Operation and Maintenance Manual QUANTUM™ System K19 (QSK19) Series Engines Copyright® 1996 Cummins Enaine C: ‘amnany Inc ae eeForeword This manual contains information for the correct operation and maintenance of your Cummins engine. It also includes important safety information, engine and systems specifications, troubleshooting guidelines, and listings ‘of Cummins Authorized Repair Locations and component manufacturers. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in this section. Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner. The information, specifications, and recommended maintenance guidelines in this manual are based on infor- mation in effect at the time of printing. Cummins Engine Company, Inc. reserves the right to make changes at any time without obligation. If you find differences between your engine and the information in this manual, contact your local Cummins Authorized Repair Location. The latest technology and the highest quality components were used to produce this engine. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts can be identified by the following trademarks: cg Note: Warranty information is located in Section W. Make sure you are familiar with the warranty or warranties applicable to your engine. Fleelguart se CCI = ieTable of Contents Introduction... Engine Identification. Operating Instructions... Maintenance Guidelines. Daily Maintenance Guidelines Weekly Maintenance Gu Maintenance Procedures Every 250 Hours or 6 Months.. Maintenance Procedures Every 1500 Hours or 1 Year Maintenance Procedures Every 6000 Hours or 2 Years Other Maintenance Procedures... Adjustment, Repair, and Replacement. ‘System Diagrams Literature. ‘Component Manufacturers. Service Assistance... Troubleshooting Specifications and Torque Values. Warranty Index.Important Reference Numbers Fill in th part name and number in the blank spaces provided below. This will give you a reference whenever service or maintenance is required. Engine Model Engine Serial Number (ESN) ‘Control Parts List (CPL) Fuel Pump Part Number Filter Part Numbers: * Air Cleaner Element * Lubricating Oil Filter — Bypass — Full-flow ~ Combination * Fuel * Fuel-Water Separator Belt Part Numbers Clutch or Marine Gear | * Model Serial Number Part Number Oil Type Raw Water Pump = Model = Part NumberSection i - Introduction aski9 Page i-t Section i - Introduction Section Contents ‘About the Manual. Definition of Terms... General Repair Instruction: ‘Welding on a Vehicle with an Electronic Cor General Safety Instruction: Important Safety Notice How to Use the Manual Ulustrations ‘Symbols To the Owner and OperatorTo the Owner and Operator Section i - Introduction Page -2 ‘askis To the Owner and Operator Preventative maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule recommendations outlined in Maintenance Guidelines (Section 2). Keep records of regularly scheduled maintenance. Use the correct fuel, oil, and coolant in your engine as specified in Engine Specifications, Section V. Cummins uses the latest technology and the highest quality components to produce its engines. Cummins recommends using only genuine Cummins parts and ReCon® exchange parts. Personnel at Cummins authorized repair locations have been trained to provide expert service and parts support. If you have a problem that can not be resolved by a Cummins authorized repair location, follow the steps outlined in the Cummins Service Assistance (Section S). About the Manual This manual contains information needed to correctly operate and maintain your engine as recommended by Cummins Engine Company, Inc. Additional service literature (Shop Manual, Troubleshooting and Repair Manual, etc.) can be ordered by filling out and mailing the Literature Order Form located in Service Literature, Section L. This manual does not cover vehicle or equipment maintenance procedures. Consult the vehicle or equipment manufacturer for specific maintenance recommendations. Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S. customary in brackets. Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to page i-3 through i-6 for a complete listing of symbols and their definitions. Each section is preceded by a Section Contents to aid in locating information more quickly. How to Use the Manual This manual is organized according to the maintenance intervals that are to be performed. A table that states the required intervals and the checks to be made is located in Section 2. Locate the maintenance interval that you are performing and follow all the procedure steps given in that section. In addition, all the previous maintenance interval procedures must also be performed. Keep a record of all the checks and inspections made. A record form for recording date, mileage/kilometer or hours, and what maintenance checks were performed is located in Section 2. Refer to Section T for a troubleshooting guide to your engine. Follow the Troubleshooting Section Contents for locating and correcting engine problems. Refer to Section V for specifications recommended by Cummins Engine Company, Inc., for your engine. Speci- fications and torque values for each engine system are given in that section.Section i - Introduction mbols Qski9 rage i-3 Symbols The following group of 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. @DSGO9D$ OMFIOHOS® DP PD & WARNING - Provides a warning to take precaution to avoid bodily injury from electrical shock or, electrocution. There is in the vicinity uninsulated high A.C. voltage. 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 main circuit breaker is closed and normal power is being supplied to the equipment. ‘The main circuit breaker must be open so that normal power is not being supplied to the equipment. The generator set is on and supplying power to the equipment. The generator set must be off and not supplying power to the equipment. ‘The wiring harness disconnect plug must be disconnected. ‘The component weighs 23 kg [50 Ib] or more. To avoid personal injury, use a hoist or get assistance to lift the component.‘Symbols Page i-4 Section i - Introduction Qski9 Simbolos Los simbolos siguientes son usados en este manual para clarificar el proceso de las instrucciones. Cuando aparece uno de estos simbolos, su significado se especifica en la parte inferior CHOBE D> PD Db @POGDS $ MOK Proporciona un aviso de precaucién para evitar dafios corporales causados por choques eléctricos © electrocucién. El peligro esta en la vecindad del alto voltaje de c.a. sin aislamiento. ADVERTENCIA - Sorios dafios personales o dafio alla propiedad puede resultar si las instrucciones de Advertencia no se consideran. PRECAUGION - Dafios menores pueden resultar, o de piezas del conjunto o el motor puede averiarse si las instrucciones de Precaucién no se siguen. indica un paso de REMOCION o DESMONTAJE. Indica un paso de INSTALACION o MONTAJE. Se requiere INSPECCION. LIMPIESE Ia pieza 0 el montaje. EJECUTESE una MEDICION mecanica o del tiempo. LUBRIQUESE la pieza o el montaje. Indica que se daré una LLAVE DE TUERCAS o el TAMANO DE HERRAMIENTA. APRIETESE hasta un par torsor especifico. EJECUTESE una MEDICION eléctrica. Para informacién adicional refiérase a otro emplazamiento de este manual o a otra publicacién anterior. Durante el procedimiento, EL DISYUNTOR PRINCIPAL ESTA CERRADO. Se suministra potencia normal al equipo. Durante este procedimiento, EL DISYUNTOR PRINCIPAL ESTA ABIERTO. No se suministra potencia normal al equipo. Este procedimiento requiere que el GRUPO ELECTROGENO ESTE CONECTADO para suministrar potencia al equipo. Este procedimiento requiere que el GRUPO ELECTROGENO ESTE DESCONECTADO. No se suministra potencia al equipo. Este procedimiento requiere que debe desconectarse el HAZ PRINCIPAL DE CONDUCTORES PREFORMADO. El componente pesa 23 kgs [50 Ib] o mas. para evitar dano corporal empleen una cabria u obtengan ayuda para elevar el componente.Section i - Introduction ‘Symbols QSK19 Page i-5 Symbole In diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. Die Symbole haben folgende Bedeutung: we @® ®O® @ § PORHONOSE DP bP D> Unfallgefahr bedingt durch elektrischen Schlag. Nichtisolierte Hochspannungsleitungen in oe Nahe. WARNUNG - Wird die Warnung nicht beachtet, dann besteht erhéhte Unfall- und Beschadigungsgefahr. VORSICHT - Werden die Vorsichtsmassnahmen nicht beachtet, dann besteht Unfall- und Beschiidigungsgefahr. ‘AUSBAU bzw. ZERLEGEN. EINBAU bzw. ZUSAMMENBAU. INSPEKTION erforderlich. Teil oder Baugruppe REINIGEN. DIMENSION - oder ZEITMESSUNG. Teil oder Baugruppe OLEN. WERKZEUGGROSSE wird angegeben. ANZUG aut vorgeschriebenes Drehmoment erforderlich. Elektrische MESSUNG DURCHFUHREN. Weitere Informationen an anderer Stelle bzw. in anderen Handbichern, Wahrend des Arbeitsgangs ist der HAUPTTRENNSCHALTER GESCHLOSSEN. Das Gerat wird von der normalen Stromversorgung versorgt. Wahrend des Arbeitsgangs ist der HAUPTTRENNSCHALTER GEOFFNET. Das Gerat wird nicht von der normalen Stromversorgung versorgt. Der Arbeitsgang erfordert, daB der LAUFENDE STROMVERSORGER das Gerat mit Strom versorgt. Der Arbeitsgang erfordert, daB der STROMVERSORGER ABGESCHALTET IST und das Gerat nicht mit Strom versorgt wird. Dieser Arbeitsgang erfordert Abklemmen des HAUPTKABELSTRANGS. Das teil weigt 23 kg [50 Ib] oder mehr. Zur vermeidung von koerperverletzung winde benutzen oder hilfe beim heben des teils in anspruch nehmen.‘Symbols Page 1-6 Section i - Introduction aski9 Symboles Les symboles suivants sont utilisés dans ce manuel pour aider 4 communiquer le but des instructions. Quand l'un de ces symboles apparait, il évoque le sens défini ci-dessous: A > QHOB®R DP @PHS 9S $POK Avertit de prendre soin d’éviter des Iésions corporelles provenant de décharge électrique ou d'électrocution. II y a dans le voisinage une haute tension C.A. non isolée. AVERTISSEMENT - De graves Iésions corporelles ou des dommages matériels considérables peuvent survenir si les’ instructions données sous les rubriques “Avertissement” ne sont pas suivies, ATTENTION - De petites Iésions corporelles peuvent survenir, ou bien une piéce, un ensemble ou le moteur peuvent étre endommagés si les instructions données sous les rubriques “Attention” ne sont pas suivies. Indique une opération de DEPOSE. Indique une opération de MONTAGE. LINSPECTION est nécessaire. NETTOYER Ia piéce ou l'ensemble. EFFECTUER une MESURE mécanique ou de temps. GRAISSER Ia piéce ou l'ensemble. Indique qu'une DIMENSION DE CLE ou D’OUTIL sera donnée. SERRER a un couple spécifique. EFFECTUER une MESURE électrique. Se reporter a un autre endroit dans ce manuel ou a une autre publication pour obtenir des informations plus complates. Pendant la procédure, le DISJONCTEUR PRINCIPAL EST FERME. L“équipement recoit I’alimenta- tion normale. Pendant cette procédure, le DISSJONCTEUR PRINCIPAL EST OUVERT. L‘équipement ne recoit pas I’alimentation normale. Cotte procédure nécessite que le GROUPE ELECTROGENE SOIT EN MARCHE pour alimenter Féquipement. Cette procédure nécessite que le GROUPE ELECTROGENE SOIT EN ARRET. Léquipement n‘est_ pas alimenté. Cette procédure nécessite de déconnecter le CABLAGE PRINCIPAL. Le Composant pese 23 kg [50 Ib] ou davantage. Pour eviter toute blessure, employer un appariel de levage ou demander de I’aide pour le soulever.Section i - Introduction aski9 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 net look exactly like the engine or paris 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. Mlustrations Page i-7General Safety Instructions Section i - Introduction Page i-8 QSK19 General Safety Instructions Important Safety Notice A 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 engine. 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. « IFan 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 util 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. + Toavoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 Ib] 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 (a component of SCA and engine oil) 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 fiood 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 fiuids 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 Recon® 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. * Some state and federal agencies in the United States of America have determined that used engine oil can bbe carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil.Section i - Introduction General Repair Instructions Qski9 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 fj 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 alll 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 ReCon® 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 ReCon® 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. - Service Literature for ordering instructions. Welding on a Vehicle with an Electronic Controlled Fuel System A caution A Disconnect both the positive ('+) and negative (-) battery cables from the battery before welding on the vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not connect the ground cable of the welder to the ECM cooling plate or ECM. Welding on the engine or engine mounted components is not recommended,Definition of Terms Page i-10 API ASTM cfm CLD. cm CPL cSt DCA EPA EPS ESN. FMI ftlb Hg HP hrigt H,0 indb LD, uwac Defi: American Petroleum Institute ‘American Society of Testing and Materials Celsius California Air Resources Board Cold Cranking Ampere Cubic Feet per Minute Cubic Inch Displacement Centimeter Control Parts List Centistokes Diesel Coolant Additive Electronic Control Module Environmental Protection Agency Engine Position Sensor Engine Serial Number Fahrenheit Failure Mode Identifier Foot Pound Gross Vehicle Weight Mercury Horsepower Hours per Quart Water Inch Pound Inside Diameter Jacket Water Aftercooled Kilograms MPH MPQ Nem NPTF oBc OEM PID psi PTO aski9 RPM SAE. vs. Section i - Introduction Qski9 Kilometers Kilometers per Liter Kilopascal Liter Low Temperature Aftercooling Meter Millimeter Megapascal Miles Per Hour Miles Per Quart Newton-meter National Pipe Thread Fine Outer Base Circle Original Equipment Manufacturer Parameter Identification Parts Per Million Pounds Per Square Inch Power Takeoft QUANTUM™ System K19 Engine Quart(s) Revolutions Per Minute Society of Automotive Engineers ‘Supplemental Coolative Additive Subsystem Identification ‘Top Center Valve Set Vehicle Speed SensorSection E - Engine and Component Identification QsKis Page E-1 Section E - Engine and Component Identification Section Contents Electronic Control Module (ECM) Dataplates .. Engine Identification... ‘ummins Engine Nomenciature. Engine Datapiate .. Fuel Pump Dataplate External Engine Components General Specifications Air Induction System. Coolant System.. Electrical System Exhaust System. Fuel System. General Engine Data Lubricating Oil SystemEngine Identification Page E-2 ‘Section E - Engine and Component Identification QSK19 Engine Identification Cummins Engine Nomenclature The model name provides the following data: ask 19 - _ oO SS = Displacement in Liters = Series (Family of Engines) FUEL PUMP DATAPLATE Fuel Revision CR Serial No. Service Bump Production Part No. Maximum Brake Horsepower Application Codes: ‘A = Agricultural = Construction D = Generator Drive F = Fire Pump G = Generator Set L = Locomotive M = Marine P = Power Unit R = Railcar T = Tactical Military Engine Dataplate The engine dataplate shows specific information about your engine. The engine serial number (E.S.N.) (1), Con- trol Parts List (CPL) (2), Model (3), and Horsepower and RPM (4) 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 Qski9 Electronic Control Module (ECM) Dataplates The external dataplates are located on top of the ECM, The dataplate on the left contains the ECM part number (PIN), serial number (S/N), manufacturing date code (D/ C), supplier identifier (S/), and input voltage rating of ECM (VIR). ‘The dataplate on the right contains engine and calibration information. This includes the engine serial number (ESN), ECM calibration date (Date), and ECM Calibration Code. Electronic Control Module (ECM) Dataplates Page E-3 soosGeneral Specifications Section E - Engine and Component Identification Page E-4 aski9 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.1.D.] Bore and Stroke .. 