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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
QSK19 - PRELIMINARY Page i-3

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
Page i-4 QSK19 - PRELIMINARY

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
QSK19 - PRELIMINARY Page i-5

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
Page i-6 QSK19 - PRELIMINARY

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
QSK19 - PRELIMINARY Page i-7

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
Page i-8 QSK19 - PRELIMINARY

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
QSK19 - PRELIMINARY Page i-9

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
Page i-10 QSK19 - PRELIMINARY

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
QSK19 - PRELIMINARY Page i-11

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
Page i-12 QSK19 - PRELIMINARY

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
QSK19 - PRELIMINARY Page i-13

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
Page i-14 QSK19 - PRELIMINARY

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
QSK19 - PRELIMINARY Page E-3

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
Page E-4 QSK19 - PRELIMINARY

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
QSK19 - PRELIMINARY Page E-5

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
Page E-6 QSK19 - PRELIMINARY

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
QSK19 - PRELIMINARY Page E-7
External Engine Components Section E - Engine and Component Identification
Page E-8 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 0-3

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
Page 0-4 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 0-5

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
Page 0-6 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 0-7

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]
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, engine lifting fixture, and two


Part No. 3823210 Lifting Hooks to install the engine.
Engine Installation (000-002) Section 0 - Complete Engine — Group 00
Page 0-8 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 0-9

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]
Refer to the equipment manufacturer’s specifications for
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
Page 0-10 QSK19 - PRELIMINARY

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 1 — Cylinder Block — Group 01


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
Inspect for Reuse (001-014-007)..................................................................................................................... 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
Section 1 — Cylinder Block — Group 01
Page 1-2 QSK19 PRELIMINARY

Page
Cylinder Block and Liner Seats (001-027) ....................................................................................................... 1-51
Inspect for Reuse (001-027-007) .................................................................................................................... 1-52
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
Inspect for Reuse (001-028-007) .................................................................................................................... 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
Inspect for Reuse (001-031-007)..................................................................................................................... 1-72
Install (001-031-026)....................................................................................................................................... 1-73
Remove (001-031-002) ................................................................................................................................... 1-67
Gear Cover Spacer Plate (001-029).................................................................................................................. 1-61
Inspect for Reuse (001-029-007) .................................................................................................................... 1-63
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
Inspect for Reuse (001-043-007) .................................................................................................................... 1-87
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
Inspect for Reuse (001-046-007)..................................................................................................................... 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)
QSK19 PRELIMINARY Page 1-3

Cylinder Block — Tool Requirements (022-001-501)

The following special tools are recommended to perform procedures in Section 01. 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


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)
QSK19 PRELIMINARY Page 1-5

Tool No. Tool Description Tool Illustration


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)
QSK19 - PRELIMINARY Page 1-7

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
Page 1-8 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-9

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
Page 1-10 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-11

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
Page 1-12 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-13

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.
Torque Value: 11 N•m [96 in-lb]

Install the accessory drive pulley. Refer to Procedure No.


009-004-026.
Bearings, Connecting Rod (001-005) Section 1 — Cylinder Block — Group 01
Page 1-14 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-15

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
Page 1-16 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-17

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).
Torque Value (Capscrew): 35 N•m [25 ft-lb]

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
Page 1-18 QSK19 - PRELIMINARY

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
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 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)
QSK19 - PRELIMINARY Page 1-19

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.
Main Bearings (001-006) Section 1 — Cylinder Block — Group 01
Page 1-20 QSK19 - PRELIMINARY

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


bearing position in the tang area.
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.
Section 1 — Cylinder Block — Group 01 Main Bearings (001-006)
QSK19 - PRELIMINARY Page 1-21

NOTE: Before installing the thrust bearings, refer to General


Information, Procedure 001-006-999.
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.
Main Bearings (001-006) Section 1 — Cylinder Block — Group 01
Page 1-22 QSK19 - PRELIMINARY

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.
Section 1 — Cylinder Block — Group 01 Main Bearings (001-006)
QSK19 - PRELIMINARY Page 1-23

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.
NOTE: The suction tube shape can vary from the illustration.
All suction tubes attach to the block in the same manner.
Install the gasket, suction tube, washers, and capscrews
(1). 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.
Torque Value: 35 N•m [25 ft-lb]

Install the oil sump and related components. Refer to


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
Page 1-24 QSK19 - PRELIMINARY

Fill the engine with clean 15W-40 oil. Refer to Procedure


007-025-028 for engine oil capacity.
Operate the engine to 70°C [160°F] coolant temperature.
Check for leaks.

Bearings, Thrust (001-007)


Remove (001-007-002)
NOTE: Before removing the thrust bearings, refer to General
Information, Procedure 001-006-999.
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)
QSK19 - PRELIMINARY Page 1-25

Install (001-007-026)
NOTE: Before installing the thrust bearings, refer to General
Information, Procedure 001-006-999.
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.

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.

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
Page 1-26 QSK19 - PRELIMINARY

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.
Section 1 — Cylinder Block — Group 01 Camshaft (001-008)
QSK19 - PRELIMINARY Page 1-27

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.
Camshaft (001-008) Section 1 — Cylinder Block — Group 01
Page 1-28 QSK19 - PRELIMINARY

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.
Section 1 — Cylinder Block — Group 01 Camshaft (001-008)
QSK19 - PRELIMINARY Page 1-29

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.
Torque Value (Capscrew): 45 N•m [35 ft-lb]
Camshaft (001-008) Section 1 — Cylinder Block — Group 01
Page 1-30 QSK19 - PRELIMINARY

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.

Caution: Wear protective clothing to prevent personal


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.
Section 1 — Cylinder Block — Group 01 Camshaft (001-008)
QSK19 - PRELIMINARY Page 1-31

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 not within specifications, check for
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.
Camshaft (001-008) Section 1 — Cylinder Block — Group 01
Page 1-32 QSK19 - PRELIMINARY

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.
Section 1 — Cylinder Block — Group 01 Camshaft (001-008)
QSK19 - PRELIMINARY Page 1-33

Install the gear cover and related components. Refer to


Procedure No. 001-031-003.

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
Page 1-34 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-35

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
Page 1-36 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-37

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
capscrews. Tighten the capscrews.
Torque Value: 45 N•m [35 ft-lb]

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.

Camshaft keys are available in different sizes (amount of


offset). The injection timing 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.
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
Page 1-38 QSK19 - PRELIMINARY

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.

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.
Install the thrust bearing plate. Install the three mounting
capscrews.
Torque Value: 45 N•m [35 ft-lb]

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 installation.
Section 1 — Cylinder Block — Group 01 Camshaft Gear (Camshaft Installed) (001-012)
QSK19 - PRELIMINARY Page 1-39

Caution: Wear protective clothing to prevent personal


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
visible from the front of the gear after it is installed on the
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
Page 1-40 QSK19 - PRELIMINARY

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)


Inspect for Reuse (001-014-007)
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)
QSK19 - PRELIMINARY Page 1-41

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
Page 1-42 QSK19 - PRELIMINARY

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.

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 installation.

Caution: Wear protective clothing to prevent personal


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
visible from the front of the gear after it is installed on the
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)
QSK19 - PRELIMINARY Page 1-43

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


to Procedure 001-052-002.

Remove the eight button head hex socket capscrews.


Crankshaft Seal, Front (001-023) Section 1 — Cylinder Block — Group 01
Page 1-44 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-45

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
Page 1-46 QSK19 - PRELIMINARY

Install the eight, button head hex socket capscrews.


Tighten the capscrews alternately and evenly.
Torque Value: 11 N•m [96 in-lb]

Install the vibration damper and fan drive pulley. Refer to


Procedure 001-052-026.

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)
QSK19 - PRELIMINARY Page 1-47

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
Page 1-48 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-49

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.
Torque Value: 11 N•m [95 in-lb]
Cylinder Block (001-026) Section 1 — Cylinder Block — Group 01
Page 1-50 QSK19 - PRELIMINARY

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)


Inspect for Reuse (001-026-007)
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)
QSK19 - PRELIMINARY Page 1-51

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
Page 1-52 QSK19 - PRELIMINARY

Inspect for Reuse (001-027-007)


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)
QSK19 - PRELIMINARY Page 1-53

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
Page 1-54 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-55

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
Page 1-56 QSK19 - PRELIMINARY

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.

Inspect for Reuse (001-028-007)


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.
Section 1 — Cylinder Block — Group 01 Cylinder Liner (001-028)
QSK19 - PRELIMINARY Page 1-57

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
capscrews. Tighten the capscrews.
Torque Value: 65 N•m [50 ft-lb]

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’’.
Cylinder Liner (001-028) Section 1 — Cylinder Block — Group 01
Page 1-58 QSK19 - PRELIMINARY

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.
Section 1 — Cylinder Block — Group 01 Cylinder Liner (001-028)
QSK19 - PRELIMINARY Page 1-59

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
capscrews. Tighten the capscrews.
Torque Value: 45 N•m [35 ft-lb]
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.
Cylinder Liner (001-028) Section 1 — Cylinder Block — Group 01
Page 1-60 QSK19 - PRELIMINARY

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


Procedure 001-043-026.
Section 1 — Cylinder Block — Group 01 Gear Cover Spacer Plate (001-029)
QSK19 - PRELIMINARY Page 1-61

Install the cylinder head and related components. Refer


to Procedure 002-004-026.

Gear Cover Spacer Plate (001-029)


Remove (001-029-002)
Remove the gear cover and all related components. Refer
to Procedure 001-031-002.

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
Page 1-62 QSK19 - PRELIMINARY

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.
Section 1 — Cylinder Block — Group 01 Gear Cover Spacer Plate (001-029)
QSK19 - PRELIMINARY Page 1-63

Inspect for Reuse (001-029-007)


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.
Gear Cover Spacer Plate (001-029) Section 1 — Cylinder Block — Group 01
Page 1-64 QSK19 - PRELIMINARY

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.
Section 1 — Cylinder Block — Group 01 Gear Cover Spacer Plate (001-029)
QSK19 - PRELIMINARY Page 1-65

Use the sequence shown and tighten the capscrews.


Torque Value: 45 N•m [35 ft-lb]
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.
Gear Cover Spacer Plate (001-029) Section 1 — Cylinder Block — Group 01
Page 1-66 QSK19 - PRELIMINARY

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


Procedure 001-031-026.
Section 1 — Cylinder Block — Group 01 Gear Cover, Front (001-031)
QSK19 - PRELIMINARY Page 1-67

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.

Remove the fan belt. Refer to Procedure 008-002-002.


Gear Cover, Front (001-031) Section 1 — Cylinder Block — Group 01
Page 1-68 QSK19 - PRELIMINARY

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.


