent fretting.
Install the oil drain tube. Tighten the capscrews.
Pour clean engine oil into the turbocharger oil supply
fitting.
Turbocharger Oil Supply: 50 to 60 cc [2.0 to 3.0 oz]
Connect the oil supply hose. Tighten the hose fitting.

Connect the coolant supply hose and the coolant return

hose to the turbocharger.
Tighten the hose fittings.
Check the air crossover-to-turbocharger alignment.

• Install the air crossover on the aftercooler.
• Look at the alignment between the crossover and
the turbocharger compressor outlet.
• Remove the crossover and proceed with the assem-
bly if the alignment is correct.
• Proceed to the next step to adjust the compressor
housing if the alignment is not correct.
To adjust the turbocharger compressor housing align-

ment:
Loosen the V-band clamp.
Turn the compressor housing to the correct alignment.
Tighten the clamp.
Tap the clamp with a mallet and tighten the clamp again.
tube.
Install the air crossover. Slide the hose down and over the
turbocharger outlet. Install the gasket and capscrews.
Use the sequence illustrated to tighten the capscrews.

Tighten the clamp.
Connect the inlet piping to the turbocharger. Tighten the

clamps.
Connect the exhaust piping to the turbocharger. Tighten

the V-band clamp.
Check for Correct Component (010-037-048)

Compare the assembly number (1) on the turbocharger
dataplate with the turbocharger specified in the engine
Control Parts List (CPL) Manual.
NOTE: The CPL number for each engine is listed on the
engine dataplate (3).
Turbocharger Axial Clearance (010-038) Section 10 — Air Intake System — Group 10
If the correct turbocharger was not installed, remove it

and install the correct turbocharger. Refer to Procedure
No. 010-033-026.
028.
Operate the engine to the required coolant temperature.
Check for leaks.
Turbocharger Axial Clearance (010-038)

Measure (010-038-010)
Remove the intake and exhaust piping from the
turbocharger.
Use dial depth gauge, Part No. ST-537, or a dial indicator.

Measure the axial motion (end-to-end). Replace the turbo-
charger is axial motion is greater than specified below.
Holset HX82
Dimension
mm in
0.05 MIN 0.002
0.13 MAX 0.005
Turbocharger Blade Damage (010-039)

Remove the intake and exhaust pipes from the
turbocharger.
Section 10 — Air Intake System — Group 10 Turbocharger Compressor Seal Leaks (010-040)
Visually inspect the turbocharger compressor impeller

blades for damage.
Rebuild or replace the turbocharger if damage is found.
If the impeller is damaged, inspect the intake air piping

and the filter element for damage.
NOTE: Repair any damage before operating the engine.
Inspect the turbine wheel for damage.

Rebuild or replace the turbocharger if damage is found.
Turbocharger Compressor Seal Leaks

(010-040)
Inspect (010-040-062)
Remove the air intake pipe (1) and air crossover (2) from
the turbocharger. Refer to Procedure No. 010-019-008.
Turbocharger Compressor Seal Leaks (010-040) Section 10 — Air Intake System — Group 10
Examine the compressor discharge and air crossover

piping for oil.
If oil is seen, check the axial motion and radial clearance

of the turbocharger. Refer to Procedure No. 010-038-010.
Check for intake restriction. Refer to Procedure No. 010-

023-008.
If the restriction exceeds specifications, replace or clean
the air filter element. Refer to the equipment manufac-
turer’s instructions.
Remove the oil drain tube and check for restrictions.

Clear any restrictions that are found.
Section 10 — Air Intake System — Group 10 Turbocharger Radial Bearing Clearance (010-047)
Check the angle of the drain tube. The angle of the tube
must be within 35 degrees of vertical. Adjust the turbo-
charger, if necessary. Refer to Procedure No. 010-033-026.
If the drain tube is free of restrictions and at the correct

angle, check the crankcase breathers and tubes to be
sure they are not plugged.
If these checks do not reveal the problem, measure the

crankcase pressure (blowby). Refer to Procedure No.
003-001-013.
Turbocharger Radial Bearing Clearance

(010-047)
Measure (010-047-010)
Use a wire-type feeler gauge to measure the radial clear-
ance (side-to-side).
Turbocharger Turbine Seal Leaks (010-049) Section 10 — Air Intake System — Group 10
Replace the turbocharger if the radial clearance is less

than specified below.
Holset
mm in
Compressor 0.15 MIN 0.006
Impeller
0.45 MAX 0.018
Turbine 0.20 MIN 0.008
Wheel
0.55 MAX 0.210
Turbocharger Turbine Seal Leaks

(010-049)
Add one unit of fluorescent tracer, Part No. 3376891, to
each 38 liters (10 U.S. gallon] of engine lubricating oil.
Operate the engine at low idle for 10 minutes.

Allow the turbocharger to cool and remove the exhaust
pipe from the turbine housing.
Use a high intensity black light to inspect the turbine

housing outlet for oil.
NOTE: A dark blue glow indicates fuel slobber, and a yellow
glow indicates oil carryover.
Section 10 — Air Intake System — Group 10 Turbocharger Turbine Seal Leaks (010-049)
If fuel is found in the turbine housing, the problem is

excess, unburned fuel. To correct the problem, decrease
the idle period or increase the idle RPM. The coolant
temperature needs to be maintained at 71°C [160°F].
If oil is found in the turbine housing, remove the oil drain

tube and check for restrictions. Clear any restrictions
found.
Check the angle of the drain tube. The angle of the tube
must be within 35 degrees of vertical. Adjust the turbo-
charger, if necessary. Refer to Procedure No. 010-033-029.
If the drain tube is free of restrictions and at the correct

angle, check the crankcase breather and tube to be sure
they are not plugged. Refer to Procedure No.
003-001-008.
Boost Pressure (010-057) Section 10 — Air Intake System — Group 10
Check the turbocharger axial motion and radial clear-

ance. Refer to Procedure No. 010-038-010.
If these checks do not reveal the problem, measure the

crankcase pressure (blowby). Refer to Procedure No. 003-
001-013.
If the blowby is acceptable, replace the turbocharger.
If the blowby is not acceptable, isolate the turbocharger
and test the blowby again.
If the blowby is now acceptable, replace the turbocharger.
Boost Pressure (010-057)

Measure (010-057-010)
Install a 0-2030 mm-Hg [0-80 in-Hg] manometer (or gauge)
in the [3/8-inch] pipe plug hole in the aftercooler housing.
Do not drill and tap a hole in the aftercooler cover. A faulty
reading can result if the aftercooler core is leaking.
Operate the engine at rated RPM and full load. Compare

the value to specifications.
NOTE: Stall speed is not full power.
Section 11 — Exhaust System — Group 11
Section 11 — Exhaust System — Group 11

Section Contents
Page
Exhaust Manifold (Dry) (011-007) .................................................................................................................... 11-5
Assemble (011-007-025).................................................................................................................................. 11-7
Inspect for Reuse (011-007-007)...................................................................................................................... 11-6
Install (011-007-026)........................................................................................................................................ 11-7
Remove (011-007-002) .................................................................................................................................... 11-5
Exhaust Restriction (011-009) .......................................................................................................................... 11-8
Measure (011-009-010).................................................................................................................................... 11-8
Exhaust System — Flow Diagrams (200-005-206) ........................................................................................... 11-3
Exhaust System — General Information (011-999-999) ................................................................................... 11-2
Exhaust System — Specifications (018-001-206) ............................................................................................ 11-2
Exhaust System — Tool Requirements (022-001-511) ..................................................................................... 11-4
Exhaust System — General Information (011-999-999) Section 11 — Exhaust System — Group 11
Exhaust System — General Informa-

tion (011-999-999)
The exhaust system consists of the exhaust manifold and
exhaust piping.
Exhaust System — Specifications

(018-001-206)
Maximum Back Pressure: 75 mm Hg [3.0 in-Hg]
Normal Exhaust Pipe Diameter: 152.4 mm [6 Inch]
Section 11 — Exhaust System — Group 11 Exhaust System — Flow Diagrams (200-005-206)
Exhaust System — Flow Diagrams (200-005-206)

Section 11 — Exhaust System — Group 11 Exhaust Manifold (Dry) (011-007)
Exhaust Manifold (Dry) (011-007)

Remove (011-007-002)
Remove the turbocharger. Refer to Procedure No.
010-033-002.
Remove the water bypass clamp (9). Loosen both clamps.

Remove the water bypass tube.
Use two [7/16-14x5 inch] guide studs (12). Remove two

capscrews as shown. Install the guide studs as shown.

To avoid personal injury, use a hoist get assistance to lift
the component.
Remove the remaining capscrews. Remove the exhaust
manifold and the gaskets. Discard the gaskets.
Exhaust Manifold (Dry) (011-007) Section 11 — Exhaust System — Group 11
Use a 240 grit emery cloth. Clean all of the exhaust
manifold gasket surfaces.
Use a mallet. Remove the end sections from the exhaust

manifold center section.

Use steam or solvent. Clean the manifold. Use a wire
brush. Clean the sealing joint inside and outside diam-
eters to remove any scale that has accumulated.
Inspect for cracks in the areas shown.
Inspect the capscrew holes in the center section for dam-

age.
NOTE: The manifold has been subjected to high tempera-
tures if the capscrew threads are visible on the side of the
capscrew holes. High temperature can cause the manifold
to shrink.
Measure the center-to-center distance between the
capscrew holes to determine if the manifold is too short.
Exhaust Manifold Capscrew Holes

mm in
191.5 MIN 7.54
193.5 MAX 7.62
Section 11 — Exhaust System — Group 11 Exhaust Manifold (Dry) (011-007)
Assemble (011-007-025)
Use an antiseize compound. Lubricate the O.D. of the end
sections in the area that slides into the center section.
Use a mallet and drive the end section into the center
section.
Install (011-007-026)
Install the guide studs used during removal.
Caution: Do not use gasket cement or the gasket will
fail.
Use contact adhesive and attach the gasket on the cyl-
inder head exhaust ports.
Install the exhaust manifold.
Apply an antiseize compound on the capscrew threads.

Install the capscrews. Remove the two guide studs and
install the remaining capscrews.

Torque Value: 40 to 50 N•m [30 to 35 ft-lb]
Exhaust Restriction (011-009) Section 11 — Exhaust System — Group 11
Lubricate the o-ring with vegetable oil and install it on the

water bypass tube.
NOTE: The raised lip on the retainer must point toward the
thermostat housing.
Install the water bypass tube, retainer, and capscrew.
Tighten the clamps.
Install the turbocharger. Refer to Procedure No.

010-033-026.
Exhaust Restriction (011-009)

Measure (011-009-010)
Connect a manometer or pressure gauge in the exhaust
piping. The gauge must have a capacity of 152 mm — Hg
[6 inch-Hg] or 1676 mm — H20 [66 inch-H20].
NOTE: The gauge adapter (or fitting) must be installed at a

90 degree angle to the exhaust flow in a straight section of
pipe. The adapter location must be no more than 1.5 times
the exhaust pipe inside diameter.
The adapter must not extend through the wall of the
exhaust tubing.
If the adapter must be located in a curved section of
tubing, locate it on the flat side of the curve, not in the
radius, or the measured value will not be accurate.
Connect a 13 mm [1/2-inch] piece of metal tubing be-
tween the gauge adapter and the gauge hose. This will
prevent damage to the hose from extreme heat.
Section 11 — Exhaust System — Group 11 Exhaust Restriction (011-009)
Operate the engine at rated RPM and load, and record the
manometer reading.
NOTE: The exhaust pressure must not exceed 75 mm [3.0
inch-Hg].
If the exhaust pressure exceeds the specification, visually

inspect the exhaust piping for damage. Refer to the equip-
ment manufacturer’s instructions.
NOTE: If no damage is visible, check the size and routing of
the exhaust piping. Refer to the Installation Recommenda-
tion Bulletin.

Exhaust Restriction (011-009) Section 11 — Exhaust System — Group 11
NOTES
Section 12 - Compressed Air System - Group 12
Section 12 - Compressed Air System - Group 12

Section Contents
Page
Air Compressor Carbon Buildup (012-003) ..................................................................................................... 12-9
Air Compressor Cylinder Head, Single Cylinder (012-008) ........................................................................... 12-11
Assemble (012-008-025)............................................................................................................................... 12-15
Disassemble (012-008-003) .......................................................................................................................... 12-12
Inspect (012-008-062) .................................................................................................................................. 12-13
Inspect for Reuse (012-008-007)................................................................................................................... 12-13
Install (012-008-026)..................................................................................................................................... 12-16
Remove (012-008-002).................................................................................................................................. 12-11
Air Compressor (Oil Carryover) (012-020) ..................................................................................................... 12-37
Air Compressor Pin Bore Wear (012-010) ...................................................................................................... 12-18
Install (012-010-026) ..................................................................................................................................... 12-20
Remove (012-010-002).................................................................................................................................. 12-18
Air Compressor, Single Cylinder (012-014) ................................................................................................... 12-26
Install (012-014-026)..................................................................................................................................... 12-28
Remove (012-014-002) ................................................................................................................................. 12-26
Air Compressor, Two Cylinder (012-015) ....................................................................................................... 12-30
Install (012-015-026) ..................................................................................................................................... 12-31
Remove (012-015-002) ................................................................................................................................. 12-30
Air Compressor Unloader and Valve Assembly (012-013)............................................................................. 12-20
Install (012-013-026)..................................................................................................................................... 12-25
Remove (012-013-002) ................................................................................................................................. 12-20
Vacuum Test (012-013-015) .......................................................................................................................... 12-23
Air Governor (Air Compressor Pumps Continuously) (012-018) ................................................................... 12-34
Air Governor (Air Compressor Will Not Pump) (012-017).............................................................................. 12-34
Air Leaks, Compressed Air System (012-019) ............................................................................................... 12-36
Compressed Air System — Flow Diagrams (200-006-207).............................................................................. 12-4
Compressed Air System — General Information (012-999-999) ..................................................................... 12-2
Compressed Air System — Specifications (018-001-207) ............................................................................... 12-5
13.2 CFM Single Cylinder Air Compressor (SS296) ....................................................................................... 12-5
15.0 CFM Single Cylinder Air Compressor (SS338) ....................................................................................... 12-5
Compressed Air System — Tool Requirements (022-001-512) ....................................................................... 12-7
Compressed Air System — General Information (012-999-999) Compressed Air System — Group 12
Compressed Air System — General

The compressed air system normally consists of a gear
driven air compressor, an air governor, air tanks, and all
necessary plumbing.
The Holset and Cummins single and two cylinder air
compressors are engine-driven, piston-type compressors
that supply compressed air to operate air activated de-
vices. The compressor runs continuously, but has a
loaded and unloaded operating mode.
The operating mode is controlled by a pressure-activated

governor and the compressor unloading assembly. When
the air system reaches a predetermined pressure, the
governor applies an air signal to the air compressor
unloader assembly, causing the unloader valve to hold
the compressor intake valve open and compressed air
stops flowing into the air system.
As the air in the air system is used, the pressure drops.
At a predetermined pressure, the governor exhausts the
air signal to the compressor to again pump compressed
air into the air system.
Holset
Holset SS and ST model air compressors built with the
E-Type unloaded can be identified by the letter "E"
(SS296E, SS338E, ST676E, and ST773E), and by the
caution on the dataplate.
All QE (QE296 and QE338) model air compressors are
equipped with the E-Type unloader.
E-Type System With Air Dryer ↔

Vehicles equipped with air dryers vented to the atmo-
sphere during unloaded compressor operation, using the
Holset E-Type air compressor, require installation of an
econ valve to prevent excessive oil consumption.
NOTE: Some air dryers can have a built-in econ valve. Check
with the manufacturer as to the type that is installed.
Compressed Air System — Group 12 Compressed Air System — General Information (012-999-999)
E-Type System Without Air Dryer ↔

Air systems without air dryers, or with air dryers not
vented to the atmosphere during unloaded compressor
operation, can use the Holset E-Type unloader valve with-
out modifying the air system.
Compressed Air System — Flow Diagrams (200-006-207) Section 12 — Compressed Air System — Group 12
Compressed Air System — Flow Diagrams (200-006-207)

Section 12 — Compressed Air System — Group 12 Compressed Air System — Specifications (018-001-207)
Compressed Air System — Specifications (018-001-207)
13.2 CFM Single Cylinder Air Compressor (SS296)

Cylinders: ..................................................................................................................................................... 1
Compressor Capacity @ 1250 RPM: ...................................................................... 6.2 L per sec [13.20 CFM]
Piston Displacement: ...................................................................................................... 296 C.C. [18.6 C.I.]
Bore: .............................................................................................................................. 92.08 mm [3.625 in]
Stroke: ........................................................................................................................... 44.45 mm [1.750 in]
Speed: .................................................................................................................................... Engine Speed
Cooling: ................................................................................................................................ Engine Coolant
Lubrication: ................................................................................................................ Engine Lubricating Oil
Plumbing Line Sizes:
Coolant Inlet and Outlet (Pipe Fitting) ................................................... 9.53 mm NPTF [0.375 in NPTF]
Air Inlet (Inside Diameter) ........................................................................................ 22.22 mm [0.875 in]
Air Outlet (Minimum Inside Diameter) .......................................................................... 12.7 mm [0.50 in)
Height, Overall (Approximate): ........................................................................................... 31.3 cm [12.25 in]
Width, Overall (Approximate): .............................................................................................. 14.6 cm [5.75 in]
Length, Overall (Approximate): ............................................................................................ 22.9 cm [9.00 in]
Weight (Approximate): ............................................................................................................ 18 Kg [40.0 lb]
15.0 CFM Single Cylinder Air Compressor (SS338)

Cylinders ...................................................................................................................................................... 1
Compressor Swept Volume @ 1250 RPM ............................................................. 7.1 L per sec. [15.00 CFM]
Piston Displacement ...................................................................................................... 338 cc [20.63 C.I.D.]
Bore .................................................................................................................................. 98.4 mm [3.875 in]
Stroke ................................................................................................................................. 44.5 mm [1.75 in]
Speed ...................................................................................................................................... Engine Speed
Cooling .................................................................................................................................. Engine Coolant
Lubricating .................................................................................................................. Engine Lubricating Oil
Plumbing Line Sizes
Coolant Inlet and Outlet (Pipe Fitting) ..................................................... 9.53 mm NPTF [0.375 in NPTF]
Air Inlet .................................................................................................................... 22.22 mm [0.875 in]
Air Outlet ..................................................................................................................... 12.7 mm [0.50 in]
Height, Overall (Approximate) ............................................................................................. 31.1 cm [12.25 in]
Width, Overall (Approximate) ................................................................................................ 14.6 cm [5.75 in]
Length, Overall (Approximate) .............................................................................................. 22.9 cm [9.00 in]
Weight (Approximate) ............................................................................................................. 18 Kg [40.0 lbs]
Compressed Air System — Specifications (018-001-207) Section 12 — Compressed Air System — Group 12
Two Cylinder Air Compressor (ST-676)

Cylinders: ................................................................................................................................................... 2
Compressor Capacity @ 1250 RPM: ................................................................... 14.2 L per sec [30.00 CFM]
Piston Displacement: ....................................................................................................... 676 C.C. [41.3 C.I.]
Bore: .............................................................................................................................. 92.08 mm [3.625 in]
Stroke: ............................................................................................................................... 50.8 mm [2.00 in]
Speed: .................................................................................................................................... Engine Speed
Cooling: ................................................................................................................................ Engine Coolant
Lubrication: ................................................................................................................ Engine Lubricating Oil
Plumbing Line Sizes
Coolant Inlet and Outlet (Pipe Fitting): .................................................... 12.70 mm NPTF [0.50 in NPTF]
Air Inlet (Inside Diameter): ............................................................................................. 22.22 mm [0.875 in]
Air Outlet (Minimum Inside Diameter): ............................................................................ 15.88 mm [0.625 in]
Height, Overall (Approximate): ........................................................................................... 34.3 cm [13.50 in]
Width, Overall (Approximate): .............................................................................................. 17.8 cm [7.00 in]
Length, Overall (Approximate): .......................................................................................... 28.7 cm [11.30 in]
Weight (Approximate): ........................................................................................................ 33.5 kg [74.50 lb]
Load Required to Compress Spring

Compressor Spring Force Specifications to Measurement Length
Approx. Measure-
Spring Free Number Wire ment
P/N Length of Diameter Length Minimum Maximum
Spring Use mm [inch] Coils mm [inch] mm [inch] kg [lb.] kg [lb]
128080 Exhaust Valve 17.02 3.0 2.03 7.11 3.6 4.7
[0.670] [0.080] [0.280] [8.55] [10.35]
190334 Intake Valve 12.70 2.8 1.58 7.11 0.35 0.5
[0.500] [0.062] [0.280] [0.65] [1.10]
150631 Unloading Valve 41.91 11.5 2.03 24.89 14.5 17.2
(naturally aspirated) [1.650] [0.080] [0.980] [32.00] [38.00]
center unloading
valve - twin
3023101 Unloading Valve 41.91 10.8 1.65 24.89 5.9 7.7
(all turbocharged [1.650] [0.065] [0.980] [13.00] [17.00]
engines)
3049553 E-Type 41.91 11.25 1.93 24.89 10.4 12.2
Unloader Valve [1.650] [0.076] [0.980] [23.00] [27.00]
800399-XW Unloader 17.02 6 1.04 6.60 N/A 2.54
[0.67] [0.041] [0.260] [5.60]
10.03 1.71 [3.78] N/A
[3.95]
802000-FZ Intake and Exhaust 10.16 4.25 0.79 4.57 N/A 0.36
[0.40] [0.031] [0.18] [0.80]
5.99 0.20 N/A
[0.275] [0.45]
3054489 Exhaust Valve 21.49 4.5 2.54 15.21 3.88 4.74
[0.846] [0.100] [0.599] [8.55] [10.45]
Compressed Air System — Tool Requirements (022-001-512) Compressed Air System — Group 12

Valve Vacuum Tester
Test intake and exhaust valve seating.
3824277
Section 12 — Compressed Air System — Group 12 Air Compressor Carbon Buildup (012-003)
Air Compressor Carbon Buildup

(012-003)
NOTE: The illustrations shown will be of the single cylinder
air compressor. Differences in procedures for one and two
cylinder Holset or Cummins air compressors will be shown
where necessary.
Open the draincock on the wet tank to release com-
pressed air from the system.
Remove the air inlet and outlet connections from the air
compressor.
Measure the total carbon deposit thickness inside the air

discharge lines as shown.
NOTE: The carbon deposit thickness must not exceed 1.5
mm [0.06 or 1/16-inch].
Carbon Deposit Thickness (Maximum):
1.5 mm [0.06 in]
Warning: The air discharge line MUST be capable of

withstanding extreme heat and pressure to prevent per-
sonal injury and property damage. Refer to the manu-
facturer’s specifications.
NOTE: If the total carbon deposit thickness exceeds speci-
fication, remove and clean, or replace the air discharge line.
Refer to the manufacturer’s material specifications.
Air Compressor Carbon Buildup (012-003) Section 12 — Compressed Air System — Group 12
Warning: The air discharge line MUST be capable of

withstanding extreme heat and pressure to prevent per-
sonal injury and property damage. Refer to the manu-
facturer’s specifications.
Continue to check for carbon buildup in the air discharge
line connections up to the first connection, or wet tank.
Clean or replace any lines and fittings with carbon de-
posits greater than 1.5 mm [0.06 or 1/16-inch]. Refer to
the manufacturer’s specifications for cleaning or replace-
ment instructions.
Carbon Deposit (Maximum): 1.5 mm [0.06 or 1/16-in]
Caution: Do not use a sharp object to remove carbon.

The sealing surfaces can be damaged.
Remove air compressor cylinder head and valve assem-
bly. Refer to Procedure No. 012-014-002 or Procedure No.
012-013-002.
Use solvent and a nonmetallic brush. Clean the carbon
from the compressor head and valve assembly compo-
nents.
Inspect the valve assembly components for reuse. Refer
Assemble the air compressor using new gaskets and

o-rings. Refer to Procedure No. 012-008-025.
Install and tighten the air inlet and outlet connections.
Close the wet tank draincock.

