Cummins QSK19 Series Engine Shop Manual – PDF DOWNLOAD

Cummins QSK19 Series Engine Shop Manual – PDF DOWNLOAD

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Cummins QSK19 Series Engine Shop Manual – PDF DOWNLOAD

Language : English
Pages : 634
Downloadable : Yes
File Type : PDF

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Cummins QSK19 Series Engine Shop Manual – PDF DOWNLOAD

Foreword:

• This manual contains complete rebuild procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing of accessory and component suppliers is located in Section M – Component Manufacturers. Suppliers can be contacted directly for any information not covered in this manual.
• Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i
  – Introduction.
• The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild
  procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures.
• When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used
  in place of the recommended item.
• A series of specific service manuals (for example: Troubleshooting and Repair, Specifications, and Alternative Repair)
  are available and can be ordered by filling out and mailing the Literature Order Form located in Section L – Service
  Literature.
• Cummins Engine Company, Inc. encourages the user of this manual to report errors, omissions, and recommendations
  for improvement. Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for
  communicating your comments.

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. Specifications
  and torque values for each engine system are given in that section.

TABLE OF CONTENTS:

Cummins QSK19 Series Engine Shop Manual – PDF DOWNLOAD

MAIN MENU.............................................................  0
TABLE OF CONTENTS.....................................................  3
INTRODUCTION..........................................................  4
	ABOUT THE MANUAL..................................................  5
	GENERAL CLEANING INSTRUCTIONS..................................... 13
		GLASS OR PLASTIC BEAD CLEANING................................ 13
		SOLVENT AND ACID CLEANING..................................... 13
		STEAM CLEANING................................................ 13
	GENERAL REPAIR INSTRUCTIONS....................................... 12
		WELDING ON A VEHICLE WITH ELECTRONIC COMPONENTS............... 12
	GENERAL SAFETY INSTRUCTIONS.......................................  4
		IMPORTANT SAFETY NOTICE.......................................  4
	HOW TO USE THE MANUAL.............................................  5
	ILLUSTRATIONS..................................................... 10
	SYMBOLS...........................................................  6
ENGINE IDENTIFICATION................................................. 15
	ENGINE DIAGRAMS................................................... 21
		ENGINE VIEWS.................................................. 21
	ENGINE IDENTIFICATION............................................. 16
		CUMMINS ENGINE NOMENCLATURE................................... 16
		ECM DATAPLATE................................................. 16
		ENGINE DATAPLATE.............................................. 16
	SPECIFICATIONS.................................................... 17
		AIR INTAKE SYSTEM............................................. 17
		BATTERIES (SPECIFICATION GRAVITY)............................. 20
		COOLING SYSTEM................................................ 19
		ELECTRICAL SYSTEM............................................. 17
		EXHAUST SYSTEM................................................ 19
		FUEL SYSTEM................................................... 17
		GENERAL SPECIFICATIONS........................................ 17
		LUBRICATING OIL SYSTEM........................................ 18
COMPLETE ENGINE - GROUP 00............................................ 24
	ENGINE ASSEMBLY................................................... 82
		ASSEMBLE...................................................... 82
	ENGINE DIASSEMBLY................................................. 32
		DISASSEMBLE................................................... 33
		GENERAL INFORMATION........................................... 32
			ASSEMBLY.................................................. 32
			DISASSEMBLY............................................... 32
	SERVICE TOOLS..................................................... 25
		ENGINE DISASSEMBLY AND ASSEMBLY............................... 25
CYLINDER BLOCK - GROUP 01.............................................179
	BEARINGS, CONNECTING ROD..........................................185
		CLEAN.........................................................185
		INSPECTION FOR REUSE..........................................185
	BEARINGS, MAIN....................................................185
		CLEAN.........................................................185
		INSPECT FOR REUSE.............................................186
		MEASURE.......................................................186
	BEARINGS, THRUST .................................................186
		ASSEMBLE......................................................187
		INSPECT FOR REUSE.............................................186
	CAMSHAFT..........................................................187
		CLEAN.........................................................187
		INSPECT FOR REUSE.............................................187
		MAGNETIC CRACK INSPECTION.....................................188