Section 1 — Cylinder Block — Group 01 Gear Cover, Front (001-031)
QSK19 - PRELIMINARY Page 1-69

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.
Gear Cover, Front (001-031) Section 1 — Cylinder Block — Group 01
Page 1-70 QSK19 - PRELIMINARY

Remove the accessory drive pulley. Refer to Procedure


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


to Procedure No. 009-004-002.
Section 1 — Cylinder Block — Group 01 Gear Cover, Front (001-031)
QSK19 - PRELIMINARY Page 1-71

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.
Gear Cover, Front (001-031) Section 1 — Cylinder Block — Group 01
Page 1-72 QSK19 - PRELIMINARY

Inspect for Reuse (001-031-007)


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
Section 1 — Cylinder Block — Group 01 Gear Cover, Front (001-031)
QSK19 - PRELIMINARY Page 1-73

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.
Gear Cover, Front (001-031) Section 1 — Cylinder Block — Group 01
Page 1-74 QSK19 - PRELIMINARY

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.
Torque Value: 45 N•m [35 ft-lb]
Section 1 — Cylinder Block — Group 01 Gear Cover, Front (001-031)
QSK19 - PRELIMINARY Page 1-75

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.
Torque Value: 45 N•m [35 ft-lb]

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.
Gear Cover, Front (001-031) Section 1 — Cylinder Block — Group 01
Page 1-76 QSK19 - PRELIMINARY

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.
Section 1 — Cylinder Block — Group 01 Gear Cover, Front (001-031)
QSK19 - PRELIMINARY Page 1-77

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.
Gear Cover, Front (001-031) Section 1 — Cylinder Block — Group 01
Page 1-78 QSK19 - PRELIMINARY

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.


Section 1 — Cylinder Block — Group 01 Gear Cover, Front (001-031)
QSK19 - PRELIMINARY Page 1-79

Install the fan belt. Refer to Procedure No. 008-002-026.

Install the fan spacer(s) and fan. Tighten the capscrews.


Torque Value: 135 N•m [100 ft-lb]

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
Page 1-80 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-81

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.
Use LubriplateW No. 105, or equivalent. Lubricate the
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
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.
Hydraulic Pump Idler Gear (001-039) Section 1 — Cylinder Block — Group 01
Page 1-82 QSK19 - PRELIMINARY

Install the front gear cover. Refer to Procedure No.


001-031-026.

Hydraulic Pump Idler Gear (001-039)


Remove (001-039-002)
Remove the front gear cover. Refer to Procedure No.
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)
QSK19 - PRELIMINARY Page 1-83

Caution: The grooves in the thrust washers must be


turned toward the gear.
Use LubriplateW No. 105, or equivalent. Lubricate the
gear bushing, shaft, and the thrust washer.
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.
Torque Value (Capscrew): 245 N•m [180 ft-lb]

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.
Torque Value (Capscrew): 65 N•m [50 ft-lb]

Use a dial indicator and measure the idler gear end clear-
ance.

Hydraulic Pump 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.
Water Pump Idler Gear (001-040) Section 1 — Cylinder Block — Group 01
Page 1-84 QSK19 - PRELIMINARY

Install the front gear cover. Refer to Procedure No.


001-031-026.

Water Pump Idler Gear (001-040)


Remove (001-040-002)
Remove the front gear cover. Refer to Procedure No.
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)
Caution: The grooves in the thrust washers must be
turned toward the gear.
Use LubriplateW No. 105, or equivalent. Lubricate the
gear bushing, shaft, and the thrust washer.
Use engine oil. Lubricate the capscrew. Assemble the
parts as shown.
Section 1 — Cylinder Block — Group 01 Piston (001-043)
QSK19 - PRELIMINARY Page 1-85

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.
Torque Value: 245 N•m [180 ft-lb]

Use a dial indicator and measure the idler gear end clear-
ance.

Water Pump — 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 washers are available.

Install the front gear cover. Refer to Procedure No.


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
Page 1-86 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-87

Inspect for Reuse (001-043-007)


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
Page 1-88 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-89

Remove the air compressor. Refer to Procedure No. 012-


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


to Procedure No. 005-053-002.

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.
Piston Cooling Nozzles (001-046) Section 1 — Cylinder Block — Group 01
Page 1-90 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 1-91

Clean (001-046-006)
Use solvent to clean the piston cooling nozzles. Dry with
compressed air.
Blow out the oil passages with compressed air.

Inspect for Reuse (001-046-007)


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.
Piston Cooling Nozzles (001-046) Section 1 — Cylinder Block — Group 01
Page 1-92 QSK19 - PRELIMINARY

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.
Torque Value: 45 N•m [35 ft-lb]

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.

Install the air compressor. Refer to Procedure No. 012-


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)
QSK19 - PRELIMINARY Page 1-93

Install the electronic fuel control valve assembly. Refer to


Procedure No. 005-053-026.

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
Page 1-94 QSK19 - PRELIMINARY

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)
Remove the fan belt. Refer to Procedure 008-002-002.

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)
QSK19 - PRELIMINARY Page 1-95

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
Page 1-96 QSK19 - PRELIMINARY

Caution: Wear protective clothing to prevent personal


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.

Caution: Wear protective clothing to prevent personal


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.
Torque Value: 140 N•m [105 ft-lb]

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)
QSK19 - PRELIMINARY Page 1-97

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
Page 1-98 QSK19 - PRELIMINARY

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.
Refer to Procedure 007-025-002.

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)
QSK19 - PRELIMINARY Page 1-99

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.
Piston and Connecting Rod Assembly (001-054) Section 1 — Cylinder Block — Group 01
Page 1-100 QSK19 - PRELIMINARY

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
bearing position in the tang area.
NOTE: Mark the bearing for future identification or for pos-
sible failure analysis.
Section 1 — Cylinder Block — Group 01 Piston and Connecting Rod Assembly (001-054)
QSK19 - PRELIMINARY Page 1-101

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.
Piston and Connecting Rod Assembly (001-054) Section 1 — Cylinder Block — Group 01
Page 1-102 QSK19 - PRELIMINARY

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.
Section 1 — Cylinder Block — Group 01 Piston and Connecting Rod Assembly (001-054)
QSK19 - PRELIMINARY Page 1-103

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.
Piston and Connecting Rod Assembly (001-054) Section 1 — Cylinder Block — Group 01
Page 1-104 QSK19 - PRELIMINARY

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.


Section 1 — Cylinder Block — Group 01 Piston and Connecting Rod Assembly (001-054)
QSK19 - PRELIMINARY Page 1-105

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.

Caution: The cylinder number on the rod and cap must


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.
Piston and Connecting Rod Assembly (001-054) Section 1 — Cylinder Block — Group 01
Page 1-106 QSK19 - PRELIMINARY

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 5 100
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.
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: 60 N•m [25 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 capscrews.
Torque Value: 35 N•m [25-lb]
Section 1 — Cylinder Block — Group 01 Piston and Connecting Rod Assembly (001-054)
QSK19 - PRELIMINARY Page 1-107

Install the oil sump and related components. Refer to


Procedure 007-025-026.

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
Page 1-108 QSK19 - PRELIMINARY

Fill the engine with clean 15W-40 oil. Refer to Procedure


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
Procedure No. 001-031-002.
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)
QSK19 - PRELIMINARY Page 1-109

Camshaft Thrust Bearing (001-056)


Inspect for Reuse (001-056-007)
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
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 seper-
ate 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 sides against each other.
Section 2 — Cylinder Head — Group 02
QSK19 - PRELIMINARY Page 2-1

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
Page 2-2 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 2-3

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)
QSK19 - PRELIMINARY Page 2-5

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
Page 2-6 QSK19 - PRELIMINARY

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.
Section 2 — Cylinder Head — Group 02 Cylinder Head (002-004)
QSK19 - PRELIMINARY Page 2-7

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


Procedure No. 008-015-002.

Remove the gear cover clamping plate.


Cylinder Head (002-004) Section 2 — Cylinder Head — Group 02
Page 2-8 QSK19 - PRELIMINARY

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.
Section 2 — Cylinder Head — Group 02 Cylinder Head (002-004)
QSK19 - PRELIMINARY Page 2-9

Inspect for Reuse (002-004-007)


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.
Cylinder Head (002-004) Section 2 — Cylinder Head — Group 02
Page 2-10 QSK19 - PRELIMINARY

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.
Section 2 — Cylinder Head — Group 02 Cylinder Head (002-004)
QSK19 - PRELIMINARY Page 2-11

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.
Cylinder Head (002-004) Section 2 — Cylinder Head — Group 02
Page 2-12 QSK19 - PRELIMINARY

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.
Section 2 — Cylinder Head — Group 02 Cylinder Head (002-004)
QSK19 - PRELIMINARY Page 2-13

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.
Cylinder Head (002-004) Section 2 — Cylinder Head — Group 02
Page 2-14 QSK19 - PRELIMINARY

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.
Tighten the capscrews.
Torque Value: 45 N•m [35 ft-lb]
Refer to Procedure No. 003-011-026.

Install the gear cover clamping plate. Tighten the


capscrews.
Torque Value: 45 N•m [35 ft-lb]

Install the coolant thermostat housing support. Refer to


Procedure No. 008-015-026.
Section 2 — Cylinder Head — Group 02 Cylinder Head (002-004)
QSK19 - PRELIMINARY Page 2-15

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
Page 2-16 QSK19 - PRELIMINARY

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-
sonal injury can result.
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)
QSK19 - PRELIMINARY Page 2-17

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-
sonal injury can result.
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
Page 2-18 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 2-19

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
Page 2-20 QSK19 - PRELIMINARY

NOTES
Section 3 — Rocker Lever — Group 03
QSK19 - PRELIMINARY Page 3-1

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
Inspect for Reuse (003-009-007)..................................................................................................................... 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
Inspect for Reuse (003-013-007) .................................................................................................................... 3-15
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
Page 3-2 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 3-3

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)
QSK19 - PRELIMINARY Page 3-5

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
Page 3-6 QSK19 - PRELIMINARY

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.
Section 3 — Rocker Lever — Group 03 Overhead Set (Outer Base Circle)
QSK19 - PRELIMINARY Page 3-7

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.
Torque Value: 1 N•m [6 in-lb]

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:
— Torque Value: 60 N•m [45 ft-lb]
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
Page 3-8 QSK19 - PRELIMINARY

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.
Torque Value: 20 N•m [175 in-lb]
Loosen the adjusting screw at least 1 revolution.
Tighten the adjusting screw again.
Torque Value: 19 N•m [165 in-lb]
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:
— Torque Value: 45 N•m [35 ft-lb]
• Without Adapter:
— Torque Value: 60 N•m [45 ft-lb]
Section 3 — Rocker Lever — Group 03 Overhead Set (Outer Base Circle)
QSK19 - PRELIMINARY Page 3-9

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
Page 3-10 QSK19 - PRELIMINARY

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.

Inspect for Reuse (003-009-007)


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)
QSK19 - PRELIMINARY Page 3-11

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.
Tighten the capscrews.
Torque Value: 225 N•m [165 ft-lb]
Rocker Lever Cover (003-011) Section 3 — Rocker Lever — Group 03
Page 3-12 QSK19 - PRELIMINARY

Adjust the valves and injectors. Refer to Procedure No.


003-006-029.

Install the rocker lever covers and related parts. Refer to


Procedure No. 003-011-026.