Operate the engine and check for air leaks.
Section 12 — Compressed Air System — Group 12 Air Compressor Cylinder Head, Single Cylinder (012-008)
Air Compressor Cylinder Head, Single

Cylinder (012-008)
Remove (012-008-002)
Warning: Hot coolant can cause severe personal injury.
Allow engine to cool before draining.
Drain the coolant. Refer to Procedure No. 008-018-005.
Remove the coolant lines from the air compressor.
Warning: ALWAYS disconnect negative (-) cable first,

and connect it last to reduce risks of arcing.
Disconnect the batteries to prevent accidental starting of
the engine.
compressor.
Caution: The unloader valve body is installed with a

spring tension. Use care when removing to prevent per-
sonal injury.
Remove the unloader body and all related parts. Refer to
Air Compressor Cylinder Head, Single Cylinder (012-008) Section 12 — Compressed Air System — Group 12
Remove the intake valve seat, intake valve, and intake

valve spring.
Use valve seat puller, ST-544, or equivalent. Remove the
exhaust valve seat, exhaust valve, and exhaust valve
spring.
Remove the capscrews, lockwashers, and plain washers.

Remove the cover and discard the gasket.
Remove the head and discard the gasket. Hold the head
bottom side up, and use thumb pressure to remove the
exhaust valve seat assembly.
NOTE: If the exhaust valve seat assembly cannot be re-
moved by thumb pressure, use compressor exhaust valve
seat kit tool, Part No. 3822674. Two cylinder air compressors
also require the use of compressor exhaust valve seat tool
kit, Part No. 3822681 for removal. An air compressor seat
driver tool, Part No. 3377416, can be used to remove the
exhaust valve seat.
Remove the o-ring seal from the exhaust valve seat. Re-
move the exhaust valve.
Remove the compression spring and wear plate from the
head.
NOTE: The cylinder head on air compressor models SS296
and ST338 cannot be rebuilt while on the engine. The ex-
haust valve requires a press for removal. Refer to the Air
Compressor Shop Manual.

Warning: Do not rotate engine by prying on fan blades.
Equipment damage and severe personal injury can re-
sult.
Use the barring mechanism or the accessory drive to
rotate the engine. Inspect the air compressor bore for
excessive wear or damage.
Inspect (012-008-062)
Clean and inspect all parts. Visually inspect the unloader
valve for deep scratches or cracks.
Inspect the spring tension of the unloader spring. Check

the free length of the intake and exhaust valve springs.
Use valve spring tester, Part No. 3375182. Replace any
springs that do not meet specifications. Refer to the gen-
eral information in this section.
NOTE: Cummins Engine Company, Inc. recommends that
new springs be installed.
NOTE: If the compressor has a flat-hat type unloader valve

(1), it must use an unloader spring and valve seat different
than that used with the three-prong unloader.
Inspect the valve assembly components. Apply a bluing

compound to the exhaust valve seating surface.
Check the exhaust valve and check the seating area.
Replace the seat if the contact area is not 100 percent.
Measure the exhaust valve seat height.

If the seat height is less than minimum required height,
replace the seat.
Seat Height (Minimum): 12.32 mm [0.485 in]
Apply a bluing compound to the intake valve seating

surfaces.
Install the intake valve and check the seating area. Re-
place the seat if the contact area is not 100 percent.
Measure the intake valve seat height. If the seat height is

less than minimum required height, replace the seat.
Seat Height (Minimum): 6.86 mm [0.270 in]
Visually inspect the intake and exhaust valves for cracks

or damage.
Measure the flatness of the intake and exhaust valves.

Both valves must be flat within the following specification.
Valve Flatness: 0.03 mm [0.001 in]
Assemble (012-008-025)
Install the exhaust valve (1) and small o-ring (2) on the
exhaust valve seat.
NOTE: The small o-ring is not required on air compressor
models, SS296 and ST676.
Install the large o-ring (3) on the exhaust valve seat.
Install the wear plate (4) and exhaust valve spring (5).
Lubricate the o-rings with engine oil and install the ex-
haust valve assembly (6).
Install the intake valve spring and intake valve as shown.

Install the intake valve seat with the flange side up as
shown.
Install (012-008-026)
Use new gaskets to install the cylinder head and cover.
Install the flat washers, lockwashers, and capscrews.
Tighten the cylinder head capscrews on the single cyl-

inder compressor in an alternating sequence to the fol-
lowing torque values.
Torque Value: Step 1 - 7 N•m [60 in-lb]
2 - 15 N•m [10 ft-lb]
3 - 20 N•m [15 ft-lb]
4 - 25 N•m [20 ft-lb]
Install the unloader body and all related parts. Refer to

Install the air inlet and outlet connections. Tighten the

clamps.
Caution: If rubber grommets are used on the coolant

lines, the grommets MUST be installed carefully to pre-
vent cuts or tears to the grommet. A damaged grommet
will leak.
Connect the coolant lines to the air compressor.
Warning: ALWAYS disconnect negative (-) cable first,

and connect it last to reduce risks of arcing.

028.
Air Compressor Pin Bore Wear (012-010) Section 12 — Compressed Air System — Group 12
Air Compressor Pin Bore Wear

(012-010)
Remove (012-010-002)
Caution: The unloader valve body is installed with spring
tension. Wear eye protection when removing to prevent
personal injury.
Hold the unloader valve body down and remove the two
captive washer capscrews and the two plain washers.
Remove the unloader valve body.
Remove the unloader valve cap and the unloader valve

spring.
NOTE: Disassembly of the center unloader valve on HolsetW
two cylinder air compressors is similar to the single cylinder
unloader valve.
Remove the intake valve seat and valve. Remove the
intake valve spring.
NOTE: Do not allow any debris to fall into the air compressor
cylinder as this can result in damage to the compressor.

NOTE: Do not use a screwdriver. A screwdriver can gouge
the top of the piston.
Insert the small end of a [3/8 inch] drive socket extension
([6 to 10 inch] long) or a 9.5290 mm [3/8 inch] rod (that has
a smooth flat end) through the exhaust valve seat onto the
top of the piston.
Bar the crankshaft over until the compressor piston

reaches Top Dead Center (TDC) and the extension or rod
starts to move downward approximately 3 to 6 mm [1/8 to
1/4 inch].
Section 12 — Compressed Air System — Group 12 Air Compressor Pin Bore Wear (012-010)
NOTE: Do not use a hammer. Damage the top of the piston

can result.
Give a quick, hard push downward on the extension or rod
and listen for a metallic click as wear clearance is taken
up.
If significant piston motion is felt or a metallic click is

heard, the pin bores can be worn and the compressor
must be examined further.
If no motion or sound is heard, the compressor is in

satisfactory condition and does not need to be replaced.
NOTE: Not all air compressors will exhibit pin bore wear.
Remove the extension or rod.

Air Compressor Unloader and Valve Assembly (012-013) Section 12 — Compressed Air System — Group 12
Install (012-010-026)
Install the intake valve spring with the tang down. Install
the intake valve and valve seat with the flange side up.
Install the unloader valve cap spring and unloader valve
cap.
Use antiseize compound to lubricate the outside diameter
of the unloader cap.
NOTE: The rectangular ring seal must be installed with the

grooved side up.
Install the rectangular ring seal and o-ring seal.
Use clean engine oil to lubricate the o-ring seal. Install the
unloading valve body. Press the unloading valve body
down to be sure the tangs of the unloader valve cap are
in the three slots of the intake valve seat.
Hold the unloading body down and install the two plain
washers and captive washer capscrews.
Tighten the capscrews
Air Compressor Unloader and Valve

Assembly (012-013)
Remove (012-013-002)
Remove the air governor or air governor signal line from
the air compressor unloader body.
Section 12 — Compressed Air System — Group 12 Air Compressor Unloader and Valve Assembly (012-013)
Warning: The unloader valve body is installed with spring

tension. Wear eye protection to avoid personal injury.
Hold the unloader body down while removing the
capscrews.
Hold the unloader body down and remove the two
capscrews and washers.
On two cylinder air compressors, remove the unloader
assemblies above each cylinder. Discard the o-rings and
seals.
On a single cylinder air compressor, remove the unloader
assembly. Discard the o-rings and seals.
Remove the center unloader valve on the two cylinder air

compressor. Two types have been used; one that is held
down by one capscrew, and one that is screwed on the
compressor.

air compressor. Differences in procedures for one and two
cylinder Cummins air compressors will be shown where
necessary.
Clean the unloader valve with solvent and a nonmetallic
brush to remove carbon. Do not use a sharp object. The
sealing surfaces can be damaged.
Visually inspect the unloader valve for deep scratches or

cracks.
Use a valve spring tester, Part No. 3375182, to check the

unloader spring.
NOTE: For Holset or Cummins two cylinder air compressors,
check both cylinder and center unloader springs. Cummins
Engine Company, Inc. recommends that new springs be
installed during rebuild.
Replace the unloader spring if it does not meet the speci-

fications or the wrong spring has been used.
Refer to the general information in this section.
Visually inspect the rectangular seal for damage or in-

correct installation.
Visually inspect the unloader body o-rings for damage.

NOTE: Replace the o-ring if it is damaged. Determine the
cause for the damage and repair the problem.
Vacuum Test (012-013-015)

Remove the air governor or air governor signal line from
the unloader body.
compressor.
Make a plate to fit over the air compressor inlet. Put a

fitting in the plate to attach the hose from the valve vacuum
tester.
Use a valve vacuum tester, Part No. 3824277, or equiva-

lent. Attach the test, plate, and gasket to the air com-
pressor inlet.
Attach a regulated air supply to the unloader valve.
Apply 690 kPa [100 psi] to the unloader valve to open the
intake valve.
Move the toggle switch (3) to the ON position. Turn the
vacuum control valve (4) to the OPEN position.
NOTE: The vacuum control valve is in the OPEN position if
the vacuum gauge needle moves clockwise.
When the gauge reads between [20 in-Hg and 25 in-Hg],

turn the toggle switch (3) to the CLOSED or OFF position.
Close the vacuum control valve (4).
Watch for a decay in vacuum. If there is a decay, replace
the exhaust valve or exhaust valve seat. Refer to Proce-
dure No. 012-007-026.
Remove the air pressure at the unloader. This will allow

the intake valve to close.
Apply [20 in-Hg to 25 in-Hg] vacuum to the intake valve.

Shut off the vacuum. If the vacuum decays, replace either
the unloader body o-ring, intake valve, or intake valve
seat.
Install (012-013-026)
Install the unloader valve cap spring in the air compres-
sor.
NOTE: Some unloader bodies require two yellow o-rings.
NOTE: The rectangular ring seal must be installed with the
grooved side positioned upward.
Install the rectangular ring seal as shown.
Use antiseize compound. Lubricate the outside diameter
of the cap.
Install the unloader valve cap in the unloader body.
Use clean, engine oil. Lubricate the o-ring seals.

Install the unloading valve body.
Caution: Press the unloading valve body down to be
sure the tangs of the unloader valve cap are in the three
slots of the intake valve seat.
Hold the unloading body down and install the two plain
washers and captive washer capscrews. Tighten the
capscrews.
Install the center unloader on the two cylinder air com-

pressor. Follow the same instructions as the one cylinder
air compressor, but use a new torque value for the
capscrews.
Air Compressor, Single Cylinder (012-014) Section 12 — Compressed Air System — Group 12
Install the air governor or air governor signal line to the

unloader body.
Operate the engine and check for leaks.
Air Compressor, Single Cylinder

(012-014)
Remove (012-014-002)
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
can cause serious personal injury.
NOTE: The illustrations shown will be of the SS model single
cylinder air compressor. Differences in procedures for SS,
QE, and ST model Cummins air compressors will be shown
where necessary.
Use steam to clean the air compressor. Dry with com-
pressed air.
005-016-002.
Section 12 — Compressed Air System — Group 12 Air Compressor, Single Cylinder (012-014)
Drain the engine coolant. Refer to Procedure No. 008-

018-005.
Remove the coolant lines from the air compressor.

lift the component.
Remove the air compressor support mounting capscrews
(26).
Remove the four capscrews (24) and the nuts (25). Re-
move the air compressor. Remove the splined coupling.

Use solvent and clean the exterior of the air compressor.
Visually inspect the compressor housing for cracks or
damage.
Visually inspect the splined coupling for cracks or damage.

Air Compressor, Single Cylinder (012-014) Section 12 — Compressed Air System — Group 12
Check the crankshaft end clearance on the single cylin-

der air compressor.

(Aluminum Support, Part No. 3005153)
mm in
0.050 MIN 0.002
0.069 MAX 0.027
Refer to the Single Cylinder Air Compressor Shop Manual
for specifications regarding air compressors using a dif-
ferent part number support, and for rebuild instructions.
Install (012-014-026)
Install the splined coupling (1), gasket, and the compres-
sor.
Caution: Do not tighten any capscrews until the support
bracket is aligned.
Install the four capscrews and two nuts (2). The capscrew
(4) must be loose.
Install the two capscrews (5) for the bracket. The support
bracket must be flat against the block. Turn the com-
pressor until the bracket is flat.
Tighten the compressor to the accessory drive capscrews

(2).
Tighten the bracket to the block capscrews (5).
Caution: The bracket must be flat against the compres-
sor.
Tighten the bracket to the compressor capscrew (4).
Section 12 — Compressed Air System — Group 12 Air Compressor, Single Cylinder (012-014)
Install the air inlet and outlet connections to the air com-
pressor. Tighten the clamps.
Caution: If rubber grommets are used on the coolant

lines, the grommets MUST be installed carefully to pre-
vent cuts or leaks to the grommet. A damaged grommet
will leak.
Connect the coolant lines to the air compressor.

028.
Air Compressor, Two Cylinder (012-015) Section 12 — Compressed Air System — Group 12
Air Compressor, Two Cylinder

(012-015)
Remove (012-015-002)
Warning: Hot coolant can cause severe personal injury.
Allow engine to cool before draining.
Drain the cooling system. Refer to Procedure No. 008-
018-005.
Disconnect the coolant lines from the air compressor.
compressor.

005-016-002.
Remove the air compressor support mounting capscrews

(5).
Remove the four capscrews (6). Remove the air com-
pressor. Remove the splined coupling (1). Remove and
discard the gasket.
Section 12 — Compressed Air System — Group 12 Air Compressor, Two Cylinder (012-015)

Use solvent and clean the exterior of the air comrpessor.
Visually inspect the compressor housing for cracks or
damage.
Visually inspect the splined coupling for cracks or damage.
Check the crankshaft end clearance on the two cylinder

air compressor.

mm in
0.038 MIN 0.0015
0.20 MAX 0.008
Refer to ST676 Two Cylinder Air Compressor Shop Manual
for rebuild instructions.
Install (012-015-026)
Install the gasket and the cover plate (support bracket) on
the compressor.
Do not tighten the six capscrews. The support must be
adjusted.
Air Compressor, Two Cylinder (012-015) Section 12 — Compressed Air System — Group 12
NOTE: Do not install the splined coupling or the mounting

gasket.
Install the compressor on the accessory drive.
Install the four capscrews (6). Only tighten the capscrews
enough to pull the compressor to the accessory drive. The
compressor must be turned to align the support bracket.
Caution: The support must be flat against the block.

Rotate the compressor until the support is aligned prop-
erly against the block. If the support is not flat, the
compressor and/or accessory drive will fail.
Tighten the four capscrews (6).
The bracket must remain flat against the block. Tighten
the support capscrews (7) that are accessible.
Remove the four capscrews (6). Remove the compressor.

Tighten the two remaining support to the compressor
capscrews.
Install the splined coupling (1), the gasket, and the com-
pressor.
Caution: The support must be flat against the block.
Rotate the compressor until the support is aligned prop-
erly against the block. If the support is not flat, the
compressor and/or accessory drive will fail.
Install the four capscrews (6) and two capscrews (5).
Capscrew Torque Values

N•m Capscrew No. ft-lb
60 (6) 45
45 (5) 35
Section 12 — Compressed Air System — Group 12 Air Compressor, Two Cylinder (012-015)
Install the air inlet and outlet connections to the air com-
pressor. Tighten the clamps.
Install the coolant lines to the air compressor.

Fill the cooling system. Refer to Procedure No.
008-018-028.
Operate the engine to operating temperature and check

for leaks.
Air Governor (Air Compressor Will Not Pump) (012-017) Compressed Air System — Group 12
Air Governor (Air Compressor Will Not

Pump) (012-017)
air compressor. Differences in procedures for one or two
necessary.
Remove the air governor or air governor line from the air
compressor unloader body.
Operate the engine to activate the air compressor.

If the air compressor is pumping, the air governor is
malfunctioning and must be repaired or replaced. Refer
to the manufacturer’s instructions.
Remove, clean, and inspect the air compressor valve

assembly if the air compressor does not pump. Refer to
Procedure No. 012-007-008 for the single cylinder air
compressor, or Procedure No. 012-008-008 for the two
cylinder air compressor.
Air Governor (Air Compressor Pumps

Continuously) (012-018)
necessary.
Remove the accessory air lines from the air governor
unloader port.
NOTE: Do not disconnect the line from the air compressor
unloader valve.
Compressed Air System — Group 12 Air Governor (Air Compressor Pumps Continuously) (012-018)
Install pipe plugs in the air governor unloader ports where

accessory air lines were removed.
If the air compressor does not pump (air pressure stops
rising) at the governed air pressure, there is a leak in an
accessory or an accessory air line. Refer to the equip-
ment manufacturer’s instructions for troubleshooting and
repair.
If the air compressor does not stop pumping (air pressure

continues to rise) at the governed air pressure, connect
a regulated shop air pressure line to one of the following:
• the air compressor unloader valve port, or
• one of the air governor unloader valve ports.
NOTE: Be sure the air pressure gauge is accurate and the

supply lines and fittings are in good condition before per-
forming any air pressure checks.
Use a master gauge of known accuracy to check the air
pressure gauge.
Apply air pressure to the unloader port.

If the air compressor stops pumping (air pressure stops
rising), the air governor is malfunctioning and must be
repaired or replaced, or the air governor mounting gasket
is leaking. Refer to the equipment manufacturer’s
instructions.
Air Leaks, Compressed Air System (012-019) Section 12 — Compressed Air System — Group 12
If the air compressor continues to pump (air pressure

continues to rise), the unloader valve is malfunctioning
and must be repaired or replaced. Refer to Procedure No.
012-013-008.
Remove the pipe plugs from the unloader ports used for
accessory air lines.
Install and tighten the accessory air lines. Connect the
unloader valve.
Air Leaks, Compressed Air System

(012-019)
necessary.
Open the draincock on the wet tank to release air pres-
sure from the system. Close the wet tank after the pres-
sure is released.
Section 12 — Compressed Air System — Group 12 Air Compressor (Oil Carryover) (012-020)

With the air compressor pumping between 550 to 690 kPa
[80 to 100 psi], use a solution of soapy water to check for
air leaks in the following areas:
• Air Compressor Cover Gasket
• Unloader Body O-Ring
• Air Compressor Head Gasket
If air leaks are found, replace the leaking gasket or o-ring.
Refer to Procedure No. 012-008-003 for the unloader
body o-ring, or Procedure No. 012-008-002 for the air
compressor head gasket.
Air Compressor (Oil Carryover)

(012-020)
air compressor. Differences in procedure for one or two
necessary.
Cycle the air compressor 5 times while viewing the dis-
charge from the air dryer. If the discharge appears ex-
cessively oily, perform the following check.
Remove the air discharge line from the air compressor.

Apply regulated air pressure to the air governor unloader
port.
Operate the engine at low idle for 10 minutes with the air
compressor unloaded (shop air applied to the unloader
port).
Remove the shop air pressure from the unloader port.
Operate the engine at low idle for 10 minutes with a white
cloth over the air compressor discharge port.
Air Compressor (Oil Carryover) (012-020) Section 12 — Compressed Air System — Group 12
Remove the white cloth and check the cloth for contami-
nation.
If the cloth indicates more than a trace of grey, the air
compressor is using an excessive amount of oil and must
be replaced. Refer to Procedure No. 012-014-026 for a
single cylinder compressor, or Procedure No. 012-015-
026 for a two cylinder compressor.
Install and tighten the air discharge line.

Section 13 - Electrical Equipment — Group 13 Section Contents
Section 13 - Electrical Equipment — Group 13

Section Contents
Page
Alternator (013-001) ......................................................................................................................................... 13-5
Install (013-001-026)....................................................................................................................................... 13-7
Remove (013-001-002) ................................................................................................................................... 13-5
Test (013-001-012).......................................................................................................................................... 13-6
Alternator Drive Belts (013-005) ...................................................................................................................... 13-9
Adjust (013-005-029) .................................................................................................................................... 13-10
Install (013-005-026) ...................................................................................................................................... 13-9
Remove (013-005-002) ................................................................................................................................... 13-9
Alternator Pulley (013-006)............................................................................................................................. 13-11
Batteries (013-007).......................................................................................................................................... 13-11
Inspect (013-007-062) ................................................................................................................................... 13-11
Battery Cables and Connections (013-009) ................................................................................................... 13-12
Electrical Equipment — General Info (013-999-999) ....................................................................................... 13-2
Electrical Equipment — Specifications (018-001-208) .................................................................................... 13-3
Electrical Equipment — Tool Requirements (022-001-513) ............................................................................. 13-4
Starter Magnetic Switch (013-017)................................................................................................................. 13-13
Starter Solenoid (013-019) ............................................................................................................................. 13-17
Voltage Check (013-019-041) ........................................................................................................................ 13-17
Starter Switch (013-018)................................................................................................................................. 13-15
Starting Motor (013-020) ................................................................................................................................ 13-19
Install (013-020-026)..................................................................................................................................... 13-20
Remove (013-020-002) ................................................................................................................................. 13-19
Electrical Equipment — General
Information (013-999-999) Section 13 - Electrical Equipment — Group 13
Electrical Equipment — General
The basic heavy-duty electrical system consists of:
• Batteries (1)
— (Usually three or four connected in parallel)
• A starting motor (2).
• An alternator (3).
• A magnetic switch (4).
• An ignition switch (5).
• All necessary wiring.
All components must be carefully matched.
The accompanying illustrations show typical parallel and

series battery connections.
• Parallel connection
• Series connection
Section 13 - Electrical Equipment — Group 13 Electrical Equipment — Specifications (018-001-208)
Electrical Equipment — Specifications (018-001-208)

Minimum battery capacity @ -18 to 0°C [0 to 32°F] ambient temperature
12-volt starter 400 ampere hour ................................................... 1800 cold cranking amps @ -18°C [0°F]
24-volt starter 200 ampere hour ..................................................... 900 cold cranking amps @ -18°C [0°F]
Minimum battery capacity above 0°C [32°F] ambient temperature
12-volt starter 300 ampere hour ................................................... 1280 cold cranking amps @ -18°C [0°F]
24-volt starter 150 ampere hour ..................................................... 640 cold cranking amps @ -18°C [0°F]
Maximum starting circuit resistance
12-volt starter ...................................................................................................................... 0.00075 OHMS
24-volt starter ..................................................................................................................... 0.00200 OHMS
Battery cable sizes - American wire gauge (Maximum length in cranking motor circuit)
12-volt
No. 00 ........................................................................................................................... 3.7 Meters [12 Feet]
No. 000 ......................................................................................................................... 4.9 Meters [16 Feet]
No. 0000 or two No. 0* ................................................................................................. 6.1 Meters [10 Feet]
Two No. 00 .................................................................................................................... 7.6 Meters [25 Feet]
12-volt High Output
No. 00 ............................................................................................................................. 2.1 Meters [7 Feet]
No. 000 ........................................................................................................................... 2.7 Meters [9 Feet]
No. 0000 or two No. 0* ................................................................................................. 3.7 Meters [12 Feet]
Two No. 00 .................................................................................................................... 4.3 Meters [14 Feet]
24 to 32-volt
No. 00 ........................................................................................................................... 6.1 Meters [20 Feet]
No. 000 ......................................................................................................................... 8.2 Meters [27 Feet]
No. 0000 or two No. 0* ............................................................................................... 10.7 Meters [35 Feet]
Two No. 00 .................................................................................................................. 13.7 Meters [45 Feet]
Minimum cranking speed without starting aid ............................................................................ 150 RPM

* Two strands of No. 0 cable can be used instead of one No. 0000 cable providing all connections are carefully
made to ensure equal current flow in each parallel cable.
Note: Starting aids such as block heaters, lubricating oil pan heaters. etc., are available to aid in cold weather
starting.
Section 13 - Electrical Equipment — Group 13 Alternator (013-001)
Alternator (013-001)
Remove (013-001-002)
Warning: Always disconnect the negative (-) cable first.
Disconnect the batteries. Disconnect the wiring from the
alternator.
Loosen the adjusting link and the alternator mounting

capscrews.
NOTE: The lower jam nut has left-hand threads.
relieve the belt tension.
Remove the alternator belt.
Remove capscrews (1) and (2) and the adjusting link.