	CAMSHAFT BUSHINGS.................................................195
		INSPECT FOR REUSE.............................................196
		INSTALL.......................................................196
		REMOVE........................................................195
	CAMSHAFT GEAR (CAMSHAFT REMOVED)..................................190
		INSPECT FOR REUSE.............................................191
		INSTALL.......................................................194
		MAGNETIC CRACK INSPECT........................................192
		REMOVE........................................................190
	CONNECTING ROD....................................................198
		CLEAN.........................................................198
		INSPECT FOR REUSE.............................................198
		MAGNETIC CRACK INSPECT........................................204
	CRANKSHAFT........................................................205
		BEND AND TWIST INSPECTION.....................................209
		CLEAN.........................................................205
		INSPECT FOR REUSE.............................................206
		MAGNETIC CRACK INSPECT........................................207
	CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED).....................214
		INSPECT FOR REUSE.............................................215
		INSTALL.......................................................215
		REMOVE........................................................214
	CRANKSHAFT GEAR, REAR (CRANKSHAFT INSTALLED)......................216
		INSTALL.......................................................216
	CRANKSHAFT PULLEY.................................................216
		CLEAN.........................................................216
		INSPECT FOR REUSE.............................................217
	CYLINDER BLOCK....................................................218
		CLEAN.........................................................219
		INSPECT FOR REUSE.............................................221
		MAGNETIC CRACK INSPECT........................................225
		WORKSHEET.....................................................218
	CYLINDER BLOCK - GENERAL INFORMATION..............................181
		GENERAL INFORMATION...........................................181
	CYLINDER BLOCK AND LINER SEATS....................................227
		GENERAL INFORMATION...........................................227
		INSPECT FOR REUSE.............................................227
		LEAK TEST.....................................................231
		MEASURE.......................................................229
	CYLINDER BLOCK COUNTERBORE........................................245
		MACHINE.......................................................245
	CYLINDER LINER....................................................231
		CLEAN.........................................................231
		INSPECT FOR REUSE.............................................232
	CYLINDER LINER PROTRUSION.........................................259
		ADJUST........................................................259
	GEAR COVER ACCESSORY DRIVE BUSHING ...............................260
		INSTALL.......................................................260
		REMOVE........................................................260
	GEAR COVER, FRONT.................................................235
		CLEAN.........................................................235
		INSPECT FOR REUSE.............................................236
		MEASURE.......................................................237
	GEAR COVER SPACER PLATE...........................................235
		CLEAN.........................................................235
		INSPECT FOR REUSE.............................................235
	IDLER GEAR, CAMSHAFT..............................................237
		CLEAN.........................................................237
		INSPECT FOR REUSE.............................................237
		MAGNETIC CRACK INSPECT........................................238
	IDLER GEAR, HYDRAULIC PUMP........................................239
		CLEAN.........................................................239
		INSPECT FOR REUSE.............................................240
	IDLER GEAR, WATER PUMP............................................240
		CLEAN.........................................................240
		INSPECT FOR REUSE.............................................240
	PISTON............................................................240
		CLEAN.........................................................240
		INSPECT FOR REUSE.............................................241
	SERVICE TOOLS.....................................................182
		CYLINDER BLOCK................................................182
	VIBRATION DAMPER..................................................243
		CLEAN.........................................................243
		INSPECT FOR REUSE.............................................243
CYLINDER HEAD - GROUP 02..............................................261
	CROSSHEAD.........................................................265
		CLEAN.........................................................265
		INSPECT FOR REUSE.............................................265
	CYLINDER HEAD.....................................................266
		ASSEMBLE......................................................275