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)
QSK19 - PRELIMINARY Page 3-13

Inspect for Reuse (003-011-007)


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.
Torque Value: 45 N•m [35 ft-lb]

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 (Capscrew): 45 N•m [35 ft-lb]
Torque Value (Clamp): 8 N•m [75 in-lb]
Rocker Lever Housing (003-013) Section 3 — Rocker Lever — Group 03
Page 3-14 QSK19 - PRELIMINARY

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.
Refer to Procedure No. 008-018-005.

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)
QSK19 - PRELIMINARY Page 3-15

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.

Inspect for Reuse (003-013-007)


Remove the parts:
1. Water transfer tube
2. O-rings
Discard the o-rings.
Use steam or solvent. Clean the parts.
Rocker Lever Housing (003-013) Section 3 — Rocker Lever — Group 03
Page 3-16 QSK19 - PRELIMINARY

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.
Torque Value: 8 N•m [70 ft-lb]

Use the sequence shown to tighten the capscrews.


Torque Value: 95 N•m [70 ft-lb]
Section 3 — Rocker Lever — Group 03 Rocker Lever Housing (003-013)
QSK19 - PRELIMINARY Page 3-17

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.

Install the rocker levers. Refer to Procedure No.


003-009-026.

Install each gasket, rocker lever cover, and capscrews.


Torque Value: 45 N•m [35 ft-lb]

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.
Rocker Lever Housing (003-013) Section 3 — Rocker Lever — Group 03
Page 3-18 QSK19 - PRELIMINARY

Fill the cooling system. Refer to Procedure No. 008-018-


028.
Operate the engine to 70°C [160°F] minimum coolant
temperature and check for leaks.
Section 4 — Cam Follower — Group 04
QSK19 - PRELIMINARY Page 4-1

Section 4 — Cam Follower — Group 04


Section Contents
Page
Cam Follower - Specifications (018-001-201) .................................................................................................... 4-2
Cam Follower Assembly (004-001) .................................................................................................................... 4-3
Inspect for Reuse (004-001-007) ...................................................................................................................... 4-4
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
Inspect for Reuse (004-014-007) ...................................................................................................................... 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
Page 4-2 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 4-3

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
Page 4-4 QSK19 - PRELIMINARY

Cam Follower Assembly (004-001)


Remove (004-001-002)
Remove the rocker lever cover. Refer to Procedure No.
003-011-002.

Remove the rocker levers. Refer to Procedure No.


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)
QSK19 - PRELIMINARY Page 4-5

Remove the cam follower assembly. Pull straight out until


the shaft is off the ring dowels.

Inspect for Reuse (004-001-007)


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
Page 4-6 QSK19 - PRELIMINARY

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.
Torque Value: 25 N•m [20 ft-lb]
Section 4 — Cam Follower — Group 04 Cam Follower Assembly (004-001)
QSK19 - PRELIMINARY Page 4-7

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.

Install the rocker levers. Refer to Procedure No.


003-009-026.

Adjust the overhead (OBC). Refer to Procedure No.


003-006-029.

Install the rocker lever cover and all related parts. Refer
to Procedure No. 008-011-026.
Push Rods (004-014) Section 4 — Cam Follower — Group 04
Page 4-8 QSK19 - PRELIMINARY

Push Rods (004-014)


Remove (004-014-002)
Remove the rocker lever cover. Refer to Procedure No.
003-011-002.

Remove the rocker levers. Refer to Procedure No.


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.

Inspect for Reuse (004-014-007)


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)
QSK19 - PRELIMINARY Page 4-9

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)
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.

Install the rocker levers. Refer to Procedure No.


003-009-026.

Adjust the overhead (OBC). Refer to Procedure No.


003-006-029.
Push Rods (004-014) Section 4 — Cam Follower — Group 04
Page 4-10 QSK19 - PRELIMINARY

Install the rocker lever covers and all related parts. Refer
to Procedure No. 003-009-026.
Section 5 — Fuel System — Group 05
QSK19 - PRELIMINARY Page 5-1

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
Inspect for Reuse (005-016-007) .................................................................................................................... 5-12
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
Inspect for Reuse (005-043-007) .................................................................................................................... 5-17
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
Page 5-2 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 5-3

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
Page 5-4 QSK19 - PRELIMINARY

Fuel System Flow Diagrams (200-001-202)


Section 5 — Fuel System — Group 05 Fuel System — Service Tools (022-001-505)
QSK19 - PRELIMINARY Page 5-5

Fuel System — Service Tools (022-001-505)

The following special tools are recommended to perform procedures in Section 05. 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


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
Page 5-6 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 5-7

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
Page 5-8 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 5-9

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
Page 5-10 QSK19 - PRELIMINARY

Fuel Consumption (005-010)


Initial Check (005-010-001)
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)
QSK19 - PRELIMINARY Page 5-11

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
Page 5-12 QSK19 - PRELIMINARY

Inspect for Reuse (005-016-007)


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.

Pressure Test (005-016-013)


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]
Section 5 — Fuel System — Group 05 Fuel Pump (005-016)
QSK19 - PRELIMINARY Page 5-13

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
Page 5-14 QSK19 - PRELIMINARY

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.
Torque Value: 45 N•m [35 ft-lb]

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).
Torque Value: 88 N•m [65 ft-lb]
Tighten the hose (2).
Torque Value: 61 N•m [45 ft-lb]

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.
Section 5 — Fuel System — Group 05 Fuel Pump (005-016)
QSK19 - PRELIMINARY Page 5-15

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.

Warning: Fuel is flammable. Do not allow cigarettes,


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
Page 5-16 QSK19 - PRELIMINARY

Install the fuel inlet hose to the gear pump.


Torque Value: 88 N•m [65 ft-lb]

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)
QSK19 - PRELIMINARY Page 5-17

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.

Inspect for Reuse (005-043-007)


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
Page 5-18 QSK19 - PRELIMINARY

Tighten the nut that holds the electrical connection post


on the fuel shutoff valve coil.
Torque Value: 3 N•m [25 in-lb]

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.
Torque Value: 8 N•m [72 in-lb]

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.
Torque Value: 2 N•m [15 in-lb]
Section 5 — Fuel System — Group 05 Electronic Fuel Control Valve Assembly (005-053)
QSK19 - PRELIMINARY Page 5-19

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
Page 5-20 QSK19 - PRELIMINARY

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.
Section 5 — Fuel System — Group 05 Electronic Fuel Control Valve Assembly (005-053)
QSK19 - PRELIMINARY Page 5-21

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.
Torque Value: 45 N•m [35 ft-lb]

Tighten the nut that holds the electrical connection post


on the fuel shutoff valve coil.
Torque Value: 3 N•m [25 in-lb]

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.
Torque Value: 2 N•m [15 in-lb]
Electronic Fuel Control Valve Assembly (005-053) Section 5 — Fuel System — Group 05
Page 5-22 QSK19 - PRELIMINARY

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).
Torque Value: 61 N•m [45 ft-lb]
Tighten the timing pressure (2) and rail pressure lines (3).
Torque Value: 27 N•m [20 ft-lb]

Install the ECM. Refer to Procedure No. 019-031-026.


Section 5 — Fuel System — Group 05 Electronic Fuel Control Valve Assembly (005-053)
QSK19 - PRELIMINARY Page 5-23

Install the crankcase vent hose. Tighten the hose clamps.


Torque Value: 4 N•m [35 in-lb]
Electronic Fuel Control Valve Assembly (005-053) Section 5 — Fuel System — Group 05
Page 5-24 QSK19 - PRELIMINARY

NOTES
Section 6 — Injectors and Fuel Lines — Group 06
QSK19 - PRELIMINARY Page 6-1

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
Inspect for Reuse (006-013-007) .................................................................................................................... 6-13
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
Inspect for Reuse (006-022-007) .................................................................................................................... 6-17
Install (006-022-026) ...................................................................................................................................... 6-19
Remove (006-022-002)................................................................................................................................... 6-16
Fuel Supply Lines (006-024) ............................................................................................................................ 6-21
Inspect for Reuse (006-024-007) .................................................................................................................... 6-22
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
Inspect for Reuse (006-026-007) .................................................................................................................... 6-27
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)


General Information (006-999-999)
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

Warning: Fuel is flammable. Do not allow cigarettes,


flames, sparks, arcing switches or equipment, pilot lights,
or other ignition sources near the fuel system.
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)
General Information (006-003-999)
Warning: Fuel is flammable. Do not allow cigarettes,
flames, sparks, arcing switches or equipment, pilot lights
or other ignition sources near the fuel system.
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.
Torque Value: 88 N•m [65 ft-lb]
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.
Torque Value: 75 N•m [55 ft-lb]

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.

Inspect for Reuse (006-013-007)


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.
Torque Value: 75 N•m [55 ft-lb]

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.
Torque Value: 47 N•m [35 ft-lb]

Fuel Filter (006-015)


Remove (006-015-002)
Warning: Fuel is flammable. Do not allow cigarettes,
flames, sparks, arcing switches or equipment, pilot lights,
or other ignition sources near the fuel system.
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
Procedure No. 019-043-002.

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.

Inspect for Reuse (006-022-007)


Remove the four fuel connection block capscrews. Re-
move the fuel connection block. Discard the o-rings.
Fuel Manifold (006-022) Section 6 — Injectors and Fuel Lines — Group 06
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.
Torque Value: 10.2 N•m [90 in-lb]

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.
Torque Value: 9.6 N•m [85 in-lb]
Repeat this process for the installation of the rear fuel
manifold.

Install the aftercooler assembly. Refer to Procedure No.


010-002-026.
Fuel Manifold (006-022) Section 6 — Injectors and Fuel Lines — Group 06
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


Procedure No. 019-043-026.
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
Procedure No. 019-043-002.

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.

Inspect for Reuse (006-024-007)


Fuel Tank-To-Fuel Filter
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 Rail Supply Line


Fuel Timing and Supply Line
Use compressed air. Flush the lines and remove any
loose dirt particles.
Section 6 — Injectors and Fuel Lines — Group 06 Fuel Supply Lines (006-024)
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


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 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)
Fuel Tank-To-Fuel Filter
Install and tighten the fuel inlet line.
Torque Value: 115 N•m [85 ft-lb]

Fuel Rail Supply 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.
Torque Value: 27 N•m [20 ft-lb]

Tighten the fuel tube clamps.


Torque Value: 27 N•m [20 ft-lb]
Section 6 — Injectors and Fuel Lines — Group 06 Fuel Supply Lines (006-024)
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]
Torque Value (Clamp): 6 N•m [50 in-lb]

Install the engine harness and the brackets. Refer to


Procedure No. 019-043-026.

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.


Torque Value: 61 N•m [45 ft-lb]
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.
Torque Value: 88 N•m [65 ft-lb]

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)
Remove the rocker lever cover. Refer to Procedure No.
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.

Inspect for Reuse (006-026-007)


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.
Injectors (006-026) Section 6 — Injectors and Fuel Lines — Group 06
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.
Section 6 — Injectors and Fuel Lines — Group 06 Injectors (006-026)
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.
Injectors (006-026) Section 6 — Injectors and Fuel Lines — Group 06
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.
Torque Value: 54 N•m [40 ft-lb]

Install the rocker lever assembly. Refer to Procedure No.