158.75 mm x 158.75 mm [6.25 in x 6.25 in] Engine Weight Wet ... . 2045 Kg [4504 Ib] Firing order .. Valve and Injector Settings: Intake valve adjustment Intake valve limits Exhaust valve adjustment .. 1-5-3-6-2-4 0.36 mm [0.014 in} . 0.28 to 0.43 mm [0.011 to 0.017 in} 0.81 mm [0.032 in} 0.74 to 0.89 mm [0.029 to 0.035 in} 19 Nem [165 in-b] Exhaust valve limits Injector OBC Method adjustment (in engine) . Compression Ratio: 525 HP to 600 HP - Jacket Water Aftercooled (JWAC) . 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Section E - Engine and Component Identification General Specifications aekie FFs pecage ES General Engine Data Cylinder location and Firing Order: ‘QSK19 Cylinder Location 159-624 Intake and Exhaust Valve locations. 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. Fuel Filter Specifications (Cummins Engine Company, Inc. Standard No. 14,223) * Efficiency 98.7% at 10 microns 96% at. 8 microns 86% at 5 microns Free = 95% Emulsified = 95% ‘* Water Removed ... Maximum Allowable Restriction to Pump (at rated power): ‘* With Clean Filter * With Dirty Filter Maximum Allowable Return Line Restriction ‘* With Check Vaive '* With Check Valve “All QSK19 engines are built with a check valve. Lubricating Oil System Oil Pressure, Main Oil Rifle (15W40 oil at 107°C [225°F)): © (Idle) RPM © (Rated) RPM 100 mm-Hg [4 in-Hg] 203 mm-Hg [8 in-Hg] 0-21 kPa [0-3 psi] 4-34 kPa [2-5 psi] 138 kPa to 483 kPa [20 psi to 75 psi] . 345 kPa to 517 kPa [50 psi to 75 psi]General Specifications Section E - Engine and Component Identification Page E-6 Eng Qski9 Oil Temperature - Maximum 120°C [250°F] it Pan Capacity . Refer to Section V Coolant System Coolant Capacity (Engine ONLY) 92.2 Liters [34 U.S. Quarts] Standard Thermostat Range ... Coolant Pressure Cap (Minimum) . Coolant Temperature . 80°C to 90°C [175°F to 195°F] . 60 kPa [7 psi] 70°C [160°F] "100°C [212°F} inimum ... Maximum (At Engine Outlet). Air Induction System Maximum Allowable Intake Restriction (at rated speed and load): * With Clean Filter Element © With Dirty Filter Element Exhaust System Back Pressure - Maximum (at rated speed and load) .. Exhaust Pipe Size (Normally Acceptable Inside Diameter) © All Re Is 380 mm-H,O [18 in-H.O] 635 mm-H,0 [25 in-H,0] 75 mm-Hg [8 in-Ho} .. 152 mm [6 inch} Electrical System Minimum Recommended Battery Capacity System Voltage ‘Ambient Temperatures -18°C [0°F] 0°C [32°F] cust Reserve Cold Reserve rani Capecity* ons 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 ocour. ** Note: Not recommended for QSK19 Engines. *** Note: CCA ratings are based on two, 12 volt batteries in series. Batteries (Specific Gravity) Battery State | Specific Gravity of Charge | @ 27°C [80°F]Section E - Engine and Component Identification External Engine Components QSK19 Ey External Engine Components The illustrations which follow 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. E 12 FUEL SIDE - QSK19 Fuel Pump Quick Disconnect Fitting Engine Speed Sensor (NOT Generator Drive) Coolant Temperature Sensor (CTS) ‘Alr Compressor OEM Interface Harness Fuel Pump Engine Harness oso Control Valve Body 1. Fuel Rail Quick Disconnect Fitting A. Fan Hub 2. Timing Fuel Quick-Disconnect Fitting B. Aftercooler Assembly 3. Oil Pressure Sensor (OPS) €. Combination Full Flow/ 4, Intake Manifold Temperature Sensor (IMTS) Bypass Oil Filters 5, Intake Manifold Pressure Sensor (IMPS) ©. Electronte Control 6. Engine Position Sensor (EPS) (NOT Generator Drive) Module (ECM) 7. Ambient Air Pressure Sensor (APS) E. Dipstick B F. Fuel Filters °. a 10. H. 1. 2.External Engine Components Page E-8 Section E - Engine and Component Identification J 2 D E 4 EXHAUST SIDE - QSK19 Coolant Outlet Turbocharger Coolant inlet Thermostat Housing Alternate Location for Engine ‘Speed Sensor (ESS)(G-Drive ONLY) 4. Coolant Pressure Sensor 5. Coolant Supply to Turbocharger 6. 7 Turbocharger Oil Drain Oil Inlet to Turbocharger Pmmoogp Fan Idler and Assembly Coolant Filter Starting Motor Flywheel Housing Oil Cooler aski9Section 1 - Operating Instructions QSK19 Page 1-1 Section 1 - Operating Instructions Section Contents Alternate Droop ‘Automotive/Variable Speed (VS) Governo! Cold Weather Engine Operation.. Cold Weather Startin; 14 Using Starling Fluid With ‘Mechanical or Electrical Metering Equipment . 14 Using Starling Fluid Without Metering Equipment Cold Weather Starting Aids Electrically Operated Eth Ether Starting Aids. Installation Recom Manually Operated Ether Valve .. Diagnostic Fault Code Engine Operating Range Engine Protection System Engine Shutdown Fault Code Snapshot Data. General information Intermediate Speed Control 1 (ISC1) Low Idle Adjustment. Normal Starting Procedure (Above 0°C [32°F] Operating the Engi Programmable Features .. QUANTUM™ Fuel System - Description . Starting Procedure - After Extended Shutdown or Oil ChangsGeneral Information Page 1-2 SS Section 1 - Operating Instructions QSKi9 General Information Correct care of your engine will result in longer life, better performance and more economical operation. * Follow the daily maintenance checks listed in Main- tenance Guidelines, Section 2. * Check the oil pressure indicators, temperature in- dicators, warning lights and other gauges daily to make sure they are operational. Warning: DO NOT OPERATE A DIESEL ENGINE WHERE ‘THERE ARE OR CAN BE COMBUSTIBLE VAPORS, These vapors can be sucked through the air intake system and cause engine acceleration and over-speeding, which can result in a fire, an explosion and extensive property dam- age. Numerous safety devices are available, such as air Intake shutoff devices, to minimize the risk of over- speeding where an engine, due to its application, might operate in a combustible environment, such as due to a fuel spill or gas leak. Remember, Cummins has no way of knowing the use you have for your engine. THE EQUIP. MENT OWNER AND OPERATOR ARE RESPONSIBLE FOR ‘SAFE OPERATION IN A HOSTILE ENVIRONMENT. CON- ‘SULT YOUR CUMMINS AUTHORIZED REPAIR LOCATION FOR FURTHER INFORMATION. Normal Starting Procedure (Above 0°C [32°F]) * Disengage the driven unit, or if equipped, put the transmission in neutral. ‘+ START the engine with the throitle in the idle posi- tion. Engines equipped with air starters require a minimum of 480 kPa [70 psi] compressed air pressure, To prevent damage to the starter, do not engage the starting motor more than 30 seconds. Wait 2 minutes between each attempt to start (electrical starting motors‘Section 1 - Operating Instructions QSK19 Caution: When using jumper cables to start the engine, make sure to connect the cables in parallel: positive (+) to positive (+) and negative (-) to negative (-). When using an external electrical source to start the engine, turn the disconnect switch to the OFF position. Remove the key before attaching the jumper cables, The accompanying illustration shows a typical parallel battery connection. This arrangement doubles the crank- ing amperage. This illustration shows a typical series battery connection. This arrangement, positive to negative, doubles the voltage. ‘+ Engine oil pressure must be indicated on the gauge within 15 seconds after starting. If oil pressure is not registered within 15 seconds, shut off the engine immediately to avoid engine damage. Confirm the correct oil level in the oil pan, * Idle the engine 3 to 5 minutes at approximately 1,000 RPM before operating with a load. A ® Normal Starting Procedure (Above 0°C [32° ¢ fi ve oases 3to 5 minutesCold Weather Starting Page 1-4 gan 9 Section 1 - Operating Instructions QsKi9 ‘* When starting a cold engine, increase the engine speed (RPM) slowly to provide adequate lubrication to the bearings, and to allow the oil pressure to Do net idle the engine for excessively long periods. Long periods of idling, more than 10 minutes, can damage an engine because combustion chamber temperatures drop 80 low the fuel will not burn completely. This will cause carbon to clog the injector spray holes and piston rings, and can cause the valves to stick. Ifthe engine coolant temperature becomes too low, 60°C 1140°F], raw fuel will wash the lubricating oil off the cy!- inder walls and dilute the crankcase oil; therefore, all moving parts of the engine will not receive the correct amount of lubrication. Cold Weather Starting Using Starting Fluid With Mechanical or Electrical Metering Equipment © Set the throttle at idle. * Disengage the driven unit, or if equipped, put the transmission in NEUTRAL. * Activate the switch to open the fuel shutoff valve.Section 1 - Operating Instructions Cold Weather Engine Operation QsKi9 je 1-5 ‘+ While cranking the engine, inject a metered amount of starting fluid, * Engine oil pressure must be indicated on the gauge @) within 15 seconds after starting. Using Starting Fluid Without Metering Equipment Warning: Do not use volatile cold starting in un- derground mine or tunnel operations due to the potential A of an explosion. Check with the local U.S. Bureau of Mines Inspector for instructions. Caution: Do not use excessive amounts of starting fluid when starting an engine. The use of too much starting AY fluid will cause engine damage. Due to increased safety hazards and potential for engine damage, Cummins Engine Company, Inc. does NOT rec- ommend the use of starting fluid without metering equipment. Cold Weather Engine Operation Satisfactory performance of a diesel engine operating in low ambient temperature conditions requires modification of the engine, surrounding equipment, operating practices and maintenance procedures. The colder the tem- peratures encountered, the greater the amount of modification required and yet with the modifications applied, the ‘engines must still be capable of operation in warmer climates without extensive changes. The following information is provided to engine owners, operators and maintenance personnel on how the modifications can be applied to obtain satisfactory performance from their diesel engines. There are three basic objectives to be accomplished: 1. Reasonable starting characteristics followed by practical and dependable warm-up of the engine and equipment. 2. A unit or installation that is as independent as possible from external influences. 3. Modifications that maintain satisfactory operating temperatures with a minimum increase in maintenance of the equipment and accessories. If satisfactory engine temperature is not maintained, higher maintenance cost will result due to the increased engine wear, poor performance and formation of excessive carbon, varnish and other deposits. Special provisions to overcome low temperatures are definitely necessary, whereas a change to warmer climate normally requires only a minimum of revision. Most of the accessories will be designed in such a way that they can be disconnected so there is little effect on the engine when they are not in use.Cold Weather Starting Aids Page 1-6 Section 1 - Operating Instructions QSki9 ‘The two most commonly used terms associated with preparation of equipment for low temperature operation are Winterization and Arctic Specifications. Winterization of the engine and/or components so starting and operation are possible in the lowest temperature to be encountered requires: 1. Use of correct materials. 2. Proper lubrication, low temperature lubricating oils. Refer to Lubricating Oil Specifications, Section V. 3. Protection from the low temperature air. The metal temperature does not change, but the rate of heat dissipation is affected. 4, Fuel of the proper grade for the lowest temperature. 5. Heating to be provided to increase the engine block and component temperature to a minimum of -82°C [-25°F] for starting in lower temperatures. 6. Proper external heating source available. 7. Electrical equipment capable of operating in the lowest expected temperature. Arctic specifications refer to the design material and specifications of the components necessary for satisfactory engine operation in extreme low temperatures -54°C [-65°F]. Contact Cummins Engine Company, Inc. or the equipment manufacturer to obtain the special items required. For additional information on cold weather operation, obtain Service Bulletin No. 3379009, Engine Operation in Cold Weather, from the nearest Cummins Distributor or dealer. Itis possible to operate diesel engines in extremely cold environments if they are properly prepared and maintained. ‘The correct lubricants, fuels and coolant must be used for the cold weather range for the environment the vehicle is being operated. Refer to the chart below for recommendations in different operating ranges. interize 0° to -23°C 132° to -10°F] Use ethylene glycol antifreeze to protect to -29°C [-20°F] Use multiviscosity oils m API, CE/SF specifications. Fue! to have maximum cloud and pour points 6°C [10°F] lower than ambient temperature where the engine operates. Winterize -23° to -32°C [-10° to -25°F] Use 50 percent ethylene glycol an- tifreeze, 50 percent water mixture. Use multiviscosity oil meeting API CEISF specifications. Fuel to have maximum cloud and pour points 6°C [10°F] lower than ambient temperatures where the engine operates, Cold Weather Starting Aids Ether Starting Aids y: Starting fluid contains ether extremely flammable. Mist ‘Artic Specifications -32° to -54°C [25° to -65°F] Use 60 percent ethylene glycol an- tifreeze, 40 percent water mixture. ic oil meeting API CE/SF tions. Use spec Fuel to have maximum cloud and pour points 6°C [10°F] lower than ambient temperature where the ‘engine operates. 