		CLEAN.........................................................267
		DISASSEMBLE...................................................274
		EXPLODED VIEW.................................................266
		INSPECT FOR REUSE.............................................267
		PRESSURE TEST.................................................269
		VACUUM TEST...................................................271
	CYLINDER HEAD - GENERAL INFORMATION...............................262
		GENERAL INFORMATION...........................................262
	CYLINDER HEAD INJECTOR BORE.......................................276
		ADJUST........................................................278
		INSPECT FOR REUSE.............................................276
	SERVICE TOOLS.....................................................263
		CYLINDER HEAD.................................................263
	VALVE, CYLINDER HEAD..............................................283
		GRIND.........................................................285
		INSPECT FOR REUSE.............................................284
		INSTALL.......................................................287
		LAP...........................................................287
		MAGNETIC CRACK INSPECT........................................284
		REMOVE........................................................283
	VALVE GUIDE, CYLINDER HEAD........................................279
		CLEAN.........................................................279
		INSPECT.......................................................280
		INSPECT FOR REUSE.............................................279
		INSTALL.......................................................280
		REMOVE........................................................279
	VALVE SEAT BORE...................................................281
		INITIAL CHECK.................................................281
	VALVE SEAT INSERT, CYLINDER HEAD..................................281
		GRIND.........................................................282
		INSTALL.......................................................282
		REMOVE........................................................281
ROCKER LEVERS - GROUP - 03............................................290
	CRANKCASE BREATHER (EXTERNAL).....................................294
		CLEAN.........................................................295
		INSTALL.......................................................296
		REMOVE........................................................294
	ROCKER LEVER......................................................297
		ASSEMBLE......................................................299
		DISASSEMBLE...................................................297
		MAGNETIC CRACK INSPECT........................................298
	ROCKER LEVER ASSEMBLY.............................................300
		ASSEMBLE......................................................304
		CLEAN.........................................................302
		DISASSEMBLE...................................................303
		EXPLODED VIEW.................................................300
		INSPECT FOR REUSE.............................................302
	ROCKER LEVER BUSHINGS.............................................304
		INSTALL.......................................................304
		REMOVE........................................................304
	ROCKER LEVER COVER................................................305
		CLEAN.........................................................305
		INSPECT FOR REUSE.............................................305
	ROCKER LEVER HOUSING..............................................305
		ASSEMBLE......................................................306
		CLEAN.........................................................305
		INSPECT FOR REUSE.............................................306
	ROCKER LEVERS - GENERAL INFORMATION...............................291
		GENERAL INFORMATION...........................................291
	SERVICE TOOLS.....................................................292
		ROCKER LEVERS.................................................292
CAM FOLLOWERS/TAPPETS - GROUP 04......................................307
	CAM FOLLOWER ASSEMBLY.............................................309
		ASSEMBLE......................................................312
		CLEAN.........................................................310
		DISASSEMBLE...................................................310
		EXPLODED VIEW.................................................309
		INSPECT FOR REUSE.............................................311
	CAM FOLLOWER COVER................................................313
		CLEAN.........................................................313
		GENERAL INFORMATION...........................................313
		INSPECT FOR REUSE.............................................313
	CAM FOLLOWERS/TAPPETS - GENERAL INFORMATION.......................308
	PUSH RODS OR TUBES................................................314
		CLEAN.........................................................314
		GENERAL INFORMATION...........................................314
		INSPECT FOR REUSE.............................................314
FUEL SYSTEM - GROUP 05................................................316
	FUEL PUMP.........................................................322
		CALIBRATE.....................................................323
		CLEAN.........................................................322