003-009-026.
Section 6 — Injectors and Fuel Lines — Group 06 Injectors (006-026)
QSK19 Page 6-31

Adjust the valves and injectors. Refer to Procedure No.


003-006-029.

Install the rocker lever cover. Refer to Procedure No.


003-011-026.
Injectors (006-026) Section 6 — Injectors and Fuel Lines — Group 06
Page 6-32 QSK19

NOTES
Section 7 — Lubricating Oil System — Group 07
QSK19 - PRELIMINARY Page 7-1

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
General Information (007-044-999) ................................................................................................................. 7-38
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
Inspect for Reuse (007-045-007)..................................................................................................................... 7-42
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
Inspect for Reuse (007-046-007)..................................................................................................................... 7-46
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
Inspect for Reuse (007-015-007)..................................................................................................................... 7-16
Install (007-015-026)....................................................................................................................................... 7-17
Remove (007-015-002) ................................................................................................................................... 7-16
Lubricating Oil Filter Head Adapter (007-018) ................................................................................................. 7-17
Inspect for Reuse (007-018-007)..................................................................................................................... 7-18
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
Inspect for Reuse (007-025-007)..................................................................................................................... 7-21
Install (007-025-026)....................................................................................................................................... 7-22
Remove (007-025-002) ................................................................................................................................... 7-21
Lubricating Oil Pan Adapter (007-026)............................................................................................................. 7-24
Inspect for Reuse (007-026-007)..................................................................................................................... 7-26
Install (007-026-026)....................................................................................................................................... 7-26
Remove (007-026-002) ................................................................................................................................... 7-24
Section 7 — Lubricating Oil System — Group 07
Page 7-2 QSK19 - PRELIMINARY

Page
Lubricating Oil Pan Adapter Cover Plate (007-027) ......................................................................................... 7-30
Inspect for Reuse (007-027-007)..................................................................................................................... 7-31
Install (007-027-026)....................................................................................................................................... 7-31
Remove (007-027-002) ................................................................................................................................... 7-30
Lubricating Oil Pressure Gauge (007-028)....................................................................................................... 7-32
Inspect for Reuse (007-028-007)..................................................................................................................... 7-32
Lubricating Oil Pressure Regulator (Main Rifle) (007-029).............................................................................. 7-32
Inspect for Reuse (007-029-007)..................................................................................................................... 7-33
Install (007-029-026)....................................................................................................................................... 7-34
Remove (007-029-002) ................................................................................................................................... 7-32
Lubricating Oil Pump (007-031) ....................................................................................................................... 7-34
Inspect for Reuse (007-031-007)..................................................................................................................... 7-35
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
Inspect for Reuse (007-038-007)..................................................................................................................... 7-37
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil System - General Information (007-999-999)
QSK19 - PRELIMINARY Page 7-3

Lubricating Oil System - General


Information (007-999-999)
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 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
Page 7-4 QSK19 - PRELIMINARY

Lubricating Oil System - Flow Diagrams (200-002-047)


Section 7 — Lubricating Oil System — Group 07 Lubricating Oil System - Flow Diagrams (200-002-047)
QSK19 - PRELIMINARY Page 7-5

Lubricating Oil System - Flow Diagrams


Lubricating Oil System - Flow Diagrams (200-002-047) Section 7 — Lubricating Oil System — Group 07
Page 7-6 QSK19 - PRELIMINARY

Lubricating Oil System - Flow Diagrams


Section 7 — Lubricating Oil System — Group 07 Lubricating Oil System - Specifications (018-001-203)
QSK19 - PRELIMINARY Page 7-7

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
Page 7-8 QSK19 - PRELIMINARY

Lubricating Oil System - Tool Requirements (022-001-507)

The following special tools are recommended to perform procedures in Section 0. 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


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)
QSK19 - PRELIMINARY Page 7-9

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
Page 7-10 QSK19 - PRELIMINARY

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.

Pressure Test (007-007-013)


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.
Air Pressure: 415 kPa [60 psi]
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)
QSK19 - PRELIMINARY Page 7-11

Install (007-007-026)
NOTE: Remove the plastic shipping plugs from the new oil
cooler elements.
Install the gaskets, oil cooler elements, and capscrews.
Tighten the capscrews.
Torque Value: 45 N•m [35 ft-lb]
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
Page 7-12 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 7-13

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)
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.
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
Page 7-14 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 7-15

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.
Minimum Gauge Capacity: 517 kPa [75 psi]

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
Page 7-16 QSK19 - PRELIMINARY

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)
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 follow the proper pro-
cedures to dispose the used oil.
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 failure
analysis.

Remove the six capscrews and the filter head assembly.


Remove and discard the gasket.

Inspect for Reuse (007-015-007)


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)
QSK19 - PRELIMINARY Page 7-17

Install (007-015-026)
Install the gasket, filter head and six capscrews. Tighten
the capscrews.
Torque Value: 45 N•m [35 ft-lb]

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.
Operate the engine to normal operating temperature and
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.
Use an oil filter wrench, Part No. 3375049, or equivalent.
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
Page 7-18 QSK19 - PRELIMINARY

Remove the four capscrews. Remove the filter head


adapter. Remove and discard the o-rings.

Inspect for Reuse (007-018-007)


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.
Tighten the capscrews.
Torque Value: 23 N•m [17 ft-lb]

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)
QSK19 - PRELIMINARY Page 7-19

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
Page 7-20 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 7-21

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].
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.
Remove the oil drain plug from the bottom of the oil sump.
Drain the oil. Tighten the drain plug.
Torque Value: 100 N•m [75 ft-lb]

Remove the 28 capscrews. Remove the oil pan. Remove


and discard the gasket.

Inspect for Reuse (007-025-007)


Use solvent that will not harm aluminum. Clean the oil
pan.
Visually inspect for cracks or other damage.
Lubricating Oil Pan (007-025) Section 7 — Lubricating Oil System — Group 07
Page 7-22 QSK19 - PRELIMINARY

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.
Torque Value: 45 N•m [35 ft-lb]

Install new oil filter elements. 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 the oil capacity of the engine.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pan (007-025)
QSK19 - PRELIMINARY Page 7-23

Fill (007-025-028)
Install the oil drain plug and tighten the plug.
Torque Value: 100 N•m [75 ft-lb]
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.

Operate the engine to normal operating temperature and


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
Page 7-24 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 7-25

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.

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 failure
analysis.

Remove the two [7/16-14 inch] capscrews, and the five


[3/8-16 inch] capscrews from the flywheel housing.
Lubricating Oil Pan Adapter (007-026) Section 7 — Lubricating Oil System — Group 07
Page 7-26 QSK19 - PRELIMINARY

Caution: The component weighs 23 kg [50 lb] or more.


To avoid personal injury, use a hoist or get assistance to
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.

Inspect for Reuse (007-026-007)


Use a solvent that will not harm aluminum. Clean the
parts.
Visually inspect for cracks or other damage.

Install (007-026-026)
NOTE: Use a contact adhesive such as 3M Spray 77 or 3M
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.

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 gasket. Make sure the gasket touches the rect-
angular seals.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pan Adapter (007-026)
QSK19 - PRELIMINARY Page 7-27

Use Cummins sealant, Part No. 3377132, or equivalent.


Apply the sealant as shown.

Caution: The component weighs 23 kg [50 lb] or more.


To avoid personal injury, use a hoist or get assistance to
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.
Torque Value: Step 1 - 15 N•m [10 ft-lb]
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.
Torque Value: Step 1 - 25 N•m [20 ft-lb]
2 - 40 N•m [30 ft-lb]
3 - 45 N•m [35 ft-lb]
Lubricating Oil Pan Adapter (007-026) Section 7 — Lubricating Oil System — Group 07
Page 7-28 QSK19 - PRELIMINARY

NOTE: Capscrews No. 24 through 28 thread into the front


cover on engines.
Torque Value: 45 N•m [35 ft-lb]
Install the remaining [3/8-inch] washers and capscrews.
Tighten the capscrews.
Torque Value: 35 N•m [45 ft-lb]

Install the two [7/16-inch] washers and capscrews shown.


Tighten the capscrews.
Torque Value: 65 N•m [50 ft-lb]

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


capscrew.
Torque Value: 150 N•m [110 ft-lb]

Install the front engine support. Refer to Procedure No.


016-002-026.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pan Adapter (007-026)
QSK19 - PRELIMINARY Page 7-29

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.
Torque Value: 95 N•m [70 ft-lb]

Connect the breather vent hose to the hand hole cover.


Tighten the hose clamps.
Torque Value: 6 N•m [50 in-lb]

Install the gasket, oil pan suction tube, and capscrews.


Tighten the two suction tube connector capscrews.
Torque Value: 60 N•m [45 ft-lb]
Tighten the clamp capscrew.
Torque Value: 35 N•m [25 ft-lb]
Lubricating Oil Pan Adapter Cover Plate (007-027) Section 7 — Lubricating Oil System — Group 07
Page 7-30 QSK19 - PRELIMINARY

Install the oil pan, Procedure No. 007-025-026, and the oil
pan adapter cover, Procedure No. 007-027-026.

Install new oil filter elements. Refer to Procedure No.


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

Fill the engine with clean, 15W-40 oil. Refer to Procedure


No. 007-027-028.
Operate the engine to normal operating temperature and
check for leaks.

Lubricating Oil Pan Adapter Cover


Plate (007-027)
Remove (007-027-002)
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. Refer to Procedure No.
007-025-005.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pan Adapter Cover Plate (007-027)
QSK19 - PRELIMINARY Page 7-31

Remove the 18 capscrews. Remove the cover plate. Re-


move and discard the gasket.

Inspect for Reuse (007-027-007)


Use solvent that will not harm aluminum. Clean the parts.
Visually inspect for cracks or other damage.

Install (007-027-026)
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 gasket and oil pan adapter cover.

Use the sequence shown to tighten the capscrews.


Torque Value: 45 N•m [35 ft-lb]
Lubricating Oil Pressure Gauge (007-028) Section 7 — Lubricating Oil System — Group 07
Page 7-32 QSK19 - PRELIMINARY

Install new oil filter elements. Refer to Procedure No.


007-012-026.
Fill the engine with clean 15W-40 oil. Refer to Procedure
No. 007-025-028.

Lubricating Oil Pressure Gauge


(007-028)
Inspect for Reuse (007-028-007)
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).
Minimum Gauge Capacity: 830 kPa [120 psi]
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)
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.
NOTE: The oil pump does not need to be removed.
Drain the lubricating oil. Refer to Procedure No.
007-037-005.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pressure Regulator (Main Rifle) (007-029)
QSK19 - PRELIMINARY Page 7-33

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.

Inspect for Reuse (007-029-007)


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
Page 7-34 QSK19 - PRELIMINARY

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.

Install new oil filter elements. Refer to Procedure No.


007-012-026.
Fill the engine with clean, 15W-40 oil. Refer to Procedure
No. 007-025-028.