Remove capscrew (3) and nut. Remove the alternator.

Remove the nut and pulley from the alternator.
Clean and inspect the pulley for reuse. Refer to Procedure
No. 013-006-007.
Alternator (013-001) Section 13 - Electrical Equipment — Group 13
Test (013-001-012)
The following instructions are for use with the an inductive
charging and cranking system analyzer.
NOTE: Before performing the following test, be sure the
alternator belt is tightened to the correct specifications. Re-
fer to the Specifications section in this manual.
Set the voltage selector knob to the appropriate scale. For

a 24 volt system, choose the 40 volt scale.
Set the amp selector knob to 100 amps.
Warning: Always DISCONNECT negative (-) cable FIRST.

Always CONNECT negative (-) cable LAST.
Disconnect the cables to any other battery in the circuit.
Connect the correct analyzer leads to the positive and
negative terminals on the battery.
Connect the clamp-on amp pick-up to the alternator out-

put cable as far away from the alternator as possible.
Section 13 - Electrical Equipment — Group 13 Alternator (013-001)
Operate the engine at high idle and turn the analyzer load
control knob clockwise until a maximum amp reading is
obtained.
NOTE: Do not let the load volts drop below 26 volts for a 24
volt system.
The maximum amp reading is the alternator output, and
must meet the alternator manufacturer’s specifications.
The alternator maximum rated output is normally stamped

or labeled on the alternator.
Also check the equipment ammeter gauge. If it does not
read approximately the same as the test equipment, it is
to be replaced.
If the alternator output is not within 10 percent of rated
output, repair or replace the alternator. Refer to the manu-
facturer’s instructions.
Turn the analyzer load control knob counterclockwise to

the OFF position and shut the engine, OFF.
Warning: Always connect the negative (-) cable last.
Remove the test equipment. Connect all battery cables
that were removed.
Install (013-001-026)
Lubricate the shaft with engine oil. Install the pulley and
nut on the alternator shaft. Tighten the nut.
Alternator (013-001) Section 13 - Electrical Equipment — Group 13
The belt must be adjusted before the capscrews are

tightened.
NOTE: The end of the adjusting link with the largest area at
the capscrew hole must be nearest to the alternator.
Install the alternator and the adjusting link as shown.
Caution: Do not attempt to pry the belt on the pulley.

Install the belt. Turn the adjusting screw counterclock-
wise to shorten the link if necessary.
Turn the adjusting screw clockwise to tighten the belt.

Tighten the belt.
Belt Tension: 220 kPa [165 ft-lb ]
Use the (Burroughs) belt tension gauge, Part No. ST-
1293, to check the belt tension.

Tighten the jam nuts on the adjusting screw.
Tighten the adjusting link and alternator mounting
capscrews.
Section 13 - Electrical Equipment — Group 13 Alternator Drive Belts (013-005)
Connect the wiring to the alternator.

Connect the batteries.
Alternator Drive Belts (013-005)

Remove (013-005-002)
Loosen the adjusting link and the alternator mounting
capscrews.
relieve the belt tension.
Remove the belt.

Inspect the belt for cracks, glazing, tears or cuts. The belt
must be replaced if damaged.
Install (013-005-026)
Do not attempt to pry the belt on the pulley. Turn the
adjusting screw counterclockwise to shorten the link if
necessary. Install the alternator belt.
Alternator Drive Belts (013-005) Section 13 - Electrical Equipment — Group 13

Tighten the jam nut on the adjusting screw.
capscrews.
Adjust (013-005-029)
Use the belt tension gauge, Part No. ST-1293. Check the
belt tension. Belt tension must be:
Belt Tension: 220 kPa [165 ft-lb]
Loosen the alternator and adjusting link mounting

capscrews.
Loosen the jam nuts on the adjusting screw.
Turn the adjusting screw clockwise to tighten the belt

tension.
Section 13 - Electrical Equipment — Group 13 Alternator Pulley (013-006)

Tighten the jam nuts on the adjusting screw.
capscrews.
Check the belt tension again to be sure it is correct. The

belt tension must be:
Belt Tension: 220 kPa [165 ft-lb]
Alternator Pulley (013-006)

Clean the alternator pulley with steam or solvent.
Inspect the grooves of the pulley for wear.
Batteries (013-007)
Inspect (013-007-062)
Use an inductive charging and cranking system analyzer
to load test the state-of-charge of maintenance-free bat-
teries. If the state-of-charge is low use a battery charger
to charge the battery. Refer to the manufacturer’s instruc-
tions.
Replace the battery if it will not charge to the manufac-
turer’s specifications or the battery will not maintain a
charge.
Battery Cables and Connections (013-009) Section 13 - Electrical Equipment — Group 13
If conventional batteries are used, remove the cell caps

or covers and check the electrolyte (water and sulfuric
acid solution) level.
Warning: Batteries emit hydrogen gas. To avoid explo-
sion and personal injury, do not smoke or allow ignition
source in area when servicing batteries.
NOTE: Maintenance-free batteries are sealed and do not
require the addition of water.
Fill each battery cell with water. Refer to the manufac-
turer’s specifications.
Refer to the accompanying chart to determine the battery

state-of-charge based on the specific gravity readings.
Use a hydrometer to measure the specific gravity of each

cell.
NOTE: If the specific gravity of any cell is below 1.200, the
battery must be charged.
NOTE: Do not attempt to check the specific gravity of a
battery immediately after adding water. If it is necessary to
add water to allow use of the hydrometer, charge the battery
several minutes at a high rate to mix the electrolyte.
Battery Cables and Connections

(013-009)
Visually inspect the battery terminals for loose, broken, or
corroded connections. Repair or replace broken cables or
terminals.
Section 13 - Electrical Equipment — Group 13 Starter Magnetic Switch (013-017)
If the connections are corroded, remove the cables and

use a battery brush to clean the cable and battery ter-
minals.
Connect and tighten the battery cables. Use grease to
coat the battery terminals to prevent corrosion.
Starter Magnetic Switch (013-017)

Before inspecting specific starting system components
with the multimeter:
• Visually inspect terminals for loose, broken, or cor-
roded connections.
• Replace or repair wiring and components as
necessary.
Warning: Be sure the starter switch is in the OFF posi-

tion to prevent electrical shock and personal injury.
Remove the cable connecting the magnetic switch to the
starter solenoid from the magnetic switch terminal.
Connect the leads of the Part No. 3377161 Digital
Multimeter to the two, large switch terminals.
Set the multimeter to measure resistance (OHMS).

With the starter switch in the OFF position, the multimeter
must indicate resistance at infinity.
• If the multimeter indicates ZERO (‘‘0’’) or very little
resistance, replace the magnetic switch.
• If the multimeter indicates resistance at infinity, pro-
ceed with the following instructions.
Starter Magnetic Switch (013-017) Section 13 - Electrical Equipment — Group 13
Turn the starter switch to the START position.

The multimeter must indicate ZERO (‘‘0’’) or very little
resistance. An audible click will be heard when the start-
ing switch is turned to the START position.
If the multimeter indicates resistance at infinity with the

starter switch in the START position and an audible click
is not heard:
• Turn the starter switch to the ‘‘OFF’’ position.
• Set the multimeter scale to indicate DC voltage.
Connect the positive lead of the one multimeter to the

magnetic switch ground wire terminal and the other lead
to the small magnetic switch terminal.
The multimeter will indicate some voltage across the mag-
netic switch terminals. If the multimeter indicates FULL
SYSTEM VOLTAGE, the magnetic switch is malfunction-
ing and must be replaced.
If the multimeter indicates no voltage, the magnetic switch

is not the cause of the complaint. Refer to Starter Switch,
Inspect for Reuse, in this section.
Section 13 - Electrical Equipment — Group 13 Starter Switch (013-018)
Turn the starter switch to the OFF position.

Remove the multimeter leads and connect the magnetic
switch to starter solenoid wire.
Starter Switch (013-018)

Warning: Be sure the starter switch is in the OFF posi-
tion to prevent electrical shock and personal injury.
Remove the wire connecting the starter switch to the
magnetic switch from the starter switch terminal.
Connect the positive lead of the digital multimeter, Part
No. 3377161, to the starter switch terminal and the nega-
tive lead to a chassis or engine ground location.
NOTE: With the starter switch in the OFF position, there

must be no voltage at the starter switch terminal. If the
multimeter indicates voltage, the starter switch is malfunc-
tioning and must be replaced.

The multimeter must indicate system voltage.
Starter Switch (013-018) Section 13 - Electrical Equipment — Group 13
If there is no voltage:
• Turn the starter switch to the OFF position.
• Connect the multimeter positive lead to the starter
switch terminal having a wire connecting the starter
switch to the starter solenoid.
If the multimeter indicates system voltage, the starter

switch is defective and must be replaced.
If the multimeter indicates no voltage, the switch is not

the cause of the complaint.
Inspect the wiring from the starter switch to the starter

solenoid and from the starter solenoid to the battery.
Replace any broken or damaged wires.
Section 13 - Electrical Equipment — Group 13 Starter Solenoid (013-019)
Starter Solenoid (013-019)

Voltage Check (013-019-041)
Use the multimeter, Part No. 3377161, and set it to mea-
sure DC voltage.
Connect the multimeter positive lead to the starter so-
lenoid positive cable terminal and the negative lead to
the battery cable connection at the starting motor. The
multimeter must show system voltage.
If the multimeter does not indicate system voltage, check

the battery to starting motor cable for broken, loose, or
corroded connections.
If the multimeter indicates system voltage, but the starting

motor will not operate, check the wire connecting the
starter solenoid to the starter switch for broken, loose, or
corroded connections.
If the wire connecting the starter solenoid and starter

switch is not loose or damaged and the starter will not
operate:
• Remove the cable connecting the starting motor
and starter solenoid from the solenoid terminal.
• Connect the multimeter positive lead to the sole-
noid positive terminal and the negative lead to a
chassis or engine ground.
Starter Solenoid (013-019) Section 13 - Electrical Equipment — Group 13

If the multimeter indicates system voltage, the starter
solenoid is malfunctioning and must be replaced.
If the multimeter does not indicate system voltage, check

the wire connecting the starter solenoid to the magnetic
switch for broken, loose, or corroded connections.
If the wire connecting the starter solenoid to the magnetic

switch is not loose or damaged and the starting motor will
not operate:
• Check the cable connecting the starter solenoid to
the starting motor for broken, loose, or corroded
connections.
Check the cable connecting the starter to the battery for

broken, loose, or corroded connections.
Section 13 - Electrical Equipment — Group 13 Starting Motor (013-020)
If the cables are not loose or damaged, the starting motor

is defective and must be replaced.
Starting Motor (013-020)

Remove (013-020-002)
Disconnect the battery.
Disconnect the electrical connections from the starting
motor.
Remove the starting motor capscrews, the starter, spac-

ers, and the gaskets. Discard the gaskets.
NOTE: All engines do not contain spacers and gaskets.

Warning: Wear protective clothing to prevent personal
injury from burns.
Clean the exterior of the motor with steam.
Inspect the gear, shaft, and the bushing for wear or dam-
age.
Lubricate the bushing with engine oil.
NOTE: A pipe plug must be removed to lubricate the bush-
ing on some starter motors.
Starting Motor (013-020) Section 13 - Electrical Equipment — Group 13
Install (013-020-026)
NOTE: All engines do not use spacers.
the starting motor.
Install any spacer or gaskets.
Install the starting motor and capscrews. Use the follow-
ing to tighten the capscrews.
Starting Motor — Torque Value

Flywheel Housing N•m [ft-lb]
Cast Iron 215 [160]
Aluminum 195 [145]
Install the electrical connections to the starting motor.

Warning: Always connect the negative cable last.
Connect the batteries.
Section 14 - Engine Testing - Group 14

Section Contents
Page
Dynamometer Worksheet (014-001)................................................................................................................. 14-7
Worksheet (014-001-056)................................................................................................................................ 14-7
Engine Run-In (Chassis Dynamometer) (014-002) .......................................................................................... 14-8
General Engine Test Procedures ............................................................................................................... 14-8
Run-In Instructions (014-002-276) ................................................................................................................ 14-10
Engine Run-In (Engine Dynamometer) (014-003) .......................................................................................... 14-12
General Information (014-003-999) ............................................................................................................... 14-12
General Engine Test Procedures.............................................................................................................. 14-12
Run-In Instructions (014-003-276) ............................................................................................................... 14-15
Engine Run-In (Without Dynamometer) (014-004) ........................................................................................ 14-18
Run-In Instructions (014-004-276) ................................................................................................................ 14-18
Engine Testing - General Information (014-999-999) ...................................................................................... 14-3
Engine Testing - Specifications (018-001-275) ................................................................................................ 14-4
Engine Testing - Tool Requirements (022-001-514) ......................................................................................... 14-5
Engine Testing (Chassis Dynamometer) (014-005)........................................................................................ 14-19
Setup (014-005-011) .................................................................................................................................... 14-19
Test (014-005-012)........................................................................................................................................ 14-22
Air Compressor........................................................................................................................................ 14-31
Coolant Pressure ..................................................................................................................................... 14-30
Engine Blowby......................................................................................................................................... 14-25
Engine Speed (RPM) With a Verified Tachometer .................................................................................... 14-22
Exhaust Restriction ................................................................................................................................. 14-25
Fuel Drain Line Restriction ...................................................................................................................... 14-23
Fuel Inlet Restriction................................................................................................................................ 14-23
Fuel Pressure .......................................................................................................................................... 14-23
Fuel Rate ................................................................................................................................................ 14-23
Intake Air Restriction ............................................................................................................................... 14-25
Intake Air Temperature Control - Chassis Dynamometer Test ................................................................... 14-24
Intake Manifold Pressure ......................................................................................................................... 14-24
Lubricating Oil Pressure .......................................................................................................................... 14-30
Lubricating Oil Temperature ..................................................................................................................... 14-30
Starting Motor.......................................................................................................................................... 14-31
Engine Testing (Engine Dynamometer) (014-006) ......................................................................................... 14-31
Install (014-006-026) .................................................................................................................................... 14-31
Coolant Plumbing .................................................................................................................................... 14-32
Engine Throttle Control............................................................................................................................ 14-35
Test (014-006-012)........................................................................................................................................ 14-35
Air Compressor ....................................................................................................................................... 14-42
Coolant Pressure ..................................................................................................................................... 14-42
Engine Blowby......................................................................................................................................... 14-38
Engine Speed (RPM) With a Verified Tachometer .................................................................................... 14-36
Exhaust Restriction ................................................................................................................................. 14-37
Fuel Drain Line Restriction ...................................................................................................................... 14-37
Fuel Inlet Restriction................................................................................................................................ 14-36
Fuel Pressure .......................................................................................................................................... 14-36
Fuel Rate ................................................................................................................................................ 14-36
Intake Air Restriction ............................................................................................................................... 14-37
Intake Manifold Pressure ......................................................................................................................... 14-37
Lubricating Oil Pressure .......................................................................................................................... 14-42
Lubricating Oil Temperature ..................................................................................................................... 14-42
Starting Motor.......................................................................................................................................... 14-43
Page
Engine Testing (Fuel Flow Rate) (014-007) .................................................................................................... 14-50
Measure (014-007-010) ................................................................................................................................ 14-50
Operation................................................................................................................................................. 14-51
Engine Testing (In-Chassis) (014-008) ........................................................................................................... 14-43
Stall Speed Check (014-008-280) ................................................................................................................. 14-43
Time Speed Check (014-008-281) ................................................................................................................ 14-46
Stall Speed Check List ............................................................................................................................ 14-48
Section 14 - Engine Testing - Group 14 Engine Testing - General Information (014-999-999)
Engine Testing - General Information

(014-999-999)
This section outlines engine testing and engine run-in
recommendations for QSK19 engines. All engines must
be run-in after a rebuild or a repair involving the replace-
ment of one or more piston ring sets, cylinder liners or
cylinder kits.
Incorrect or insufficient break-in of the piston rings
will lead to early oil consumption or high blowby com-
plaints. Adherence to these run-in guidelines will al-
low the full durability of new pistons, liners, and rings
to be realized.
Before running the engine, make sure the engine is filled
with the proper coolant. Also, make sure the lubricating
oil system is filled and primed.
In-Service Run-In
The following in-service run-in guidelines are recommended for QSK19 engines after a repair involving replace-
ment of one or more of the piston ring sets, cylinder liners or cylinder kits where engine or an engine dynamometer
and/or chassis dynamometer run-in cannot be performed.
The majority of heavy duty diesel applications will provide sufficient run-in under normal loaded operations.
However, light load/high rpm operation must be avoided during the run-in period.
Engine Dynamometer Run-In
This is the preferred method of run-in for engines that have been rebuilt out-of-chassis. It is not practical, nor
recommended that an engine be removed from the application to conduct the run-in after a rebuild or cylinder repair
has been performed in-chassis. There is no requirement, nor is it recommended for an engine that has been run-in
and tested on an engine dynamometer to be run-in again after it has been reinstalled in the vehicle or equipment.
Chassis Dynamometer, Portable Dynamometer or Load Bank Run-In
When it is not possible to load an engine immediately after rebuild or repair, (example: on-highway tractor that must
be ‘‘bobtailed’’ for delivery, a stand-by generator or fire pump that cannot be operated because of customer
restrictions, a fire truck that cannot be loaded with the water pump, etc.), the engine must be run-in on a chassis
dynamometer, portable dynamometer or load bank following the recommendations outlined in the attached
procedures.
Engine Testing - Specifications (018-001-275) Section 14 - Engine Testing - Group 14
Engine Testing - Specifications (018-001-275)

Maintain the following limits during the engine test/run-in procedures:
Due to variations in ratings of different engine models, refer to the specific ‘‘Engine Data Sheet’’ for the particular
engine model being tested.
Intake Restriction (Maximum at Advertised Horsepower)
• Clean Air Filter ................................................................................................. 381 mm H20 [15 in. H20]
• Dirty Air Filter ................................................................................................... 635 mm H20 [25 in. H20]
Exhaust Back Pressure (Maximum at Advertised Horsepower) .................................... 75 mm Hg [3 in. Hg]
Blowby* (Maximum at Advertised Horsepower)
• New or rebuilt engines
(Maximum) (Less than 160,000 km [100,000 miles] or 3600 hours) .................................................. TBD
• Used Engines
(Maximum) (Over 160,000 km [100,000 miles] or 3600 hours) .......................................................... TBD
Oil Pressure (With 15W-40 oil at 107°C [225°F])
• Low Idle (Minimum Allowable) ........................................................................................ 138 kPa [20 psi]
• At 1200 RPM or Torque Peak (Minimum allowable) ........................................................ 207 kPa [30 psi]
Fuel Inlet Restriction measured at fuel pump inlet (Maximum at Advertised Horsepower)
• Clean Fuel Filter .......................................................................................................... 102 mm [4 in Hg]
• Dirty Fuel Filter .......................................................................................................... 254 mm [10 in Hg]
• Maximum Allowable Fuel Inlet Temperature ........................................................................ 71°C [160°F]
• Blowby checking tool, Part No. 3822566, has a special orifice that must be used to be certain an accurate reading
is obtained.
Section 14 - Engine Testing - Group 14 Dynamometer Worksheet (014-001)
Dynamometer Worksheet (014-001)

Worksheet (014-001-056)
Date Repair Order No. Operator
ESN CPL Fuel Pump Code
Complaint SC Code
PARAMETER CODE SPECIFICATIONS ACTUAL READING

Fuel Pressure (psi @ RPM) 150 to 180 at Governed
Fuel Rate (lb/hr)
Intake Mfd. Pressure (in.Hg) See Fuel Pump Code
Intake Mfd. Temperature
*Intake Air Restriction 25 in. H20, Maximum
*Exhaust Air Restriction 3 in. Hg, Maximum
*Fuel Inlet Restriction 10 in. Hg (Dirty Filter), Maximum
*Fuel Drain Line Restriction 10 in. Hg
Engine Blowby 12 in. H20 New Engines, Max.
18 in. H20 Used Engines, Max.
*Recorded at Maximum Horsepower Speed and Full Load
Road Speed Limit Engine High Speed Limit
Check Oil Level Low High OK Fuel Quality OK Not OK
Horse
Turbo Intake Lube power
Engine Fuel Fuel Inlet Manifold Coolant Engine Oil or
Speed *Rate/Press Temp Air Temp Temp/Press Temp/Press Blowby Press Torque
* Be sure that the fuel rate is corrected for temperature.
Fuel Temperature Correction for Flow Rate Pressure Conversions

Less than 7°C[45°F] Flow meter not accurate
7 to 13°C[45 to 55°F] Subtract 2% from flow rate reading
1 in. H20 = 0.074 in. Hg = 0.036 psi
13.0 to 20.0°C[55 to 68°F] Subtract 1% from flow rate reading
20.0 to 29°C[68 to 85°F] No Correction 1 in. Hg = 13.514 in. H20 = 0.491 psi
29 to 42°C[85 to 108°F] Add 1% to flow rate reading 1 psi = 2.036 in. Hg = 27.7 in. H20
42 to 56°C[108 to 132°F] Add 2% to flow rate reading
56°C above [132°F] Flow meter not accurate.
This Page Can Be Copied For Your Convenience.

Engine Run-In (Chassis Dynamometer) (014-002) Section 14 - Engine Testing - Group 14
Engine Run-In (Chassis Dynamometer)

(014-002)
General Engine Test Procedures
Remove the large plug from the oil cooler housing.

Check the engine lubricating oil level to be sure it is filled

to the proper level.
Check the engine coolant level to make sure it is filled to

the proper level. Refer to Procedure 008-018-028.
is stopped. Wait until the coolant temperature is below
50°C [120°F] before removing the pressure cap. Failure
to do so can cause personal injury from heated coolant
spray.
Caution: Do not add cold coolant to a hot engine. This
can cause engine casting damage. Allow the engine to
cool to below 50°C [120°F] before adding coolant.
Section 14 - Engine Testing - Group 14 Engine Run-In (Chassis Dynamometer) (014-002)
NOTE: Use a known source of good quality No. 2 diesel fuel.
This is very important since No. 1 diesel fuels, along with

most other alternate fuels, are lighter (lower specific gravity,
higher API gravity) than No. 2 diesel fuel. The lighter the fuel,
the lower the energy content (BTU) per gallon (liter, etc.).
Engine Run-In (Chassis Dynamometer) (014-002) Section 14 - Engine Testing - Group 14
Run-In Instructions (014-002-276)

Refer to Chassis Dynamometer - Operation, Procedure
No. 014-005, for general operating procedures and safety
precautions.
Use this chart to determine the test load.