9 mishandling can cause an Warni A explosion. NEVER handle starting fluid near an open flame. NEVER use starting fluid with a preheater, glow lug, flame thrower or other type of electrical starting equipment. Do NOT breathe the fumes as serious injury to the human respiratory system will result. Fuel oil or volatile fuel cold starting aids are NOT to be used in underground mine or tunnel operations. A Caution: Using too much starting fluid will cause extremely high pressures and detonation in the engine cylinders, resulting in damage to the cylinder parts and bearings. Too much starting fluid can also cause damage from engine overspeed.Section 1 - Operating Instructions aski9 Manually Operated Ether Valve The manually operated ether valve includes the valve body assembly (5), clamp (2), and nylon tube (3). The fue! cylinder (1), atomizer fitting (4) and pull control (6) must be ordered separately. ‘Standard pull or throttle control cables can be used to actuate the manual valve, if desired, Electrically Operated Ether Valve The electrically operated ether valve includes the valve body (7), 90 degree elbow (5), clamp (2), push button ‘switch (6), and nylon tube (3). A thermostat is mounted to the cylinder block or coolant passage and stops electrical Power to the atomizer solenoid when the engine is warm. See the Parts Catalog for fuel cylinder (1) and fuel atom- izer fittings (4). These fittings must be ordered separately, as required, Installation Recommendations The atomizer fittings must be mounted in the engine air intake manifold to provide an equal distribution of starting fuel to each cylinder. The atomizer holes are 180 degrees apart and must be mounted so the spray is injected in the length of the manifold, or across the crossover pipe. if incorrectly installed, the spray goes across the manifold. Cold Weather Starting Aids Page 1-7 cxtvage SS inateStarting Procedure - After Extended Shutdown or Oil Change Section 1 - Operating Instructions Page 1-8 Qskis ‘The following cold weather operating aids are required for cold weather situations: Cold Weather Operating Aids ‘Under Temperature Starting |Cootam | on | hood | Fuel | Battery} Racator| Engine | Winter | Therma Bid | Heater | Heater | Ale | Heater | Hosier | Shotter[encioeute| Front | Fan sow 32°F tow 0c 210 -10°F O19 23°C 109 25°F : 2510-92" 6 neauired * Requires dependent upon viscosttyipour point. Starting Procedure - After Extended Shutdown or Oil Change Complete the following steps after each oil change, or after the engine has been shut off for more than five (5) days to be sure the engine receives the correct oil flow through the lubricating oil system: Ga ‘* Disconnect the Engine Position Sensor (EPS). * Rotate the crankshaft, using the starting motor, until @ oil pressure appears on the gauge or the warning light goes out. jy —* Connect the EPS. (215 = start the engine. Refer to Normal Starting Proce- dures in this section. SSSection 1 - Operating Instructions Operating the Engine aski9 Page 1-9 Operating the Engine + Allow the engine to idle 3 to 5 minutes before turning it OFF after a full load operation. This allows ad- equate cool down of pistons, cylinder liners, bear- ings and turbocharger components. on syant a TO 5 MINUTES 21800008, Caution: Continuous operation with low coolant tem- perature, below 60°C [140°F], or high coolant tempera. AL ture, above 100°C [212°F], can damage the engine. * Monitor the oil pressure and coolant temperature gauges frequently. Refer to Lubricating Oil System Specifications or Cooling System Specifications, Section V, for recommended operating pressures and temperatures. Turn the engine OFF if any pres- sure or temperature does not meet the specifications. * If an overheating condition starts to occur, reduce the power output of the engine by releasing the throttle pressure or shifting the transmission to a lower gear, or both, until the temperature returns to normal operating range. If engine temperature does not return to normal, turn the engine OFF and refer to Troubleshooting, Section T, or contact a Cummins Authorized Repair Location. ‘+ Most failures give an early warning. Look and listen for changes in performance, sound or engine ap- pearance that can indicate service or engine repair ) is needed. Some changes to look for are as follows: — Engine misfires — Vibration — Unusual engine noises 2 Sound Service — Sudden changes in engine operating tempera- ture or pressure 2 Pertormance| — Excessive smoke > Engine — Loss of power Apuearance — An increase in oil consumption earar . — An increase in fuel consumption cient — Fuel, oil, or coolant leaksEngine Operating Range Page 10 TOS MINUTES -&, A Section 1 - Operating instructions Qskis Engine Operating Range Caution: Excessive full throttle operation below peak torque RPM (lugging) will shorten engine life to overhaul, can cause serious engine damage and is considered engine abuse. Cummins engines are designed to operate successfully at full throttle under transient conditions down to peak torque engine speed. Operation of the engine below peak torque RPM can ‘occur during gear shifting due to the difference of ratios between transmission gears, but engine operation must not be sustained more than 30 seconds at full throttle below peak torque RPM. Caution: Operating the engine beyond high idle speed can cause severe engine damage. The engine speed must not exceed 2400 RPM under any circumstances. When descet ig a steep grade, use a combination of transmission gears and service brakes to control the vehicle and engine speed. Engine Shutdown * Allow the engine to idle 3 to 5 minutes after a full load operation before turning it OFF. This allows the ‘engine to cool gradually and uniformly. * Turn the ignition key switch to the OFF position.Section 1 - Operating Instructions asKi9 QUANTUM™ Fuel System - Description The QUANTUM" Fuel System is an electronic engine control system designed to optimize engine control and reduce exhaust emissions. This system can be applied to all high horsepower industrial engine models that use the PT fuel system. The QUANTUM" Fuel System controls engine speed and fuel pressure based on input from the electric throttle and other equipment specific and/or model specific features. Programmable Features The QUANTUM™ Fuel System has been designed to be flexible to meet the wide variety of engine control needs for off-highway equipment. Automotive/Variable Speed (VS) Governor ‘The automotive/variable speed (VS) governor provides a choice of engine governors. The automotive governor operates like a conventional PT governor which provides constant fueling for a given throttle position (engine speed varies with load). The VS governor maintains a constant engine speed for a given throttle position under varying load conditions. Governor type can be selected by using the INSITE™ Part No. 3824801. Low Idle Adjustment This feature allows the idle or intermediate speed control 1 (ISC1) speed to be increased or decreased in 25 RPM increments through an operator controlled switch. This switch can be disabled by turning this feature off with the INSITE™. Ifthis feature is turned off the low idle speed can still be adjusted using the INSITE™ Part No. 3824801. QUANTUM™ Fuel System - Description Page 1-11 QUANTUM System * Optimized Engine Control * Reduced Exhaust Emissions sao? Automotive Governor + Engine Speed Varies With Load Variable Speed Governor + Engine Speed is Constant Under Varying Loads o4aoste +425 RPM PrDsIDU ae B |~oFF © O° | arr O° DEC Dec PTO/IDLE ProvIOLe, ToTIntermediate Speed Control 1 (ISC1) Page 1-12 OEM ISC Switch On ® ss4o0221 Intermediate Speed Control Overrides Throttle ‘Maximum Governed Torque Curve Torque Isochronous Low Intermediate High ile ‘Speed tie Engine Speed 900223 Int. Switeh 28 ‘Switch Validations |, ECM Section 1 - Operating Instructions Qskis Intermediate Speed Control 1 (ISC1) ‘The ISC1 feature controls the engine at a constant RPM. selected by the operator through an Original Equipment Manufacturer (OEM) mounted switch. This feature will override the throttle and control the en- gine speed to the ISC1 speed setting. This speed can not be adjusted below the low idle speed or above high idle speed. The ISC1 feature provides a separate droop for interme- diate speeds. This droop is independent of all other se- lectable droops and is enforced during ISC operation only. ‘The intermediate speed feature is activated whenever the normally open intermediate speed control switch is closed and less than 1 volts detected on the intermediate speed signal line. If the switch validation is used, both the in- termediate speed and switch validation signals must be less than 1 volt before this feature can be activated.Section 1 - Operating Instructions aeaie | OP Alternate Droop The Alternate Droop feature allows the droop character- istics to be changed for high engine governed speeds or the High Speed Governor (HSG) and for the VS Governor. Droop is usually expressed as a percentage. This Graph illustrates the isocronous (0 percent droop) and droop (more than 0 percent droop) governor characteristics. Less governor droop provides a more responsive gover- nor for more precise engine control. More Governor droop provides smoother shifting and smoother mechanical clutch engagement. The alternate droop feature provides, depending on OEM availability, the ability to select up to 2 additonal alternate droop settings by means of an OEM provided switch. Each alternate droop setting provides the ability to select the breakpoint speed and droop percent for the HSG and droop percent for VS Governor. The breakpoint speed determines at what posi ‘on the engine torque curve where HSG will startto limit engine torque output. As with all other features, the selection of the alternate droop feature is accomplished by using the electronic service tool INSITE™ Part No. 3824801, Diagnostic Fault Codes The QUANTUM™ Fuel System can display and record certain detectable fault conditions. These failures are dis- played as fault codes simplify troubleshooting efforts. The fault codes are retained in the Electronic Control Module (ECM). Torque 000525 Torque Engine Speed Fault Code f ECM oonAlternate Droop Page 1-14 Diagnostic Fault Codes Engine Electronic Fuel ‘System Fault Codes Engine Protection System Fault Codes so1onsee 19400882 Section 1 - Operating Instructions aski9 There are two types of fault codes. There are engine electronic fuel system fault codes and engine protection system fault codes. All fault codes recorded will either be active (fault code is presently active on the engine) or inactive (fault code was active at some time, but it not presently active). Active fault codes can be read using the warning and stop lamps (red or yellow) in the cab panel or INSITE™, Part No. 3824801. Inactive fault codes can only be viewed on INSITE™. When the vehicle key switch is turned ON, and the di- agnostic switch is OFF the fault code lamps (red, yellow, and engine protection) will illuminate for approximately 2 seconds, one after the other, to check their operation. The lights will remain off until a fault code is recorded. If a stop (red) light comes on while the engine is in opera- tion, the fault can be engine disabling. Stop the engine operation in a safe manner as soon as possible. If the yellow warning (yellow) light illuminates, the engine can still be operated, but it can lose some system features that can sometimes result in a power loss. The failure must be repaired as soon as convenient.Section 1 - Operating Instructions askig ‘The engine protection system records separate fault codes when an out-of-range condition is found for any of the sensors in the engine protection system. The engine protection system will light the fluid lamp (orange) when an out-of-range condition occurs. NOTE: Lamp colors and labels will vary by OEM. Ifthe engine protection system fluid lamp comes on while driving, it means that a fault code has been recorded. The light will remain on as long as the fault is occurring. The light will begin to flash if the condition continues to get worse. The engine power and/or speed will be gradu- ally reduced. If the engine protection shutdown feature is enabled, the engine will shut down to prevent engine damage. To check for active fault codes first turn the vehicle key switch to the OFF position. Move the diagnostic switch to the ON position. NOTE: Some OEM's use a shorting plug. Engine Protection System Out-of-Range Fault Codes * Coolant Temperature + Coolant Level + Oil Temperature Check for Fault Codes ae “os T Alternate Droop Page 1-15 rotons 1900004Alternate Droop Page 1-16 Example Fault Code Sequences Pause Fault Code 23: G- ae Blink 2Blinks 3 Blinks 5 Blinks 1 Blink IN TBlink Blink Blink 2 Blinks ah ‘Step Forward to ‘Step Backward to ‘Next Fault Code Previous Fault Code Troubleshooting And Repair Charts se%00s40 Ss Section 1 - Operating Instructions Qski9 ‘Turn the vehicle key switch to the ON position. If no active fault codes are recorded, all three lights will come on and stay on. If active fault codes are recorded, all three lights will come on momentarily. The yellow (warning) and red (stop) lights will begin to fiaah the code ofthe recorded fault. The fault code will lash in the following sequence. First the yellow (warming) lamp will flash. Then there will be a short 1 second pause where both the yellow and red lights are off. Then the numbers of the recorded fault code will flash in red. There will be a 1 second pause between each number. When the number is done, a flashing yellow light will appear again. The number will repeat in the same sequence. The lights will continue to flash the same fault code until the system is advanced to the next active fault code. To go to the second fault code, move the idle speed adjust switch to” +”, then release it. You can also go back to the previous fault code by moving the switch to ”-”, then releasing it. To check the third or fourth fault code, move the switch to ”+”, then release it when all active fault codes have been viewed. Moving the switch to” +” will go back to the first fault code. A brief explanation of all of the fault codes is in Section T of this manual.Section 1 - Operating Instructions aeie |” OP ‘To stop the diagnostic system, move the diagnostic switch to the OFF position or remove the shorting plug. Turn the vehicle key switch to the OFF position. NOTE: Some OEM's use a shorting plug. Fault Code Snapshot Data When a diagnostic fault code is recorded in the ECM, ECM input and output data is recorded from all sensors and switches. Snapshot data allows the relationships be- tween ECM inputs and outputs to be viewed and used during troubleshooting. Fault code snapshot data can only be viewed on INSITE™. Engine Protection System Engines equipped with the QUANTUM™ Fuel System are equipped with an engine protection system. The system monitors critical engine temperatures, fluid level, switch position, and pressure, and will log diagnostic faults when an over or under normal operating range condition oc- curs. If an out-of-range condition exists, engine derate action will be initiated. The operator will be alerted by the illumination of the in-cab fluid lamp. The warning lamp will ‘start to flash when out-of-range condition continues to get worse and engine shutdown will occur. The operator must pull to the side of the road when itis safe to do soto reduce ‘the possibility of engine damage. The engine protection system monitors for high coolant temperature, low coolant level (optional sensor or short- ing plug) idle validation/throttle pedal switch mismatch, high intake manifold temperature, low and very low oil Pressure, and high fuel rail pressure. Fault Code Snapshot Data Page 1-17 on la xeon Engine Protection System Monitors * Coolant Temperature * Coolant Level (Optional) + Idle Validation Switch + Intake Manifold Pressure Oil Pressure * Fuel Rail Pressure 9400042 Engine Protection System Monitors Quantum Engines for: + High Coolant Temperature * Low Coolant Level (Optional) ile Validation Switch Mismatch * High Intake Manifold Temperature + Low/Very Low Oil Pressure + High Fuel Rail Pressure 0400343Engine Protection System Page 1-18 Engine Protection Features + Engine Protection Enable + Engine Protection Shutdown soon Section 1 - Operating Instructions QSK19 ‘The engine protection system has two selectable fea- tures, namely engine protection enable and engine pro- tection shutdown. If engine protection enable feature has been selected, engine power and speed will be gradually reduced depending on the level of severity of the ob- served condition. If engine protection shutdown feature has been selected the engine will be shutdown. The en- gine can be restarted by turning the keyswitch OFF and back ON.Section 2 - Maintenance Guidelines aski9 Page 2-1 Section 2 - Maintenance Guidelines Section Contents Engine Maintenance Schedule... j@ References for Maintenance instruction: General Information... Tool Requirements...General Information Page 2- General Information Cummins Engine Company, Inc. recommends that the engine be maintained according to the Maintenance Schedule on the following page. Some of these maintenance procedures require special tools or must be done by qualified personnel. the engine is operating in ambient temperatures consistently below -18°C [0°F] or above 38°C [100°F], perform maintenance at shorter intervals. Shorter maintenance intervals are also required if the engine is operated dusty environment or a frequent stops operation. See your Cummins Authorized Repair Location for recommended intervals. If your engine is equipped with a component or an accessory not manufactured by Cummins Engine Company, Inc., refer to the component manufacturer's maintenance recommendations. A listing of suppliers’ addresses and telephone numbers is provided in Component Manufacturers, Section M. Use the chart provided in this Section as a convenient aid to keep a record of maintenance performed. Tool Requirements Most of the maintenance operations described in this manual can be performed with common hand tools (S.A.E. wrenches, sockets, and screwdrivers). The following is a list of special service tools required for some maintenance operations: ‘Too! Part No. Description ‘ST-1293 Belt Tension Gauge (V-belts) 3375049 il Filter Wrench 3376807 Water/Fuel Filter Wrench 3822524 Belt Tension Gauge (Click-Type) 3822525 Belt Tension Gauge (Click-Type) 3824783, Inch Pound Torque Wrench Refer to the appropriate sections for a description of the tools and how to use them, Contact your nearest Cummins Authorized Repair Location for the required service tools.Section 2 - Maintenance Guidelines Engine Maintenance Schedule Qski9 Page 2-3 Engine Maintenance Schedule i Equipment No.