Lubricating Oil Pump (007-031)


Remove (007-031-002)
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. Refer to Procedure No.
007-037-005.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pump (007-031)
QSK19 - PRELIMINARY Page 7-35

Remove the front gear cover. Refer to Procedure No.


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.

Inspect for Reuse (007-031-007)


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.
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
Page 7-36 QSK19 - PRELIMINARY

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.
Torque Value: 45 N•m [35 ft-lb]

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)
QSK19 - PRELIMINARY Page 7-37

Install the front cover and remaining components. Refer


to Procedure No. 001-003-026.

Lubricating Oil Temperature Gauge


(007-038)
Inspect for Reuse (007-038-007)
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 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
Page 7-38 QSK19 - PRELIMINARY

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.

Fill the engine with oil. Refer to Procedure No. 007-025-


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

Lubricating Oil Contamination


(007-044)
General Information (007-044-999)
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)
QSK19 - PRELIMINARY Page 7-39

Pressure Test (007-044-013)


Oil Diluted with Coolant
Refer to Procedure No. 008-018-013.

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
Page 7-40 QSK19 - PRELIMINARY

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
to Procedure No. 006-026-002.

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)
QSK19 - PRELIMINARY Page 7-41

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
Page 7-42 QSK19 - PRELIMINARY

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.

Inspect for Reuse (007-045-007)


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)
QSK19 - PRELIMINARY Page 7-43

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.
Torque Value: 45 N•m [35 ft-lb]

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.
Torque Value: 45 N•m [35 ft-lb]
Lubricating Oil Cooler Cover (007-045) Section 7 — Lubricating Oil System — Group 07
Page 7-44 QSK19 - PRELIMINARY

Connect the aftercooler supply hose to the water pump


outlet connection. Tighten the clamps.
Torque Value: 6 N•m [50 in-lb]

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.
Torque Value: 95 N•m [70 ft-lb]
Connect the coolant supply hose to the turbocharger.

Fill the cooling system. Refer to Procedure No. 008-018-


028.
Operate the engine to normal operating temperature and
check for leaks.
Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Cooler Housing (007-046)
QSK19 - PRELIMINARY Page 7-45

Lubricating Oil Cooler Housing


(007-046)
Remove (007-046-002)
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.
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
Page 7-46 QSK19 - PRELIMINARY

Inspect for Reuse (007-046-007)


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)
QSK19 - PRELIMINARY Page 7-47

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)
Fluorescent Dye Tracer (007-050-054)
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
Page 7-48 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 7-49

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
Page 7-50 QSK19 - PRELIMINARY

NOTES
Section 8 — Cooling System — Group 08
QSK19 - PRELIMINARY Page 8-1

Section 8 — Cooling System — Group 08


Section Contents
Page
Belt, Cooling Fan Drive (008-002).................................................................................................................... 8-15
Adjust (008-002-029)...................................................................................................................................... 8-16
Inspect for Reuse (008-002-007) .................................................................................................................... 8-15
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
Inspect for Reuse (008-013-007) .................................................................................................................... 8-21
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
General Information (008-017-999) ................................................................................................................. 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
Inspect for Reuse (008-029-007) .................................................................................................................... 8-53
Install (008-029-026) ...................................................................................................................................... 8-54
Remove (008-029-002)................................................................................................................................... 8-52
Section 8 — Cooling System — Group 08
Page 8-2 QSK19 - PRELIMINARY

Page
Fan Hub, Belt Driven (008-036)........................................................................................................................ 8-54
Inspect for Reuse (008-036-007) .................................................................................................................... 8-55
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
Inspect for Reuse (008-045-007) .................................................................................................................... 8-62
Install (008-045-026) ...................................................................................................................................... 8-62
Remove (008-045-002)................................................................................................................................... 8-62
Radiator Hose, Upper (008-046) ...................................................................................................................... 8-63
Inspect for Reuse (008-046-007) .................................................................................................................... 8-64
Install (008-046-026) ...................................................................................................................................... 8-64
Remove (008-046-002)................................................................................................................................... 8-63
Radiator Pressure Cap (008-047)..................................................................................................................... 8-66
Inspect for Reuse (008-047-007) .................................................................................................................... 8-66
Pressure Test (008-047-013)........................................................................................................................... 8-66
Radiator Shroud (008-048)............................................................................................................................... 8-66
Inspect for Reuse (008-048-007) .................................................................................................................... 8-66
Radiator Top Tank (008-051) ............................................................................................................................ 8-66
Leak Test (008-051-014) ................................................................................................................................. 8-66
Supplemental Coolant Additive (SCA) (008-060)............................................................................................. 8-67
Inspect for Reuse (008-060-007) .................................................................................................................... 8-67
Torque Converter Cooler (008-065) ................................................................................................................. 8-74
Inspect for Reuse (008-065-007) .................................................................................................................... 8-76
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)
QSK19 - PRELIMINARY Page 8-3

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
Page 8-4 QSK19 - PRELIMINARY

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.
Section 8 — Cooling System — Group 08 Cooling System — General Information (008-999-999)
QSK19 - PRELIMINARY Page 8-5

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
Page 8-6 QSK19 - PRELIMINARY

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
Section 8 — Cooling System — Group 08 Cooling System — General Information (008-999-999)
QSK19 - PRELIMINARY Page 8-7

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
Page 8-8 QSK19 - PRELIMINARY

Cooling System — Flow Diagrams (200-003-204)


Section 8 — Cooling System — Group 08 Cooling System — Flow Diagrams (200-003-204)
QSK19 - PRELIMINARY Page 8-9

Cooling System — Flow Diagrams (200-003-204)


Jacket Water-Aftercooled
Cooling System — Flow Diagrams (200-003-204) Section 8 — Cooling System — Group 08
Page 8-10 QSK19 - PRELIMINARY

Cooling System — Flow Diagrams (200-003-204)


LTA
Section 8 — Cooling System — Group 08 Cooling System — Flow Diagrams (200-003-204)
QSK19 - PRELIMINARY Page 8-11

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
Page 8-12 QSK19 - PRELIMINARY

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
Page 8-14 QSK19 - PRELIMINARY

Tool No. Tool Description Tool Illustration


Digital Optical Tachometer
Used to measure RPM of a viscous fan.
3377462
Section 8 — Cooling System — Group 08 Belt, Cooling Fan Drive (008-002)
QSK19 - PRELIMINARY Page 8-15

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 for Reuse (008-002-007)


Inspect the belt for:
• Cracks
• Glazing
• Tears or cuts
Belt, Cooling Fan Drive (008-002) Section 8 — Cooling System — Group 08
Page 8-16 QSK19 - PRELIMINARY

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).
Torque Value: 81 N•m [60 ft-lb]

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)
QSK19 - PRELIMINARY Page 8-17

Coolant Temperature Gauge (008-004)


Initial Check (008-004-008)
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
Page 8-18 QSK19 - PRELIMINARY

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
Drain the cooling system. Refer to Procedure No.
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)
QSK19 - PRELIMINARY Page 8-19

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


Procedure No. 008-016-002.

LTA
Drain the cooling system. Refer to Procedure No.
008-018-005).
Coolant Thermostat (008-013) Section 8 — Cooling System — Group 08
Page 8-20 QSK19 - PRELIMINARY

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).
Section 8 — Cooling System — Group 08 Coolant Thermostat (008-013)
QSK19 - PRELIMINARY Page 8-21

Remove both of the engine thermostats (1). Remove the


LTA thermostat (2). Remove the seals (3).
Refer to Procedure No. 008-016-002.

Inspect for Reuse (008-013-007)


Conventional Aftercooling
LTA
Visually inspect the thermostat for damage.

Test (008-013-012)
Conventional Aftercooling
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
nominal temperature.
The fully open distance between the thermostat flange
and housing is 9.525 mm [0.3750-inch].
Coolant Thermostat (008-013) Section 8 — Cooling System — Group 08
Page 8-22 QSK19 - PRELIMINARY

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
nominal temperature.
• Thermostat must be fully open at 12°C [22°F] above
nominal temperature.
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.
Section 8 — Cooling System — Group 08 Coolant Thermostat (008-013)
QSK19 - PRELIMINARY Page 8-23

Leak Test (008-013-014)


Conventional Aftercooling
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].
Coolant Thermostat (008-013) Section 8 — Cooling System — Group 08
Page 8-24 QSK19 - PRELIMINARY

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.
Section 8 — Cooling System — Group 08 Coolant Thermostat (008-013)
QSK19 - PRELIMINARY Page 8-25

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)
Conventional Aftercooling
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


capscrews. Tighten the capscrews.
Torque Value: 45 N•m [35 ft-lb]

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.
Torque Value (Capscrew): 45 N•m [35 ft-lb]
Torque Value (Hose Clamp): 6 N•m [50 in-lb]
Coolant Thermostat (008-013) Section 8 — Cooling System — Group 08
Page 8-26 QSK19 - PRELIMINARY

Install the two upper radiator hoses. Tighten the hoses


clamps.
Torque Value: 6 N•m [50 in-lb]
Install the vent lines.
NOTE: If the engine is equipped with an air compressor,
install the air compressor coolant return tube.

Fill the cooling system. Refer to Procedure No. 008-018-


028.
Operate the engine to 70°C [160°F] coolant temperature.
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


capscrews. Tighten the capscrews.
Torque Value: 45 N•m [35 ft-lb]
Section 8 — Cooling System — Group 08 Coolant Thermostat (008-013)
QSK19 - PRELIMINARY Page 8-27

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.
Torque Value (Capscrew): 45 N•m [35 ft-lb]
Torque Value (Hose Clamp): 6 N•m [50 in-lb]

Install the aftercooler water return tube (1). Install the tube
clip and capscrew (2).
Tighten the hose clamps and capscrew.
Torque Value (Capscrew): 20 N•m [15 ft-lb]
Torque Value (Hose Clamp): 6 N•m [50 in-lb]

Install both vent lines to the top of the thermostat housing.


Install both upper LTA hoses. Tighten the hose clamps.
Torque Value: 6 N•m [50 in-lb]
Install both upper engine radiator hoses. Tighten the hose
clamps.
Torque Value: 6 N•m [50 in-lb]

Fill the cooling system. Refer to Procedure No. 008-018-


028.
Operate the engine to 70°C [160°F] coolant temperature.
Check for leaks.
Coolant Thermostat Housing Support (008-015) Section 8 — Cooling System — Group 08
Page 8-28 QSK19 - PRELIMINARY

Coolant Thermostat Housing Support


(008-015)
Remove (008-015-002)
Conventional Aftercooling
Drain the cooling system. Refer to Procedure No.
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)
QSK19 - PRELIMINARY Page 8-29

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
Drain the cooling system. Refer to Procedure No.
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.
Coolant Thermostat Housing Support (008-015) Section 8 — Cooling System — Group 08
Page 8-30 QSK19 - PRELIMINARY

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)
Conventional Aftercooling
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.
Section 8 — Cooling System — Group 08 Coolant Thermostat Housing Support (008-015)
QSK19 - PRELIMINARY Page 8-31

NOTE: The outside capscrew holds a clip for the aftercooler


water inlet tube.
Install the four lockwashers and capscrews. Tighten the
capscrews.
Torque Value: 45 N•m [35 ft-lb]

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.
Torque Value: 20 N•m [15 ft-lb]
Tighten the hose clamps.
Torque Value: 6 N•m [50 in-lb]
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
capscrews. Tighten the capscrews.
Torque Value: 6 N•m [50 in-lb]
Install the vent hose (6).
Connect the coolant temperature sensor wire.
NOTE: If the engine is equipped with an air compressor,
install the air compressor coolant return tube.