		INSPECT FOR REUSE.............................................322
	FUEL SHUTOFF VALVE (FSOV).........................................325
		CLEAN.........................................................326
		INSPECT FOR REUSE.............................................326
		INSTALL.......................................................327
		REMOVE........................................................325
	FUEL SYSTEM - GENERAL INFORMATION.................................317
		GENERAL INFORMATION...........................................317
	SERVICE TOOLS.....................................................320
		FUEL SYSTEM...................................................320
INJECTORS AND FUEL LINES - GROUP 06...................................329
	FUEL FILTER HEAD..................................................331
		INSTALL.......................................................331
		REMOVE........................................................331
	FUEL MANIFOLD (SUPPLY)............................................332
		CLEAN.........................................................332
		INSPECT FOR REUSE.............................................333
	FUEL SUPPLY LINES.................................................333
		CLEAN.........................................................333
		INSPECT FOR REUSE.............................................334
			FUEL CONTROL SUPPLY LINE..................................334
			FUEL INLET LINE...........................................335
			FUEL RAIL SUPPLY LINE.....................................334
			FUEL TANK-TO-FUEL FILTER..................................334
			FUEL TIMING SUPPLY LINE...................................334
	INJECTOR..........................................................335
		CLEAN.........................................................335
		INSPECT FOR REUSE.............................................335
	INJECTORS AND FUEL LINES - GENERAL INFORMATION....................330
		GENERAL INFORMATION...........................................330
LUBRICATING OIL SYSTEM - GROUP 7......................................338
	LUBRICATING OIL COOLER............................................341
		CLEAN.........................................................342
		EXPLODED VIEW.................................................341
		GENERAL INFORMATION...........................................342
		INSPECT FOR REUSE.............................................342
	LUBRICATING OIL FILTER HEAD.......................................343
		ASSEMBLE......................................................348
		CLEAN.........................................................347
		DISASSEMBLE...................................................346
		EXPLODED VIEW.................................................344
		GENERAL INFORMATION...........................................343
		INSPECT FOR REUSE.............................................347
	LUBRICATING OIL FILTER HEAD ADAPTER...............................351
		CLEAN.........................................................351
		GENERAL INFORMATION...........................................351
		INSPECT FOR REUSE.............................................351
	LUBRICATING OIL FILTER HEAD (REMOTE-MOUNTED)......................349
		ASSEMBLE......................................................350
		CLEAN.........................................................350
		DISASSEMBLE...................................................349
		INSPECT FOR REUSE.............................................350
	LUBRICATING OIL PAN...............................................353
		GENERAL INFORMATION...........................................353
			OIL PAN CAPACITY..........................................353
	LUBRICATING OIL PAN ADAPTER.......................................354
		CLEAN.........................................................354
		INSPECT FOR REUSE.............................................354
	LUBRICATING OIL PUMP..............................................355
		ASSEMBLE......................................................360
		CLEAN.........................................................357
		DISASSEMBLE...................................................357
		EXPLODED VIEW.................................................356
		GENERAL INFORMATION...........................................355
		INSPECT FOR REUSE.............................................358
	LUBRICATING OIL SYSTEM - GENERAL INFORMATION......................339
		GENERAL INFORMATION...........................................339
	OIL TRANSFER CONNECTION...........................................361
		ASSEMBLE......................................................362
		CLEAN.........................................................361
		DISASSEMBLE...................................................361
		INSPECT FOR REUSE.............................................361
	SERVICE TOOLS.....................................................340
		LUBRICATING OIL SYSTEM........................................340
COOLING SYSTEM - GROUP 08.............................................363
	COOLANT THERMOSTAT................................................367
		INSTALL.......................................................369
			CONVENTIONAL AFTERCOOLING.................................369
			LOW TEMPERATURE AFTERCOOLING..............................370
		REMOVE........................................................367
		TEST..........................................................371