________ Engine Serlal No___ Maintenance Schedule See —— Fei Slama, Pane Se om ——— ‘QSK19 Series Cummins Diesel Engines [Check each operation as performed. 350 Howe “E00 Hows 000 Hows Daty Meaty ios, 1 Moor 2 ore otter (seeteh 3 sedien’s stein 5 (séete) tenn (sector 8) est Day Check | Repest(Daliy/Wceki | Repeat Prviouw | Repeat Previous Repeat Day (at ‘tena ire 1 Shesk pours. |r cigar sean: | otros engine ot | Sean can one [C1 Swap anscarate | «Atom oe eae Chaoge tere +cat aves ad ++ Genero, 0 Cheek ogi: TEST Eembiaion | igaclet Ci Ingpestcreckine | E Psi 2 Bere {Biowing essen: | +Stator 5 aa vt 2 Espiner | Luete Myer | ae comprocsoe ima ean | Aisemeresor ar | Panky Miao amp |) +A ees rau, Sox ner omer’ | choctepiace roses | * A comacostor cancion ral Boreal conee- ‘must be cbocked) |) Orin ar tanks |) Lubvioate seroqund See Ohne oven Unusual Engine Noise i | Check During the daily maintenance check, listen for any un- © usual engine noise that can indicate that service is —— required. oS i r i To -vome Fuel-Water Separator Drain Ifthe engine is equipped with a fuel-water separator, drain the water and sediment from the separator daily. Shut the engine OFF. Use your hand to open the drain — valve. Turn the valve counterclockwise approximately bend 2-1/2 turns until draining occurs. Drain the filter sump of water until clear fuel is visible. Cc > A Caution: Do not overtighten the valve. Overtightening c > ewe can damage the threads. Turn the valve clockwise approximately 2-1/2 turns to close the drain valve.Section 3 - Daily Maintenance Procedures aski9 Oil Level Check Cheek the oil level daily. Never operate the engine with the oil level below the L (Low) mark or above the H (High) mark. Wait at least 5 minutes after shutting off the engine to check the oil. This allows time for the oil to drain to the oil pan. NOTE: The vehicle must be level when checking the oil level to be sure the measurement is correct. Coolant Level Check Warning: Do not remove the radiator cap from a hot engine. Wait until the temperature is below 50°C [120°F] before removing the pressure cap. Fallure to do so can result in personal injury from heated coolant spray or steam. Remove the filler cap slowly to relieve coolant system pressure. Caution: Never use a sealing additive to stop leaks in the coolant system. This can result in coolant system plug- ging and inadequate coolant flow. ‘The coolant level must be checked daily. Caution: Do NOT add cold coolant to a hot engine. En- gine castings can be damaged. Allow the engine to cool to below 50°C [120°F] BEFORE adding coolant. Fill the cooling system with coolant to the bottom of the fill neck in the radiator fill or expansion tank. NOTE: Some radiators have two fill necks. Both must be filled when the cooling system is drained. Oil Level Page 3-3Belts Page 3-4 Section 3 - Daily Maintenance Procedures ‘QSK19 Belts Check ‘Visually inspect the belts daily. Replace the belts that are cracked or frayed. Adjust belts that have a glazed or shiny surface that indicates belt slippage. Correctly installed and tensioned belts will show even pulley and belt wear. Belt damage can be caused by: * Incorrect tension * Incorrect size or length * Pulley misalignment * Incorrect installation * Severe operating environment Oil or grease on the belts Air Cleaner Precleaner and Dust Pan Check/Clean Under extremely dirty conditions an air precleaner can be used. Clean the precleaner jar and dry-type air cleaner dust pans daily or more often, as necessary, depending ‘on operating conditions.Section 4 - Weekly Maintenance Procedures QsKi9 Page 4-1 Section 4 - Weekly Maintenance Procedures Section Contents Page 42 45 Air Cleaner Element - Replace Cartridge Type Element - Repiace Dual Heavy Duty Dry-Type Element - Replace Single Heavy Duty Dry-Iype Element - Replace Air Intake Hoses, Pipes, and Clamps’ Check Air Tanks Drain’ General Information Inlet Air Restriction Indicators Mechanical Indicator Vacuum Indicator & 35 $8 8 42 42 42General Information Page 4-2 tot @@ Section 4 - Weekly Maintenance Procedures QSK19 General Information All checks or inspections listed under the daily mainte- nance interval must also be performed at this time in addition to those listed under this maintenance interval. Inlet Air Restriction Indicators Mechanical Indicator ‘A mechanical restriction indicator is available to indicate excessive air restriction through a dry-type air cleaner. This instrument can be mounted in the air cleaner outlet or on the vehicle instrument panel. The red flag (1) in the window gradually rises as the cartridge loads with dirt. After changing or replacing the cartridge, reset the indi- cator by pushing the reset button (2). Restriction or vacuum indicators are to be installed as, close as possible to the turbocharger air inlet in order to obtain a true indication of restrictions. NOTE: Never remove the absorbent washer from the indi- ator. The washer absorbs moisture. Vacuum Indicator Vacuum switches actuate a warning light on the instru- ment panel when the air restriction becomes excessive. ‘Turbocharger Air Restriction (Maximum): 635 mm-H,0 [25 in-H,0] Cleaner Element - Replace NOTE: The illustrations in this section show typical dry-type air cleaner parts. The particular engine parts can vary. Replace the element if the inlet restriction or vacuum at {ull power exceeds 635 mm-H,0 [25 in-H0] water. Chang- ing filters or breaking the seal on the intake system more than necessary will result in excess dirt in the engine and must be avoided.Section 4 - Weekly Maintenance Procedures aski9 NOTE: Cummins Engine Company, Inc. does not recom- mend cleaning paper-type air cleaner elements, Elements that have been cleaned several times will finally clog and air flow to the engine will be restricted. After cleaning, check the restriction as previously described. Replace the element if necessary. Caution: Holes, loose end seals, dented sealing sur- faces and other forms of damage render the cleaner inoperative and require immediate element replacement. Remove the wing nut (1) that secures the bottom cover (2) to the cleaner housing (3). Remove the cover. Pull the element (6) down from the center bolt (4). Caution: Pull the cover and the element straight out during removal from the housing to avoid damage to the element. Remove the gasket (5) from the outlet end (7) of the housing. Single Heavy Duty Dry-Type Element - Replace Heavy duty air cleaners combine centrifugal clea with element filtering before air enters the engines, Before disassembly, wipe dirt from the cover and the upper portion of the air cleaner. To clean the single types: Loosen the wing bolt (2) and remove the band securing the dust pan (1). Loosen the wing nut (2). Remove the dust shield (3) from the dust pan (1). Clean the dust pan and shield, Remove the wing nut (5) that secures the air cleaner primary element in the air cleaner housing. Inspect the rubber sealing washer on the wing nut (4). Install the new primary element. Be sure the gasket washer is in position under the wing nut before tightening, Assemble the dust shield and dust pan again. Position them to the air cleaner housing and secure with the band. Air Cleaner Element - Replace Page 4-3 sc4eta ‘sctetad sctetooAir Cleaner Element - Replace Section 4 - Weekly Maintenance Procedures Page 4-4 Qski9 Dual Heavy Duty Dry-Type Element - Replace Heavy duty air cleaners combine centrifugal cleaning with element filtering before air enters the engines. Before disassembly, wipe dirt from the cover and the R upper portion of the air cleaner. To clean the dual types: Loosen the wing bolt (1) and remove the band securing the dust pan (2). sotatge Loosen the wing nut (3). Remove the dust shield (4) from the dust pan (2). Clean the dust pan and shield. Remove the wing nut (5) that secures the air cleaner first stage element (6) in the air cleaner housing. inspect the rubber sealing washer on the wing nut. scteige Install the new air cleaner element. Be sure the gasket washer is in position under the wing nut before tightening. Assemble the dust shield and dust pan again. Position them to the air cleaner housing and secure with the band. On the dual element type Cyclopac cleaner: Check the air restriction indicator. If the air restriction is excessive, disassemble the air cleaner, remove the wing nut (7) and replace the safety element (8). Assemble the air cleaner as described above.‘Section 4 - Weekly Maintenance Procedures aski9 Cartridge Type Element - Replace Loosen the wing nuts (4) on the air cleaner housing (5) to remove the precleaner panel with the dust bin (6). To remove the precleaner panel (2) equipped with an ex- haust aspirator, loosen the U-bolt clamp securing the precleaner to the aspirator tubing. Remove the dirty Pamic cartridge (3) by inserting your fingers in the cartridge opening (loosen all four corners of the cartridge one at a time) and pulling it straight out. With the larger cartridge, it may be necessary to break the seal along the edges of the cartridge. After the seal has been broken, pull the cartridge straight out and slightly up so the cartridge will clear the sealing frame and edges of the air cleaner housing. Cleaning and Inspection Clean the precleaner openings (2) of all soot, oil film, and any other objects that can become lodged in the open- ings. Remove any dust or dirt in the lower portion of the precleaner and aspirator tubing, Inspect the inside of the air cleaner housing for foreign material. Inspect the dirty cartridge for soot or oil. If there is soot inside the Pamic tubes, check for leaks in the engine exhaust system, exhaust blow-back into the air intake, and exhaust from other equipment. If the cartridge ap- pears oily, check for fumes escaping from the crankcase breather, Excessive oil mist shortens the life of any dry- type cartridge. Troubleshooting at this point can appre- ciably lengthen new cartridge life. It is not recommended to clean and reuse the cartridge. When returned to service, life expectancy of a cleaned cartridge will be only a fraction of the original service life. Inspect clamps and flexible hose or tubing to be sure all fittings are air tight on cleaners with exhaust aspirators. The precleaner dust (6) bin is self-cleaning. Assembly Inspect the new filter cartridge for shipping damage be- fore installation. To install a new cartridge, hold the cartridge (3) in the same manner as when removing it from the housing. Insert the clean cartridge into the housing, avoiding hit- ting the cartridge tubes against the sealing flange on the ‘edges of the air cleaner housing. Air Cleaner Element - Replace Pag QaAir Intake Hoses, Pipes, and Clamps Page 4-6 Section 4 - Weekly Maintenance Procedures ‘QSK19 As the cleaner requires no separate gaskets for seals, care must be exercised when inserting the cartridge to insure a proper seat within the cleaner housing. Firmly press all edges and comers of the cartridge with your fingers to effect a positive air seal against the sealing flange of the housing. The cartridge must not be pounded or pressed in the center to seal. Replace the precleaner panel (2) and tighten the wing nuts (4) by hand. For final tightness turn the wing nuts 1 to 1-1/2 turns with a small adjustable wrench. Do not tighten too much. On a precleaner with an exhaust as- pirator, assemble the aspirator tube to the precleaner panel and tighten the U-bolt. Care must be exercised to keep the cleaner face unobstructed. Air Intake Hoses, Pipes, and Clamps Check Inspect the intake piping for cracked hoses, loose clamps, or punctures that can damage the engine, Tighten or replace parts as necessary to be sure the air intake system does not leak. ‘Check for corrosion of the intake system piping under the clamps and hoses. Corrosion can allow corrosive prod- ucts and dirt to enter the intake system. Disassemble and clean as required. Air Tanks Drain Drain the moisture from the air system wet tank weekly.Section 5 - Maintenance Procedures Every 250 Hours or 6 Months OSK19 Page 5-1 Section 5 - Maintenance Procedures Every 250 Hours or 6 Months Section Contents Air Compressor Air Cleaner Element. Bendix-Westinghouse Paper Element - Replace Bendix-Westinghouse Sponge Element - Replace Crankcase Breather Tube/Hose CheckiClean ... Engine Wiring. Inspect Fan Idler Pivot Arm Lubricate .. General Information. Lubricating Oil and Oil Filter Change/Replace. Supplemental Coolant Additive (SCA) laintenance Check.General Information Section 5 - Maintenance Procedures Every 250 Hours or 6 Months QSK19 General Information All checks or inspections listed under the previous main- tenance intervals must also be performed at this time in addition to those listed under this maintenance interval. Fuel Filter(s) Replace Warning: Fuel is flammable. Do not allow cigarettes, flames, sparks, arcing switches or equipment, pilotllights, or other ignition sources near the fuel system. <4 Close the fuel line shutoff valve before changing the fuel filters or the overhead tank can drain causing a fuel leak. ] Remove the fuel fiter with filter wrench, Part No. 3376807. Ra Remove the thread adapter sealing ring (1). Use a clean, lint-free towel and clean the surface of the filter head gasket. Use the correct filters, Cummins Part No. 3889716 and Fleetguard® Part No. FS1000, for your engine. Fuel Filter Specifications (Cummins Engine Company, Inc. Standard No, 14,223) Efficiency: 98.7% at 10 microns 96% at 8 microns 86% at 5 microns Water Removed: Free = 95% Emulsified = 95% Install a new thread adapter sealing ring supplied with the new filter. A tuel-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.Section 5 - Maintenance Procedures Every 250 Hours or 6 Months Qski9 Install the filter on the filter head. Turn the filter until the jx, gasket touches the surface of the filter head. Ce Tighten the fiter 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. Lubricating Oil and Oil Filter Lubricating Oil and Oil Filter Page 5-3 +¥2 to % Turn cod Change/Replace : Avoid direct contact of hot oil with your skin. A san cause personal injury. Change the lubricating oilandoilfiters atevery ollchange [\] interval. Operate the engine until the water temperature reaches. @ 60°C [140°F]. Turn the engine OFF. Remove the oil drain plug. Drain the oil immediately to be sure all the oil and suspended contaminates are removed from the engine. &Re Clean the area around the lubricating oil filter head. Clean the gasket surface of the filter head. NOTE: The o-ring can stick on the filter head. Be sure the o-ring is removed. Use an oil filter wrench, Part No. 3376807, or equivalent. Remove the oil filters. Discard the filters if they are not needed for a failure analysis. Cutall the way around the top of the oil filters using a pipe cutter or hack saw. Inspect the pleated paper element for metal debris. Metal debris in the filter can reveal impend- ing engine failure. if debris is found, find the reason for the debris and perform the needed repairs. Use the correct oil filters for your engine. Combination Full Flow/Bypass Filter (2 required) Cummins Part No. 3318853 Fleetguard® Part No. LF-3000 rscoanSection 5 - A Lubricating Oil and Oil Filter Page 5-4 ovso00n seco SES Maintenance Procedures Every 250 Hours or 6 Months QsKi9 Caution: Fill the oil filters with clean lubricating oil. The lack of lubrication during the delay until the filters are pumped full of oil is harmful to the engine. Apply a light film of lubricating oil to the gasket sealing surface before installing the new filters. Caution: Mechanical overtightening can distort the threads or damage the filter element seal. Install the filter as specified by the filter manufacturer. The tightening instructions are normally printed on the out- side of the filter. Check and clean the oil drain plug threads and the seal surface. Install and tighten the oil drain plug. Torque Value: 100 Nem [75 ft-lbs] NOTE: Use a high quality 15W-40 multiviscosity oil such as Cummins Premium Blue™, or equivalent, in Cummins en- gines. Choose the correct oil for your operating climate as outlined in Section V of this manual.