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.
Torque Value: 45 N•m [35 ft-lb]
Tighten the hose clamps.
Torque Value: 6 N•m [50 in-lb]
Coolant Thermostat Housing Support (008-015) Section 8 — Cooling System — Group 08
Page 8-32 QSK19 - PRELIMINARY

Install the two upper radiator hoses. Tighten the hose


clamps.
Torque Value: 6 N•m [50 in-lb]
Install the vent lines.

Fill the cooling system. Refer to Procedure No. 008-018-


028.
Operate the engine to 70°C [160°F] coolant temperature
and check for leaks.

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.
Torque Value: 45 N•m [35 ft-lb]
Section 8 — Cooling System — Group 08 Coolant Thermostat Housing Support (008-015)
QSK19 - PRELIMINARY Page 8-33

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.
Torque Value: 45 N•m [35 ft-lb]
Tighten the hose clamps.
Torque Value: 6 N•m [50 in-lb]

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.
Torque Value: 20 N•m [15 ft-lb]
Tighten the hose clamps.
Torque Value: 6 N•m [50 in-lb]
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.
Tighten the capscrews.
Torque Value: 20 N•m [15 ft-lb]
Tighten the hose clamps.
Torque Value: 6 N•m [50 in-lb]
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.
Torque Value: 6 N•m [50 ft-lb]
Install both of the upper engine radiator hoses. Tighten
the clamps.
Torque Value: 6 N•m [50 in-lb]
Coolant Thermostat Seal (008-016) Section 8 — Cooling System — Group 08
Page 8-34 QSK19 - PRELIMINARY

Fill the cooling system. Refer to Procedure No. 008-018-


028.
Operate the engine to 70°C [160°F] coolant temperature.
Check for leaks.

Coolant Thermostat Seal (008-016)


Remove (008-016-002)
Conventional Aftercooling
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)
QSK19 - PRELIMINARY Page 8-35

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)
Conventional Aftercooling
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)


General Information (008-017-999)
Conventional Aftercooling
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
Page 8-36 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 8-37

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)
Conventional Aftercooling
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
Page 8-38 QSK19 - PRELIMINARY

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
heated coolant spray.

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.
Section 8 — Cooling System — Group 08 Cooling System (008-018)
QSK19 - PRELIMINARY Page 8-39

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.
Cooling System (008-018) Section 8 — Cooling System — Group 08
Page 8-40 QSK19 - PRELIMINARY

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.

Pressure Test (008-018-013)


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
Procedure No. 007-007-026.

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.
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.
Refer to Procedure No. 010-001-008.
Section 8 — Cooling System — Group 08 Cooling System (008-018)
QSK19 - PRELIMINARY Page 8-41

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.
Air Pressure: 415 kPa [60 psi]
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.
Cooling System (008-018) Section 8 — Cooling System — Group 08
Page 8-42 QSK19 - PRELIMINARY

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
heated coolant spray.
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.
Section 8 — Cooling System — Group 08 Cooling System (008-018)
QSK19 - PRELIMINARY Page 8-43

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)
Conventional Aftercooling
LTA
Close the radiator draincocks.
Install the lower radiator hose(s). Tighten the hose clamps.
Torque Value: 5 N•m [40 in-lb]
Cooling System (008-018) Section 8 — Cooling System — Group 08
Page 8-44 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 8-45

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
heated coolant spray.
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
Page 8-46 QSK19 - PRELIMINARY

• 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.


Remove the test equipment.
Check the coolant level and fill if necessary.
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.
Section 8 — Cooling System — Group 08 Cooling System — Air or Combustion Gas (008-019)
QSK19 - PRELIMINARY Page 8-47

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
Page 8-48 QSK19 - PRELIMINARY

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
Procedure No. 001-028-002.

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.
Section 8 — Cooling System — Group 08 Cooling System — Air or Combustion Gas (008-019)
QSK19 - PRELIMINARY Page 8-49

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:
Remove the test equipment.
Check the coolant level and fill if necessary.
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
Page 8-50 QSK19 - PRELIMINARY

Cooling System Diagnostics (008-020)


Pressure Test (008-020-013)
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)
QSK19 - PRELIMINARY Page 8-51

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)
General Information (008-022-999)
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
Page 8-52 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 8-53

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 for Reuse (008-029-007)


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
Page 8-54 QSK19 - PRELIMINARY

Install (008-029-026)
Install the belt tensioner on the idler arm. Tighten the
capscrews.
Torque Value: 102 N•m [75 ft-lb]

Install the idler arm assembly and capscrews (2). Tighten


the capscrews.
Torque Value: 45 N•m [35 ft-lb]
Install the belt tensioning nut (1). Do not tighten the nut.

Install the fan belt. Refer to Procedure No. 008-002-026.

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)
QSK19 - PRELIMINARY Page 8-55

Caution: This assembly weighs more than 23 kg [50 lb].


To avoid personal injury, use a hoise or get personal
assistance.
Remove the eight nuts and washers, and the fan hub.

Inspect for Reuse (008-036-007)


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.
Torque Value: 45 N•m [35 ft-lb]

Install the fan belt. Refer to Procedure No. 008-002-026.


Install the fan. Refer to Procedure No. 008-040-026.
Fan, Cooling (008-040) Section 8 — Cooling System — Group 08
Page 8-56 QSK19 - PRELIMINARY

Fan, Cooling (008-040)


Initial Check (008-040-001)
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)
QSK19 - PRELIMINARY Page 8-57

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.
Torque Value: 135 N•m [100 ft-lb]

Connect the batteries or air starter supply line.


Fan, Cooling (008-040) Section 8 — Cooling System — Group 08
Page 8-58 QSK19 - PRELIMINARY

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
289 mm [11.4 in] .70 x engine RPM
338 mm [13.3 in] .60 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)
QSK19 - PRELIMINARY Page 8-59

If the fan RPM is not correct, check the belt tension. Refer
to Procedure No. 008-002-027.

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
Page 8-60 QSK19 - PRELIMINARY

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.

Initial Check (008-042-008)


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.
Air Pressure: 552 kPa [80 psi]

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)
QSK19 - PRELIMINARY Page 8-61

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
Page 8-62 QSK19 - PRELIMINARY

Radiator Hose, Lower (008-045)


Remove (008-045-002)
Drain the cooling system. Refer to Procedure No.
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.

Inspect for Reuse (008-045-007)


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]
Torque Value (T-Bolt Clamp): 8 N•m [70 in-lb]
Section 8 — Cooling System — Group 08 Radiator Hose, Upper (008-046)
QSK19 - PRELIMINARY Page 8-63

Fill the cooling system. Refer to Procedure No. 008-018-


028.
Operate the engine to 70°C [160°F] coolant temperature.
Check for leaks.

Radiator Hose, Upper (008-046)


Remove (008-046-002)
Conventional Aftercooling
Drain the cooling system. Refer to Procedure No.
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
Page 8-64 QSK19 - PRELIMINARY

LTA
Remove the LTA hoses from the thermostat housing.

Remove the LTA radiator hoses from the top tank of the
radiator.

Inspect for Reuse (008-046-007)


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)
Conventional Aftercooling
Install the upper radiator hoses to the thermostat housing.
Tighten the clamps.
Torque Value (Worm Clamp): 5 N•m [50 in-lb]
Torque Value (T-Bolt Clamp): 8 N•m [70 in-lb]
Section 8 — Cooling System — Group 08 Radiator Hose, Upper (008-046)
QSK19 - PRELIMINARY Page 8-65

Install the upper radiator hoses to the top tank of the


radiator. Tighten the clamps.
Torque Value (Worm Clamp): 5 N•m [50 in-lb]
Torque Value (T-Bolt Clamp): 8 N•m [70 in-lb]

LTA
Install the upper LTA radiator hoses to the thermostat
housing. Tighten the clamps.
Torque Value (Worm Clamp): 5 N•m [50 in-lb]
Torque Value (T-Bolt Clamp): 8 N•m [70 in-lb]

Install the LTA radiator hoses to the top tank of the radiator.
Tighten the clamps.
Torque Value (Worm Clamp): 5 N•m [50 in-lb]
Torque Value (T-Bolt Clamp): 8 N•m [70 in-lb]

Fill the cooling system. Refer to Procedure No. 008-018-


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
Page 8-66 QSK19 - PRELIMINARY

Radiator Pressure Cap (008-047)


Inspect for Reuse (008-047-007)
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 (008-047-013)


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 for Reuse (008-048-007)
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)
Conventional Aftercooling
Drain the cooling system. Refer to Procedure No.
008-018-005.
Section 8 — Cooling System — Group 08 Supplemental Coolant Additive (SCA) (008-060)
QSK19 - PRELIMINARY Page 8-67

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)
Inspect for Reuse (008-060-007)
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
Page 8-68 QSK19 - PRELIMINARY

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.
Drain the cooling system. Refer to Procedure No.
008-018-005.
Section 8 — Cooling System — Group 08 Water Pump (008-062)
QSK19 - PRELIMINARY Page 8-69

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.

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.
Water Pump (008-062) Section 8 — Cooling System — Group 08
Page 8-70 QSK19 - PRELIMINARY

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.
Section 8 — Cooling System — Group 08 Water Pump (008-062)
QSK19 - PRELIMINARY Page 8-71

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.
Tighten the capscrews.
Torque Value: 40 N•m [30 ft-lb]
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.
Water Pump (008-062) Section 8 — Cooling System — Group 08
Page 8-72 QSK19 - PRELIMINARY

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.
Torque Value: 45 N•m [35 ft-lb]

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.
Torque Value: 206 N•m [150 ft-lb]
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.
Torque Value: 45 N•m [35 ft-lb]

Connect the lower radiator hose. Tighten the clamps.


Torque Value: 6 N•m [50 in-lb]

Use vegetable oil and 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. Tighten the capscrews.
Torque Value: 45 N•m [35 ft-lb]
Section 8 — Cooling System — Group 08 Water Pump (008-062)
QSK19 - PRELIMINARY Page 8-73

Connect the aftercooler supply hose to the water pump


outlet connection. Tighten the clamps.
Torque Value: 6 N•m [50 in-lb]

Install the bypass connection gasket. Tighten the


capscrews.
Torque Value: 40 N•m [30 ft-lb]
Use vegetable oil and 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.
Torque Value (Capscrew): 45 N•m [35 ft-lb]
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.