Example: The test load for a 475 HP engine rated at 2000 RPM with a 15 percent torque rise is 225 ft-lb.
NOTE: This chart assumes the dynamometer constant is 5252. If the dynamometer constant is not 5252, use the
following formula to determine the correct test load:
Correct test load = (Dynamometer constant) x (Test load) ÷ 5252.
Example: The dynamometer constant for testing the engine in the above example is 4000.
Correct test load = (4000 x 225) ÷ 5252 = 171 ft-lb.
NOTE: This chart assumes vehicle run-in on a chassis dynamometer.
Rated RPM Rated Horsepower Torque Rise Test Load

1200 All All 305 N•m [225 ft-lb]
1500 All All 305 N•m [225 ft-lb]
1800 0 to 499 All 305 N•m [225 ft-lb]
1800 500 and ABOVE All 380 N•m [280 ft-lb]
1900 0 to 474 All 305 N•m [225 ft-lb]
2000 0 to 499 0 to 24% 305 N•m [225 ft-lb]
2000 0 to 499 25% and ABOVE 380 N•m [280 ft-lb]
2100 0 to 474 0 to 32% 305 N•m [225 ft-lb]
2100 0 to 474 33% Plus 305 N•m [225 ft-lb]
2100 475 to 530 0 to 15% 305 N•m [225 ft-lb]
2100 531 to 649 All 380 N•m [280 ft-lb]
Section 14 - Engine Testing - Group 14 Engine Run-In (Chassis Dynamometer) (014-002)
Adjust the engine RPM to 1200 RPM. Adjust the dyna-

mometer load to the test load as previously determined.
Operate the engine at this setting until the coolant tem-
perature indicates 70°C [160°F].
Check for leaks. Fix all leaks.
Check all of the gauges and record the readings.
Do not proceed to the next step until the blowby becomes
stable within specifications.
Adjust the engine RPM to the torque peak RPM. Adjust

the dynamometer load to equal two times the test load.
Operate the engine for 2 minutes.
Check all the gauges and record the readings.
Maintain the engine RPM at torque peak RPM. Increase

the dynamometer load to equal three times the test load.
Operate the engine at this load for 2 minutes.
Move the throttle lever to the FULL OPEN position. In-

crease the load until the engine RPM is at torque peak
RPM.
Operate the engine at this setting for 10 minutes or until
the blowby becomes stable within specifications.
Engine Run-In (Engine Dynamometer) (014-003) Section 14 - Engine Testing - Group 14
Decrease the dynamometer load until the engine RPM

increases to the rated RPM.
Decrease the dynamometer load completely.

Caution: Do not turn the engine OFF immediately. The
engine must be allowed to cool.
Move the throttle lever to the LOW IDLE position. Operate
the engine at this setting for 3 to 5 minutes. This will allow
the turbocharger and the other engine components to
cool.
Caution: Do not operate the engine at IDLE longer than
specified. Excessive carbon formation can cause engine
damage.
Turn the engine OFF.
Engine Run-In (Engine Dynamometer)

(014-003)
Section 14 - Engine Testing - Group 14 Engine Run-In (Engine Dynamometer) (014-003)


Check the engine coolant level to make sure it is filled to

the proper level. Refer to Procedure 008-018-028.
spray.

Engine operating specifications can be found in publica-

tions available from your local Cummins Authorized Re-
pair Location.

Refer to Chassis Dynamometer - Operation, Procedure
No. 014-005, for general operating procedures and safety
precautions.
Use this chart to determine the test load.

The run-in test must be performed with the engine operating at torque peak RPM. Operate a generator set engine
at rated RPM.
Example: The test load for a 475 HP engine rated at 2000 RPM with a 15 percent torque rise is [300 ft-lb].
NOTE: This chart assumes the dynamometer constant is 5252. If the dynamometer constant is not 5252, use the
following formula to determine the correct test load:
Correct test load = (Dynamometer constant) x (Test load) ÷ 5252.
Example: The dynamometer constant for testing the engine in the above example is 4000.
Correct test load = (4000 x 300) ÷ 5252 = [228 ft-lb].
NOTE: This chart assumes vehicle run-in on a chassis dynamometer.
Rated RPM Rated Horsepower Torque Rise Test Load

1200 All All 405 N•m [300 ft-lb]
1500 All All 405 N•m [300 ft-lb]
1800 0 to 499 All 405 N•m [300 ft-lb]
1900 0 to 474 All 405 N•m [300 ft-lb]
2000 0 to 499 0 to 24% 405 N•m [300 ft-lb]
2100 0 to 474 0 to 32% 405 N•m [300 ft-lb]
2100 0 to 474 33% Plus 405 N•m [300 ft-lb]
2100 475 to 530 0 to 15% 405 N•m [300 ft-lb]
2100 531 to 649 All 510 N•m [375 ft-lb]
Caution: Do not crank the starting motor for more than

30 seconds. Excessive heat will damage the starter.
START the engine. If the engine does not begin operating
after 30 seconds, allow two minutes for the starting motor
to cool.
Caution: If the oil pressure is not within specifications,
STOP the engine immediately. Both low and high oil
pressure will cause engine damage.
Main Oil Rifle Pressure (at Idle)

kPa psi
138 MIN 20
483 MAX 70
Operate the engine at the IDLE position. Check for leaks.

specified. Excessive carbon formation will cause engine
damage.
Adjust the engine RPM to 1200 RPM. Adjust the dyna-

mometer load to the test load as previously determined.
Operate the engine at this setting until the coolant tem-
perature indicates 70°C [160°F].
Check for leaks. Fix all leaks.
Check all of the gauges and record the readings.
Adjust the engine RPM to the torque peak RPM. Adjust

the dynamometer load to equal two times the test load.
Operate the engine for two minutes.
Maintain the engine RPM at torque peak RPM. Increase

the dynamometer load to equal three times the test load.
Move the throttle lever to the FULL OPEN position. In-

crease the load until the engine RPM is at torque peak
RPM.
Operate the engine at this setting for 10 minutes or until
the blowby becomes stable within specifications.
Decrease the dynamometer load until the engine RPM

increases to the rated RPM.
Decrease the dynamometer load completely.

Caution: Do not turn the engine OFF immediately. The
engine must be allowed to cool.
Move the throttle lever to the LOW IDLE position. Operate
the engine at this setting for 3 to 5 minutes. This will allow
the turbocharger and the other engine components to
cool.
specified. Excessive carbon formation can cause engine
damage.
Engine Run-In (Without Dynamometer) (014-004) Section 14 - Engine Testing - Group 14
Turn the engine OFF.
Engine Run-In (Without Dynamometer)

(014-004)
Generator Set
Caution: Refer to Procedure before operating engine to
avoid internal component damage.
Operate the engine in steps, varying the load from 25 to
100 percent, until blowby remains constant.
Off-Highway
Caution: Refer to Procedure before operating engine to
avoid internal component damage.
Operate the equipment in the normal duty cycle at part
load during the first 3 hours after rebuild.
Do not idle the engine for more than 5 minutes at any one
time.
Do not operate the engine at rated rpm. Operate at 75
percent of rated RPM or lower.
Rated RPM Max RPM for First 3 Hrs.

2100 1575
2000 1500
1900 1425
1800 1350
Section 14 - Engine Testing - Group 14 Engine Testing (Chassis Dynamometer) (014-005)
Do not operate the engine at full load for more than 5

minutes at any one time.
Engine Testing (Chassis Dynamom-

eter) (014-005)
Setup (014-005-011)
The performance of an engine installed in on-highway
vehicles can be tested on a chassis dynamometer.
NOTE: Due to driveline inefficiencies and engine-driven ac-
cessories, the rated horsepower will be reduced by approxi-
mately:
• 20 percent for single axle vehicles
• 25 percent for tandem axle vehicles
The net horsepower available is called wheel horsepower
(WHP).
NOTE: Operate the vehicle in a gear that produces a road
speed of 90 to 95 Km/H [55 to 60 MPH].
Caution: Before installing or operating a vehicle on a

chassis dynamometer, follow all the vehicle manufac-
turer’s safety precautions.
Engine Testing (Chassis Dynamometer) (014-005) Section 14 - Engine Testing - Group 14
Caution: Low profile radial tires are more sensitive to

heat than bias ply tires. Excessive operating time at full
load can damage tires due to overheating. Check the tire
manufacturer’s recommendations for the maximum al-
lowable chassis dynamometer operating time.
Adjust the vehicle and dynamometer room exhaust sys-

tem to be sure that all exhaust gases are removed from
the room.
Refer to the chassis dynamometer and vehicle manufac-
turer’s recommendations and specifications for testing
procedures.
Be sure all instrumentation is removed before removing

the vehicle from the dynamometer.



Check the engine coolant level to be sure it is filled to the

proper level. Refer to Procedure 008-018-028.
spray.

Engine operating specifications can be found in publica-

tions available from your local Cummins Authorized Re-
pair Location.
Test (014-005-012)
To properly monitor engine performance, record the fol-
lowing parameters. To limit dynamometer operating time,
instrument the engine to perform as many checks as
possible.
• Engine speed RPM with a verified tachometer
• Fuel pressure
• Fuel rate (Use Service Tool, Part No. 3376375)
• Fuel temperature (if needed to correct fuel rate)
• Fuel inlet restriction
• Fuel drain line restriction
• Intake manifold pressure
• Intake air restriction

• Exhaust air restriction
• Coolant temperature
• Engine blowby
• Lubricating oil pressure
• Coolant pressure
• Inlet manifold air temperature
• Turbocharger inlet air temperature
Engine Speed (RPM) With a Verified Tachometer

Use digital optical tachometer, Part No. 3377462, to check
and verify engine speed.
Rail Pressure
Fuel Rate
Use fuel measuring device, Part No. 3376375, to measure
the rate of fuel consumption. Refer to Procedure
014-007-010.
Fuel Inlet Restriction

Measure the fuel inlet restriction. Install a vacuum gauge,
Part No. ST-434, between the fuel filter and the gear
pump inlet.
NOTE: Do not measure fuel inlet restriction with the fuel
measuring device installed. This will not measure the inlet
restriction of the vehicle’s supply plumbing.
Fuel Drain Line Restriction

Use Pressure Gauge, Part No. ST-1273, to measure fuel
drain line restriction.
NOTE: Do not measure fuel drain line restriction with the
fuel measuring device installed. This will not measure the
drain line restriction of the vehicle’s return plumbing.
Intake Manifold Pressure

Measure the intake manifold or INSITE™ pressure (turbo-
charger boost). Install pressure gauge, Part No. ST-1273,
in the intake manifold as shown.
Observe the reading on the pressure gauge.
Intake Air Temperature Control - Chassis Dynamom-

eter Test
When operating an engine on a chassis dynamometer,
follow these steps for best results and safe operation.
If the engine is equipped with automatic fan, lock the
cooling fan in the ON mode. This can be done by installing
a jumper across the temperature switch, or by supplying
shop air to the control valve. Refer to the fan drive manu-
facturer for the recommended procedure.
Monitor the intake manifold air temperature using INSITE™

in the monitor mode, or install Fluke digital thermometer,
Part No. 3822666, and thermocouple wire kit, Part No.
3822988, into the intake manifold.
The intake manifold air temperature must not exceed
77°C [170°F].
Maintain intake manifold air temperature to 66°C [150°F]
or below during chassis dynamometer operation.
If the intake manifold temperature exceeds 77°C [170°F],

shut off the engine. Allow the engine to cool.
Check the fan drive. Be sure the fan is locked in the ON
mode.
Remove any obstructions such as a winterfront or debris.
Manually lock the shutters in the OPEN position if
equipped.
Inspect the dynamometer room for adequate supply of
suitably cool or outside air. Make sure that dynamometer
room recirculation is not an issue.
Resume the test.
Intake Air Restriction

Measure the inlet air restriction. Install the vacuum gauge,
Part No. ST-434, or a manometer in the intake air piping.
NOTE: The gauge adapter must be installed at a 90 degree
angle to the air flow in a straight section of pipe at a minimum
of one pipe diameter before the turbocharger.
Exhaust Restriction
Measure the exhaust air restriction. Install the pressure
gauge, Part No. ST-1273, or a manometer in the exhaust
air piping.
The gauge adapter must be installed near the turbo-
charger in a straight section of pipe at the turbine outlet.
Engine Blowby
NOTE: Excessive blowby indicates an air compressor, a
turbocharger, or an engine malfunction, allowing combus-
tion gases or air to enter the crankcase and build a pressure
higher than normal.
This procedure describes how to measure crankcase pres-
sure and how to determine the component that is mal-
functioning.
Use one of the three blowby service tools and a water
manometer Part No. ST-1111-3. Minimum gauge capacity
is 1270 mm-H20 [50 in-H20].
The engine blowby tools are similar in design. The dif-
ference between the tools is in the size of the orifice.
Blowby Tool Orifice Size

Part No. [inch]
3822566 [0.302]
3822567 [0.354]
3822568 [0.406]
Use a length of hose (1) to attach the blowby tool to one

of the crankcase breathers.
Plug all of the other breathers.
Attach a manometer to the location shown (2).
Operate the engine at rated RPM and full load (wide open
throttle) until a steady reading is obtained.
Compare the blowby readings to previous readings on the
engine. If previous readings for the engine are not avail-
able, compare the blowby reading to new engine speci-
fications.
NOTE: A sudden increase in blowby indicates a problem. A
gradual increase over a period of time is normal (due to wear
of internal engine components).
Specifications (New Engines)

Engine Blowby 7.67 mm [0.302 in] Orifice:
RPM mm H20 [in H20]
All ratings 508 [20]
2000 and above 355 [14]
1200 to 1900 305 [12]
2000 and above 254 [10]
1500 to 1900 203 [8]
All ratings 229 [9]
2000 and above 203 [8]
1200 to 1900 178 [7]
2000 and above 152 [6]
1500 to 1900 127 [5]
All ratings 127 [5]
If the blowby is higher than normal, check the crankcase

breathers and breather tubes to see if they are plugged.
Check the engine oil level. If the level is too high it can
cause a higher than normal crankcase pressure.
Isolate the turbocharger to determine if the high crank-

case pressure is due to seal leakage in the turbocharger.
Warning: Some state and federal agencies in the United
Disconnect the turbocharger drain line from the oil pan
adaptor.
Install a hose assembly with the two shutoff valves ar-
ranged as shown. Place the other hose in an 8 to 19 liter
[2 to 5 gallon] bucket.
NOTE: The valves must have a minimum inside diameter of
19 mm [0.75 in].
Close the valve (A) that allows the oil to drain to the
bucket.
Open the valve (B) that allows the oil to drain into the
engine.
Operate the engine at rated speed. Record the blowby

value.
Caution: Do not operate the engine with valve A open
and valve B closed for more than 1 minute. Operation for
more than 1 minute can result in severe engine damage.
Continue operating at rated speed and load. Open valve
A and close valve B. Record the blowby reading.
Compare the value to the original reading. If the blowby

is acceptable, replace the turbocharger. Refer to Proce-
dure No. 010-037-002.
Isolate the air compressor to determine if it is malfunc-

tioning and causing the high blowby pressure.
Relieve the air pressure on the first air tank in the system
after the air compressor (wet tank).
Disconnect the air inlet and outlet connections. Plug the
intake manifold or air piping where the inlet connection
was removed.
Operate the engine at rated speed and full load (wide

open throttle) until a steady blowby reading is obtained.
Compare the blowby readings to the previous value. If the
blowby is satisfactory, replace the air compressor. Refer
to Procedure No. 012-014-002 or 012-015-002.
A sudden increase in blowby or a high reading that is not

steady indicates that there is internal damage in the en-
gine. To determine which cylinder is at fault, refer to the
Troubleshooting Trees, Section T.
Lubricating Oil Pressure

Use Pressure Gauge, Part No. 3375275, to measure lu-
bricating oil pressure.
Install the pressure gauge to the main oil rifle (1) or oil filter
head (2).
Low Idle (minimum allowable) 138 kPa [20 psi]
At 1200 RPM (minimum allowable) 207 kPa [30 psi]
Coolant Pressure
Measure the coolant pressure at the water manifold (1).
Maximum Coolant Pressure with Closed Thermostat
and No Pressure Cap:
241 kPa [35 psi]
Lubricating Oil Temperature

Refer to Procedure No. 007-038.
Section 14 - Engine Testing - Group 14 Engine Testing (Engine Dynamometer) (014-006)
Air Compressor
NOTE: All air compressors manufactured by Cummins En-
gine Company, Inc. must be operating during the engine
run-in. During the performance check, all air compressors
must be in the unload or non-operating mode.
Connect a source of compressed air capable of produc-
ing 665 kPa [95 psi] to the air compressor unloader (1).
This air line must contain a valve between the source and
the unloader.
NOTE: The compressed air load in the accompanying illus-
tration must be attached to the air compressor outlet (2).
Use an air tank (2). Install an air regulator (3) capable of

maintaining 345 to 517 kPa [50 to 75 psi] air pressure at
both minimum and maximum engine RPM.
Install a steel tube or high temperature hose (1).
Hose Temperature (Minimum): 235°C [500°F].
Connect the tube or hose (1) to the air compressor outlet.
Starting Motor
Inspect the voltage rating on the starting motor before
installing the electrical wiring.
Install the electrical wiring to the starting motor and bat-
teries, if used.
NOTE: If another method of starting the engine is used,
follow the manufacturer’s instructions to make the neces-
sary connections.
Engine Testing (Engine Dynamometer) (014-006)

Install (014-006-026)
NOTE: Make sure the dynamometer capacity is sufficient to permit testing at 100 percent of the engine rated horsepower.
If the capacity is not enough, the testing procedure must be modified to the restrictions of the dynamometer.
Use engine lifting fixture, Part No. 3822512, to install the engine to the test stand. Align and connect the
dynamometer. Refer to the manufacturer’s instructions for aligning and testing the engine.
Refer to Service Bulletin No. 3666005, Dynamometer and Road Engine Testing, for detailed instructions on
auxiliary aftercooling system attachment.
Engine Testing (Engine Dynamometer) (014-006) Section 14 - Engine Testing - Group 14
NOTE: Some engines are equipped with fittings used for

CompuchekW testing sensors. The sensor probes used for
CompuchekW and dynamometer testing are not compat-
ible. If the same location is used, remove the CompuchekW
fitting and install adapters for the dynamometer sensor.
Install the coolant pressure sensor (1).
Install the coolant temperature sensor (2).
Coolant Plumbing
Connect the coolant supply to the water inlet connection.
Connect the coolant return to the water outlet connection.
Install the drain plugs and close all of the water drain
cocks.
NOTE: LTA engines require connecting the LTA water lines
to a remote heat exchanger.
• Intake Air Temperature Control

The use of a remote heat exchanger is mandatory
whenever a Cummins LTA engine is attached to an
engine dynamometer for the purpose of engine run-
in, performance testing and engine diagnostics. Do
not attempt to run a Cummins LTA engine without
any means of controlling the intake manifold air
temperature.
A = Aftercooler water OUT
B = Aftercooler water IN
C = Water OUT to drain
D = Cool water IN
• LTA (Low Temperature Afterooling)

The 750 bhp Q/19 rating and its derates require low
temperature aftercooling (LTA) and therefore have a
unique radiator requirements. The ratings of 525
bhp and 600 bhp and their derates do not require
LTA. The LTA is a one-pump, two-loop cooling system.
Note: The heat exchanger must be sized to main-
tain 70°C [160°F] maximum intake air temperature
at full power.
This graphic shows the schematic of the aftercooler
water flow using a remote heat exchanger.
A = Water IN
B = Thermostat housing
C = LTA OUT
D = Water OUT
E = LTA return


Check the engine coolant level to be sure it is filled to the

proper level. Refer to Procedure 008-018-028.
spray.


Engine Throttle Control

Engines that are run on an engine dynamometer require
that the engine harness be installed, and connected to
the engine. Additionally, a special engine dynamometer
version of the OEM wiring harness and throttle control
must be installed.
A special wiring harness and throttle control has been
developed to enable engine operation out of the chassis.
Engine operating specifications are available from your

local Cummins Authorized Repair Location.
Test (014-006-012)
To properly monitor engine performance, record the fol-
lowing parameters. To limit dynamometer operating time,
instrument the engine to make as many checks as pos-
sible.
• Engine speed RPM with a verified tachometer
• Fuel pressure
• Fuel rate (Use Service Tool, Part No. 3376375)
• Fuel temperature (if needed to correct fuel rate)
• Fuel inlet restriction
• Fuel drain line restriction
• Intake manifold pressure
• Intake air restriction

• Exhaust air restriction
• Coolant temperature
• Engine blowby
• Lubricating oil pressure
• Coolant pressure
• Inlet manifold air temperature
• Turbocharger inlet air temperature
Engine Speed (RPM) With a Verified Tachometer

Use digital optical tachometer, Part No. 3377462, to check
and verify engine speed.
Fuel Supply Pressure

Fuel Rate
Use fuel measuring device, Part No. 3376375, to measure
the rate of fuel consumption. Refer to Procedure
014-007-010.
Fuel Inlet Restriction

Measure the fuel inlet restriction. Install a vacuum gauge,
Part No. ST-434, between the fuel filter and the gear
pump inlet.
NOTE: Do not measure fuel inlet restriction with the fuel
measuring device installed. This will not measure the inlet
restriction of the vehicle’s supply plumbing.
Fuel Drain Line Restriction

Use Pressure Gauge, Part No. ST-1273, to measure fuel
drain line restriction.
NOTE: Do not measure fuel drain line restriction with the
fuel measuring device installed. This will not measure the
drain line restriction of the vehicle’s return plumbing.
Intake Manifold Pressure

Measure the intake manifold pressure (turbocharger
boost). Install pressure gauge, Part No. ST-1273, in the
intake manifold as shown.
Observe the reading on the pressure gauge.
Intake Air Restriction

Measure the inlet air restriction. Install the vacuum gauge,
Part No. ST-434, or a manometer in the intake air piping.
NOTE: The gauge adapter must be installed at a 90 degree
angle to the air flow in a straight section of pipe at a minimum
of one pipe diameter before the turbocharger.
Exhaust Restriction
Measure the exhaust air restriction. Install the pressure
gauge, Part No. ST-1273, or a manometer in the exhaust
air piping.
The gauge adapter must be installed near the turbo-
charger in a straight section of pipe at the turbine outlet.
Engine Blowby
NOTE: Excessive blowby indicates an air compressor, a
turbocharger, or an engine malfunction, allowing combus-
tion gases or air to enter the crankcase and build a pressure
higher than normal.
This procedure describes how to measure crankcase pres-
sure and how to determine the component that is mal-
functioning.
Use one of the three blowby service tools and a water
manometer, Part No. ST-1111-3. Minimum gauge capacity
is 1270 mm-H20 [50 in-H20].
The engine blowby tools are similar in design. The dif-
ference between the tools is in the size of the orifice.
Blowby Tool Orifice Size

Part No. [inch]
3822566 [0.302]
3822567 [0.354]
3822568 [0.406]
Use a length of hose (1) to attach the blowby tool to one

of the crankcase breathers.
Plug all of the other breathers.
Attach a manometer to the location shown (2).
Operate the engine at rated RPM and full load (wide open
throttle) until a steady reading is obtained.
Compare the blowby readings to previous readings on the
engine. If previous readings for the engine are not avail-
able, compare the blowby reading to new engine speci-
fications.
NOTE: A sudden increase in blowby indicates a problem. A
gradual increase over a period of time is normal (due to wear
of internal engine components).
Specifications (New Engines)

RPM mm H20 [in H20]
All ratings 508 [20]
2000 and above 355 [14]
1200 to 1900 305 [12]
2000 and above 254 [10]
1500 to 1900 203 [8]
All ratings 229 [9]
2000 and above 203 [8]
1200 to 1900 178 [7]
2000 and above 152 [6]
1500 to 1900 127 [5]
All ratings 127 [5]
If the blowby is higher than normal, check the crankcase

breathers and breather tubes to see if they are plugged.
Check the engine oil level. If the level is too high it can
cause a higher than normal crankcase pressure.
Isolate the turbocharger to determine if the high crank-

case pressure is due to seal leakage in the turbocharger.
Disconnect the turbocharger drain line from the oil pan
adaptor.
Install a hose assembly with the two shutoff valves ar-
ranged as shown. Place the other hose in an 8 to 19 liter
[2 to 5 gallon] bucket.
NOTE: The valves must have a minimum inside diameter of
19 mm [0.75 inch].
Close the valve (A) that allows the oil to drain to the
bucket.
Open the valve (B) that allows the oil to drain into the
engine.
Operate the engine at rated speed.