			ENGINE THEMOSTATS.........................................371
			LOW TEMPERATURE AFTERCOOLING THERMOSTAT...................372
	COOLANT THERMOSTAT HOUSING SUPPORT................................373
		GENERAL INFORMATION...........................................373
			LTA COOLING SYSTEM........................................373
			THERMOSTAT................................................373
			THERMOSTAT SEAL...........................................373
			THERMOSTAT SUPPORT........................................373
	COOLING SYSTEM - GENERAL INFORMATION..............................364
		GENERAL INFORMATION...........................................364
	FAN, COOLING......................................................381
		GENERAL INFORMATION...........................................381
	FAN DRIVE IDLER ARM ASSEMBLY......................................374
		ASSEMBLE......................................................375
		CLEAN.........................................................374
		DISASSEMBLE...................................................374
		INSPECT FOR REUSE.............................................374
	FAN DRIVE IDLER PULLEY ASSEMBLY...................................375
		CLEAN.........................................................375
		INSPECT FOR REUSE.............................................376
	FAN HUB, BELT DRIVEN..............................................377
		ASSEMBLE......................................................379
		CLEAN.........................................................378
		GENERAL INFORMATION...........................................377
		INSPECT FOR REUSE.............................................378
	SERVICE TOOLS.....................................................366
		COOLING SYSTEM................................................366
	TORQUE CONVERTER COOLER...........................................389
		ASSEMBLE......................................................390
		CLEAN.........................................................391
		DISASSEMBLE...................................................391
		EXPLODED VIEW.................................................389
		GENERAL INFORMATION...........................................389
		INSPECT FOR REUSE.............................................390
	WATER PUMP........................................................382
		ASSEMBLE......................................................385
		CLEAN.........................................................384
		DISASSEMBLE...................................................382
		INSPECT.......................................................384
		INSPECT FOR REUSE.............................................382
	WATER PUMP BEARINGS ..............................................391
		INSTALL.......................................................392
		MEASURE.......................................................391
		REMOVE........................................................391
DRIVE UNITS - GROUP 09................................................394
	ACCESSORY DRIVE PULLEY............................................398
		INSPECT FOR REUSE.............................................398
		INSTALL.......................................................398
		REMOVE........................................................398
	DRIVE UNITS - GENERAL INFORMATION.................................396
		GENERAL INFORMATION...........................................396
	FUEL PUMP DRIVE...................................................400
		ASSEMBLE......................................................405
		CLEAN.........................................................402
		DISASSEMBLE...................................................404
		EXPLODED VIEW.................................................401
		GENERAL INFORMATION...........................................400
		INSPECT FOR REUSE.............................................402
	FUEL PUMP DRIVE GEAR AND SHAFT....................................406
		ASSEMBLE......................................................407
		DISASSEMBLE...................................................406
	HYDRAULIC PUMP DRIVE..............................................409
		ASSEMBLE .....................................................411
		CLEAN.........................................................410
		DISASSEMBLE...................................................410
		EXPLODED VIEW.................................................409
		GENERAL INFORMATION...........................................409
		INSPECT FOR REUSE.............................................410
	HYDRAULIC PUMP DRIVE GEAR AND SHAFT...............................412
		ASSEMBLE......................................................413
		DISASSEMBLE...................................................412
	HYDRAULIC PUMP SUPPORT BUSHING....................................452
		INSPECT FOR REUSE.............................................453
		INSTALL.......................................................453
		REMOVE........................................................452
	OUTER HYDRAULIC PUMP SUPPORT DRIVE................................448
		ASSEMBLE......................................................451
		DISASSEMBLE...................................................448
		INSPECT FOR REUSE.............................................449
		INSTALL.......................................................450
	REAR GEAR DRIVE (LOWER ASSEMBLY)..................................413