‘Section 5 - Maintenance Procedures Every 250 Hours or 6 Mont Qski9 Fill the engine with clean oil to the correct level. Total get system capacity including filters is listed in Section V of this manual. Caution: Before starting the engine, complete the steps A given in Starting Procedure After Extended Shutdown in Section 1 to be sure the engine receives correct lubri- cation. Lack of lubrication will damage the engine. Operate the engine at idle speed to inspect for leaks at the filters and the drain plug. the oil drain from the upper parts of the engine. Check the oil level again. ‘Add oil as necessary to bring the oil level to the high mark (H) on the dipstick. ‘Turn the engine OFF. Wait approximately 5 minutes to let Crankcase Breather Tube/Hose Check/Clean Every 250 hours or 6 months, check and clean the crank- case breather tube/hose. The tube ie to be removed and checked internally for 7.) obstructions or sludge buildup. If the tube is blocked, it is to be cleaned to prevent excess crankcase pressure buildup. &Re ths Crankcase Breather Tube/Hose Page 5-5DCA4 Concentration Page 5-6 Syringe Section 5 - Maintenance Procedures Every 250 Hours or 6 Months ‘Small Plastic Container Qski9 Supplemental Coolant Additive (SCA) Maintenance Check Check the SCA concentration level: ** at least twice a year. * at every subsequent oil drain interval if the con- centration is above 3 units. * whenever coolant is added to the cooling system between filter changes. Use Fleetguard® coolant test kit, Part No. CC2602, to check the concentration level. instructions are included with the test kit. Refer to Coolant Recommendations and ‘Specifications in Section V for the correct SCA level. Warning: Check the coolant level ONLY when the engine is stopped. Wait until the coolant temperature is below 50°C [120°F] BEFORE removing the pressure cap. Fail- ure to do so can cause personal injury from heated cool- ant spray. Operate the engine and check for coolant leaks. After the air has been purged from the system, check the coolant level again. Diesel coolant additives (or equivalent) aro used to pre- vent the buildup of corrosion and scale deposits in the cooling system. Caution: Under-concentration of coolant additives can result in liner pitting and system corrosion. Over- concentration can result in water pump seal leakage. The recommendad concentration level of supplemental coolant additives is 1.5 per U.S. gallon of coolant. The additive level must never drop below 1.2 units or exceed 3 units per U.S. gallon.Section 5 - Maintenance Procedures Every 250 Hours or 6 Months Qsk19 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. ‘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 DCAd (or equivalent). Refer to Section V for cleaning in- structions. If coolant is added between drain intervals, additional DCA4 (or equivalent) will be required unless the added coolant is percharged with additives as described in this, section. If coolant is added between drain intervals, additional DCA (or equivalent) will be required. Use coolant test kit, Fleetguard® Part No, C2602, to ‘check the coolant additive concentration when Fleetguard ‘SCAs are used. Coolant Filter Use the correct Fleetguard® coolant filter to maintain the correct DCA4 concentration in the system. Maintain the correct concentration by changing the ser- vice coolant filter at each oil drain interval. Refer to Fleetguard® DCA4 Service Filters and Liquid Precharge in Section V of this manual for further information. aS Coolant Filter Page 5-7 FE} 28000 98400076Coolant Filter R ee Section 5 - Maintenance Procedures Every 250 Hours or 6 Months askis Replace Change the service coolant filter at every oil and filter change interval. ‘The correct service coolant filter to be used is determined by the total cooling system capacity and other operational factors. Refer to the DCA4 Maintenance Guide in Section V for the correct filter selection. Do NOT remove the radiator cap from a hot engine. Hot steam will cause serious personal injury. Remove the coolant system pressure cap and close the shutoff valve(s), if equipped, before removing the cool- ant filter. Failure to do so can result in personal injury from heated coolant spray. Jum the valve on the filter head to the OFF position. Remove and discard the coolant filter. Use engine oil and lubricate the seal on the new filter. NOTE: Do not allow oil to get in the filter. It will adversely affect the DCA4.Section 5 - Maintenance Procedures Every 250 Hours or 6 Months Air Compressor Air Cleaner Element Page 5-9 Install the new coolant filter. Turn the filter until the seal apy. touches the filter head. Turn the filter an additional 1/2 to ep 3/4 of a turn after contact. ‘Turn the valve to the ON position. Air Compressor Air Cleaner Element Bendix-Westinghouse Paper Element - Replace Remove the breather cover and element. Clean by re- verse flushing with compressed air. Assemble on the com- pressor. Discard the element if it is damaged or can not be cleaned. Bendix-Westinghouse Sponge Element - Replace Remove the breather from the air compressor. Disas- semble the breather, wash all metal parts in solvent, and blow dry with compressed air, Wash the element in sol- vent. Remove all solvent from the element. Dip the ele- ment in clean engine oil and squeeze excess oil from the element. NOTE: If other compressors are used, follow the manufac- turer’s service requirements.Belt Tension Page 5-10 Section 5 - Maintenance Procedures Every 250 Hours or 6 Months: askis Belt Tension Check Measure the belt tension in the center span of the pulleys. Refer to the Drive Belt Tension Chart, Section V, for the correct gauge and tension value for the belt width used. Cooling Fan Check Warning: Personal injury can result from a fan blade failure, Never pull or pry on the fan. This can damage the fan blade(s) and cause fan failure. NOTE: Rotate the crankshaft by using the engine barring gear. ‘Check the cooling fan every 250 hours or 6 months. Check for cracks, loose rivets, and bent or loose blades. Check the fan to be sure it is securely mounted. Tighten the capscrews if necessary. Replace any fan that is damaged. Fan Idler Pivot Arm Lubricate Use water pump type grease to lubricate the fan idler pivot arm assembly. Lubricate the pivot arm until grease ap- pears from under the bushings. Engine Wiring Inspect Caution: Never touch the wiring connections when the key switch is turned on. Electrical shock can result. Visually inspect all wiring connections and wiring har- ness for damage. Faulty wiring can cause improper en- gine operation and poor performance.Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year QSk19 Page 6-1 Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Section Contents Batteries Check .. Cold Start Aids (Seasonal) ‘Check Crankease Breather Element ‘Screen Element Breather - Clean/Replace Crankshaft End Ci Inspect jine Mounting Bolts and Nuts heck /Tighten ... Fan Hub, Belt Driven Lubricate .. General Information. Hoses .. Checkiepiace Overhead Set (OBC) Adjust, ance Valve and Injectors General Information - Check and Adjust ..General Information Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Page 6-2 askis General Information All checks or inspections listed under the previous maintenance intervals must also be performed at this time in addition to those listed under this maintenance interval. Steam Clean the Engine Caution: Coverall engine openings and electrical equip- ment to prevent water damage. Steam clean the engine before conducting any 1500 hour maintenance. Steam is the best method of cleaning a dirty engine or a piece of equipment. If steam is not available, use a solvent to wash the engine. Protect all electrical components, openings, and wiring from the full force of the cleaner spray nozzle, Valve and Injectors General Information - Check and Adjust Valves and injectors must be correctly adjusted for the engine to operate efficiently. Valve and injector adjustment must be performed using the values listed in this section. ‘Cummins engines in most applications will not experience significant valve and injector train wear after an initial adjustment is made at 1500 hours. After this adjustment, Cummins recommends the valves and injectors not be adjusted again until the 6000 hour or 2 year injector calibration interval. Because injector train hardware is typically mixed between cylinders during injector replacement, Cummins recommends to adjust valves and injectors 1500 hours after all injector replacements. 1. Engine firing order 1-5-3-6-2-4. Cylinders are numbered from the front gear cover end of the engine, ‘Two crankshaft revolutions are required to adjust all of the valves and the injectors. ‘One pair of valves and one injector are adjusted at each pulley index mark before rotating the engine to the next index mark. BeoN The valves and the injectors on the same cylinder are not adjusted at the same mark. Each cylinder has three rocker levers. The lever nearest to the front of the engine is the exhaust lever. The injectors are adjusted by the outer base circle (OBC) method. Instructions for adjusting the injectors are included in the Injector-Adjust section, PNOeSection 6 - Maintenance Procedures Every 1500 Hours or 1 Year Valve and Injectors aski9 Page 6-3 QUANTUM™ Fuel System InjectorOverhead Set (OBC) Page VALE AND mUCTOR ‘ADUSTMENT LATS INJECTOR 19Nm [165inib] OBC Method met INTAKE VALVE 0.28 (0.014) EXHAUST VALVE 0.81 [0.032] RECHECK LIMITS. INJECTOR 498m [165inb} OBC Method mm fn) weraxevaLve 0.28 MIN [0.011] 0.43 MAX [0.017] EXHAUST VALVE 0.74 MIN [0.029] 0.89 MAX [0.035] ‘96400006 R aS Section 6 - Maintenance Procedures Every 1500 Hours or 1 Ye: aski9 Overhead Set (OBC) Check Valves and injectors must be correctly adjusted for the engine to operate efficiently. Valve and injector adjust- ment must be performed using the values listed in this section. Cummins has found that engines in most applications will not experience significant valve/injector train wear after an initial adjustment is performed at 1500 hours. After this adjustment, it is recommended that the valves and in- jectors not be adjusted again previous to injector c bration at the 6000 hour or 2 year interval. Because in- jector train hardware is typically mixed between cylinders during injector replacement, it is recommended to adjust valves and injectors 1500 hours after all injector replacements. : Itvalve and injector adjustment is checked during trouble- shooting or before the recommended maintenance inter- val, adjustment is not required if measurements are within the recheck limits. Adjust ‘Turn the engine OFF. Remove the rocker lever cover and all related components.Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year aski9 NOTE: Some engines have different index marks than A, B, and C. These engines, * 5-2 VS is the same as A. + 3-4 VS is the same as B. * 6-1 VS is the same as C. NOTE: VS represents the valve set. Ignore any 1-6 TC mark during adjustment. NOTE: The barring device shaft turns approximately 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 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. Betermine the Cylinder in Position for Valve et The vaives will be adjusted on the cylinder that has all the valves closed. Use the table to determine the cylinders to check 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 alll 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. Tum 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, NOTE: The number of threads visible above the adjusting ut will net be the same. There will be more threads visible fn the intake adjusting screw than on the exhaust. Overhead Set (OBC) Page 6-5 if Valve Check Valve Set Mark Is: Position On: A 1,6 B 25 Cc 3,4 ‘woeOverhead Set (OBC) Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year 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. 2 are closed (ready to set). 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 vaives 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 Recheck Limits mm in MIN, i MAX .01 Exhaust Valve 0.74 MIN [0.029] oa MAX [occas Select a feeler gauge for the correct valve lash specifi- cation. insert the gauge (2) between the rocker socket and the crosshead. NOTE: Be sure the feeler gauge is centered under the foot ‘on the rocker lever.Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Overhead Set (OBC) rage 6-: ask19 ‘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. ~ Torque Value: 0.68 Nem [6 in-Ib] * 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 Nem (6 in-Ib] Feel Method The feeler gauge must slide backward and forward with only a slight drag. 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. 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 Nem [35 ft-lb] * Without Adapter: — Torque Value: 60 Nem [45 ft-1b] ® ©‘Overhead Set (OBC) Page 6-8 © Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year aski9 Injectors The torque wrench must be calibrated, have a resolution of 0.28 Nem [2.5 in-Ib], and have a range of 17 to 23 Nem [150 to 200 in-Ib]. Do not use acclicker-type torque wrench. Use a dial-type torque wrench to tighten the injector rocker lever adjusting screw. If the screw causes chattering dur- ing 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 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 Nem [180 in-Ib] Loosen the adjusting screw at least 1 revolution. Tighten the adjusting screw again. Torque Value: 19 Nem [165 in-Ib] 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-669: — Torque Value: 45 Nem [35 ftb] * Without Adapter: — Torque Value: 60 Nem [45 ft-b}Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Overhead Set (OBC) Qski9 Page 6-9 Worksheet“ °° 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, 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. o Inspection Report for Valve Lash and Injector Travel VS Mark and Injector Work Valves to Reset Cylinder Torque Sequence Be Set Intake Exhaust (VIN) No. Adjustment AS 3 = BS — an = 6 — Ce —_—— an —_ 2 — A2 — = —_— 4 = Ba — a —_ 1 — Ct _ > —_ 5 Customer: Location: Unit No. Hours: Date: Job N Engine Model Ni Engine Serial No.: ‘Type of Inspection (Failure, Routine, Complaint): Inspection Notes: This page can be copied for your convenience.Fan Hub, Belt Driven Page 6-10 Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year roatne brane aski9 Fan Hub, Belt Driven Lubricate Caution: If vent plug is not removed, the seal can be damaged and lead to bearing failure. Use Chevron SRI™ grease, or equivalent, to lubricate the fan hub. Remove the vent plug from the fan hub grease cavity. Apply grease through the grease fitting until grease comes out of the vent hole. Install the vent plug in the vent hole. Torque Value: 20 Nem [15 fib} Crankcase Breather Element Screen Element Breather - Clean/Replace Every 1500 hours or 1 year, clean and/or replace the crankcase breather element. The tube is to be removed and checked internally for obstructions or sludge buildup. Ifthe tube is blocked, itis to be cleaned to prevent excess crankcase pressure buildup. Remove the vent tube. Remove the following parts from the breather body (6): (1) Wing Nut (2) Washer (8) Breather Cap (4) Screen Mesh (©) Element Clean the vent tube and screens in an approved cleaning solvent. Dry with compressed air. Wipe out the breather housing (6). Install the parts in the following order: (4) Screen Mesh (5) Element (4) Screen Mesh (8) Breather Cap (2) Washer (1) Wing Nut Replace the vent tube.Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year ask19 Crankshaft End Clearance Inspect Measure the crankshaft end clearance with a dial indi cator. Measure the clearance. ‘Crankshaft End Clearance Table New New Worn Minimum Maximum Limit 0.18 mm 0.43 mm 0.56 mm. [0.007 inch] [0.017 inch} [0.022 inch] ‘The check can be made by attaching an indicator to rest against the damper or pulley while prying against the front cover and inner part of the pulley or damper. End clearance must be in specification with the engine ‘mounted in the unit and assembled to the transmission or converter. Caution: Extreme care MUST be used in prying against the viscous damper. Sharp pry bars can damage the damper casing, resulting in a leak of the viscous fluid and ultimate failure of the damper. If the clearance is not within specifications, contact your ‘Cummins Repair location. Batteries Check If vonventional batteries are used, remove the cell caps ‘or covers and check the electrolyte (water and sulfuric acid solution) level. NOTE: Maintenance-free batteries are sealed and do not require the addition of water. Fill each battery cell with distilled water. Refer to the manufacturer's specifications. Use the Fleetguard® refractometer, Part No. CC-2800, to check the condition of the battery. Refer to the battery fluid column in the refractometer to determine the state-of-charge of each battery cell. Crankshaft End Clearance Page 6-11Cold Start Aids (Seasonal) Page 6-12 ‘Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Qski9 Use a battery tester to test the state-of-charge of maintenance-free batteries. If the state-of-charge is low, use a battery charger to ‘=> charge the battery. Refer to the manufacturer's instruc- tions. Replace the battery if it will not charge to the manufac- turer's specifications or will not maintain a charge. Cold Start Aids (Seasonal) Check © Oil pan heater Check for proper operation. Inspect for loose connec- @ tions, frayed wires, and oil leaks. Repair or replace as needed. © Block heater Check for proper operation. Inspect for loose connec- tions, frayed wires, and oil leaks. Repair or replace as needed. + Engine Preheater (Coolant) Check for proper operation. Inspect for loose connec- tions, frayed wires, and coolant leaks. Clean out the unit of alkali and sludge. Clean the scale from the copper heating element with a wire brush.Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year asKi9 Engine Mounting Bolts and Nuts Check/Tighten Check the torque on the nuts and bolts annually. Tighten any that are loose. Inspect the rubber for deterioration and age hardening. Replace any broken or lost bolts, capscrews, or damaged rubber. ‘Capscrew size and grade vary with the flywheel housing and mounting arrangement. Determine the size and grade of the mounting bolts. Refer to the capscrew torque val- ues in Section V of this manual. Hoses Check/Replace Annually inspect the bypass oil filter and cooling system hoses and hose connections for leaks or deterioration, Particles of deteriorated hose can be carried through the cooling system or lubricating system and restrict or clog small passages, especially radiator core, and lubricating cil cooler, and partially stop circulation. Replace as necessary. Engine Mounting Bolts and Nuts Page 6-13Hoses Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Page 6-14 @skis NOTESSection 7 - Maintenance Procedures Every 6,000 Hours or 2 Years QSK19 Page 7-1 Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years Section Contents Page Air Compressor Air Compressor Discharge - Check Air Compressor Intake - Check .. Inspect Coolant and Filters Change Fan Hub, Belt Driven Inspect. Fan Idler Pulley Assembly Inspect General Information Injectors .. Clean and Calibrate Filter Screen - Inspet Filter Screen - Install Filter Screen - Remove. Inspect. Install Remove. ‘Turbocharger Inspect Vibration Viscous Water Pump Inspect...General Information Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years Page 7-2 QSK19 General Information All checks or inspections listed under the previous main- tenance intervals must also be performed at this time in addition to those listed under this maintenance interval. Injectors . Clean and Calibrate Every 6,000 hours or 2 years clean and calibrate the injectors. NOTE: This procedure requires special equipment and must be done at a Cummins Authorized Repair Location. Remove => Remove the rocker cover. Refer to QSK19 Troubleshoot- ing and Repair Manual, Bulletin No. 3666098. Remove the rocker lever assembly. Refer to the QSK19 Troubleshooting and Repair Manual, Bulletin No. 3666098,Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years aski9 NOTE: The hold-down clamp is not removable until the injector is removed. Remove the injector hold-down capscrew. Remove the injector and clamp. Use injector puller, Part No. 3823579, to remove QUAN- TUM™ injectors. Insert the pin of the tool into the hole provided in the body of the injector. The hole faces the front of the engine. If the injector pullers mentioned above are not available, carefully use a pry bar. Pry upward on the injector against the cylinder head. Inspect Remove the sealing ring (1) and note the cylinder loca- tion. NOTE: Sealing rings are available in different thicknesses. Be sure to install the same thickness sealing ring as the ‘one removed. Remove the o-rings (2, 3, 4, and 5). Use a lint free cloth and clean the exterior of the injector. Carefully check the area where the sealing ring contacts 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. O-ring (2), Part No. 3042543, is brown and is smaller in diameter than the other three. O-ring (8), Part No. 3076094, is black. O-ring (4), Part No. 3076095, is brown and is larger in diameter than (2), buthas asmaller cross section than (6). O-ring (6), Part No. 3076096, is brown and is the largest in diameter and cross section. Injectors BeSection 7 ~ Maintenance Procedures Every 8,000 Hours or 2 Yeat B rs SK19 NOTE: Do not lubricate the o-rings until the injector is ready for installation into the cylinder head. Install four new o-rings on the injector. Do not twist the ‘o-rings, Install the proper size sealing ring. Filter Screen - Inspect NOTE: If cleaning the filters, use solvent. The screens must be dried before being installed. 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 in position. Filter Screen - Remove Use a small screwdriver to remove the filter screen. Gen- tly pry up on the connector clip.Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years Injectors Qski9 Page 7-5 Filter Screen - Install Wrap the filter screen around the inlet groove. Apply pressure on the filter screen connector clip. A prop- jx, erly secured connector clip will create a single, snapping Rp sound. Install Use clean 15W-40 oil. Lubricate the o-rings. Install the hold-down clamp onto the side of the injector.Injectors Page 7-6 Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years askt9oBc ooBour askis Install the injector and hold-down clamp into the cylinder head. Use injector installation tool, Part No. 3824830 and 3823579, to set the injector in the bore. Asingle, snapping sound will be heard when the injector is seated properly. NOTE: If the injector installation tool, Part No. 3824830, is not available, use a 40 mm [1 9/16 in] socket with an ex- tension and a rubber mallet to install the injector. fa !nstall the injector hold-down capscrew. Gn Install the rocker lever assembly. Refer to the QSK19 ep Troubleshooting and Repair Manual, Bulletin No. 3666098. SF Torque Value: 225 Nem [165 ft-lb] Adjust the valves and injectors. Refer to the Overhead SS (OBC) Adjustment in this manual.‘Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years QSK19 Install the rocker lever cover. Refer to the QSK19 Trouble- shooting and Repair Manual, Bulletin No. 3666098. Torque Value: 45 Nem [365 ft-lb] Coolant and Filters Change Caution: Do NOT use caustic cleaners in the cooling system. Aluminum components will be damaged. Every 6,000 hours or 2 years change the coolant and the antifreeze. The cooling system must be clean to work correctly. Drain the system, and flush with clean water. If the system shows mineral buildup, scale, rust, or oil, clean with a heavy duty engine coolant cleaner and foliow the manu- facturer's directions. Fill the cooling system with the correct mixture of anti- freeze, water, and the correct DCA4, or equivalent units as outlined in Section V of this manual. Warning: Check the coolant level only when the engine is stopped. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Failure to do so can cause personal injury from heated coolant spray. Operate the engine, and check for coolant leaks. After the air has been purged from the system, check the coolant level again. Coolant and Filters Page 7-7Fan Hub, Belt Driven Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years ge 7-1 QSK19 Fan Hub, Belt Driven Inspect Every 6,000 hours or 2 years inspect the fan hub for @) wobble and grease leakage. Replace with a new or rebuilt unit as necessary. Refer to the Troubleshooting and Re- ‘> pair Manual, QSK19 Engines, Bulletin No. 666098, for removal and replacement instructions. Fan Idler Pulley Assembly Inspect Every 6,000 hours or 2 years inspect the fan idler pulley assembly. Rebuild or replace the idler pulley as neces- sary, Refer to the Troubleshooting and Repair Manual, QSK19 Engines, Bulletin No. 3666098, for rebuild or re- placement procedures. Water Pump Inspect Every 6,000 hours or 2 years inspect the water pump for coolant or oil leakage at the water pump weep hole. NOTE: A minor chemical buildup or streaking at the water pump weep hole is normal. Do not repair or replace the water pump unless an actual leak is confirmed. Refer to the ‘Troubleshooting and Repair Manual, QSK19 Engines, Bul- letin No. 3666098. Turbocharger Inspect Ifthe engine is equipped with a turbocharger, inspect the turbocharger every 6,000 hours or 2 years. Remove the air intake and the exhaust piping. Check the turbocharger as follows. Inspect for damaged or cracked compressor or turbine blades. Check to see that the turbocharger shaft spins freely. NOTE: If visual inspections or dimensional checks indicate a probl ntact a Cummin: \orized Repair LocationSection 7 - Maintenance Procedures Every 6,000 Hours or 2 Years Air Compressor askis Page 7-9 Measure the axial clearance (end-to-end). Rebuild or re- place the turbocharger if axial motion is greater than specified below. Refer to the Troubleshooting and Repair Manual QSK19 Engines, Bulletin No. 3666098, for re- moval procedures. Model Dimension Min Max Xe2 0,05 mm 0.13 mm [0.002 in} {0.005 in] Measure the radial clearance (side-to-side). NOTE: Hold the shaft toward the feeler gauge to check this dimension. Model HX82 ‘Compressor Impeller Min Max 0.15 mm [0.006 in} 0.45 mm [0.018 in} ‘Turbine Wheel Min Max 0.20 mm [0.008 in} 0.55 mm [0.024 in] Air Compressor Inspect Complete air compressor inspection is required every 6,000 hours or 2 years. NOTE: All air compressors have a small amount of oil car- ryover which lubricates the piston rings and moving parts. When this oil is exposed to normal air compressor operating temperatures over a period of time, it will form varnish or carbon deposits. If the following inspections are not done, the air compressor piston rings will be affected by high operating temperatures and pressures, and will not seal correctly. Air Compressor Discharge - Check Drain the air system wet tank to release the system air pressure. Remove the air discharge line from the air ‘compressor.Air Compressor Page 7-10 ID of Discharge Line Section 7 - Ss B Maintenance Procedures Every 6,000 Hours or 2 Years QSKi9 Measure the total carbon deposit thickness inside the air discharge line as shown. If the total carbon deposit (X + X) exceeds 2 mm [1/16 inch], clean and inspect the cyl- inder head, the valve assembly, and the discharge line. Replace if necessary. Refer to the appropriate Air Equip- ment Manual listed below for procedures, or contact your ‘Cummins Authorized Repair Location: ‘+ Holset Air Compressor Master Repair Manual, Bulletin No. 3666121 If the total carbon deposit exceeds specifications, con- tinue checking the air discharge line connections, up to the first tank, until total carbon deposit is less than 2mm [1/6 inch}. Clean or replace any lines or connections that exceed this specification. Inspect any air driers, spitter valves, pressure relief valves, and alcohol injectors for carbon deposits or malfunction- ing parts. Inspect for air leaks. Maintain and repair the parts according to the manufacturer's specifications. Air Compressor Intake - Check 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. Remove the air governor or air governor signal line from the air compressor unloader body.Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years ‘Air Compressor ge 7-1 Qski9 Warning: The unloader valve body's installed with spring tension. 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 two 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 cyl- inder air compressor. Two types have been used; ‘one that is secured by one capscrew, and one that is screwed in. Visually inspect the unloader vaive for carbon buildup. If carbon or heavy vamish is present, remove, clean, and inspect the compressor head and the valve assembly, Replace the parts as necessary. Refer to the appropriate Air Equipment Manual listed below for procedures, or contact your nearest Cummins Authorized Repair Loca- tion: * Holset Air Compressor Master Repair Manual, Bulletin No. 3666121 Clean the unloader valve with solvent and a non-metallic brush to remove carbon. Do not use a sharp object. The sealing surfaces can be damaged. Check for reuse. Refer to the Check procedure. SsAir Compressor Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years Page 7-12 Qski9 Use antiseize compound to lubricate the unloader cap. Use engine oil to lubricate the unloader body o-ring. As- semble the unloader assembly to the cylinder head cover. Tighten the capscrews. & Torque Value: 14 Nem [10 ftb] NOTE: Ifthe compressor has the three-prong unloader valve as shown, be sure the prongs are aligned with the slots in the intake vaive retainer. Install the center unloader on the two cylinder air com- pressor. Follow the previous steps. Tighten the capscrews. Torque Value: 40. Nem [30 ftbj Ga, Install the air governor or air governor signal line to the (Sis unloader body.Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years aski9 Vibration Dampers Viscous Vibration Dampers - Check ne fluid in the damper will become solid after extended service and the damper will be in- operative. An inoperative damper can cause major en- gine or driveline failures. 