Caution: Do not operate the engine with valve A open
and valve B closed for more than 1 minute. Operation for
more than 1 minute can result in severe engine damage.
Continue operating at rated speed and load. Open valve
A and close valve B. Record the blowby reading.
Compare the value to the original reading. If the blowby

is not acceptable, replace the turbocharger. Refer to Pro-
cedure No. 010-037-026.
Isolate the air compressor to determine if it is malfunc-

tioning and causing the high blowby pressure.
Relieve the air pressure on the first air tank in the system
after the air compressor (wet tank).
Disconnect the air inlet and outlet connections. Plug the
intake manifold or air piping where the inlet connection
was removed.
Operate the engine at rated speed and full load (wide

open throttle) until a steady blowby reading is obtained.
Compare the blowby readings to the previous value. If the
blowby is now satisfactory, replace the air compressor.
Refer to Procedure No. 012-014 or 012-015.
A sudden increase in blowby or a high reading that is not

steady indicates that there is internal damage in the
engine.
Lubricating Oil Pressure

Use Pressure Gauge, Part No. 3375275, to measure lu-
bricating oil pressure.
Install the pressure gauge to the main oil rifle (1) or air
filter head (2).
Low Idle (Minimum Allowable): 138 kPa [20 psi]
At 1200 RPM (Minimum Allowable): 207 kPa [30 psi]
Coolant Pressure
Measure the coolant pressure at the water manifold (1).
Maximum Coolant Pressure with Closed Thermostat
and No Pressure Cap:
241 kPa [35 psi]
Lubricating Oil Temperature

Refer to Procedure No. 007-038.
Air Compressor
NOTE: All air compressors manufactured by Cummins En-
gine Company, Inc. must be operating during the engine
run-in. During the performance check, all air compressors
must be in the unload or non-operating mode.
Connect a source of compressed air capable of produc-
ing 665 kPa [95 psi] to the air compressor unloader (1).
This air line must contain a valve between the source and
the unloader.
NOTE: The compressed air load in the accompanying illus-
tration must be attached to the air compressor outlet (2).
Section 14 - Engine Testing - Group 14 Engine Testing (In-Chassis) (014-008)
Use an air tank (2). Install an air regulator (3) capable of

maintaining 345 to 517 kPa [50 to 75 psi] air pressure at
both minimum and maximum engine RPM.
Install a steel tube or high temperature hose (1).
Hose Temperature (Minimum): 235°C [500°F].
Connect the tube or hose (1) to the air compressor outlet.
Starting Motor
Inspect the voltage rating on the starting motor before
installing the electrical wiring.
Install the electrical wiring to the starting motor and bat-
teries, if used.
NOTE: If another method of starting the engine is used,
follow the manufacturer’s instructions to make the neces-
sary connections.
Engine Testing (In-Chassis) (014-008)

Stall Speed Check (014-008-280)
The stall speed is the engine speed (RPM) obtained at full
throttle when the converter output shaft is locked.
The vehicle brakes do not always hold an electronically
controlled transmission.
Caution: Do not exceed 120°C [250°F] converter oil tem-

perature. If the oil temperature exceeds 120°C [250°F],
put the transmission in neutral and operate the engine
until the oil temperature is below 120°C [250°F]. Check
the converter oil level.
Engine Testing (In-Chassis) (014-008) Section 14 - Engine Testing - Group 14
Place the gear selector in the highest gear or full forward.

In some types of equipment it is also necessary to engage
the hydraulics.
Be sure the vehicle has good brakes and air pressure in

the brake system.
The brakes must prevent the vehicle from moving when
the engine is at full throttle.
Engage the vehicle brakes or keep the vehicle from
moving.
Operate the engine until the coolant temperature is up to

70°C [160°F] and the converter temperature is 80°C
[180°F] or above.
Alternately shift from neutral to the highest speed gear
possible and operate at part throttle. This will warm the
entire system uniformly.
Bring the engine speed back to low idle.

NOTE: Do not exceed 120°C [250°F] converter oil tem-

perature.
Move the throttle to the full open position. Do not perform
this test for more than 15 seconds. If the engine speed
continues to slowly increase, the torque converter fluid is
being overheated.
Check the engine speed (RPM) at the point of stall.

Always hold the speed until it is stable.
Take several readings. Be sure the reading is accurate.
Check the stall speed (RPM) against the specifications

that are for the equipment, converter, or automatic trans-
mission.
NOTE: The stall speed for the engine and converter/
transmission can vary plus/minus 8 percent (±8) from the
manufacturer’s specifications.
If the stall speed is not within the specifications, refer to

the Stall Speed Check List at the end of this section.
Check the equipment manufacturer’s troubleshooting pro-
cedures for other reasons for stall speed problems.
If the cause for the stall speed being too low is low engine
power output, refer to the Engine Power Output Low
Troubleshooting Chart. Make the correct repair based on
the fuel rate, fuel pressure, and intake manifold pressure
readings.
Time Speed Check (014-008-281)

After performing the Stall Speed Check through the torque
converter fluid being overheated, calculate the engine
stall speed.
Example: Stall speed 1089 (1089 x .90 = 1880 RPM).
Quickly move the throttle to the full open position and start
the stop watch at the same time.
When the engine speed is 90 percent of the stall speed

RPM, stop the stop watch.
NOTE: The type of unit and the stall speed RPM will be
different for different types of equipment. Most types have a
stall speed between 8 and 12 seconds.
Check the equipment manufacturer’s specifications for

the time to stall or the acceleration time.
If the time is excessive, check the fuel pump AFC for an
air leak. Refer to Procedure 005-016-008.
Stall Speed Check List

If The Stall Speed Is Too Low, Check The Following:
Yes No
1. The tachometer is in error.
2. The engine is up to or above 70°C [160°F].
3. The converter oil is up to temperature 80°C [180°F].
4. The stall has been held long enough for the engine to accelerate to full
power.
5. The match curve stall speed was recorded correctly.
6. The converter oil is to the converter manufacturer’s recommendation. Society
of Automotive Engineers (Example: SAE 30 instead of SAE 10).
7. The engine driven accessory power requirements exceed 10 percent of the
gross engine power. Check for abnormal accessory horsepower losses such
as hydraulic pumps, large fans, oversize, compressors, etc. Either remove the
accessory or accurately determine the power requirement and adjust
accordingly.
8. The Air Fuel Control (AFC) is properly adjusted.
9. The unit is operating at an altitude high enough to affect the engine power.
10. The converter charging pressure is correct.
11. The tailshaft governor is interfering with and preventing a full throttle open-
ing. (Disconnect the tailshaft governor.)
12. The converter blading is interfering or in a stage of failure. Check the sump
or filter for metal particles.
13. The converter stators are free-wheeling instead of locking.
14. The engine is set for power other than that specified on the power curve.
15. The converter is wrong, due to improper build or rebuild of unit.
16. The converter is performing to the published absorption curve.
17. The engine and converter match is correct. Check the engine and converter
models for the proper match.
18. The engine is matched to an oversized converter. (If this condition is believed
to exist, please report the engine-converter-accessory information to the Fac-
tory.)
19. The engine power is down. (The engine torque rise could be less than shown
on the standard engine curve.) See the fuel setting adjustments and the
turbocharger air manifold pressure check.
It is sometimes easier to change the engine fuel rate than to determine the true cause for low stall speed, but the
customer ends up with an over-fueled engine that will also negatively affect durability. Do not increase the fuel
rate as a CURE-ALL.
If The Stall Speed Is Too High, Check The Following:
Yes No
1. The engine is high in power.
2. The tachometer is in error.
3. The accessory power requirements are less than 10 percent of the gross
engine power.
4. The converter oil is aerating (foaming) - check for low oil level, air leaks in
suction line, oil does not contain a foam inhibitor, or suction screen or filter.
(Should be accompanied by a noticeable loss of machine performance.)
5. The converter is being held at full stall. Check for a clipping front disconnect
clutch or a rotating output shaft. On the converter-transmission package, this
can be impossible to check.
6. The converter turbine element is beginning to fail and losing blades or the
converter was originally built with the wrong size element.
7. The engine and converter match is correct (due to a revision in the engine
rating or the converter performance).
8. On the transmission-converter units with oil sump in the transmission, if the
oil level is too high, it can cause severe aeration due to parts dipping in the
oil.
9. The converter is performing to the published absorption curve.
10. The converter charging pressure is correct.
The reasons for abnormal stall speeds listed above are some which have been encountered by Cummins
representatives and probably do not include all possible causes. The correction of the problem is either covered
in the vehicle service manual, the converter service manual, or is self-explanatory.
Engine Testing (Fuel Flow Rate) (014-007) Section 14 - Engine Testing - Group 14
Engine Testing (Fuel Flow Rate)

(014-007)
Measure (014-007-010)
Accurate fuel flow measurement is important for evalua-
tion of engine performance and troubleshooting on an
engine or chassis dynamometer. The only way accurate
fuel flow measurement can be obtained is through proper
use of the available equipment. Below is a description of
the fuel measuring device, available from Cummins En-
gine Company, along with installation and operation rec-
ommendations. The fuel measuring device, Part No.
3376375, can be used with either a chassis or engine
dynamometer.
Installation
When installing the fuel measuring device, it is important
to reduce the amount of air that can be introduced into the
system when the device is not in use. Therefore, the
plumbing used must include non-restrictive shutoff valves,
such as ballcock valves, to contain fuel in the device after
each use. Additional installation considerations are:
• The fuel measuring device, Part No. 3376375, must
be mounted vertically to ensure accuracy and proper
operation.
• A separate fuel supply for use on the dynamometer
is recommended. All fuel used in the measuring
device must be clean for consistent operation.
• Care must be taken to reduce fuel line restriction to
and from the engine. Minimum recommended hose
sizes are No. 10 for the engine fuel inlet, and No. 8
for the engine fuel drain. The length of either hose
must not exceed 15 feet.
• For accurate fuel consumption or flow measurement
while testing on a chassis dynamometer, it is rec-
ommended to use a fuel cooler to maintain inlet
temperature to the fuel gear pump at 49°C [120°F]
or below.
Section 14 - Engine Testing - Group 14 Engine Testing (Fuel Flow Rate) (014-007)
Operation
This is a schematic of the fuel measuring device, Part No. 3376375. The device consists of the following
components:
• Fuel Filter
• Flowmeter
• Float Tank
• Fuel Rail Pressure Gauge
• Fuel Cooler is not a part of fuel measuring device, Part No. 3376375; however, must be used when conducting
test with the flow meter.
The fuel measuring device recirculates return fuel to the engine fuel inlet by routing the return fuel to the top side
of the float tank. The fuel is deaerated as it passes through the baffling in the float tank. A ball float valve at the
bottom of the float tank maintains an adequate volume in the tank for deaeration. The fuel is then returned to the
engine fuel inlet. Refer to the sketch for fuel line connection points on the fuel measuring device.
1. Fuel Supply From Tank
2. Fuel Flow to Fuel Meter
3. Fuel Flow From Fuel Meter
4. Fuel Flow to Fuel Cooler
5. Injector Return Fuel
6. Fuel Rail Pressure
Note: The fuel supply tank must be below the level of the fuel measuring device to prevent overflow of the float
tank. If an overhead fuel supply tank is used, a float controlled reservoir must be installed between the fuel supply
tank and the fuel measuring device, and below the level of the device.
Section 14 - Engine Testing - Group 14 Engine Testing (Fuel Flow Rate) (014-007)
The fuel measuring device is installed in series between the fuel supply tank and the engine fuel inlet. The quantity
of fuel being drawn through the flowmeter is known as MAKE-UP fuel or the amount of fuel being burned by the
engine.
The flowmeter is graduated to read fuel flow in pounds per hour. The flowmeter contains two floats with respective
scales on either side of the flowmeter. The small float is used to measure lower flows and must be read on the
left scale, as shown. The larger float is for measuring higher flows and must be read on the right scale.
To obtain an accurate fuel rate measurement, the flowmeter reading must be corrected based on the fuel
temperature. There is a fuel temperature gauge on the front panel of the fuel measuring device. The gauge is
graduated in percent of error by which the reading requires correction. An example is: The fuel of an engine reads
125 lbs/hr on the flowmeter, and the temperature gauge reads +2 percent; the corrected fuel flow rate will be 125
plus 2 percent, or 127.5 lbs/hr.
NOTES
Section 16 — Mounting Adaptations — Group 16 Section Contents
Section 16 — Mounting Adaptations — Group 16

Section Contents
Page
Engine Support Bracket, Front (016-002)........................................................................................................ 16-5
Install (016-002-026) ...................................................................................................................................... 16-6
Remove (016-002-002) ................................................................................................................................... 16-5
Flywheel (016-005) ........................................................................................................................................... 16-7
Install (016-005-026) ...................................................................................................................................... 16-9
Remove (016-005-002) ................................................................................................................................... 16-7
Flywheel Housing (016-006) ........................................................................................................................... 16-11
Install (016-006-026)..................................................................................................................................... 16-18
Redowel (016-006-023) ................................................................................................................................ 16-14
Remove (016-006-002).................................................................................................................................. 16-11
Mounting Adaptations — General Information (016-999-999)......................................................................... 16-2
Mounting Adaptations — Specifications (018-001-516) .................................................................................. 16-3
Mounting Adaptations — Tool Requirements (022-001-516) ........................................................................... 16-4
Mounting Adaptations — General Information (016-999-999) Section 16 — Mounting Adaptations — Group 16
Mounting Adaptations — General Information (016-999-999)

The Mounting Adaptations group consists of the flywheel housing, flywheel, and the front engine support.
Flywheel Housing
For various applications, the flywheel housings are available in different styles, sizes, and materials. Check the
appropriate parts book and the engine parts listing for the correct part number for the engine application being
serviced.
Flywheel and Ring Gear
The flywheel is available only as an assembly. The assembly includes the flywheel and the ring gear. The ring
gear is available for service.
Flywheel Housing — Redowel To the Cylinder Block
Procedure No. 016-006-023 Flywheel Housing — Redowel to Cylinder Block, will describe how to install the oversize
locating dowel pins in a flywheel housing and a cylinder block.
There are two dowel pins in the cylinder block. The pins protrude into holes in the flywheel housing. The pins are
used to align the housing properly to the cylinder block when it is installed.
The flywheel housing must be in proper alignment. If the housing is not in proper alignment, the holes in the
flywheel housing and the block must be reamed for a bigger dowel.
The dowel holes on QSK19 engine blocks and flywheel housings are precision doweled. The holes are machined
to 12.7 mm [0.500 inch] separately. The parts are assembled and the alignment is checked. If the alignment is not
within specifications, oversize dowels are installed at the factory. Replacing the block or the flywheel housing does
not necessarily mean that the flywheel housing and the cylinder block have to be redoweled.
Section 16 — Mounting Adaptations — Group 16 Mounting Adaptations — Specifications (018-001-516)
Mounting Adaptations — Specifications (018-001-516)

Front Engine Support Capscrews - Torque Value:
• Exterior: 195 N•m [145 ft-lb]
• Interior: 205 N•m [150 ft-lb]
Flywheel Housing Capscrews - Torque Value:
Step 1 - 100 N•m [75 ft-lb]
2 - 205 N•m [150 ft-lb]
Oil Pan Adapter Capscrews - Torque Value:
• [3/8-Inch]
Step 1 - 25 N•m [20 ft-lb]
Step 2 - 40 N•m [30 ft-lb]
Step 3 - 45 N•m [35 ft-lb]
• [7/16-Inch]
65 N•m [50 ft-lb]
Flywheel Capscrews - Torque Value:
Step 1 - 150 N•m [110 ft-lb]
Step 2 - 285 N•m [210 ft-lb]
Flywheel Alignment - Maximum Radial Run Out:.............................................................0.013 mm [0.005 in]
Flywheel Housing Bore and Face Run Out

SAE No. Bore I.D. Maximum T.I.R.
00 788 mm [31.0 in] 0.31 mm [0.012 in]
0 648 mm [25.5 in] 0.25 mm [0.010 in]
1/2 584 mm [23.0 in] 0.25 mm [0.010 in]
1 511 mm [20.1 in] 0.20 mm [0.008 in]
Overall Dowel Pin O.D.

Overall Dimension Oversize
13.08 mm [0.515 in] 0.38 mm [0.015 in]
13.46 mm [0.530 in] 0.76 mm [0.030 in]
13.84 mm [0.545 in] 1.14 mm [0.045 in]
Starting Motor Capscrews:

• Cast Iron Flywheel Housing: 215 N•m [160 ft-lb]
• Aluminum Flywheel Housing: 195 N•m [145 ft-lb]
Oil Pan:
• Capscrews: 45 N•m [35 ft-lb]
• Drain Plugs: 100 N•m [75 ft-lb]
Section 16 — Mounting Adaptations — Group 16 Engine Support Bracket, Front (016-002)
Engine Support Bracket, Front

(016-002)
Remove (016-002-002)
lift the component.
Install lifting hook, Part No. 3823210, on the cast boss of
the rocker housing shown.
Remove the two capscrews that attach the support to the

equipment frame.
Use a hoist to lift the weight of the engine off the front
support.
Use the engine support bracket kit, Part No. 3375272.

Install one bracket on each side of the engine.
Lower the engine until the brackets are supporting the

weight.
Engine Support Bracket, Front (016-002) Section 16 — Mounting Adaptations — Group 16
Remove the front engine support.

Clean and check the support for reuse. Check for cracks
or damage.

lift the component.
Clean and inspect the mounts for reuse. Check all rubber-
cushioned mounts for cracks or damage.
Inspect all mounting brackets for cracks or damaged bolt
holes.
NOTE: Damaged engine mounts and brackets can cause
the engine to move out of alignment, damage the driveline
components in the equipment, and result in vibration
complaints.
Install (016-002-026)
lift the component.
Install the support, washers, and capscrews. Tighten the
capscrews.
Raise the engine to remove the weight from the support

brackets. Remove the support brackets.
Section 16 — Mounting Adaptations — Group 16 Flywheel (016-005)
Lower the engine until the front engine support is in po-

sition. Install and tighten the capscrews.
Flywheel (016-005)
Remove (016-005-002)
Warning: Always disconnect the negative cable first.
Disconnect the batteries or air starter to prevent acci-
dental engine starting.

lift the component.

lift the component.
Use two [5/8-18 inch] guide studs to prevent the flywheel
from rotating. Remove two capscrews and install the guide
studs.
Use a hoist, two tee handles, and a lifting sling. Install the
tee handles. Remove the remaining capscrews. Remove
the flywheel.
NOTE: Use a mallet to tap the flywheel from the crankshaft,
if necessary.
Flywheel (016-005) Section 16 — Mounting Adaptations — Group 16

Use a wire brush to clean the crankshaft pilot bore. Use
steam or solvent to clean the flywheel. Dry with com-
pressed air.
Visually inspect for nicks or burrs. Use a crocus cloth to

remove small nicks and burrs.
Visually inspect the flywheel for cracks.

Warning: Do not use a cracked flywheel. A cracked fly-
wheel can break or cause serious personal injury.
Visually inspect the flywheel ring gear teeth for cracks

and chips.
NOTE: If the ring gear teeth are cracked or broken, the ring
gear must be replaced.
Section 16 — Mounting Adaptations — Group 16 Flywheel (016-005)
Install (016-005-026)
Warning: The flywheel mounting capscrews must be a
minimum of SAE Grade 8 with rolled threads. The fly-
wheel mounting washers are special hardened plain
washers. Use identical replacements to avoid possible
flywheel failure resulting in personal injury or property
damage.
lift the component.
Lubricate the capscrews and washers with engine oil.
Allow the excess oil to drip off the parts. Do not lubricate
the threads of the crankshaft.
A guide stud will help during assembly. Install the fly-
wheel, washers, and capscrews. The flywheel must be
firmly against the crankshaft.
Use the following steps and the torque sequence shown

to install the flywheel.
2 - 285 N•m [210 ft-lb]
Measure the alignment of the flywheel.

pulled in the same direction each time a point is measured.
Attach an indicator as shown. Measure the flywheel align-
ment at 4 equally spaced points.
Measure the distance from the center of the crankshaft to
the indicator tip. Multiply the distance to obtain the maxi-
mum runout.
The alignment specification is 0.025 mm [0.001 inch] per
25.4 mm [1.0 inch] distance from the center of the crank-
shaft.
Center of Crankshaft-To-Indicator Tip:
Multiply by 0.025 mm [0.001 inch]
If the flywheel alignment is not within specifications, check
for interference between the flywheel and the crankshaft.
Flywheel (016-005) Section 16 — Mounting Adaptations — Group 16
Attach an indicator as shown. Continue to look at the

indicator while rotating the engine.
Maximum Radial Runout: 0.13 mm [0.005 Inch]
If the runout is not within specification, the pilot on the
flywheel is not positioned correctly on the crankshaft.
If the pilot is damaged, the flywheel must be replaced.

lift the component.
Warning: Always connect the negative cable last.

Connect the batteries and air starter.
Start the engine. Check the operation of the equipment.

Section 16 — Mounting Adaptations — Group 16 Flywheel Housing (016-006)
Flywheel Housing (016-006)

Remove (016-006-002)
Disconnect the batteries and air starter to prevent acci-
dental engine starting.

lift the component.
nents. Refer to the equipment manufacturer’s instruc-
tions.
Remove the flywheel. Refer to Procedure No.
016-005-002.

NOTE: Drain the oil when the oil temperature is less than
60°C [140°F].
Caution: Hot oil can cause minor injury.
Remove the drain plugs from the sump. Drain the oil.
Replace the o-rings. Tighten the drain plugs.
Remove the rear crankshaft seal. Refer to Procedure No.

001-024-002.
Flywheel Housing (016-006) Section 16 — Mounting Adaptations — Group 16
Remove the starting motor capscrews, the starter, the

spacers, and the gaskets. Discard the gaskets.
NOTE: All engines do not contain spacers and gaskets.
Remove the adapter cover plate or oil sump (whichever

is in the rear position).
Put a wooden block the width of the oil pan adapter

between the floor jack and the oil pan adapter to prevent
damage to the engine.
Use a floor jack or a suitable lifting fixture to support the
rear of the engine. Put the support in position to allow
access to the capscrews in the oil pan adapter that attach
to the flywheel housing.
Remove the rear engine mounts from the flywheel

housing.
Remove the two [7/16-14 inch] capscrews, and the five

[3/8-16 inch] capscrews from the flywheel housing.

lift the component.
Use two guide studs to prevent the flywheel housing from
rotating during disassembly. Remove two capscrews. In-
stall the guide studs.
Use a hoist, a tee handle, and a lifting sling. Install the tee
handle. Adjust the hoist until there is tension in the lifting
sling. Remove the remaining capscrews.
Use a mallet and tap the flywheel housing off the two
locating dowels. Remove and discard the rectangular seal
and the bolt seals (44).

Steam clean or use solvent to clean the housing. Dry with
compressed air.
Visually inspect all surfaces for nicks, burrs, or cracks.

Use a fine crocus cloth to remove small nicks and burrs.
Visually inspect all threaded capscrew holes for damage.

Repair or replace the housing if the capscrew holes are
damaged.
Redowel (016-006-023)
The tools needed to perform this procedure are:
Drill Ream Fixture, Part No. ST-1232, that contains:
1. Plate, Part No. ST-1232-1
2. Locator Pin, Part No. 3375052
3. Spacer Washer, Part No. ST-1232-2
4. Drill/Ream Bushing Set (Actual sizes depend on the
dowel size as listed in this Procedure.)
5. Drill Adapter (Locally obtained; use to adapt open-1
shank reamers to drill-chuck)
6. Reamer (Locally obtained)
7. Drill Bit (Locally obtained)
Remove the flywheel housing. Remove and discard the

rectangular seals (8).
Use a dowel pin extractor, Part No. ST-1134, or equivalent.