		ASSEMBLE......................................................421
		DISASSEMBLE...................................................420
		EXPLODED VIEW.................................................418
		INSPECT FOR REUSE.............................................421
		INSTALL.......................................................424
		REMOVE........................................................413
	REAR GEAR DRIVE (UPPER ASSEMBLY)..................................430
		ASSEMBLE......................................................437
		DISASSEMBLE...................................................432
		EXPLODED VIEW.................................................430
		INSPECT FOR REUSE.............................................435
	SERVICE TOOLS.....................................................397
		DRIVE UNITS...................................................397
	WATER PUMP DRIVE BUSHING..........................................447
		ASSEMBLE......................................................447
		DISASSEMBLE...................................................447
	WATER PUMP DRIVER GEAR AND SHAFT..................................446
		ASSEMBLE......................................................447
		DISASSEMBLE...................................................446
	WATER PUMP DRIVE PULLEY...........................................447
		CLEAN.........................................................447
		INSPECT FOR REUSE.............................................448
AIR INTAKE SYSTEM - GROUP 10..........................................454
	AFTERCOOLER ASSEMBLY..............................................457
		ASSEMBLE......................................................459
		CLEAN.........................................................458
		DISASSEMBLE...................................................458
		EXPLODED VIEW.................................................457
		INSPECT FOR REUSE.............................................458
	AFTERCOOLER COOLANT TUBE..........................................460
		CLEAN.........................................................460
		INSPECT FOR REUSE.............................................460
	AIR CROSSOVER.....................................................461
		CLEAN.........................................................461
		INSPECT FOR REUSE.............................................461
	AIR INTAKE SYSTEM - GENERAL INFORMATION...........................455
		PREPARATORY...................................................455
	CHARGE AIR COOLER (CAC)...........................................462
		CLEAN.........................................................462
		INSPECT FOR REUSE.............................................462
		LEAK TEST.....................................................463
	SERVICE TOOLS.....................................................456
		AIR INTAKE SYSTEM.............................................456
	TURBOCHARGER HEAT SHIELD..........................................465
		CLEAN.........................................................465
			MARINE APLICATIONS........................................465
		INSPECT FOR REUSE.............................................465
			MARINE APPLICATIONS.......................................465
		INSTALL ......................................................465
			MARINE APPLICATIONS.......................................465
		REMOVE........................................................465
			MARINE APPLICATIONS.......................................465
	TURBOCHARGER, WATER-COOLED........................................464
		CLEAN.........................................................464
		INSPECT FOR REUSE.............................................464
EXHAUST SYSTEM - GROUP 11.............................................467
	EXHAUST MANIFOLD, DRY.............................................468
		ASSEMBLE......................................................470
		CLEAN.........................................................468
			MARINE APPLICATIONS.......................................469
		DISASSEMBLE...................................................469
		INSPECT FOR REUSE.............................................469
			MARINE APPLICATIONS.......................................470
	EXHAUST MANIFOLD HEAT SHIELD......................................470
		CLEAN.........................................................470
		INSPECT FOR REUSE.............................................471
	EXHAUST SYSTEM - GENERAL INFORMATION..............................468
		GENERAL INFORMATION...........................................468
COMPRESSED AIR SYSTEM - GROUP 12......................................472
	COMPRESSED AIR SYSTEM - GENERAL INFORMATION.......................473
		GENERAL INFORMATION...........................................473
ELECTRICAL EQUIPMENT - GROUP 13.......................................475
	ALTERNATOR ADJUSTING LINK.........................................479
		CLEAN.........................................................479
		INSPECT FOR REUSE.............................................479
	ALTERNATOR BRACKET................................................477
		CLEAN.........................................................477
		INSPECT FOR REUSE.............................................477
	DRIVE BELT, ALTERNATOR............................................477
		ADJUST........................................................477
	ELECTRICAL EQUIPMENT - GENERAL INFORMATION........................476