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. Check the damper for evidence of fluid loss, dents, and wobble, Visually inspect the vibration damper thickness for any deformation or raising of the damper front cover plate. Hfany variations or deformations are detected, refer to the ‘Troubleshooting and Repair Manual, QSK19 Engines, Bul- letin No. 3666098, for inspection procedures. [e SS Vibration Dampers Page 7-13Vibration Dampers Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years Page 7-14 aski9 NOTESSection 8 - Other Maintenance Procedures SK19 Page 8-1 Section 8 - Other Maintenance Procedures Section Contents Miscellaneous ..Miscellaneous Section 8 - Other Maintenance Procedures Qski9 Miscellaneous On the following components follow the manufacturer's <5 recommended maintenance procedures. Refer to Sec- tion M for Component Manufacturers’ locations. Air Compressor Alternator Batteries Clutched Fan Drives Freon Compressor Generator (Main Power) Hydraulic Pumps Marine Gear StarterSection A - Adjustment, Repair, and Replacement QSki9 Page A-1 Section A - Adjustment, Repair, and Replacement Section Contents Air Starting Motors .. Maintenance .. Alternator Belt .. Adjust. Battery Connections Fan Belt - Replace Adjust Check for Reuse Install Remove Lubricating Calibrate . Storage for Engines Out of ServiceAir Starting Motors. Page A:2 Parallel Connection Section A - Adjustment, Repair, and Replacement Qski9 Air Starting Motors The air starting motor system (tanks, line sizes, and valves) is designed and installed by the original equipment manu- facturer and the starting motor supplier. Refer any ques- tions about the air starting systems to the manufacturer. Maintenance * Do not operate the air starting motor with air pres- sure lower than 480 kPa [70 psi]. * Maintain the air compressor according to the rec- ‘ommendations outlined in the manual. * For maximum efficiency, the hoses, tubes, and lines must not leak. * Refer to the original equipment manufacturer and starting motor manufacturer manuals for specific information regarding the starting motors, valves, and systems. Battery Connections Caution: When using jumper cables to start the engine, be sure to connect the cables in parallel: positive (+) to positive (+) and negative (-) to negative (-). When using an external electrical source to start the engine, turn the disconnect switch to the OFF position and remove the key before attaching the jumper cables. ‘The accompanying illustration shows a typical parallel battery connection. This arrangement doubles the crank- ing amperage. This illustration shows a typical series battery connec- tion. This arrangement, positive to negative, doubles the voltage.Section A - Adjustment, Repair, and Replacement aski9 Alternator Belt Adjust NOTE: The lower jam nut has left-hand threads. Loosen the alternator and adjusting link mounting capscrews. Loosen the jam nuts on the adjusting screw. Turn the adjusting screw clockwise to tighten the belt tension. Belt Tension: 225 Nem [165 ft-lb] NOTE: The lower jam nut has left-hand threads. Tighten the jam nuts on the adjusting screw. Torque Value: 55 Nem [40 ft-lb] Tighten the adjusting link and alternator mounting capscrews. Torque Value: 55 Nem [40 ft-lb] Check the belt tension again to be sure the tension is correct. ws © a Alternator Belt Page A-3 ohneFan Belt - Replace Section A - Adjustment, Repair, and Replacement Page A-4 skis Fan Belt - Replace Remove 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).Tumn nut (1)counterclockwise to ‘end of the threaded rod to relieve the tension on the belt. Re Remove the fan belt. Check for Reuse Visually check the beft for: * Cracks * Glazing © Tears or cuts Install fay Install the belt. ipeagtion A- Adjustment, Repair, and Replacement ‘Storage for Engines Out of Service 19, Adjust Loosen the 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 Nem [60 ft-lb] NOTE: If the belt was not replaced, it is net 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. Storage for Engines Out of Service If the engine will be out of service longer than 6 months, take special precautions to prevent rust. Contact the near- B est Cummins Authorized Repair Location for information “=> concerning engine storage procedures. Lubricating Oil Dipstick Calibrate NOTE: This procedure must begin with the oll pan drained lay and machine and engine level. Rp 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 Lubricating Oil ‘System - Specifications, for the correct engine oil capac- ity for the application.Lubricating Oil Dipstick Page AG gs fap SE B Section A - Adjustment, Repair, and Replacement Qski9 Caution: Exercise 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. 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.Section D - Systems Diagrams aski9 yte ° Page D-1 Section D - Systems Diagrams Section Contents Page D-12 DA3 D8, D-1 Combustion Air System Flow Diagram.. Compressed Air System Flow Diagrams Coolant System Flow Diagram. Coolant System Flow Diagram - Jacket Water Aftercooled D9 Coolant System Flow Diagram - LTA. D0 Fuel Systems Flow Diagram .. D3 General Information be Lubricating System Flow Diagram. D-4, D-5, D-6, D-7General Information Page D-2 Section D - Systems Diagrams QSKi9 General Information The following drawings show the flow through the engine systems. Although parts can change between different applications and installations, the flow remains the same. The systems shown are: Fuel System Lubricating Oil System Coolant System| Intake Air System Exhaust System Compressed Air System Knowledge of the engine systems can help you in trouble- shooting, service, and general maintenance of your engine.Section D - Systems Diagrams Fuel Systems Flow Diagram ask19 Page D-3 Fuel Systems Flow Diagram 1. Fuel Manifold (Front) 10 2. Injector 3. Fuel Manifold (Rear) 4. Fuel Drain Line 5. Fuel Drain Line (Engine to Fuel Tank) 6. Fuel Control Valve Supply Line 7. Electronic Fuel Control Valve Assembly 8, Fuel Inlet Line 9. Fuel Filters with Water Separation 10, Fuel Inlet Line (Tank to Fuel Filters) 11. Fuel Pump 12, Fuel Supply Check Valve (Integral to Fitting) 13. Fuel Rall Supply Line 14, Fuel Timing Supply LineLubricating System Flow Diagram Section D - Systems Diagrams Page D-4 Lubricating System Flow Diagramsction D - Systems Diagrams SK19. Lubricating System Flow Diagram (Continue page BS Lubricating System Flow Diagram (Continued) FILTER HEAD (Oil In) 1. . Filter Bypass Valve . Oil Before Filter }. Full Flow Filter . Oil Filter to Head Pen Filter Head FILTER HEAD (Oil Out) Main Oil Rifle Oil Filter Head Full Flow Filter Piston Cooling Control Valve Piston Cooling Oil Rifle Piston Cooling Nozzle 7. Oil After Fitter ea repys FRONT OF ENGINE 1. Oil Supply to Turbocharger 2. Oil Supply to Cam Bushing 3. Main Oil Rifle 4, Oil Supply to Idler Gear and Hydraulic Pump Drive 5. Oil Supply to Air Compressor and Fuel Pump Drive 6. Oil Supply to Main Bearing and Idler 7. Oil Supply to Water Pump and Drive: 74008Lubricating System Flow Diagram (Continued) poe Sap axSection D - Systems Diagrams Lubricating System Flow Diagram (Continued) Qsk19 Page D- Lubricating System Flow Diagram (Continued) 1. Engine Oil Ritle Pressure Plug 2, Plug - Filtered Oil 3. Plug - Unfiltered Oil 7400043 3Coolant System Flow Diagram Section D - Systems Diagrams Page D-8 K19 Coolant System Flow Diagram COOLANT SYSTEM FLOW DIAGRAMon D - Systems Diagrams Coolant System Flow Diagram - Jacket Water Aftercooled 9 Page D-9 Coolant System Flow Diagram - Jacket Water Aftercooled OOLANT SYSTEM FLOW DIAGRAM . Vent to Radiator Top Tank . Coolant to Radiator . Vent Line from Aftercooler - Coolant Out of Aftercooler . Thermostats |. Coolant before Thermostats - Coolant Bypass - Coolant ManifoldCoolant System Flow Diagram - LTA Section D - Systems Diagrar Page D-10 SK: Coolant System Flow Diagram - LTA COOLANT SYSTEM FLOW DIAGRAM (CONTINUED) 8, To Aftercooler Radiator 9, From Aftercooler Radiator 10. To Radiator ‘11. From Aftercooler 12. To Aftercooler 13, From Water Pump XX LTA THERMOSTAT - CLOSED LTA THERMOSTAT - OPENection D - Systems Diagrams Coolant System Flow Diagram (Continued) SK19 Page D-11 Coolant System Flow Diagram (Continued) §. Converter Oil Inlet 7. Converter Oil OutletCombustion Air System Flow Diagram Section D - Systems Diagrams Page D-12 S8k19 Combustion Air System Flow Diagram COMBUSTION AIR SYSTEM FLOW DIAGRAM INTAKE SYSTEM 1. Intake Air Inlet to Turbocharger 2, Turbocharger Air to Aftercooler 3. Aftercooler 4, Intake Manifold 5, Intake Valve Ports EXHAUST SYSTEM 2, Exhaust Manifold 3. Turbocharger Exhaust OutletSection D - Systems Diagrams Compressed Air System Flow Diagrams aski9 ste Page O-13 Compressed Air System Flow Diagrams Air Governor Signal Coolant Lubricant =— LubricantCompressed Air System Flow Diagrams Section D - Systems Diagrams Page D-14 yet aS NOTESSection L - Service Literature K19 Page L-1 Section L - Service Literature Section Contents Literature Survey Form. Publications Titles. Service Literature Ordering Location ..Publications Titles Section L - Service Literature Page L-2 Qski9 Publications Titles The following publications can be purchased by filling in and mailing the Service Literature Order Form: Bulletin No. Title of Publication 3379084 Fuel Pump Rebuild Manual 3666098 ‘Troubleshooting and Repair Manual QUANTUM™ System K19 (QSK19) Series Engines. (Base Engine) 3666113 oubleshooting and Repair Manual QUANTUM™ System QSK19 Series Electronics rm) 3666121 Holset Air Compressor Master Repair Manual Installation Recommendations Bulletin Construction, Mining, Logging, and Agriculture : 3382108 Air Intake System 3382118 Cold Weather Operation 3382171 Cooling System 3382362 Engine Mounting 3382138 Engine Performance 3382109 Exhaust System 3382409 Fuel System 3382113 Lubrication 3382110 Noise Control 3382014 Power Trains 3382150 Service Accessibil 3382452 Starting & Electrical System 3382135 ‘Torsional Vibration 3672094 QSK19 Construction Parts CatalogSection L - Service Literature aski9 Service Literature Ordering Location Page L-3 Service Literature Ordering Location Region United States and Canada U.K., Europe, Mid-East, Africa, and Eastern European Countries ‘South and Central America (excluding Brazil and Mexico) Brazil and Mexico Far East (excluding Australia and New Zealand) Australia and New Zealand Ordering Location Cummins Distributors or Contact 1-800-DIESELS (1-800-343-7357) Cummins Engine Co., Lid, Royal Oak Way South Daver ntry Northants, NN11 5NU, England Cummins Americas, Inc. 16085 N.W. 52nd Avenue Hialeah, FL 33104 Cummins Engine Co., inc. International ‘Order Dept., MC 40931 Box 3005 ‘Columbus, IN 47202-3005 ‘Cummins Diesel Sales Corp. Literature Center 8 Tanjong Penjuru Jurong Industrial Estate Singapore Cummins Diesel Australia Maroondah Highway, P.O.B. 139 Ringwood 3134 Victoria, Australia Obtain current_price information from your local Cummins Distributor or (for U.S.A. and Canada) by calling Cummins Toll Free Number 1-800-DIESELS (1-800-343-7357).Service Literature Ordering Location Section L - Service Literature Page L-4 Qski9 NOTESSection L - Service Literature Service Literature Ordering Location QsK19 Page L-5 Literature Order Form Use this form for prompt handling of your literature order. Bulletin Title of ~ US, Price Item Number Publication Quantity Each Amount 1 5 $s —- 2 3 4 5 6 . Order Total Contact your Cummins distributor for prices and availability. For problems with literature orders, contact 1-800-DIESELS (1-800-343-7357) (for U.S.A. and Canada). Prices subject to change without notice. Please cut on dotted line Literature Order Form Use this form for prompt handling of your literature order. Bulletin Title of US. Price Each. item. Number Publication Quantity Amount @ ja fa fo fro Order Total Contact your Cummins distributor for prices and availability. For problems with literature orders, contact 1-800-DIESELS (1-800-343-7357) (for U.S.A. and Canada). Prices subject to change without notice.Service Literature Ordering Location Section L - Service Literature Page L-6 aski9 Mail the Literature Order Form along with your ship-to address to your nearest Cummins distributor. FROM: State: Zip Code: SHIP TO: (Name and address where literature is to be shipped) Name: Street Address: City: State: ______ Zip Code: Country: Please cut on dotted line Mail the Literature Order Form along with your ship-to address to your nearest Cummins distributor. FROM: Name: ‘Street Address: City: State: Zip Code: Country: SHIP TO: (Name and address where literature is to be shipped) Name: Street Address: City: State: Country:Section M - Component Manufacturers Page M-1 Section M - Component Manufacturers Section Contents yz 3 Component Manufacturers’ Addresses ‘Air Compressors. Air Cylinders Air Heater Air Starting Motors Alternators, ‘Auxiliary Brakes. Belts Catalytic Convertors « Clutches... Coolant Heaters Drive Plates. Electric Starting Motors Engine Protection Controi Fan Clutches. Fans. Filters. Flexplaies, Fuel Warmers. Gauges Governors Hydraulic and Power Steering Pumps. Oil Heaters... ‘Torque Converters . z= z= Seaeoeeeee === GOGGGGG0RN SESSEzz= z= EEEEComponent Manufacturers’ Addresses page M-2 ‘Section M - Component Manufacturers Component Manufacturers’ Addresses NOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins engines. Suppliers can be contacted directly for any specifications not covered in this manual. Air Compressors Bendix Heavy Vehicles Systems Div of Aled automotive ‘901 Cleveland Street Elyria, OF 44096, Telephone: (216) 329-9000 Holset Engineering Co., Inc. 1820 Kemper Meadow Drive Suite 500 Cincinnati, OH 45240 ‘Telephone: (513) 825-9600 Midland-Grau Heavy Duy Systems Buty Group Headquarters 10890 N, Parone Avenue Kansas City, MO 64153 Telephone: (616) 691-2470 Air Cylinders Bendix Ltd. Douglas Road Kingswood ia la Telephone: 0117-671881 Catching Engineering 1738 North 25th Avenue Melrose Park, IL 60160 ‘Telephone: (708) 344.2334 TEC - Hackett inc. ‘8909 Rawies Avenue Indianapolis, IN 46219 ‘Telephone: (317) 895-3670 Air Heaters: Fleetguard, Inc. 1200 Fleetguard Road Cookeville, TN 38502 ‘Telephone: (616) 526-9551 Kim Hotstart Co. PO. Box 11245 Spokane, WA 99211-0245 Telephone: (509) 534-6171 Air Starting Motors Ingersoll Rand Ghorley New Road io Bolton Lancashire England BLE 6JN ‘Telephone: 01204-65544 Ingersol-Rand Engine Starting Systems 888 Industrial Drive Elmhurst, IL 60126 Telephone: (708) 590-3875 StartMaster Ar Starting Systems ‘A Division of Sycon Corporation ‘9595 Cheney Avenue P. 0. Box 491 Marion, OH 43302 Telephone: (614) 982-571 Alternators Robert Bosch Ltd. PO. Box 98 Broadwater Park North Orbital Road Denham Uxbridge Middlesex UD9 SHG England ‘Telephone: 01895-830683 Butec Electrics Cleveland Road Leyland PRS 1XB England Telephone: 01744-21663 CAV. Electrical Equipment RO. Box 36 ‘Warple Way London W3 78S England ‘Telephone: 01-74-3111 A. Dolco Components Group Civic Offices Central Milton Keynes Mk9 SEL England Telephone: 01908-66001 C.E. Nichotf & Co. 2021 Lee Street Evanston, IL 60202 ‘Telephone: (708) 866-6080 Delco-Remy America 2401 Columbus Avenue RO. Box 2439 Anderson, IN 46018. Telephone: (317) 646-3528 Leece-Neville Corp. 400 Main Street Arcade, NY 14009 ‘Telephone: (716) 492-1700 Auxiliary Brakes ‘The Jacobs Manufacturing Company Vehicle Equipment Division 22 East Dudley Town Road Bloomfield, CT 06002 Telephone: (203) 243-1441 Belts Dayco Rubber U.K. Sodigen cl Cheshire SK41RV England Telephone: 061-432-5163 TBA. Belting Ltd. BO. Box 77 Wigan Lancashire WN2 4xQ England Telephone: 01942-69221 Dayco Mig. Bel Technical Center 1955 Entorprize Rochester Hills, Ml 48309 ‘Telephone: (810) 853-8300 Gates Rubber Company 900 S. Broadway Denver, GO 80217 Goodyear Tire and Rubber Company Industrial Products Div. 2601 Fortune Circle East Indianapolis, IN 46241 Telephone: (317) 898-4170 Catalytic Convertors Donaldson Company, Inc. 1400 West 94th Streot PO. Box 1299 Minneapolis, MN 55440 Telephone: (612) 887-3895, Nelson Division Exhaust and Filtration Systems 1801 U.S. Highway 51 PO. Box 428 Stoughton, WI 53589 ‘Telephone! (608) 873-4200 Walker Manufacturing 3901 Willis Road PO. Box 157 Grass Lake, Mi 49240 ‘Telephone: (517) 522-5500 Clutches Twin Disc International S.A. Chaussee de Namur Nivelles Belguim Telephone: 067-224941 ‘Twin Disc Incorporated 1828 Racine Street Racine, Wi 53403 Telephone: (414) 634-1981 Coolant Heaters Telephone: (616) 526-9551 Drive Plates Detroit Diesel Allison Division of General Motors Corporation PO. Box 894 Indianapolis, IN 46206-0894 ‘Telephone: (317) 242-5000Section M - Component Manufacturers Electric Starting Motors Butec Electrics Cleveland Road Leyland PRS 1XB England ‘Telephone: 01744-21668 CAV. Electrical Equig nt RO, Box 36 Eauipmer Warpie Way London we 78s A.C. Delco Components Group tome ‘MKS 3EL England ‘Telephone: 0908-66001 Delco-Remy America P.O. Box 2439 Anderson, IN 46018. ‘Telephone: (317) 646-3528 