Remove the two dowels (9) from the block.
Measure a dowel pin that is removed so that an oversize
dowel pin can be determined.
NOTE: Do not torque the capscrews. The flywheel housing

must be aligned first.
Install the new rectangular seals (8) in the flywheel
housing.
Align the flywheel housing to the crankshaft. Refer to

Procedure No. 016-006-026 for the procedure to measure
the housing alignment.
Move the housing with a mallet until the bore is within
specification. Check to be sure that the face of the hous-
ing is in alignment. When the housing is in alignment,
tighten the capscrews. Refer to Procedure No. 016-006-
026 for the capscrew torque.
After the capscrews are torqued, check the alignment
again.
Use the appropriate size capscrews. Attach the plate, Part

No. ST-1232-1, that is contained in Part No. ST-1232 Drill
Ream Fixture.
Hand-tighten the capscrews so the plate can be moved.
Use the locator pin to align the plate with the hole for the
dowel pin. Tighten the capscrews. The taper on the pin
must engage the dowel pin hole.
The locator pin must rotate easily after the capscrews are
tightened.
Caution: If the crankshaft is not LOCKED in position, it
can turn during reaming.
LOCK the crankshaft in position. Check to be sure the
locator pin is still in alignment and that the locator pin can
be rotated easily.
Measure the dowel pins to be installed.

Obtain a reamer (5) that is 0.13 mm to 0.02 mm [0.0005
inch to 0.001 inch] smaller than the dowel.
The dowel must be long enough to protrude from the
block one-half of the flywheel housing wall thickness.
NOTE: There are three oversize dowel pins available from
Cummins Engine Company, Inc.
Oversize Dowel Pin O.D.

Overall Dimension Oversize
13.08 mm [0.515 in] 0.38 mm [0.015 in]
13.46 mm [0.530 in] 0.76 mm [0.030 in]
13.84 mm [0.545 in] 1.14 mm [0.045 in]
Install the appropriate drill bushings (4). The table shows

the bushings available from Cummins Engine Company,
Inc.
Drill/Ream Bushing Sets — 25.4 mm [1 Inch] O.D.

Oversize Bushing
Size
mm Inch mm Inch
3376495 Special 12.304 [0.4844]
Standard 12.700 [0.5000]
0.38 [0.015] 13.096 [0.5156]
0.76 [0.30] 13.494 [0.5312]
1.14 [0.045] 13.879 [0.5464]
ST-1234 Standard 14.288 [0.5625]

0.38 [0.015] 14.684 [0.5781]
0.76 [0.030] 15.081 [0.5937]
1.14 [0.045] 15.478 [0.6094]
ST-1235 Standard 15.875 [0.6250]

0.38 [0.015] 16.272 [0.6406]
0.76 [0.030] 16.669 [0.6562]
1.14 [0.045] 17.066 [0.6719]
ST-1236 Standard 17.463 [0.6875]

0.38 [0.015] 17.859 [0.7031]
0.76 [0.030] 18.256 [0.7187]
1.14 [0.045] 18.653 [0.7344]
ST-1237 Standard 19.050 [0.7500]

0.38 [0.015] 19.447 [0.7656]
0.76 [0.030] 19.844 [0.7812]
ST-1238 22.621 [0.8906]

21.093 [0.9375]
The drill bushing that is used must be the same size as
the reamer (or the drill) that is used.
If the new dowel pins are more than 0.38 mm [0.015 inch]
larger than the old dowels, drill the hole to a size that is
slightly smaller than the reamer. Then the reamer will not
have to remove an excess amount of material.
Caution: Do not allow metal chips to enter the engine.
Damage to the engine will result.
Ream the hole until the reamer touches the bottom of the
hole in the block.
Remove the reamer. Clean the hole and run the reamer
through the hold again. The reamer must touch the bot-
tom of the hole in the block.
After reaming one hole, turn the plate and align it with the
second dowel hole. Repeat the procedure in the second
hole.
Remove the plate from the crankshaft.

Caution: Be sure the dowel hole does not contain any
metal chips. Engine damage will result.
Use a square nose drift. Drive each dowel in until it touches
the bottom of the hole in the block.
After the dowels are installed, measure the bore and the
face alignment again.
Install (016-006-026)
NOTE: Be sure the flywheel housing dowels have been
installed in the block.
Install the sealing ring (7) in the groove on the housing.
If a wet type is used, install the seals (8) in the counterbores
as shown. The holes (9) do not require seals.
Use guide bolts to help during alignment. Install the hous-
ing and the capscrews.
Use the following steps. Apply torque to the flywheel

housing capscrews using the sequence shown.
Torque Value: Step 1 - 100 N•m [ 75 ft-lb]
2 - 205 N•m [150 ft-lb]
Measure the flywheel housing alignment.

NOTE: The bore and the face of the housing must be in
alignment with the crankshaft.
NOTE: The indicator arm must be rigid for an accurate
reading. It must not sag.
Attach an indicator to the crankshaft as shown.
Position the indicator at the 12 o’clock position. Adjust the

dial until the needle points to ZERO. Rotate the crankshaft
one complete revolution (360 degrees). Record the TIR.
The maximum allowable TIR depends on the diameter of

the bore.
Bore Diameter/Maximum TIR

MIN/MAX MIN/MAX SAE
mm in No. mm in
787.4/810. 5 [31.00 /31.91] 00 0.30 [0.012]
647.7/648. 0 [25.50 /25.51] 0 0.25 [0.010]
584.2/584. 4 [23.00 /23.008] 1/2 0.25 [0.010]
511.2/511. 3 [20.125/20.130] 1 0.20 [0.008]
If the alignment is not within specifications and the bore
is round, the housing can be shifted.
If the alignment is not within specifications and the bore
is not round, the housing must be replaced.

pulled in the same direction each time a point is measured.
Attach an indicator as shown. Position the indicator at the
12 o’clock position. Adjust the dial until the needle points
to ZERO.
Record the indicator reading at 3 different points; 3 o’clock,

6 o’clock, and 9 o’clock.
Turn backward to the original position. Be sure the needle
still points to ZERO. Determine the total indicator runout
(TIR).
mm in
Example:
3 o’clock 0.00 [0.00]
6 o’clock +0.08 [+0.003]
9 o’clock -0.05 [-0.002]
——— ———-
Equal TIR: 0.13 [0.005]
The maximum allowable TIR depends on the diameter of

the bore.
Bore Diameter/Maximum TIR

MIN/MAX MIN/MAX SAE
mm in No. mm in
787.4/810. 5 [31.00 /31.91] 00 0.30 [0.012]
647.7/648. 0 [25.50 /25.51] 0 0.25 [0.010]
584.2/584. 4 [23.00 /23.008] 1/2 0.25 [0.010]
511.2/511. 3 [20.125/20.130] 1 0.20 [0.008]
NOTE: If the alignment is not within specifications, remove
the housing. Check for nicks, burrs, or foreign material be-
tween the block and the housing. Check the alignment again.
If the alignment is not within specifications, the block or the
housing is not machined correctly.
Use the following steps. Tighten the five [3/8-inch] wash-

ers and capscrews in the sequence shown.
2 - 40 N•m [30 ft-lb]
3 - 45 N•m [35 ft-lb]
Install the two [7/16-inch] washers and capscrews as

shown. Tighten the capscrews.
Install the flywheel housing mounting capscrews. Tighten

the capscrews.
NOTE: Gasket cement will prevent the gasket from sealing

properly. Use a contact adhesive, such as 3M Spray 77 or 3M
1463, to hold the gasket in position.
Install the gasket, oil plate (or sump), washers, and
capscrews.

NOTE: Not all engines are equipped with starting motor

spacers.
starting motor installation.
Install any spacer or gaskets. Install the starting motor
and the capscrews.
Starting Motor Torque Value:
Cast Iron Flywheel Housing: 215 N•m [160 ft-lb]
Aluminum Flywheel Housing: 195 N•m [145 ft-lb]
Install the rear crankshaft seal. Refer to Procedure No.

001-024-026.
Install the flywheel. Refer to Procedure No. 016-005-026.

Measure the crankshaft end clearance after installing the
driven member. Refer to Procedure No. 001-016-010. The
end clearance must be the same as when the driven
member is not installed.
Install new LF3000 combination oil filters. Refer to Pro-

cedure No. 007-013-026.

028 for engine oil capacity.

Connect the batteries and air starter to allow engine
operation.
Operate the engine to operating temperature. Check for

leaks. Monitor the operation of the equipment.
NOTES
Section M - Component Manufacturers
Page M-1
Section M - Component Manufacturers

Section Contents
Page
Component Manufacturers’ Addresses ............................................................................................................ M-2
Air Compressors............................................................................................................................................. M-2
Air Cylinders .................................................................................................................................................. M-2
Air Heaters ..................................................................................................................................................... M-2
Air Starting Motors ......................................................................................................................................... M-2
Alternators...................................................................................................................................................... M-2
Auxiliary Brakes.............................................................................................................................................. M-3
Belts............................................................................................................................................................... M-3
Catalytic Convertors ....................................................................................................................................... M-3
Clutches......................................................................................................................................................... M-3
Coolant Heaters ............................................................................................................................................. M-3
Drive Plates.................................................................................................................................................... M-4
Electric Starting Motors .................................................................................................................................. M-4
Engine Protection Controls ............................................................................................................................. M-4
Fan Clutches .................................................................................................................................................. M-4
Fans............................................................................................................................................................... M-4
Filters............................................................................................................................................................. M-5
Flexplates....................................................................................................................................................... M-5
Fuel Warmers................................................................................................................................................. M-5
Gauges .......................................................................................................................................................... M-5
Governors ...................................................................................................................................................... M-6
Hydraulic and Power Steering Pumps............................................................................................................. M-6
Oil Heaters ..................................................................................................................................................... M-6
Torque Converters .......................................................................................................................................... M-6
g-01
Component Manufacturers’ Addresses Section M - Component Manufacturers
Page M-2
Component Manufacturers’ Addresses

NOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins
engines. Suppliers can be contacted directly for any specifications not covered in this manual.
Air Compressors Alternators T.B.A. Belting Ltd.

P.O. Box 77
Bendix Heavy Vehicles Systems Robert Bosch Ltd. Wigan
Div. of Allied Automotive P.O. Box 98 Lancashire
901 Cleveland Street Broadwater Park WN2 4XQ
Elyria, OH 44036 North Orbital Road England
Telephone: (216) 329-9000 Denham Telephone: 01942-59221
Holset Engineering Co., Inc. Uxbridge
Middlesex UD9 5HG Dayco Mfg.
1320 Kemper Meadow Drive Belt Technical Center
Suite 500 England
Telephone: 01895-833633 1955 Enterprize
Cincinnati, OH 45240 Rochester Hills, MI 48309
Telephone: (513) 825-9600 Butec Electrics Telephone: (810) 853-8300
Midland-Grau Cleveland Road
Leyland Gates Rubber Company
Heavy Duty Systems 900 S. Broadway
Heavy Duty Group Headquarters PR5 1XB
England Denver, CO 80217
10930 N. Pamona Avenue
Kansas City, MO 64153 Telephone: 01744-21663 Goodyear Tire and
Telephone: (816) 891-2470 C.A.V. Electrical Equipment Rubber Company
P.O. Box 36 Industrial Products Div.
Air Cylinders Warple Way 2601 Fortune Circle East
London Indianapolis, IN 46241
Bendix Ltd. Telephone: (317) 898-4170
Douglas Road W3 7SS
Kingswood England
Bristol Telephone: 01-743-3111 Catalytic Convertors
England Donaldson Company, Inc.
Telephone: 0117-671881 A.C. Delco Components Group 1400 West 94th Street
Civic Offices P.O. Box 1299
Catching Engineering Central Milton Keynes
1733 North 25th Avenue Minneapolis, MN 55440
MK9 3EL Telephone: (612) 887-3835
Melrose Park, IL 60160 England
Telephone: (708) 344-2334 Telephone: 01908-66001 Nelson Division
TEC - Hackett Inc. Exhaust and Filtration Systems
8909 Rawles Avenue C. E. Niehoff & Co. 1801 U.S. Highway 51 P.O. Box 428
Indianapolis, IN 46219 2021 Lee Street Stoughton, WI 53589
Telephone: (317) 895-3670 Evanston, IL 60202 Telephone: (608) 873-4200
Telephone: (708) 866-6030
Air Heaters Walker Manufacturing
Fleetguard, Inc. Delco-Remy America 3901 Willis Road
1200 Fleetguard Road 2401 Columbus Avenue P.O. Box 157
Cookeville, TN 38502 P.O. Box 2439 Grass Lake, MI 49240
Telephone: (615) 526-9551 Anderson, IN 46018 Telephone: (517) 522-5500
Telephone: (317) 646-3528
Kim Hotstart Co. Clutches
P.O. Box 11245
Spokane, WA 99211-0245 Leece-Neville Corp. Twin Disc International S.A.
Telephone: (509) 534-6171 400 Main Street Chaussee de Namur
Arcade, NY 14009 Nivelles
Air Starting Motors Telephone: (716) 492-1700 Belguim
Telephone: 067-224941
Ingersoll Rand Auxiliary Brakes
Chorley New Road Twin Disc Incorporated
Horwich The Jacobs Manufacturing Company 1328 Racine Street
Bolton Vehicle Equipment Division Racine, WI 53403
Lancashire 22 East Dudley Town Road Telephone: (414) 634-1981
England Bloomfield, CT 06002
BL6 6JN Telephone: (203) 243-1441 Coolant Heaters
Telephone: 01204-65544 Fleetguard, Inc.
Belts 1200 Fleetguard Road
Ingersoll-Rand Engine
Starting Systems Dayco Rubber U.K. Cookeville, TN 38502
888 Industrial Drive Sheffield Street Telephone: (615) 526-9551
Elmhurst, IL 60126 Stockport
Telephone: (708) 530-3875 Cheshire Drive Plates
SK4 1RV
StartMaster England Detroit Diesel Allison
Air Starting Systems Telephone: 061-432-5163 Division of General Motors
A Division of Sycon Corporation Corporation
9595 Cheney Avenue P.O. Box 894
P. O. Box 491 Indianapolis, IN 46206-0894
Marion, OH 43302 Telephone: (317) 242-5000
Telephone: (614) 382-5771
g-01
Section M - Component Manufacturers Component Manufacturers’ Addresses
Page M-3
Electric Starting Motors Fans Fuel Warmers

Butec Electrics Truflo Ltd. Fleetguard, Inc.
Cleveland Road Westwood Road 1200 Fleetguard Road
Leyland Birmingham Cookeville, TN 38502
PR5 1XB B6 7JF Telephone: (615) 526-9551
England England
Telephone: 01744-21663 Telephone: 021-557-4101 Gauges
C.A.V. Electrical Equipment Hayes-Albion Corporation A.I.S.
P.O. Box 36 Jackson Manufacturing Plant Dyffon Industrial Estate
Warple Way 1999 Wildwood Avenue Ystrad Mynach
London Jackson, MI 49202 Hengoed
W3 7SS Telephone: (517) 782-9421 Mid Glamorgan
England CF8 7XD
Engineered Cooling Systems, Inc. England
Telephone: 01-743-3111 201 W. Carmel Drive Telephone: 01443-812791
A.C. Delco Components Group Carmel, IN 46032
Civic Offices Telephone: (317) 846-3438 Grasslin U.K. Ltd.
Central Milton Keynes Vale Rise
Brookside Corporation Tonbridge
MK9 3EL P.O. Box 30
England Kent
McCordsville, IN 46055 TN9 1TB
Telephone: 0908-66001 Telephone: (317) 335-2014 England
Delco-Remy America TCF Aerovent Company Telephone: 01732-359888
2401 Columbus Avenue 9100 Purdue Rd., Suite 101
P.O. Box 2439 Icknield Instruments Ltd.
Indianapolis, IN 46268-1190 Jubilee Road
Anderson, IN 46018 Telephone: (317) 872-0030
Telephone: (317) 646-3528 Letchworth
Kysor-Cadillac Herts
Leece-Neville Corp. 1100 Wright Street England
400 Main Street Cadillac, MI 49601 Telephone: 04626-5551
Arcade, NY 14009 Telephone: (616) 775-4681
Telephone: (716) 492-1700 Superb Tool and Gauge Co.
Schwitzer 21 Princip Street
Nippondenso Inc. 6040 West 62nd Street Birmingham
2477 Denso Drive P.O. Box 80-B B4 61E
P.O. Box 5133 Indianapolis, IN 46206 England
Southfield, MI 48086 Telephone: (317) 328-3010 Telephone: 021-359-4876
Telephone: (313) 350-7500
Filters Kabi Electrical and Plastics
Cranborne Road
Engine Protection Controls Fleetguard International Corp. Potters Bar
The Nason Company Cavalry Hill Industrial Park Herts
2810 Blue Ridge Blvd. Weedon EN6 3JP
West Union, SC 29696 Northampton NN7 4TD England
Telephone: (803) 638-9521 England Telephone: 01707-53444
Teddington Industrial Telephone: 01327-41313
Datcon Instruments
Equipment Fleetguard, Inc. P.O. Box 128
Windmill Road 1200 Fleetguard Road East Petersburg, PA 17520
Sunburn on Thames Cookeville, TN 38502 Telephone: (717) 569-5713
Middlesex Telephone: (615) 526-9551
TW16 7HF Rochester Gauges, Inc.
England Flexplates 11616 Harry Hines Blvd.
Telephone: 09327-85500 P.O. Box 29242
Corrugated Packing and Dallas, TX 75229
Sheet Metal Telephone: (214) 241-2161
Fan Clutches Hamsterley
Holset Engineering Co. Ltd. Newcastle Upon Tyne Governors
P.O. Box A9 England
Turnbridge Telephone: 01207-560-505 Woodward Governors Ltd.
Huddersfield, West Yorkshire P.O. Box 15
Allison Transmission 663/664 Ajax Avenue
England HD6 7RD Division of General Motors
Telephone: 01484-22244 Slough
Corporation Bucks
Horton Industries, Inc. P.O. Box 894 SL1 4DD
P.O. Box 9455 Indianapolis, IN 46206-0894 England
Minneapolis, MN 55440 Telephone: (317) 242-5000 Telephone: 01753-26835
Telephone: (612) 378-6410 Midwest Mfg. Co. Woodward Governor Co.
Rockford Clutch Company 29500 Southfield Road, Suite 122 P.O. Box 1519
1200 Windsor Road Southfield, MI 48076 Fort Collins, CO 80522
P.O. Box 2908 Telephone: (313) 642-5355 Telephone: (303) 482-5811
Rockford, IL 61132-2908 (800) 523-2831
Telephone: (815) 633-7460 Wohlert Corporation Barber Colman Co.
708 East Grand River Avenue 1354 Clifford Avenue
P.O. Box 20217 Loves Park, IL 61132
Lansing, MI 48901 Telephone: (815) 637-3000
Telephone: (517) 485-3750
g-01
Component Manufacturers’ Addresses Section M - Component Manufacturers
Page M-4
United Technologies Sundstrand Hydratec Ltd. Torque Converters

Diesel Systems Cheney Manor Trading Estate
1000 Jorie Blvd. Swindon Twin Disc International S.A.
Suite 111 Wiltshire Chaussee de Namur
Oak Brook, IL 69521 SN2 2PZ Nivelles
Telephone: (312) 325-2020 England Belgium
Telephone: 01793-30101 Telephone: 067-224941
Heat Sleeves Sperry Vickers Twin Disc Incorporated
Bentley Harris Manufacturing Co. P.O. Box 302 1328 Racine Street
100 Bentley Harris Way Troy, MI 48084 Racine, WI 53403-1758
Gordonville, TN 38563 Telephone: (313) 280-3000 Telephone: (414) 634-1981
Telephone: (313) 348-5779 Z.F. Rockford Powertrain, Inc.
P.O. Box 1340 Off-Highway Systems
Hydraulic and Power Steer- Grafvonsoden Strasse 1200 Windsor Road
ing Pumps 5-9 D7070 P.O. Box 2908
Schwaebisch Gmuend Rockford, IL 61132-2908
Hobourn Automotive Telephone: (815) 633-7460
Temple Farm Works West Germany
Priory Road Telephone: 7070-7171-31510 Modine Mfg. Co.
Strood 1500 DeKoven Avenue
Rochester Oil Heaters Racine, WI 53401
Kent, England Fleetguard, Inc. Telephone: (414) 636-1640
ME2 2BD 1200 Fleetguard Road
Telephone: 01634-71773 Cookeville, TN 38502
Honeywell Control Systems Ltd. Telephone: (615) 526-9551
Honeywell House Kim Hotstart Co.
Charles Square P.O. Box 11245
Bracknell Spokane, WA 99211-0245
Berks RG12 1EB Telephone: (509) 534-6171
Telephone: 01344-4245
g-01
Section V - Specifications and Torque Values - Group 18
QSK19-PRELIMINARY Page V-1
Section V - Specifications and Torque Values - Group 18

Section Contents
Page
Capscrew Markings and Torque Values ............................................................................................................ V-8
Capscrew Markings and Torque Values - Metric .............................................................................................. V-8
Capscrew Markings and Torque Values - U.S. Customary ............................................................................... V-9
Engine Components - General Information ...................................................................................................... V-2
Fraction, Decimal, Millimeter Conversions....................................................................................................... V-5
Newton-Meter to Foot-Pound Conversion Chart............................................................................................... V-7
Pipe Plug Torque Values ................................................................................................................................... V-9
Straight Threaded O-Ring Plugs ....................................................................................................................... V-3
Tap-Drill Chart - U.S. Customary & Metric ...................................................................................................... V-10
Weight and Measures - Conversion Factors ..................................................................................................... V-6
Engine Components - General Information Section V - Specifications and Torque Values - Group 18
Page V-2 QSK19-PRELIMINARY
Engine Components - General Information

This section will contain the engine and component specifications used in this manual, separated by systems in
the same sequence they appear in the manual at the time of final publication. A procedure number will appear
with each component description to aid in locating illustrations that describe inspection procedures. Component
capscrew installation torque values will follow the specifications in each systems procedure.
At the time of this preliminary publication, you will find some informative service conversion charts contained in
this section.
Section V - Specifications and Torque Values - Group 18 Straight Threaded O-Ring Plugs
Straight Threaded O-Ring Plugs

Thread Size Torque - lbf
inches N•m in-lb N•m ft-lb
1/4 4 35
3/8 6 50
1/2 8 70
9/16 12 105
5/8 16 145
3/4 20 15
7/8 35 25
1 40 30
1 1/16 45 35
1 3/16 55 40
Drive Belt Tension Section V - Specifications and Torque Values - Group 18
Drive Belt Tension

SAE Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used*
Click-type Burroughs N lbf N lbf
0.380 in 3822524 620 140 270 to 490 60 to 110
0.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822525 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 890 200 360 to 710 80 to 160
10 rib 3822525 3823138 1110 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
12 rib K section 3822525 3823138 1330 300 890 to 1070 200 to 240
NOTE: This chart does not apply to automatic belt tensioners.
* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
g-01
Section V - Specifications and Torque Values - Group 18 Fraction, Decimal, Millimeter Conversions
Fraction, Decimal, Millimeter Conversions