Fill the cooling system. Refer to Procedure No. 008-018-


028.
Operate the engine to 70°C [160°F] coolant temperature
and check for leaks.
Torque Converter Cooler (008-065) Section 8 — Cooling System — Group 08
Page 8-74 QSK19 - PRELIMINARY

Torque Converter Cooler (008-065)


Remove (008-065-002)
Drain the cooling system. Refer to Procedure No.
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)
QSK19 - PRELIMINARY Page 8-75

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 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.
Torque Converter Cooler (008-065) Section 8 — Cooling System — Group 08
Page 8-76 QSK19 - PRELIMINARY

Caution: This component weighs 23 kg [50 lb] or more.


To avoid personal injury, use a hoist or get assistance to
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.

Inspect for Reuse (008-065-007)


Use a solvent that will not harm aluminum. Clean the
parts.
Visually inspect the parts for cracks or other damage.

Pressure Test (008-065-013)


NOTE: Heating the water in the tank to 50°C [120°] will
improve the test results.
Pressure test the elements to check for leaks.
Air Pressure: 415 kPa [60 psi]
Section 8 — Cooling System — Group 08 Torque Converter Cooler (008-065)
QSK19 - PRELIMINARY Page 8-77

Install (008-065-026)
Install the elements. Tighten the self-locking nuts.
Torque Value: 130 N•m [95 ft-lb]
Use new o-rings. Lubricate the o-rings with vegetable oil.
Install the o-rings on the cooler elements.

Caution: This component weighs 23 kg [50 lb] or more.


To avoid personal injury, use a hoist or get assistance to
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.
Torque Converter Cooler (008-065) Section 8 — Cooling System — Group 08
Page 8-78 QSK19 - PRELIMINARY

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.
Torque Value: 45 N•m [35 ft-lb]

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. Tighten the capscrews.
Torque Value: 45 N•m [35 ft-lb]

Connect the aftercooler supply hose to the water pump


outlet connection. Tighten the clamps.
Torque Value: 5.6 N•m [50 in-lb]

Use vegetable oil. Lubricate the o-ring on the water by-


pass 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 hose clamps.
Torque Value (Capscrew): 45 N•m [35 ft-lb]
Torque Value (Clamp): 5.6 N•m [50 in-lb]
Section 8 — Cooling System — Group 08 Torque Converter Cooler (008-065)
QSK19 - PRELIMINARY Page 8-79

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.
Torque Value: 45 N•m [35 ft-lb]
Connect the coolant supply hose to the turbocharger.

Fill the cooling system. Refer to Procedure No. 008-018-


028.
Operate the engine to 70°C [160°F] coolant temperature.
Check for leaks.
Torque Converter Cooler (008-065) Section 8 — Cooling System — Group 08
Page 8-80 QSK19 - PRELIMINARY

NOTES
Section 9 — Drive Units — Group 09
QSK19 - PRELIMINARY Page 9-1

Section 9 — Drive Units — Group 09


Section Contents
Page
Accessory Drive (009-001) ................................................................................................................................. 9-6
Clean (009-001-006) ........................................................................................................................................ 9-7
Inspect for Reuse (009-001-007) ...................................................................................................................... 9-7
Install (009-001-026) ........................................................................................................................................ 9-8
Remove (009-001-002)..................................................................................................................................... 9-6
Accessory Drive Pulley (009-004) .................................................................................................................... 9-10
Inspect for Reuse (009-004-007)..................................................................................................................... 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
Inspect for Reuse (009-029-007) .................................................................................................................... 9-13
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
Page 9-2 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 9-3

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
Page 9-4 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 9-5

Drive Units — Tool Requirements (022-001-509)

The following special tools are recommended to perform procedures in Section 09. 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


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
Page 9-6 QSK19 - PRELIMINARY

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.

Remove the fuel pump. Refer to Procedure No.


005-016-002.

Remove the air compressor. Refer to Procedure No. 012-


014-002 for single cylinder compressor, or Procedure No.
012-015-002 for two cylinder compressor.

Remove the accessory drive pulley. Refer to Procedure


No. 009-004-002.
Section 9 — Drive Units — Group 09 Accessory Drive (009-001)
QSK19 - PRELIMINARY Page 9-7

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.

Inspect for Reuse (009-001-007)


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
Page 9-8 QSK19 - PRELIMINARY

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.
Torque Value: 45 N•m [35 ft-lb]
Section 9 — Drive Units — Group 09 Accessory Drive (009-001)
QSK19 - PRELIMINARY Page 9-9

Install the straight threaded o-ring plugs. Tighten the o-ring


plugs.
Torque Value: 25 N•m [20 ft-lb]

Install the oil slinger (4). Install the accessory drive pulley
alignment key (5).

Install the alternator drive seal. Refer to Procedure No.


001-001-026.
Install the tool adapter (7). Install the accessory drive
pulley. Refer to Procedure No. 009-004-026.

Install the air compressor. Refer to Procedure No. 002-


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
Page 9-10 QSK19 - PRELIMINARY

Install the fuel pump and related components. Refer to


Procedure No. 005-016-026.

Fill the cooling system. Refer to Procedure No. 008-018-


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.

Inspect for Reuse (009-004-007)


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)
QSK19 - PRELIMINARY Page 9-11

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
Page 9-12 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 9-13

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.

Inspect for Reuse (009-029-007)


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.
Water Pump Drive (009-029) Section 9 — Drive Units — Group 09
Page 9-14 QSK19 - PRELIMINARY

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.

Install the alternator drive seal. Refer to Procedure No.


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)
QSK19 - PRELIMINARY Page 9-15

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.
Water Pump Drive (009-029) Section 9 — Drive Units — Group 09
Page 9-16 QSK19 - PRELIMINARY

NOTES
Section 10 — Air Intake System — Group 10
QSK19 - PRELIMINARY Page 10-1

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
Inspect for Reuse (010-024-007) ................................................................................................................... 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
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
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
Page 10-2 QSK19 - PRELIMINARY

Air Intake Information — General


Information (010-999-999)
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)
QSK19 - PRELIMINARY Page 10-3

Air Intake System — Flow Diagrams (010-200-281)


Air Intake System - Specifications (018-001-205) Section 10 — Air Intake System — Group 10
Page 10-4 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 10-5

Air Intake System - Tool Requirements (022-001-510)

The following special tools are recommended to perform procedures in Section 10. 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


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
Page 10-6 QSK19 - PRELIMINARY

Aftercooler Assembly (010-002)


Remove (010-002-002)
Drain the cooling system. Refer to Procedure No.
008-018-005.

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.

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)
QSK19 - PRELIMINARY Page 10-7

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.

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.
For removal of wiring harness, refer to Procedure No.
019-043-002.
For removal of the intake manifold pressure sensor, refer
to Procedure No. 019-061-002.
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.
Aftercooler Assembly (010-002) Section 10 — Air Intake System — Group 10
Page 10-8 QSK19 - PRELIMINARY

Inspect for Reuse (010-002-007)


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.

Caution: This component weighs 23 kg [50 lb] or more.


To avoid personal injury, use a hoist or get assistance to
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)
QSK19 - PRELIMINARY Page 10-9

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]
Torque Value (Clamp): 6 N•m [50 in-lb]
Install the fuel tubing. Refer to Procedure No. 006-013-
002 or 006-024-002.

Connect the inlet hose. Tighten the clamps.


Torque Value: 6 N•m [50 in-lb]
Aftercooler Assembly (010-002) Section 10 — Air Intake System — Group 10
Page 10-10 QSK19 - PRELIMINARY

Connect the water outlet hose. Tighten the clamps.


Torque Value: 6 N•m [50 in-lb]

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.
Torque Value (Capscrew): 45 N•m [35 ft-lb]
Torque Value (Clamp): 8 N•m [75 in-lb]

Fill the Cooling System


Refer to Procedure No. 008-018-028.
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)
QSK19 - PRELIMINARY Page 10-11

Aftercooler Element (010-008)


Remove (010-008-002)
Drain the cooling system. Refer to Procedure No.
008-018-005.

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.

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
Page 10-12 QSK19 - PRELIMINARY

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.

Pressure Test (010-008-013)


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.
Air Pressure: 415 kPa [60 psi]
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)
QSK19 - PRELIMINARY Page 10-13

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.
Torque Value: 35 N•m [25 ft-lb]

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
Page 10-14 QSK19 - PRELIMINARY

Connect the water inlet hose. Tighten the clamps.


Torque Value: 6 N•m [50 in-lb]

Connect the water outlet hose. Tighten the clamps.


Torque Value: 6 N•m [50 in-lb]

Install the hose and two hose clamps on the air crossover
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.


Torque Value: 45 N•m [35 ft-lb]
Tighten the clamp.
Torque Value: 8 N•m [75 in-lb]
Section 10 — Air Intake System — Group 10 Air Leaks, Air Intake System (010-024)
QSK19 - PRELIMINARY Page 10-15

Fill Cooling System


Refer to Procedure No. 008-018-028.
Operate the engine to coolant temperature. Check for
leaks.
Operating Coolant Temperature: 71°C [160°F]

Air Leaks, Air Intake System (010-024)


Inspect for Reuse (010-024-007)
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.
Torque Value (Clamp): 8 N•m [75 in-lb]

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.
Refer to Procedure No. 010-043-007.
Air Leaks, Air Intake System (010-024) Section 10 — Air Intake System — Group 10
Page 10-16 QSK19 - PRELIMINARY

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.
Torque Value: 20 N•m [180 in-lb]
If an air leak is still present, replace the turbocharger.
Refer to Procedure No. 010-033-026.

Compressor Housing Sealing Surface Air Leak


Tighten the V-band HX82 clamp.
Torque Value: 9 N•m [75 in-lb]
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)
QSK19 - PRELIMINARY Page 10-17

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
Page 10-18 QSK19 - PRELIMINARY

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.

Remove the test equipment.

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.

Drain the cooling system. Refer to Procedure No.


008-018-005.
Section 10 — Air Intake System — Group 10 Turbocharger (Water-Cooled) (010-037)
QSK19 - PRELIMINARY Page 10-19

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.

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.
Turbocharger (Water-Cooled) (010-037) Section 10 — Air Intake System — Group 10
Page 10-20 QSK19 - PRELIMINARY

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.
Torque Value: 40 N•m [30 ft-lb]

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.
Section 10 — Air Intake System — Group 10 Turbocharger (Water-Cooled) (010-037)
QSK19 - PRELIMINARY Page 10-21

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.


Torque Value: 8 N•m [180 in-lb]
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.
Torque Value: 45 N•m [35 ft-lb]
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.


Torque Value: 31 N•m [23 ft-lb]
Turbocharger (Water-Cooled) (010-037) Section 10 — Air Intake System — Group 10
Page 10-22 QSK19 - PRELIMINARY

Connect the coolant supply hose and the coolant return


hose to the turbocharger.
Tighten the hose fittings.
Torque Value: 54 N•m [40 ft-lb]

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.
Torque Value: 9 N•m [75 in-lb]
Tap the clamp with a mallet and tighten the clamp again.

Install the hose and two hose clamps on the air crossover
tube.
Install the air crossover. Slide the hose down and over the
turbocharger outlet. Install the gasket and capscrews.
Section 10 — Air Intake System — Group 10 Turbocharger (Water-Cooled) (010-037)
QSK19 - PRELIMINARY Page 10-23

Use the sequence illustrated to tighten the capscrews.