Leece-Neville Corp. 400 Main Street Arcade, NY 14009 ‘Telephone: (716) 492-1700 Nippondenso Inc. 2477 Denso Drive BO. Box 5133, Southfield, Ml 48086 ‘Telephone: (813) 350-7500 Engine Protection Controls The Nason Company 2810 Blue Ridge Bivd. West Union, SC 20696 ‘Telephone: (803) 638-9521 Teddington Industrial ulpment indmill Road Sunburn on Thames Middlesex wie THF Englan Telephone: 09927-85500 Fan Clutches Holset Engineering Co. Lid. P.O. Box Ag ‘Turnbridge Huddersfield, West Yorkshire England HD6 7AD Telephone: 01484-22244 Horton Industries, Inc. PO. Box 9455 Minneapolis, MN 65440 ‘Telephone: (612) 378-6410 Rockford Clutch Company 1200 Windsor Road P.O. Box 2908 Rockford, iL 61192-2908 Telephone: (815) 633-7460 Fans Trutlo Lid. Westwood Road Birmingham Bs 741 England Telephone: 021-557-4101 Hayes-Albion Corporation Jackson Manufacturing Plant 1999 Wildwood Avenue Jackson, Ml 49202 Telephone: (517) 782-9421 Engineered Cooling Systems, Inc. 201 W. Carmel Drive Carmel, IN 46032 ‘Telephone: (317) 846-3498 Brookside Corporation P.O. Box 30 McCordsville, IN 46055 Telephone: ($17) 335-2014 ‘TGF Acrovent Company 8100 Purdue Rd., Suite 101 Indianapolis, IN 46268-1190 Telephone: (317) 872-0080 Kysor-Cadillac 1100 Wright Street Cadillac, MI 49601 ‘Telephone: (616) 775-4681 ‘Schwitzer 6040 West 62nd Street P.O. Box 80-8 Indianapolis, IN 46206 Telephone: (817) 328-3010 Filters Fleetquard International Corp. Gavalty Fil Indust! Park Weedon Northampton NN7 4TD England ‘Telephone: 01927-41313 Fleetguard, Inc, 1200 Fleetguard Road Cookeville, TN 38502 Telephone: (615) 526-9551 Flexplates Corrugated Packing and ‘Sheet Metal Hamsterley Neweastle Upon Tyne England Telephone: 01207-560-505 Allison Transmission Division of General Motors Corporation PO. Box 894 Indianapolis, IN 46206-0894 ‘Telephone: (817) 242-5000 Midwest Mig. Co. 29500 Southfield Road, Suite 122 ‘Southfield, Mi 48076 ‘Telephone: (313) 642-5355 Wohlert Corporation 708 East Grand River Avenue PO. Box 20217 Lansing, MI 48901 Telephone: (517) 485-3750 Component Manufacturers’ Addresses Fuel Warmers Fleetguard, Inc. 1200 Fleetauerd Road Cookeville, TN 38502 ‘Telephone: (615) 526-9551 Gauges ALS. Dyifon industrial Estete Yetrad Mynach Hen Mid Glamorgan CFB 7xD England Telephone: 01443-812791 Grasslin U.K. Ltd. Vale Rise ‘Tonbridge Kent TNS 17B England Telephone: 01732-35888 loknield Instruments Ltd. Jubilee Road Letchworth Herts England Telephone: 04626-5551 ‘Superb Tool and Gauge Co. 21 Princip Street Birmingham Bé 61 England Telephone: 021-959-4876 abi Electrical and Plastics Granborne Road Potiers Bar Herts ENG SUP England Telephone: 01707-58444 Datcon instruments RO. Box 128 East Petersburg, PA 17520 Telephone: (717) 569-5713, Rochester Gauges, Inc. 11616 Harry Hines Bivd. PO. Box 29242 Dalias, TX 75229 ‘Telephone: (214) 241-2161 Governors ‘Woodward Governors Lid. PO. Box 15 (863/664 Ajax Avenue Slough Bucks SL1 40D England Telephone: 01753-26835 Woodward Governor Co. RO. Box 1519 Fort Collins, CO 80522 Telephone: (303) 482-5811 (600) 523-2831 Barber Colman Co, 1954 Clifford Avenue Loves Park, IL 61132 Telephone: (815) 637-3000 Page M-3Component Manufacturers’ Addresses Page M-4 United Technologies Diesel Systems 4000 Jorie Bivd. Suite 111 Oak Brook, IL 69521 ‘Telephone: (312) 325-2020 Heat Sleeves Boney Haris Manufacturing Co. jentley Harris Gordonvil, TN 38368 Telephone: (813) 348-5779 Hydraulic and Power Steer- ing Pumps Hobourn Automotive ‘Temple Farm Works Priory Road Strood Rochester Kent, England ME? 21 Telephone: 01634-71778 Honeywell Control Systems Ltd. Honeywell House Charles Square Bracknell Berks RG12 1E8 Telephone: 01944-4245 ‘Sundstrand Hydratec Lid. Cheney Manor Trading Estate ‘Swindon Wiltshire ‘SN2 2PZ England ‘Telephone: 01783-30101 Sperry Vickers PO. Box 302 Troy, Ml 48084 ‘Telephone: (312) 280-3000 Schwaebisch Gmuend West Germany ‘Telephone: 7070-7171-31510 Oil Heaters Flootguard, Inc. 1200 Fiestquard Road Cookeville, TN 38502 Telephone: (615) 526-9551 Kim Hotstart Co. PO. Box 11245 Spokane, WA 99211-0245 ‘Telephone: (509) 534-6171 Section M - Component Manufacturers ‘Torque Converters ‘Twin Disc International S.A. Chaussee de Namur Nivelles Belgium ‘Telephone: 067-224941 “Twin Disc Incorporated 41828 Racine Sireot Racine, WI 3403-1758 Telephone: (414) 634-1981 Rockford Powertrain, Inc. Of Highway Systems ‘1200 Windsor Road PO. Box 2908 Rockford, IL 61132-2908 Telephone: (618) 639-7460 Modine Mtg, Co. 1500 DeKoven Avenue Racine, WI 53401 ‘Telephone: (414) 696-1640Section S - Service Assistance aski9 Page S-1 Section S - Service Assistance Section Contents Service Assistance... s2 Distributors - International $21 Distributors and Branches - Australia S15 Distributors and Branches - Canada. S13 Distributors and Branches - New Zealand S17 Distributors and Branches - United States. 5 Division and Regional Offices. s4 Emergency and Technical Service.. $2 Problem Solving Regional Offices - international Routine Service and Parts.Service Assistance Page S-2 Section S - Service Assistance QSk19 Service Assistance Routine Service and Parts Personnel at Cummins Authorized Repair Locations can assist you with the correct operation and service of your engine. Cummins has a worldwide service network of more than 5,000 Distributors and Dealers who have been trained to provide sound advice, expert service, and complete parts support. Check the telephone directory yellow pages or refer to the directory in this section for the nearest Cummins Authorized Repair Location. Emergency and Technical Service The Cummins Customer Assistance Center provides a 24-hour, toll free telephone number to aid in technical and ‘emergency service when a Cummins Authorized Repair Location can not be reached or is unable to resolve an issue with a Cummins product. If additional assistance is required, call Toll-Free: 1-800-DIESELS (1-800-343-7357) * Includes all 50 states, Bermuda, Puerto Rico, Virgin Islands, and the Bahamas. ‘+ Outside of North America contact your Regional Of- fice. Telephone numbers and addresses are listed in the International Directory.Section S - Service Assistance Service Assistance QSKi9 Page S-3 Problem Solving Normally, any problem that arises with the sale, service, or repair of your engine can be handled by a Cummins Authorized Repair Location in your area. Refer to the telephone directory yellow pages for the one nearest you. If the problem has not been handled satisfactorily, follow the steps outlined below: 1. If the disagreement is with a Dealer, talk to the Cummins Distributor with whom he has his service agreement. 2. If the disagreement is with a Distributor, call the nearest Cummins Division or Regional Office; however, most problems are solved below the Division or Regional office level. Telephone numbers and addresses are listed in this section. Before calling, write down the following information: a. Engine model and serial number b. Type and make of equipment ©. Total kilometers [miles] or hours of operation d. Warranty start date e. Nature of problem f. Summary of the current problem arranged in the order of occurrence 9. Name and location of the Cummins Distributor or Dealer 8. If a problem can not be resolved satisfactorily through your Cummins Authorized Repair Location or Division Office, write to: ‘Customer Relations - 41403, Cummins Engine Company, Inc., Box 3005, Columbus, IN 47202-3005Service Assistance Section S - Service Assistance Page S-4 Qskia Division and Regional Offices NOTE: The following list contains offices in U.S., Canada, Australia, New Zealand, and Puerto Rico. United States Australia Regional Office Northern Division Office Diesel ReCon Australia ‘Cummins Engine Company, Inc. 2 Caribbean Drive 21 Southpark Bivd. Scoresby, Victoria 3179 Greenwood, IN 46143 Australia Telephone: (317) 885-4400 Fgphone: (61) 3-765-3222 FAX: (317) 885-4423 ‘ (61) 3-763-0079 Southern Division Office NOTE: This office also serves New ‘Cummins Engine Company, Ine. Zealand. BB Fagin Road SW. Cummins Americas Regional Mariota, GA 30067 Office Fae (o05) 4en240 Cummins Caribbean . 16085 N. W. 52nd Avenue Western Division Office Hialeah, FL 33014 ‘Cummins Engine Company, Inc. 5660 Greenwood Plaza Blvd. . i Englewood, CO 8011 office serves Puerto Rico Telephone: (303) 773-2866 and South America excluding Brazil. FAX: (803) 778-1629, Western Regional Office Cummins Engine Company, Inc. 569 First Street West ‘Sonoma, CA 95476 Telephone: (707) 935-3842 FAX: NA Plains Regional Office Cummins Engine Company, Inc. 1901 Central Drive ‘Suite 356 See ara one: z FAX: NIA Canada Canadian Division Office Cummins Diese! of Canada, Ltd. 700 Dorval Drive Suite 600 Oaiville, Ontario Lek 3V3 Telephone: (905) 842-8070 FAX. (005) 642-0075 Western Canada Regional Office ‘Cummins Diesel of Canada, Ltd. 18452 - 96th Avenue Surrey, B.C. VST 4w2. Telephone: (604) 882-5727 FAX: (604) 882-9110 Eastern Canada Regional Office Cummins Diesel of Canada Ltd. 7200 Trans Canada Huy. Pt. Cuaire, Quebec H9R 1CO Telephone: (514) 695-2402 FAX: (614) 695-8917 Central Canada Regional Office ‘Cummins Diesel of Canada Ltd. 4887 - 35th Street SE. Calgary, Alberta T2B 306 axe (a3) 869-2874Section S - Service Assistance Service Assistance OsKki19 Page S-5 Distributors and Branches - United States Alabama Arkansas Stockton Branch Birmingham Distributor Little Rock - (Branch of Memphis) Cumming West, Inc. Cummins Alabama, inc. Cummins Mid-South, Inc. Suite 131 2200 Pinson Highway 6600 Interstate 30 Stockton, CA 95207 PO. Box 1147 Little Rock, AR 72209 Telephone: (209) 473-0386 Birmingham, AL 35201 Telephone se00 FAX: (208) 478-2454 Telephone: (208) 84 FASE (oo) Sab deze Sane: (01) 5605656 West Sacramento Branch rs: West Mobile Branch FAX: (601) 565-2199, Sear Errgreek Mesnue feoe'Botine highway California TRepone 16) 37-0680 LBB North " San Leandro Distributor FAX: (916) 971-2849 Mobile, AL 36601 Cummins west, Inc. Los Angeles Distributor Telephone: (334) 456-2296 urora Drive. ins Cal Pacific | FAX: (834) 452-0418 San Leandro, CA 94577 $359 Deore wena tate) Telephone: (610) 351-6101 Iwvine, CA 92714 Mobile Onan/Marine Branch FAX! (610) 352-3028 ‘Rlephone: (714) 253-6000 Suramins Alsbame, Ine. Arcata Branch FAX: (714) 28 or 253-6080 corgia jenue Mobile, AL abt? urine Wes In, Montebello Branch ‘Telephone: (334) 452-6426 st Cummins Cal Pacific Inc. FAX: (334) 473-6657 Arcata, CA 95521 1105 South Greenwood Avenue h ‘Telephone: (707) 822-7992 Montebello, CA 90640 Montgomery Branc! FAX: (707) 822-7585 Telephone: (213) 726-8111 Summins Alabama, In. Bakersfield Branch FAX @18) 889-7422 Sa8 in Box an venue Cummins yest Inc, La Rialto Branch 4601 East Brundage Lane Cummins Cal Pacific Inc, Bakorsteld, CA 93307 3061'S. Riverside Avenue Telephone: (805) 325-9404 Pualto, CA Sse FAX: (805) 861-8719 Telephone: (808) 877-0433 Fresno Branch FAX: (909) 877-787 Anchorage - (Branch of Seattle) Suni Wet ne San Diego Branch Cummins Northwest, Inc. 2740 Church Avenue ‘Cummins Cal Pacific | 2618 Commercial Drive, Fresno, CA 89700 SION, Johnson Avenue” Anchorage, AK 99501-3905. ‘Telephone: (209) 495-4745 El Cajon, CA 92020 ‘Telephone: FAX: (209) 486-7402 Telephone: (619) 593-3093 (907) 276 Hayward Distribution Center FAX: (618) 585-0600 Arizona Cummins West, inc. Colorado Phoenix Distributor and Branch Eyer C8 ah so Denver Distributor Cummins Southwest, Inc. ‘Telephone: ins Rocky Mountain, Inc. 2280 Nor Black Canyon Hoy. FAX: (G1) Ae0.0067 Sto0'East Sah Avenue 2.0. Box City, CO 80022 Phoenix, AZ 85005-6688 Redding Branch Faophone: 60) 287-0201 Somrins West, ns. FAX: (303) 288-7080 20247 Cherlanno Drive i i Industrial Branch Tucson Branch Redding, CA 96002 Denver Onan/industrial Bra E : ‘Telephone: (916) 222.4070 Cummins Rocky Mountain, Inc, Summins Southwest, inc. FAX: (916) 224-4075 5720 Holly Street, Unit A 1912 West Prince. & ity, CO 80022 Tucson, AZ 85705 San Leandro Branch ‘hophone. (308) 206-7097 Telephone: (602) 887-7440 Cummins West, Inc. FAX: (303) 287-4837 FAX: (602) 887-4173 1601 Aurora Drive Ser ard, Xr Durango Branch Telephone: (610) 351-6101 7 FAX: (610) 614-9159 $3800 Coury Bows (me Durango, CO 81301 ‘Rigpnone: (870) 260-7470 FAX: (970) 259-7482Service Assistance Page S-6 Grand Junction Branch Cumming Rocky Mountain, inc, 2380 U.S. Highway 6 & 50 RO. Box 339) Grand Junction, CO 81501 Telephone: (303) 242-5776 FAX: (803) 243-5495 Greeley Branch Cummins Mountain, Ino. 120 East 18th Street Greeley, CO 80631 ‘Telephone: (970) 351-0448, FAX: NIA Connecticut Hartford Distributor Cummins - Connecticut, Inc. 260 Murphy Road Hartford, CT 06114 Telephone: (203) 527-9156 FAX: (203) 827- Florida Tampa Distributor Cummins Southeastern Power, Inc. Corporate Office S421 N. 89th Stroct Tampa, FL 33610 Telephone: (813) 621-7202 FAX: (618) 621-8250 Ft. Myers Branch Cummins Southeastern Power, Inc. 2671 Edison Avenue, Unit #3 Fi. Myers, FL 33916 Telephone: (813) 337-1211 FAX: (819) 397. Jacksonville Branch ‘Cummins Southeastern Power, Inc, 2060 West 21st Street PO. Box 12036 Jacksonville, FL. 32209 Telephone: (904) 955-8497 FAX: (904) 354-4594 Hialeah (Miami) Branch ‘Cummins Southeastern Power, Inc. ‘9900 N.W. 77th Court Hialeah Gardens, FL 33016 Telephone: (205) 821-4200 FAX: (805) 557-2982 Orlando Branch ‘Cummins Southeastern Power, Inc. 4820 North Orange Blossom Trail Orlando, FL 32810 Tlephore: (407) 206-2080 (407) 290-8727 Tampa Branch ‘Cummins Southeastern Power, Inc. 8910 E. Hillsborough Avenue P.O. Box 11737 Tampa, FL 33680 ‘Telephone: (813) 626-1101 FAX: (619) 626-4100 Georgia Atlanta Distributor Cummins South, Inc. 5125 Georgia Highway College Par, 30818-5976 Telephone: (404) 763-0161 FAX: (404) 766-2132 Albany Branch Cummins South, Inc. 1915 W. Oakridge Drive Albany, GA 31767-4938 Telephone: (912) 888-6210 FAX: (812) 883-1670 Atlanta Branch Cummins South, Inc. 100 University Avenue, S.W. Atlanta, GA 30315-2202 ‘Telephone: (404) 527-7800 FAX: (404) 527-7832 ‘Augusta Branch ‘Cummins South, Inc. 1255 New Savannah Road Augusta, GA 30901-3891 Blephone: (706) 722-8625 (708) 722-7853 Savannah Branch Cummins South, Inc. 8 Interchange Court Savannah, GA 31401-1627 ‘Telephone: (912) 232-5565 FAX: (912) 282-5145 Hawaii Kapolei Distributor Cummins Hawaii Diesel Power, Inc. 91-230 Kalaeloa Blvd. Kapolei, Hi 96707. lepnone 608) ea2-en10 idaho. Boise - (Branch of Salt Lake City) ‘Cummins Intermountain, Inc. 2851 Federal Way PO, Box 5212 Boise, ID 83705 ‘Telephone: (208) 336-5000 FAX: NA Pocatello - (Branch of Salt Lake City) uring Intermountain, Inc 14299 Highway 30 West Boca 1D 84201 ‘Telephone: (208) 234-1661 FAX: (208) 284-1662 Illinois Chicago Distributor Cummins Northern iinois, Inc. ‘7145 Santa Fe Drive Hodgkins, IL 60525 ‘Telephone: (708) 579.9222 FAX: (708) 352-7547 ‘Section S - Service Assistance QSK19 Bloomington-Normal - (Branch of Indianapolis) ‘Cummins Mid-States Power, Inc. RO. Box 348 (at U.S. 51 N and I-55) 414 W. Northtown Road Bioomington-Normal, IL 61761 Telephone: (309) 452-4454 FAX: (808) 452-1642 Harrisburg (Branch of St. Louis) ‘Cummins Gateway, Inc. Rt. 4, Box 629 Harrisburg, IL 62946 ‘Telephone: (618) 273-4138 FAX: (618) 279-4531 Rock Island - (Branch of Omaha) ‘Cummins Great Plains Diesel, Inc. ‘7@20-42nd Street West RO. Box 4445 Rock Island, IL 61204 Blephons: (209) 787-4300 109) 787-4397 Indianapolis Distributor ‘Cummins Mid-States Power, Inc. PO, Box 42917 ‘8762 West Morris Street Indianapolis, IN 46242-0917 Telephone: (317) 243-7979 FAX: (817) 240-1925 Evansville - (Branch of Louisville) Cummins Cumberland, inc. 720 Highway at North Evansville, IN 47711 Telephone: (812) 867-4400 FAX ote) Aai-dawe Ft. Wayne Branch Cummins Mid-States Power, Inc. 3416 Coliseum Bivd. West (At Jet 69 & 20/33) | Wayne, IN 46808 ‘Telephone: (219) 482-3691 FAX: (219) 484-8930 Gary - (Branch of Chicago) ‘Cummins Northern Illinois, Inc. 1440 Texas Street Gary, IN 40402 ‘Telephone: (219) 885-5591 FAX: (219) 883-4817 Indianapolis Branch Cummins Mid-States Power, In. P.O. Box 42917 3621 West Morris Street Indianapolis, IN 46242-917 Telephone: (317) 244-7251 FAX: (817) 240-1218