Fraction inch mm Fraction inch mm
1/64 0.0156 0.397 33/64 0.5156 13.097
1/32 0.0313 0.794 17/32 0.5313 13.494
3/64 0.0469 1.191 35/64 0.5469 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.0781 1.984 37/64 0.5781 14.684
3/32 0.0938 2.381 19/32 0.5938 15.081
7/64 0.1094 2.778 39/64 0.6094 15.478
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.1406 3.572 41/64 0.6406 16.272
5/32 0.1563 3.969 21/32 0.6563 16.669
11/64 0.1719 4.366 43/64 0.6719 17.066
3/16 0.1875 4.763 11/16 0.6875 17.463
13/64 0.2031 5.159 45/64 0.7031 17.859
7/32 0.2188 5.556 23/32 0.7188 18.256
15/64 0.2344 5.953 47/64 0.7344 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.2656 6.747 49/64 0.7656 19.447
9/32 0.2813 7.144 25/32 0.7813 19.844
19/64 0.2969 7.541 51/64 0.7969 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.3281 8.334 53/64 0.8281 21.034
11/32 0.3438 8.731 27/32 0.8438 21.431
23/64 0.3594 9.128 55/64 0.8594 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.3906 9.922 57/64 0.8906 22.622
13/32 0.4063 10.319 29/32 0.9063 23.019
27/64 0.4219 10.716 59/64 0.9219 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.4531 11.509 61/64 0.9531 24.209
15/32 0.4688 11.906 31/32 0.9688 24.606
31/64 0.4844 12.303 63/64 0.9844 25.003
1/2 0.5000 12.700 1 1.0000 25.400
Conversion Factor: 1 inch = 25.4 mm
g-01
Weight and Measures - Conversion Factors Section V - Specifications and Torque Values - Group 18
Weight and Measures - Conversion Factors

Quantity U.S. Customary Metric From U.S. From Metric
Customary To U.S.
To Metric Customary
Multiply By Multiply By
Unit Name Abbr. Unit Name Abbr.
2
Area sq. inch in sq. millimeters mm2 645.16 0.001550
sq. centimeters cm2 6.452 0.155
2 2
sq. foot ft sq. meter m 0.0929 10.764
Fuel pounds per lb/hp-hr grams per kilowatt g/kW-hr 608.277 0.001645
Consumption horsepower hour hour
Fuel miles per gallon mpg kilometers per liter km/l 0.4251 2.352
Performance
gallons per mile gpm liters per kilometer l/km 2.352 0.4251
Force pounds force lbf Newton N 4.4482 0.224809
Length inch in millimeters mm 25.40 0.039370
foot ft millimeters mm 304.801 0.00328
Power horsepower hp kilowatt kW 0.746 1.341
Pressure pounds force per psi kilopascal kPa 6.8948 0.145037
sq. inch
inches of mercury in Hg kilopascal kPa 3.3769 0.29613
inches of water in H2O kilopascal kPa 0.2488 4.019299
inches of mercury in Hg millimeters of mm Hg 25.40 0.039370
mercury
inches of water in H2O millimeters of water mm H2O 25.40 0.039370
bars bars kilopascals kPa 100.001 0.00999
bars bars millimeters of mm Hg 750.06 0.001333
mercury
Temperature fahrenheit °F centigrade °C (°F-32) ÷1.8 (1.8 x °C) +32
Torque pound force per foot ft-lb Newton-meter N•m 1.35582 0.737562
pound force per inch in-lb Newton-meter N•m 0.113 8.850756
Velocity miles/hour mph kilometers/hour kph 1.6093 0.6214
Volume: gallon (U.S.) gal. liter l 3.7853 0.264179
liquid
displacement gallon (Imp*) gal. liter l 4.546 0.219976
cubic inch in3 liter l 0.01639 61.02545
3 3
cubic inch in cubic centimeter cm 16.387 0.06102
Weight (mass) pounds (avoir.) lb kilograms kg 0.4536 2.204623
Work British Thermal Unit BTU joules J 1054.5 0.000948
British Thermal Unit BTU kilowatt-hour kW-hr 0.000293 3414
horsepower hours hp-hr kilowatt-hour kW-hr 0.746 1.341
Section V - Specifications and Torque Values - Group 18 Newton-Meter to Foot-Pound Conversion Chart
Newton-Meter to Foot-Pound Conversion Chart

N•m ft-lb N•m ft-lb N•m ft-lb
1 8.850756 in-lb 55 41 155 114
5 44 in-lb 60 44 160 118
6 53 in-lb 65 48 165 122
7 62 in-lb 70 52 170 125
8 71 in-lb 75 55 175 129
9 80 in-lb 80 59 180 133
10 89 in-lb 85 63 185 136
1 0.737562 ft-lb 90 66 190 140
12 9 95 70 195 144
14 10 100 74 200 148
15 11 105 77 205 151
16 12 110 81 210 155
18 13 115 85 215 159
20 15 120 89 220 162
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184
NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.
Capscrew Markings and Torque Values Section V - Specifications and Torque Values - Group 18
Capscrew Markings and Torque Values

CAUTION
When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being
replaced. Using the wrong capscrews can result in engine damage.
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the
surface of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.
The following examples indicate how capscrews are identified:
NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other sections of this manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque
wrench. Example: 6 ft-lb equals 72 in-lb.
Capscrew Markings and Torque Values - Metric
Body
Size Torque Torque Torque
Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
6 9 5 7 4 12 9 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 25 18 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 60 45 30 25 70 50 30 25
12 80 60 55 40 105 75 55 40 125 95 55 40
14 125 90 90 65 165 122 90 65 195 145 90 65
16 180 130 140 100 240 175 140 100 290 210 140 100
18 230 170 180 135 320 240 180 135 400 290 180 135
g-01
Section V - Specifications and Torque Values - Group 18 Pipe Plug Torque Values
Capscrew Markings and Torque Values - U.S. Customary
Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum

N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
1/4 - 20 9 7 8 6 15 11 8 6
- 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
- 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
- 24 40 30 35 25 60 45 35 25
7/16 - 14 60 45 45 35 90 65 45 35
- 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
- 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
- 18 150 110 115 85 210 155 115 85
5/8 - 11 180 135 150 110 255 190 150 110
- 18 210 155 160 120 290 215 160 120
3/4 - 10 325 240 255 190 460 340 255 190
- 16 365 270 285 210 515 380 285 210
7/8 - 9 490 360 380 280 745 550 380 280
- 14 530 390 420 310 825 610 420 310
1 - 8 720 530 570 420 1100 820 570 420
- 14 800 590 650 480 1200 890 650 480
Pipe Plug Torque Values

Size Torque Torque
In Cast Iron or
Thread Actual Thread O.D. In Aluminum Components Steel Components
in in N•m ft-lb N•m ft-lb
1/16 0.32 5 45 in-lb 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100
Tap-Drill Chart - U.S. Customary & Metric Section V - Specifications and Torque Values - Group 18
Tap-Drill Chart - U.S. Customary & Metric

Index
Page X-1
About the Manual ....................................................................... i-2 Install (001-001-026) ................................................................. 1-8

Accessory Drive (009-001) ........................................................ 9-6 Remove (001-001-002) .............................................................. 1-7
Clean (009-001-006) ................................................................. 9-7 Alternator Pulley (013-006) .................................................... 13-11
Inspect for Reuse (009-001-007) ............................................... 9-7 Inspect for Reuse (013-006-007) ............................................ 13-11
Install (009-001-026) ................................................................. 9-8 Batteries (013-007) ................................................................. 13-11
Remove (009-001-002).............................................................. 9-6 Inspect (013-007-062) ............................................................ 13-11
Accessory Drive Pulley (009-004)............................................ 9-10 Battery Cables and Connections (013-009) .......................... 13-12
Inspect for Reuse (009-004-007).............................................. 9-10 Inspect for Reuse (013-009-007)............................................ 13-12
Install (009-004-026)................................................................ 9-11 Bearings, Connecting Rod (001-005) ...................................... 1-14
Remove (009-004-002) ............................................................ 9-10 Install (001-005-026) ............................................................... 1-15
Accessory Drive Seal (001-003)............................................... 1-10 Remove (001-005-002) ............................................................ 1-14
Install (001-003-026) ................................................................ 1-11 Bearings, Thrust (001-007) ...................................................... 1-24
Remove (001-003-002) ............................................................ 1-10 Inspect for Reuse (001-007-007).............................................. 1-24
Aftercooler Assembly (010-002) .............................................. 10-6 Install (001-007-026)................................................................ 1-25
Inspect for Reuse (010-002-007) .............................................. 10-8 Remove (001-007-002) ............................................................ 1-24
Install (010-002-026) ................................................................ 10-8 Belt, Cooling Fan Drive (008-002) ........................................... 8-15
Remove (010-002-002) ............................................................ 10-6 Adjust (008-002-029)............................................................... 8-16
Aftercooler Element (010-008) ............................................... 10-11 Inspect for Reuse (008-002-007) ............................................. 8-15
Install (010-008-026) .............................................................. 10-13 Install (008-002-026) ............................................................... 8-16
Pressure Test (010-008-013) .................................................. 10-12 Remove (008-002-002)............................................................ 8-15
Remove (010-008-002) ........................................................... 10-11 Boost Pressure (010-057)....................................................... 10-30
Air Compressor Carbon Buildup (012-003) ............................. 12-9 Measure (010-057-010) .......................................................... 10-30
Inspect for Reuse (012-003-007) ............................................. 12-9 Cam Follower - Specifications (018-001-201)............................ 4-3
Air Compressor Cylinder Head, Single Cylinder (012-008)... 12-11 Cam Follower Assembly (004-001) ............................................ 4-4
Assemble (012-008-025)........................................................ 12-15 Inspect for Reuse (004-001-007) ............................................... 4-5
Disassemble (012-008-003) ................................................... 12-12 Install (004-001-026) ................................................................. 4-6
Inspect (012-008-062) ........................................................... 12-13 Remove (004-001-002).............................................................. 4-4
Inspect for Reuse (012-008-007)............................................ 12-13 Cam Follower — General Information (003-999-999)................ 4-2
Install (012-008-026).............................................................. 12-16 Camshaft (001-008) ................................................................. 1-25
Remove (012-008-002) .......................................................... 12-11 Inspect (001-008-062) ............................................................. 1-33
Air Compressor (Oil Carryover)............................................. 12-37 Install (001-008-026) ............................................................... 1-29
Inspect for Reuse (012-020-007)............................................ 12-37 Remove (001-008-002) ............................................................ 1-25
Air Compressor Pin Bore Wear ............................................. 12-18 Camshaft Bushings (001-010).................................................. 1-34
Inspect for Reuse (012-010-007) ............................................ 12-18 Inspect (001-010-062).............................................................. 1-36
Install (012-010-026) .............................................................. 12-20 Install (001-010-026) ................................................................ 1-35
Remove (012-010-002) .......................................................... 12-18 Remove (001-010-002) ............................................................ 1-34
Air Compressor, Single Cylinder (012-014) ........................... 12-26 Camshaft Cover Plate (001-011) .............................................. 1-36
Inspect for Reuse (012-014-007)............................................ 12-27 Install (001-011-026) ................................................................ 1-37
Install (012-014-026).............................................................. 12-28 Remove (001-011-002)............................................................. 1-36
Remove (012-014-002) .......................................................... 12-26 Camshaft Gear (Camshaft Installed) (001-012) ....................... 1-37
Air Compressor, Two Cylinder............................................... 12-30 Inspect (001-012-062) ............................................................. 1-39
Inspect for Reuse (012-015-007) ............................................ 12-31 Install (001-012-026)................................................................ 1-38
Install (012-015-026) .............................................................. 12-31 Remove (001-012-002) ............................................................ 1-37
Remove (012-015-002) .......................................................... 12-30 Camshaft Idler Gear (001-036) ................................................ 1-80
Air Compressor Unloader and Valve Assembly (012-013) .... 12-20 Install (001-036-026) ............................................................... 1-80
Inspect for Reuse (012-013-007) ............................................ 12-21 Remove (001-036-002) ............................................................ 1-80
Install (012-013-026).............................................................. 12-25 Camshaft Thrust Bearing (001-056) ...................................... 1-109
Remove (012-013-002) .......................................................... 12-20 Inspect for Reuse (001-056-007)............................................ 1-109
Vacuum Test (012-013-015) ................................................... 12-23 Capscrew Markings and Torque Values.................................... V-8
Air Governor (Air Compressor Pumps Continuously) (012-018) Capscrew Markings and Torque Values - Metric ....................... V-8
............................................................................................... 12-34 Capscrew Markings and Torque Values - U.S. Customary ........ V-9
Inspect for Reuse (012-018-007)............................................ 12-34 Complete Engine — General Information (000-000-999).......... 0-2
Air Governor (Air Compressor Will Not Pump) (012-017) ..... 12-34 Complete Engine — Tool Requirements — (022-001-500) ....... 0-3
Inspect for Reuse (012-017-007)............................................ 12-34 Component Manufacturers’ Addresses ................................... M-2
Air Intake Information — General Information (010-999-999) . 10-2 Air Compressors...................................................................... M-2
Air Intake System - Specifications (018-001-205) ................... 10-4 Air Cylinders ........................................................................... M-2
Air Intake System - Tool Requirements (022-001-510) ............ 10-5 Air Heaters .............................................................................. M-2
Air Intake System — Flow Diagrams (010-200-281) ................ 10-3 Air Starting Motors .................................................................. M-2
Air Leaks, Air Intake System (010-024).................................. 10-15 Alternators............................................................................... M-2
Inspect for Reuse (010-024-007) ............................................ 10-15 Auxiliary Brakes ...................................................................... M-2
Air Leaks, Compressed Air System (012-019)....................... 12-36 Belts........................................................................................ M-2
Inspect for Reuse (012-019-007)............................................ 12-36 Catalytic Convertors ................................................................ M-2
Air-In-Fuel (006-003).................................................................. 6-9 Clutches.................................................................................. M-2
General Information (006-003-999)............................................ 6-9 Coolant Heaters ...................................................................... M-2
Test (006-003-012) .................................................................... 6-9 Drive Plates............................................................................. M-2
Alternator (013-001)................................................................. 13-5 Electric Starting Motors ........................................................... M-3
Inspect for Reuse (013-001-007).............................................. 13-5 Engine Protection Controls ...................................................... M-3
Install (013-001-026)................................................................ 13-7 Fan Clutches ........................................................................... M-3
Remove (013-001-002) ............................................................ 13-5 Fans........................................................................................ M-3
Test (013-001-012)................................................................... 13-6 Filters...................................................................................... M-3
Alternator Drive Belts (013-005).............................................. 13-9 Flexplates................................................................................ M-3
Adjust (013-005-029) ............................................................. 13-10 Fuel Warmers.......................................................................... M-3
Inspect for Reuse (013-005-007) ............................................. 13-9 Gauges ................................................................................... M-3
Install (013-005-026) ............................................................... 13-9 Governors ............................................................................... M-3
Remove (013-005-002) ............................................................ 13-9 Hydraulic and Power Steering Pumps...................................... M-4
Alternator Drive Seal (001-001) ................................................. 1-7 Oil Heaters .............................................................................. M-4
Index
Page X-2
Torque Converters ................................................................... M-4 Install (002-004-026) ............................................................... 2-12

Compressed Air System — Flow Diagrams (200-006-207) ..... 12-4 Pressure Test (002-004-013)...................................................... 2-9
Compressed Air System — General Information (012-999-999) Remove (002-004-002).............................................................. 2-5
................................................................................................. 12-2 Cylinder Head Gasket (002-021).............................................. 2-17
Compressed Air System — Specifications (018-001-207) ...... 12-5 Leak Test (002-021-014) .......................................................... 2-17
13.2 CFM Single Cylinder Air Compressor (SS296) ................ 12-5 Cylinder Head Valve (002-0020) .............................................. 2-16
15.0 CFM Single Cylinder Air Compressor (SS338) ................ 12-5 Remove (002-020-002)............................................................ 2-16
Compressed Air System — Tool Requirements (022-001-512). 12-7 Cylinder Liner (001-028) .......................................................... 1-55
Connecting Rod (001-014)....................................................... 1-40 Clean (001-028-006) ............................................................... 1-56
Inspect for Reuse (001-014-007).............................................. 1-40 Inspect for Reuse (001-028-007) ............................................. 1-56
Coolant Filter (008-006)........................................................... 8-17 Install (001-028-026) ............................................................... 1-58
Install (008-006-026) ............................................................... 8-17 Measure (001-028-010)............................................................ 1-57
Remove (008-006-002)............................................................ 8-17 Remove (001-028-002) ............................................................ 1-55
Coolant Temperature Gauge (008-004) ................................... 8-17 Cylinder Smokes (Blue Smoke) (007-050)............................... 7-47
Initial Check (008-004-008) ..................................................... 8-17 Fluorescent Dye Tracer (007-050-054) ..................................... 7-47
Coolant Thermostat (008-013)................................................. 8-18 Definition Of Terms................................................................... i-11
Inspect for Reuse (008-013-007) ............................................. 8-21 Drive Units — General Information (009-999-999).................... 9-2
Install (008-013-026) ............................................................... 8-25 Drive Units — Specifications .................................................... 9-3
Leak Test (008-013-014) .......................................................... 8-23 Drive Units — Tool Requirements (022-001-509) ...................... 9-5
Remove (008-013-002) ............................................................ 8-18 Dynamometer Worksheet (014-001) ........................................ 14-7
Test (008-013-012)................................................................... 8-21 Worksheet (014-001-056)......................................................... 14-7
Coolant Thermostat Housing Support (008-015).................... 8-28 Electrical Equipment — General ............................................. 13-2
Install (008-015-026) ............................................................... 8-30 Electrical Equipment — Specifications (018-001-208)............ 13-3
Remove (008-015-002) ............................................................ 8-28 Electrical Equipment — Tool Requirements (022-001-513) .... 13-4
Coolant Thermostat Seal (008-016) ........................................ 8-34 Electronic Fuel Control Valve Assembly (005-053)................. 5-19
Install (008-016-026) ............................................................... 8-35 Install (005-053-026) ............................................................... 5-21
Remove (008-016-002) ............................................................ 8-34 Remove (005-053-002)............................................................ 5-19
Coolant Vent Lines (008-017) .................................................. 8-35 Engine Components - General Information.............................. V-2
General Information (008-017-999) .......................................... 8-35 Engine Identification................................................................. E-2
Cooling System (008-018) ....................................................... 8-37 Cummins Engine Nomenclature............................................... E-2
Drain (008-018-005) ................................................................ 8-37 Engine Dataplate ..................................................................... E-2
Fill (008-018-028) .................................................................... 8-43 Fuel Pump Dataplate ............................................................... E-2
Flush (008-018-009) ................................................................ 8-38 Engine Installation (000-002) .................................................... 0-7
Pressure Test (008-018-013) .................................................... 8-40 Install (000-002-026) ................................................................. 0-7
Cooling System Diagnostics (008-020) ................................... 8-50 Engine Removal (000-001)......................................................... 0-4
Pressure Test (008-020-013).................................................... 8-50 Remove (000-001-002).............................................................. 0-4
Cooling System — Air or Combustion Gas (008-019) ............ 8-45 Engine Run-In (Chassis Dynamometer) (014-002) .................. 14-8
Test (008-019-012)................................................................... 8-45 General Information (014-002-999) .......................................... 14-8
Cooling System — Flow Diagrams (200-003-204) .................... 8-8 General Engine Test Procedures .......................................... 14-8
Jacket Water-Aftercooled .......................................................... 8-9 Run-In Instructions (014-002-276) ......................................... 14-10
LTA ......................................................................................... 8-10 Engine Run-In (Engine Dynamometer) (014-003) ................. 14-12
LTA Torque Converter .............................................................. 8-11 General Information (014-003-999) ........................................ 14-12
Cooling System — General Information (008-999-999) ............ 8-3 General Engine Test Procedures ........................................ 14-12
FleetguardW Products for Cummins Engines ............................ 8-5 Run-In Instructions (014-003-276) ........................................ 14-15
Cooling System — Required Tools (022-001-508) .................. 8-13 Engine Run-In (Without Dynamometer) (014-004) ................ 14-18
Cooling System — Specifications (018-001-204).................... 8-12 Run-In Instructions (014-004-276) ......................................... 14-18
Cooling System Service Requirements (008-022) .................. 8-51 Engine Support Bracket, Front ............................................... 16-5
General Information (008-022-999) ......................................... 8-51 Inspect for Reuse (016-002-007) ............................................. 16-6
Crankshaft (001-016)................................................................ 1-41 Install (016-002-026) ............................................................... 16-6
Initial Check (001-016-008)...................................................... 1-41 Remove (016-002-002) ............................................................ 16-5
Crankshaft Gear, Front (Crankshaft Installed) (001-018)......... 1-41 Engine Testing - General Information (014-999-999) ............. 14-3
Inspect For Reuse (001-018-007)............................................. 1-42 Engine Testing - Specifications (018-001-275)........................ 14-4
Install (001-018-026)................................................................ 1-42 Engine Testing - Tool Requirements (022-001-514) ................ 14-5
Remove (001-018-002) ............................................................ 1-41 Engine Testing (Chassis Dynamometer) (014-005) ............... 14-19
Crankshaft Seal, Front (001-023) ............................................ 1-43 Setup (014-005-011) ............................................................. 14-19
Clean (001-023-006) ............................................................... 1-44 General Engine Test Procedures ........................................ 14-20
Install (001-023-026) ............................................................... 1-44 Test (014-005-012)................................................................. 14-22
Remove (001-023-002) ............................................................ 1-43 Air Compressor .................................................................. 14-31
Crankshaft Seal, Rear (001-024) ............................................. 1-47 Coolant Pressure ............................................................... 14-30
Clean (001-024-006) ............................................................... 1-47 Engine Blowby ................................................................... 14-25
Install (001-024-026) ............................................................... 1-48 Engine Speed (RPM) With a Verified Tachometer ............... 14-22
Remove (001-024-002) ............................................................ 1-47 Exhaust Restriction ............................................................ 14-25
Cylinder Block (001-026) ......................................................... 1-50 Fuel Drain Line Restriction................................................. 14-23
Inspect for Reuse (001-026-007) ............................................. 1-50 Fuel Inlet Restriction .......................................................... 14-23
Magnetic Crack Inspection (001-026-016)................................ 1-50 Fuel Pressure..................................................................... 14-23
Cylinder Block and Liner Seats (001-027)............................... 1-51 Fuel Rate ........................................................................... 14-23
Inspect for Reuse (001-027-007) ............................................. 1-52 Intake Air Restriction.......................................................... 14-25
Measure (001-027-010)............................................................ 1-53 Intake Air Temperature Control - Chassis Dynamometer Test. 14-24
Preparatory (001-027-001) ....................................................... 1-51 Intake Manifold Pressure.................................................... 14-24
Cylinder Block — Tool Requirements (022-001-501) ................ 1-3 Lubricating Oil Pressure..................................................... 14-30
Cylinder Head - General Information (002-999-999) ................. 2-2 Lubricating Oil Temperature ............................................... 14-30
Cylinder Head - Specifications (018-001-502)........................... 2-3 Starting Motor .................................................................... 14-31
Cylinder Head - Tool Requirements (022-001-502) ................... 2-4 Engine Testing (Engine Dynamometer) (014-006)................. 14-31
Cylinder Head (002-004)............................................................ 2-5 Install (014-006-026) ............................................................. 14-31
Clean (002-004-006) ................................................................. 2-8 Coolant Plumbing .............................................................. 14-32
Inspect for Reuse (002-004-007) ............................................... 2-9 Engine Throttle Control ...................................................... 14-35
Index
Page X-3
General Engine Test Procedures ........................................ 14-33 Fuel Pump (005-016) ................................................................ 5-11
Test (014-006-012)................................................................. 14-35 Inspect for Reuse (005-016-007) ............................................. 5-12
Air Compressor .................................................................. 14-42 Install (005-016-026) ............................................................... 5-14
Coolant Pressure ............................................................... 14-42 Pressure Test (005-016-013) .................................................... 5-12
Engine Blowby ................................................................... 14-38 Prime (005-016-050) ............................................................... 5-15
Engine Speed (RPM) With a Verified Tachometer ............... 14-36 Remove (005-016-002) ............................................................ 5-11
Exhaust Restriction ............................................................ 14-37 Fuel Shutoff Valve (005-043) ................................................... 5-16
Fuel Drain Line Restriction................................................. 14-37 Inspect for Reuse (005-043-007) ............................................. 5-17
Fuel Inlet Restriction .......................................................... 14-36 Install (005-043-026) ............................................................... 5-18
Fuel Pressure..................................................................... 14-36 Remove (005-043-002)............................................................ 5-16
Fuel Rate ........................................................................... 14-36 Fuel Supply Lines (006-024).................................................... 6-21
Intake Air Restriction.......................................................... 14-37 Inspect for Reuse (006-024-007) ............................................. 6-22
Intake Manifold Pressure.................................................... 14-37 Install (006-024-026) ............................................................... 6-24
Lubricating Oil Pressure..................................................... 14-42 Remove (006-024-002) ............................................................ 6-21
Lubricating Oil Temperature ............................................... 14-42 Fuel System Flow Diagrams (200-001-202)............................... 5-4
Starting Motor .................................................................... 14-43 Fuel System — General Information (005-999-999).................. 5-2
Engine Testing (Fuel Flow Rate) (014-007) ........................... 14-50 Fuel System — Service Tools (022-001-505) ............................ 5-5
Measure (014-007-010) ......................................................... 14-50 Fuel System — Specifications (018-001-202) ........................... 5-6
Operation ........................................................................... 14-51 Installation Recommendations (005-999-248) ............................ 5-7
Engine Testing (In-Chassis) (014-008)................................... 14-43 Gear Cover, Front (001-031) .................................................... 1-67
Stall Speed Check (014-008-280) .......................................... 14-43 Inspect for Reuse (001-031-007).............................................. 1-72
Time Speed Check (014-008-281) ......................................... 14-46 Install (001-031-026)................................................................ 1-73
Stall Speed Check List....................................................... 14-48 Remove (001-031-002) ............................................................ 1-67
Exhaust Manifold (Dry) (011-007) ............................................ 11-5 Gear Cover Spacer Plate (001-029) ......................................... 1-61
Assemble (011-007-025)........................................................... 11-7 Inspect for Reuse (001-029-007) ............................................. 1-63
Inspect for Reuse (011-007-007)............................................... 11-6 Install (001-029-026) ............................................................... 1-63
Install (011-007-026)................................................................. 11-7 Remove (001-029-002) ............................................................ 1-61
Remove (011-007-002) ............................................................. 11-5 Gear Train Backlash, Front (001-055).................................... 1-108
Exhaust Restriction (011-009).................................................. 11-8 Measure (001-055-010) .......................................................... 1-108
Measure (011-009-010) ............................................................ 11-8 General Cleaning Instructions.................................................. i-10
Exhaust System — Flow Diagrams (200-005-206) .................. 11-3 Glass or Plastic Bead Cleaning ............................................... i-10
Exhaust System — General Information (011-999-999)........... 11-2 Solvent and Acid Cleaning ....................................................... i-10
Exhaust System — Specifications (018-001-206).................... 11-2 Steam Cleaning ....................................................................... i-10
Exhaust System — Tool Requirements (022-001-511)............. 11-4 General Repair Instructions ....................................................... i-9
External Engine Components................................................... E-6 Welding on a QUANTUM™ Fuel System Controlled Vehicle ....... i-9
Fan, Cooling (008-040) ............................................................ 8-56 General Safety Instructions ....................................................... i-8
Initial Check (008-040-001) ..................................................... 8-56 Important Safety Notice ............................................................. i-8
Install (008-040-026) ............................................................... 8-57 General Specifications.............................................................. E-3
Remove (008-040-002)............................................................ 8-56 Air Induction System................................................................ E-4
Rotation Check (008-040-052)................................................. 8-58 Cooling System........................................................................ E-5
Fan Drive Ilder Arm Assembly (008-029) ................................ 8-52 Electrical System ..................................................................... E-5
Inspect for Reuse (008-029-007) ............................................. 8-53 Exhaust System ....................................................................... E-5
Install (008-029-026) ............................................................... 8-54 Fuel System............................................................................. E-5
Remove (008-029-002)............................................................ 8-52 General Engine Data................................................................ E-4
Fan Hub, Belt Driven (008-036) ............................................... 8-54 Lubricating Oil System ............................................................. E-4
Inspect for Reuse (008-036-007) ............................................. 8-55 How to Use the Manual .............................................................. i-2
Install (008-036-026) ............................................................... 8-55 Hydraulic Pump Idler Gear (001-039) ...................................... 1-82
Remove (008-036-002)............................................................ 8-54 Install (001-039-026) .............................................................. 1-82
Flywheel (016-005) .................................................................. 16-7 Remove (001-039-002) ............................................................ 1-82
Inspect for Reuse (016-005-007) ............................................. 16-8 Illustrations................................................................................. i-7
Install (016-005-026) ............................................................... 16-9 Injector and Fuel Lines — QUANTUMW Injector ...................... 6-5
Remove (016-005-002) ............................................................ 16-7 Injectors (006-026)................................................................... 6-26
Flywheel Housing (016-006) .................................................. 16-11 Calibrate (006-026-030)........................................................... 6-26
Inspect for Reuse (016-006-007)............................................ 16-13 Inspect for Reuse (006-026-007) ............................................. 6-27
Install (016-006-026).............................................................. 16-18 Install (006-026-026) ............................................................... 6-29
Redowel (016-006-023) ......................................................... 16-14 Remove (006-026-002)............................................................ 6-26
Remove (016-006-002) .......................................................... 16-11 Injectors and Fuel Lines (006-999) ........................................... 6-2
Fraction, Decimal, Millimeter Conversions .............................. V-5 General Information (006-999-999)............................................ 6-2
Fuel Consumption (005-010).................................................... 5-10 Injectors and Fuel Lines — Flow Diagram (200-001-202)......... 6-4
Initial Check (005-010-001) ...................................................... 5-10 Injectors and Fuel Lines — Required Service Tools (022-001-505)
Test (005-010-012) ................................................................... 5-10 ................................................................................................... 6-7
Fuel Drain Line Restriction (006-012)...................................... 6-11 Injectors and Fuel Lines — Specifications (018-001-202) ........ 6-6
Measure (006-012-010) ............................................................ 6-11 Intake Air Restriction (010-031) ............................................. 10-17
Fuel Drain Lines (006-013) ...................................................... 6-12 Measure (010-031-010) .......................................................... 10-17
Inspect for Reuse (006-013-007) ............................................. 6-13 Lubricating Oil Contamination ................................................ 7-38
Install (006-013-026) ............................................................... 6-14 Fluorescent Dye Tracer Test (007-044-054) .............................. 7-39
Remove (006-013-002) ............................................................ 6-12 Oil Diluted with Fuel ............................................................ 7-39
Fuel Filter (006-015) ................................................................ 6-14 General Information (007-044-999) .......................................... 7-38
Install (006-015-026) ............................................................... 6-15 Pressure Test (007-044-013) .................................................... 7-39
Remove (006-015-002) ............................................................ 6-14 Oil Diluted with Coolant ....................................................... 7-39
Fuel Inlet Restriction (006-020)............................................... 6-15 Lubricating Oil Cooler (007-003) ............................................... 7-9
Measure (006-020-010) ........................................................... 6-15 Pressure Differential Test (007-003-063) .................................... 7-9
Fuel Manifold (006-022)........................................................... 6-16 Lubricating Oil Cooler Cover (007-045) ................................... 7-41
Inspect for Reuse (006-022-007) ............................................. 6-17 Inspect for Reuse (007-045-007).............................................. 7-42
Install (006-022-026) ............................................................... 6-19 Install (007-045-026) ............................................................... 7-43
Remove (006-022-002)............................................................ 6-16 Remove (007-045-002) ............................................................ 7-41
Index
Page X-4
Lubricating Oil Cooler Element ............................................... 7-10 Install (001-054-026).............................................................. 1-103