Torque Value: 45 N•m [35 ft-lb]
Tighten the clamp.
Torque Value: 8 N•m [75 in-lb]

Connect the inlet piping to the turbocharger. Tighten the


clamps.
Torque Value: 8 N•m [75 in-lb]

Connect the exhaust piping to the turbocharger. Tighten


the V-band clamp.
Torque Value: 4 N•m [35 in-lb]

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
Page 10-24 QSK19 - PRELIMINARY

If the correct turbocharger was not installed, remove it


and install the correct turbocharger. Refer to Procedure
No. 010-033-026.
Fill the cooling system. Refer to Procedure No. 008-018-
028.
Operate the engine to the required coolant temperature.
Check for leaks.
Operating Coolant Temperature: 71°C [160°F]

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)


Inspect for Reuse (010-039-007)
Remove the intake and exhaust pipes from the
turbocharger.
Section 10 — Air Intake System — Group 10 Turbocharger Compressor Seal Leaks (010-040)
QSK19 - PRELIMINARY Page 10-25

Visually inspect the turbocharger compressor impeller


blades for damage.
Rebuild or replace the turbocharger if damage is found.
Refer to Procedure No. 010-033-026.

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.
Refer to Procedure No. 010-033-026.

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
Page 10-26 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 10-27

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
Page 10-28 QSK19 - PRELIMINARY

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)
Fluorescent Dye Tracer (010-049-054)
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.

Shut the engine OFF.


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)
QSK19 - PRELIMINARY Page 10-29

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
Page 10-30 QSK19 - PRELIMINARY

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.
Refer to Procedure No. 010-033-026.

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
QSK19 - PRELIMINARY Page 11-1

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
Page 11-2 QSK19 - PRELIMINARY

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)
QSK19 - PRELIMINARY Page 11-3

Exhaust System — Flow Diagrams (200-005-206)


Section 11 — Exhaust System — Group 11 Exhaust Manifold (Dry) (011-007)
QSK19 - PRELIMINARY Page 11-5

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.

Caution: This assembly weighs more than 23 kg [50 lb].


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
Page 11-6 QSK19 - PRELIMINARY

Disassemble (011-007-003)
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.

Inspect for Reuse (011-007-007)


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)
QSK19 - PRELIMINARY Page 11-7

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.

Tighten the capscrews in the sequence shown.


Torque Value: 40 to 50 N•m [30 to 35 ft-lb]
Exhaust Restriction (011-009) Section 11 — Exhaust System — Group 11
Page 11-8 QSK19 - PRELIMINARY

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.
Torque Value (Capscrew): 45 N•m [35 ft-lb]
Torque Value (Clamp): 6 N•m [50 in-lb]

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)
QSK19 - PRELIMINARY Page 11-9

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.

Remove the test equipment.


Exhaust Restriction (011-009) Section 11 — Exhaust System — Group 11
Page 11-10 QSK19 - PRELIMINARY

NOTES
Section 12 - Compressed Air System - Group 12
QSK19 - PRELIMINARY Page 12-1

Section 12 - Compressed Air System - Group 12


Section Contents
Page
Air Compressor Carbon Buildup (012-003) ..................................................................................................... 12-9
Inspect for Reuse (012-003-007) .................................................................................................................... 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
Inspect for Reuse (012-020-007)................................................................................................................... 12-37
Air Compressor Pin Bore Wear (012-010) ...................................................................................................... 12-18
Inspect for Reuse (012-010-007) ................................................................................................................... 12-18
Install (012-010-026) ..................................................................................................................................... 12-20
Remove (012-010-002).................................................................................................................................. 12-18
Air Compressor, Single Cylinder (012-014) ................................................................................................... 12-26
Inspect for Reuse (012-014-007)................................................................................................................... 12-27
Install (012-014-026)..................................................................................................................................... 12-28
Remove (012-014-002) ................................................................................................................................. 12-26
Air Compressor, Two Cylinder (012-015) ....................................................................................................... 12-30
Inspect for Reuse (012-015-007) ................................................................................................................... 12-31
Install (012-015-026) ..................................................................................................................................... 12-31
Remove (012-015-002) ................................................................................................................................. 12-30
Air Compressor Unloader and Valve Assembly (012-013)............................................................................. 12-20
Inspect for Reuse (012-013-007) ................................................................................................................... 12-21
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
Inspect for Reuse (012-018-007)................................................................................................................... 12-34
Air Governor (Air Compressor Will Not Pump) (012-017).............................................................................. 12-34
Inspect for Reuse (012-017-007)................................................................................................................... 12-34
Air Leaks, Compressed Air System (012-019) ............................................................................................... 12-36
Inspect for Reuse (012-019-007)................................................................................................................... 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
Page 12-2 QSK19 - PRELIMINARY

Compressed Air System — General


Information (012-999-999)
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)
QSK19 - PRELIMINARY Page 12-3

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
Page 12-4 QSK19 - PRELIMINARY

Compressed Air System — Flow Diagrams (200-006-207)


Section 12 — Compressed Air System — Group 12 Compressed Air System — Specifications (018-001-207)
QSK19 - PRELIMINARY Page 12-5

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
Page 12-6 QSK19 - PRELIMINARY

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
Page 12-8 QSK19 - PRELIMINARY

Tool No. Tool Description Tool Illustration


Valve Vacuum Tester
Test intake and exhaust valve seating.
3824277
Section 12 — Compressed Air System — Group 12 Air Compressor Carbon Buildup (012-003)
QSK19 - PRELIMINARY Page 12-9

Air Compressor Carbon Buildup


(012-003)
Inspect for Reuse (012-003-007)
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.
Shut the engine OFF.
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
Page 12-10 QSK19 - PRELIMINARY

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
to Procedure No. 012-013-007.

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)
QSK19 - PRELIMINARY Page 12-11

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.

Remove the air inlet and outlet connections from the air
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
Procedure No. 012-013-002.
Air Compressor Cylinder Head, Single Cylinder (012-008) Section 12 — Compressed Air System — Group 12
Page 12-12 QSK19 - PRELIMINARY

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.

Disassemble (012-008-003)
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.
Section 12 — Compressed Air System — Group 12 Air Compressor Cylinder Head, Single Cylinder (012-008)
QSK19 - PRELIMINARY Page 12-13

Inspect for Reuse (012-008-007)


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.
Air Compressor Cylinder Head, Single Cylinder (012-008) Section 12 — Compressed Air System — Group 12
Page 12-14 QSK19 - PRELIMINARY

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]
Section 12 — Compressed Air System — Group 12 Air Compressor Cylinder Head, Single Cylinder (012-008)
QSK19 - PRELIMINARY Page 12-15

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).
Air Compressor Cylinder Head, Single Cylinder (012-008) Section 12 — Compressed Air System — Group 12
Page 12-16 QSK19 - PRELIMINARY

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


Procedure No. 012-013-026.
Section 12 — Compressed Air System — Group 12 Air Compressor Cylinder Head, Single Cylinder (012-008)
QSK19 - PRELIMINARY Page 12-17

Install the air inlet and outlet connections. Tighten the


clamps.
Torque Value: 6 N•m [50 in-lb]

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.

Fill the cooling system. Refer to Procedure No. 008-018-


028.
Operate the engine to 71°C [160°F] coolant temperature
and check for leaks.
Air Compressor Pin Bore Wear (012-010) Section 12 — Compressed Air System — Group 12
Page 12-18 QSK19 - PRELIMINARY

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.

Inspect for Reuse (012-010-007)


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)
QSK19 - PRELIMINARY Page 12-19

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
Page 12-20 QSK19 - PRELIMINARY

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
Torque Value: 14 N•m [10 ft-lb]

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)
QSK19 - PRELIMINARY Page 12-21

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.

Inspect for Reuse (012-013-007)


NOTE: The illustrations shown will be of the single cylinder
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.
Air Compressor Unloader and Valve Assembly (012-013) Section 12 — Compressed Air System — Group 12
Page 12-22 QSK19 - PRELIMINARY

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.
Section 12 — Compressed Air System — Group 12 Air Compressor Unloader and Valve Assembly (012-013)
QSK19 - PRELIMINARY Page 12-23

Vacuum Test (012-013-015)


Remove the air governor or air governor signal line from
the unloader body.

Remove the air inlet and outlet connections from the air
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.
Air Compressor Unloader and Valve Assembly (012-013) Section 12 — Compressed Air System — Group 12
Page 12-24 QSK19 - PRELIMINARY

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.
Section 12 — Compressed Air System — Group 12 Air Compressor Unloader and Valve Assembly (012-013)
QSK19 - PRELIMINARY Page 12-25

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.
Torque Value: 15 N•m [120 in-lb]

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.
Torque Value: 40 N•m [30 ft-lb]
Air Compressor, Single Cylinder (012-014) Section 12 — Compressed Air System — Group 12
Page 12-26 QSK19 - PRELIMINARY

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.
Remove the fuel pump. Refer to Procedure No.
005-016-002.
Section 12 — Compressed Air System — Group 12 Air Compressor, Single Cylinder (012-014)
QSK19 - PRELIMINARY Page 12-27

Drain the engine coolant. Refer to Procedure No. 008-


018-005.
Remove the coolant lines from the air compressor.

Caution: This assembly weighs more than 23 kg [50 lb].


To avoid personal injury, use a hoist or get assistance to
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.
Remove and discard the gasket.

Inspect for Reuse (012-014-007)


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
Page 12-28 QSK19 - PRELIMINARY

Check the crankshaft end clearance on the single cylin-


der air compressor.

Crankshaft End Clearance


(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).
Torque Value: 45 N•m [35 ft-lb]
Tighten the bracket to the block capscrews (5).
Torque Value: 45 N•m [35 ft-lb]
Caution: The bracket must be flat against the compres-
sor.
Tighten the bracket to the compressor capscrew (4).
Torque Value: 45 N•m [35 ft-lb]
Section 12 — Compressed Air System — Group 12 Air Compressor, Single Cylinder (012-014)
QSK19 - PRELIMINARY Page 12-29

Install the fuel pump. Refer to Procedure No. 005-016-026.

Install the air inlet and outlet connections to the air com-
pressor. Tighten the clamps.
Torque Value: 6 N•m [50 in-lb]

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.

Fill the cooling system. Refer to Procedure No. 008-018-


028.
Operate the engine to 71°C [160°F] coolant temperature
and check for leaks.
Air Compressor, Two Cylinder (012-015) Section 12 — Compressed Air System — Group 12
Page 12-30 QSK19 - PRELIMINARY

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.

Remove the air inlet and outlet connections from the air
compressor.

Remove the fuel pump. Refer to Procedure No.


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)
QSK19 - PRELIMINARY Page 12-31

Inspect for Reuse (012-015-007)


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.

Crankshaft End Clearance


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
Page 12-32 QSK19 - PRELIMINARY

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).
Torque Value: 60 N•m [45 ft-lb]
The bracket must remain flat against the block. Tighten
the support capscrews (7) that are accessible.
Torque Value: 45 N•m [35 ft-lb]

Remove the four capscrews (6). Remove the compressor.