Install (007-007-026) ................................................................ 7-11 Remove (001-054-002) ............................................................ 1-98
Pressure Test (007-007-013) .................................................... 7-10 Piston Cooling Nozzles (001-046) ........................................... 1-88
Remove (007-007-002) ............................................................ 7-10 Clean (001-046-006)................................................................ 1-91
Lubricating Oil Cooler Housing............................................... 7-45 Inspect for Reuse (001-046-007).............................................. 1-91
Inspect for Reuse (007-046-007).............................................. 7-46 Install (001-046-026)................................................................ 1-91
Install (007-046-026) ............................................................... 7-46 Remove (001-046-002) ............................................................ 1-88
Remove (007-046-002) ............................................................ 7-45 Piston Rings (001-047) ............................................................ 1-93
Lubricating Oil Dipstick (007-009) ........................................... 7-11 Install (001-047-026) ............................................................... 1-94
Calibrate (007-009-030) ........................................................... 7-11 Measure (001-047-010)............................................................ 1-93
Lubricating Oil Dipstick Tube (007-011)................................... 7-12 Push Rods (004-014) ................................................................. 4-8
Install (007-011-026) ................................................................ 7-12 Inspect for Reuse (004-014-007) ............................................... 4-8
Remove (007-011-002)............................................................. 7-12 Install (004-014-026) ................................................................. 4-9
Lubricating Oil Filter (007-013)................................................ 7-13 Remove (004-014-002).............................................................. 4-8
Inspect (007-013-062).............................................................. 7-13 Radiator (008-042) ................................................................... 8-59
Pressure Differential Test (007-013-063) .................................. 7-15 Initial Check (008-042-008) ..................................................... 8-60
Remove (007-013-002) ............................................................ 7-13 Test (008-042-012) .................................................................. 8-59
Lubricating Oil Filter Head (007-015) ...................................... 7-16 Radiator Hose, Lower (008-045) .............................................. 8-62
Install (007-015-026)................................................................ 7-17 Install (008-045-026) ............................................................... 8-62
Remove (007-015-002) ............................................................ 7-16 Remove (008-045-002)............................................................ 8-62
Lubricating Oil Filter Head Adapter (007-018) ........................ 7-17 Radiator Hose, Upper (008-046).............................................. 8-63
Install (007-018-026)................................................................ 7-18 Install (008-046-026) ............................................................... 8-64
Remove (007-018-002) ............................................................ 7-17 Remove (008-046-002)............................................................ 8-63
Lubricating Oil Leaks (007-024)............................................... 7-18 Radiator Pressure Cap (008-047) ............................................ 8-66
Fluorescent Dye Tracer (007-024-054) ..................................... 7-19 Inspect for Reuse (008-047-007) ............................................. 8-66
Inspect (007-024-062) ............................................................. 7-18 Pressure Test (008-047-013).................................................... 8-66
Lubricating Oil Pan (007-025) .................................................. 7-21 Radiator Shroud (008-048) ...................................................... 8-66
Fill (007-025-028) .................................................................... 7-23 Inspect for Reuse (008-048-007) ............................................. 8-66
Inspect for Reuse (007-025-007).............................................. 7-21 Radiator Top Tank (008-051).................................................... 8-66
Install (007-025-026) ............................................................... 7-22 Leak Test (008-051-014) .......................................................... 8-66
Remove (007-025-002) ............................................................ 7-21 Rocker Lever Assembly (003-009) ........................................... 3-10
Lubricating Oil Pan Adapter (007-026) .................................... 7-24 Inspect for Reuse (003-009-007).............................................. 3-10
Inspect for Reuse (007-026-007).............................................. 7-26 Install (003-009-026)................................................................ 3-11
Install (007-026-026) ............................................................... 7-26 Remove (003-009-002) ............................................................ 3-10
Remove (007-026-002) ............................................................ 7-24 Rocker Lever Cover (003-011).................................................. 3-12
Lubricating Oil Pan Adapter Cover Plate (007-027) ................ 7-30 Inspect for Reuse (003-011-007) .............................................. 3-13
Inspect for Reuse (007-027-007).............................................. 7-31 Install (003-011-026) ................................................................ 3-13
Install (007-027-026)................................................................ 7-31 Remove (003-011-002) ............................................................ 3-12
Remove (007-027-002) ............................................................ 7-30 Rocker Lever Housing (003-013) ............................................. 3-14
Lubricating Oil Pressure Gauge (007-028) .............................. 7-32 Inspect for Reuse (003-013-007) ............................................. 3-15
Inspect for Reuse (007-028-007).............................................. 7-32 Install (003-013-026) ............................................................... 3-16
Lubricating Oil Pressure Regulator (Main Rifle) (007-029) ..... 7-32 Remove (003-013-002) ............................................................ 3-14
Inspect for Reuse (007-029-007).............................................. 7-33 Rocker Lever — General Information (003-999-999) ................ 3-2
Install (007-029-026) ............................................................... 7-34 Rocker Lever — Specifications (018-003-201) .......................... 3-3
Remove (007-029-002) ............................................................ 7-32 Rocker Lever — Tool Requirements (022-001-503)................... 3-4
Lubricating Oil Pump (007-031)............................................... 7-34 Section Contents..................................................................... 13-1
Inspect for Reuse (007-031-007).............................................. 7-35 Simbolos ................................................................................... i-4
Install (007-031-026)................................................................ 7-36 Starter Magnetic Switch (013-017) ........................................ 13-13
Remove (007-031-002) ............................................................ 7-34 Inspect for Reuse (013-017-007)............................................ 13-13
Lubricating Oil System - Flow Diagrams (200-002-047) ........... 7-4 Starter Solenoid (013-019)..................................................... 13-17
Lubricating Oil System - General Information (007-999-999) ... 7-3 Voltage Check (013-019-041)................................................. 13-17
Lubricating Oil System - Specifications (018-001-203) ............ 7-7 Starter Switch (013-018) ........................................................ 13-15
Lubricating Oil System - Tool Requirements (022-001-507) ..... 7-8 Inspect for Reuse (013-018-007)............................................ 13-15
Lubricating Oil Temperature Gauge (007-038) ........................ 7-37 Starting Motor (013-020)........................................................ 13-19
Inspect for Reuse (007-038-007).............................................. 7-37 Inspect for Reuse (013-020-007)............................................ 13-19
Main Bearings (001-006).......................................................... 1-18 Install (013-020-026).............................................................. 13-20
General Information (001-006-999) .......................................... 1-18 Remove (013-020-002) .......................................................... 13-19
Install (001-006-026) ............................................................... 1-20 Straight Threaded O-Ring Plugs .............................................. V-3
Remove (001-006-002) ............................................................ 1-18 Supplemental Coolant Additive (SCA) (008-060) .................... 8-67
Mounting Adaptations — General Information (016-999-999). 16-2 Inspect for Reuse (008-060-007) ............................................. 8-67
Mounting Adaptations — Specifications (018-001-516) .......... 16-3 Symbole...................................................................................... i-5
Mounting Adaptations — Tool Requirements (022-001-516) .. 16-4 Symboles ................................................................................... i-6
Newton-Meter to Foot-Pound Conversion Chart ...................... V-7 Symbols ..................................................................................... i-3
Overhead Set (Outer Base Circle) ............................................ 3-5 Tap-Drill Chart - U.S. Customary & Metric.............................. V-10
Adjust (003-006-029)................................................................. 3-5 Torque Converter Cooler (008-065)......................................... 8-74
Determine the Cylinder in Position for Valve Set .................... 3-5 Inspect for Reuse (008-065-007) ............................................. 8-76
Worksheet (003-006-056) .......................................................... 3-9 Install (008-065-026) ............................................................... 8-77
Pipe Plug Torque Values ........................................................... V-9 Pressure Test (008-065-013).................................................... 8-76
Piston (001-043)....................................................................... 1-85 Remove (008-065-002)............................................................ 8-74
Clean (001-043-006) ............................................................... 1-85 Troubleshooting Procedures and Techniques .......................... T-3
Inspect for Reuse (001-043-007) ............................................. 1-87 Troubleshooting Symptoms Charts .......................................... T-3
Piston and Connecting Rod Assembly (001-054) ................... 1-98 Air Compressor Air Pressure Rises Slowly ............................... T-4
Assemble, Articulated (001-054-025)...................................... 1-102 Air Compressor Noise Excessive.............................................. T-5
Disassemble (001-054-003) ................................................... 1-101
Index
Page X-5
Air Compressor Pumping Excess Lubricating Oil Into Air System Install (010-037-026) .............................................................. 10-20
................................................................................................ T-6 Remove (010-037-002)........................................................... 10-18
Air Compressor Will Not Maintain Adequate Air Pressure - Not Vibration Damper, Single (001-052) ........................................ 1-94
Pumping Continuously ............................................................. T-8 Eccentricity Check (001-052-064)............................................ 1-97
Air Compressor Will Not Pump Air ........................................... T-9 Inspect for Reuse 001-052-007 ............................................... 1-95
Air Compressor Will Not Stop Pumping .................................. T-10 Install (001-052-026) ............................................................... 1-96
Alternator Not Charging or Insufficient Charging ..................... T-11 Remove (001-052-002) ............................................................ 1-94
Alternator Overcharging ......................................................... T-12 Wobble Check (001-052-065) .................................................. 1-97
Connecting Rod Bearing Noise .............................................. T-91 Water Pump (008-062) ............................................................. 8-68
Coolant Loss - External .......................................................... T-13 Inspect (008-062-062) ............................................................. 8-70
Coolant Loss - Internal ........................................................... T-15 Install (008-062-026) ............................................................... 8-71
Coolant Temperature Above Normal - Gradual Overheat......... T-16 Remove (008-062-002)............................................................ 8-68
Coolant Temperature Above Normal - Sudden Overheat ......... T-19 Water Pump Drive (009-029) ................................................... 9-12
Coolant Temperature Below Normal........................................ T-21 Inspect for Reuse (009-029-007) ............................................. 9-13
Crankcase Gases (Blowby) - Excessive .................................. T-22 Install (009-029-026) ............................................................... 9-14
Driveability - General Information ........................................... T-92 Remove (009-029-002)............................................................ 9-12
Driveability/Low Power - Customer Complaint Form ................ T-94 Water Pump Idler Gear (001-040) ............................................ 1-84
Driveability/Low Power/Excessive Fuel Consumption - Checklist Install (001-040-026) ............................................................... 1-84
.............................................................................................. T-95 Remove (001-040-002) ............................................................ 1-84
Electronic Service Tool Communication Error ......................... T-23 Weight and Measures - Conversion Factors............................. V-6
Engine Acceleration/Response Poor ....................................... T-24
Engine Decelerates Slowly ..................................................... T-27
Engine Difficult to Start or Will Not Start (Exhaust Smoke) ..... T-28
Engine Difficult to Start or Will Not Start (No Exhaust Smoke). T-31
Engine Noise Diagnostic Procedures - General Information .... T-91
Engine Noise Excessive* ....................................................... T-33
Engine Noise Excessive - Combustion Knocks ....................... T-37
Engine Noise Excessive - Connecting Rod* ........................... T-38
Engine Noise Excessive - Main Bearing* ............................... T-39
Engine Noise Excessive - Piston* .......................................... T-40
Engine Noise Excessive - Turbocharger*................................ T-42
Engine Power Output Low ...................................................... T-44
Engine Runs Rough at Idle .................................................... T-48
Engine Runs Rough or Misfires.............................................. T-50
Engine Shuts Off Unexpectedly or Dies During Deceleration .. T-52
Engine Speed Surges at Low or High Idle .............................. T-54
Engine Vibration - Excessive .................................................. T-56
Engine Will Not Crank or Cranks Slowly (Air Starting Motor)... T-58
Engine Will Not Crank or Cranks Slowly (Electric Starting Motor)
.............................................................................................. T-60
Engine Will Not Reach Rated Speed (RPM) ........................... T-63
Engine Will Not Shut Off ........................................................ T-62
Engine Will Start But Will Not Keep Running.......................... T-65
Fault Code Warning Lamps Do Not Illuminate ........................ T-68
Fault Code Warning Lamps Stay On (No Apparent Reason) ... T-67
Fuel Consumption - General Information ................................ T-96
Fuel Consumption Excessive.................................................. T-69
Fuel in the Coolant................................................................. T-72
Fuel in the Lubricating Oil ...................................................... T-73
Intake Manifold Air Temperature Above Specification .............. T-74
Low Idle Adjust Switch Inoperative ......................................... T-75
Lubricating Oil Consumption Excessive .................................. T-76
Lubricating Oil Pressure - High............................................... T-78
Lubricating Oil Pressure - Low................................................ T-79
Lubricating Oil Sludge in the Engine Crankcase Excessive..... T-81
Lubricating Oil Temperature Above Specification .................... T-83
Lubricating or Transmission Oil in the Coolant........................ T-84
Main Bearing Noise................................................................ T-91
Oil Consumption ................................................................... T-97
Piston Noise ........................................................................... T-91
Smoke, Black - Excessive....................................................... T-85
Smoke, White - Excessive ...................................................... T-87
Turbocharger Boost Pressure Low .......................................... T-89
Turbocharger Leaks - Engine Oil or Fuel................................. T-90
Turbocharger Axial Clearance (010-038)................................ 10-24
Measure (010-038-010) .......................................................... 10-24
Turbocharger Blade Damage (010-039) ................................. 10-24
Inspect for Reuse (010-039-007) ............................................ 10-24
Turbocharger Compressor Seal Leaks (010-040)................... 10-25
Inspect (010-040-062) ............................................................ 10-25
Turbocharger Radial Bearing Clearance (010-047)................ 10-27
Measure (010-047-010) .......................................................... 10-27
Turbocharger Turbine Seal Leaks (010-049) .......................... 10-28
Fluorescent Dye Tracer (010-049-054).................................... 10-28
Turbocharger (Water-Cooled) (010-037)................................. 10-18
Check for Correct Component (010-037-048) ......................... 10-23
Cummins Engine Company, Inc.
Box 3005
Columbus, IN, U.S.A., 47202-3005
Cable: CUMDIEX COLUMBUS
Cummins Engine Company Ltd.

46-50 Coombe Road
New Malden,
Surrey KT3 4QL,
England
Cable: CUMEUR G
Registration No. 573951 England
Bulletin No.
Printed in U.S.A. 07/95 1241

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Troubleshooting

and Repair Manual

CopyrightR 1995 Bulletin No.

About the Manual

How to Use the Manual

(STEP 1.) Locate the symptom on the list.

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque.

PERFORM an electrical MEASUREMENT.

Indica un paso de REMOCION o DESMONTAJE.

Indica un paso de INSTALACION o MONTAJE.

LIMPIESE la pieza o el montaje.

EJECUTESE una MEDICION mecánica o del tiempo.

LUBRIQUESE la pieza o el montaje.

Indica que se dará una LLAVE DE TUERCAS o el TAMAÑO DE HERRAMIENTA.

APRIETESE hasta un par torsor especı́fico.

EJECUTESE una MEDICION eléctrica.

AUSBAU bzw. ZERLEGEN.

EINBAU bzw. ZUSAMMENBAU.

Teil oder Baugruppe REINIGEN.

DIMENSION - oder ZEITMESSUNG.

Teil oder Baugruppe ÖLEN.

WERKZEUGGRÖSSE wird angegeben.

ANZUG auf vorgeschriebenes Drehmoment erforderlich.

Elektrische MESSUNG DURCHFÜHREN.

Weitere Informationen an anderer Stelle bzw. in anderen Handbüchern.

AVERTISSEMENT - De graves lésions corporelles ou des dommages matériels considérables

Indique une opération de MONTAGE.

L’INSPECTION est nécessaire.

NETTOYER la pièce ou l’ensemble.

EFFECTUER une MESURE mécanique ou de temps.

GRAISSER la pièce ou l’ensemble.

Indique qu’une DIMENSION DE CLE ou D’OUTIL sera donnée.

SERRER à un couple spécifique.

EFFECTUER une MESURE électrique.

The illustrations are intended to show repair or replace-

General Safety Instructions

General Repair Instructions

General Cleaning Instructions

E.S.N.: Engine Serial Number

Section E - Engine and Component Identification

= Maximum Brake Horsepower

Fuel Pump Dataplate

General Engine Data

Cylinder location and Firing Order:

Intake and Exhaust Valve locations.

Air Induction System

System Voltage Ambient Temperatures

External Engine Components

Section 0 - Complete Engine — Group 00

Complete Engine — General Informa-

Complete Engine — Tool Requirements — (022-001-500)

Tool No. Tool Description Tool Illustration

Engine Liftiing Hook

Engine Removal (000-001)

Warning: Always disconnect negative (-) cable first.

Warning: Some state and federal agencies in the United

Disconnect the intake and exhaust system pipes.