		GENERAL INFORMATION...........................................476
	STARTING MOTOR....................................................478
		CLEAN.........................................................478
		INSPECT FOR REUSE.............................................479
ENGINE TESTING - GROUP 14.............................................480
	DYNAMOMETER WORKSHEET.............................................490
		WORKSHEET.....................................................490
	ENGINE RUN-IN (CHASSIS DYNAMOMETER)...............................503
		GENERAL INFORMATION...........................................503
			ENGINE THROTTLE CONTROL...................................504
		RUN-IN INSTRUCTIONS...........................................506
	ENGINE RUN-IN (ENGINE DYNAMOMETER)................................522
		GENERAL INFORMATION...........................................522
		RUN-IN INSTRUCTIONS...........................................524
	ENGINE RUN-IN (WITHOUT DYNAMOMETER)...............................508
		PREPARATORY...................................................508
			GENERAL ENGINE TEST PROCEDURES............................508
		RUN-IN INSTRUCTIONS...........................................510
			GENERATOR SET.............................................510
			OFF-HIGHWAY...............................................510
	ENGINE TESTING - GENERAL INFORMATION..............................481
		FUEL FLOW MEASUREMENT ON ENGINE OR CHASSIS DYNAMOMETER........482
			INSTALLATION..............................................482
			OPERATION.................................................483
		GENERAL INFORMATION...........................................481
	ENGINE TESTING (CHASSIS DYNAMOMETER)..............................491
		SETUP.........................................................491
		TEST..........................................................494
	ENGINE TESTING (ENGINE DYNAMOMETER)...............................511
		INSTALL.......................................................511
		TEST..........................................................514
	ENGINE TESTING (IN CHASSIS).......................................527
		STALL SPEED CHECK.............................................527
		TIME SPEED CHECK..............................................530
	SERVICE TOOLS.....................................................488
		ENGINE TESTING................................................488
	SPECIFICATIONS....................................................486
		COOLING SYSTEM................................................487
		ENGINE TESTING................................................486
		EXHAUST SYSTEM................................................487
		LUBRICATING OIL SYSTEM........................................487
MOUNTING ADAPTATIONS - GROUP 16.......................................535
	ENGINE SUPPORT BRACKET, FRONT.....................................539
		CLEAN.........................................................539
		INSPECT FOR REUSE.............................................539
	FLYWHEEL..........................................................539
		CLEAN.........................................................539
		INSPECT FOR REUSE.............................................540
	FLYWHEEL HOUSING..................................................541
		CLEAN.........................................................541
		INSPECT FOR REUSE.............................................541
		REDOWEL.......................................................542
	FLYWHEEL RING GEAR................................................545
		ASSEMBLE......................................................546
		DISASSEMBLE...................................................545
	MOUNTING ADAPTATIONS - GENERAL INFORMATIONBGENERAL INFORMATION....536
		GENERAL INFORMATION...........................................536
	SERVICE TOOLS.....................................................538
		MOUNTING ADAPTATIONS..........................................538
ELECTRONIC ENGINE CONTROLS - GROUP 19.................................548
	ELECTRONIC ENGINE CONTROLS - GENERAL INFORMATION..................549
		GENERAL INFORMATION...........................................549
			CONNECTOR PINS - CHECKING.................................551
			CONTINUITY CHECK..........................................555
			HOW TO FIND THE INTERNAL RESISTANCE OF THE METER..........550
			HOW TO MEASURE CURRENT....................................549
			HOW TO MEASURE RESISTANCE.................................550
			HOW TO MEASURE VOLTAGE....................................550
			HOW TO TEST FOR CONTINUITY................................550
			HOW TO USE A DIGITAL VOLT/OHM METER.......................549
			POLARITY CHECK............................................554
			RESISTANCE CHECK - COIL...................................556
			SHORT CIRCUIT FROM PIN TO PIN - CHECK.....................553
			SHORT CIRCUIT TO GROUND - CHECK...........................552
			USE OF SPECIAL TEST LEADS.................................549
			VOLTAGE CHECKING..........................................553
		ENGINE WIRING HARNESS.........................................556
			INSPECT FOR REUSE.........................................556
		OEM INTERFACE HARNESS.........................................557
			GENERAL INFORMATION.......................................557
		OEM WIRING HARNESS............................................557
			GENERAL INFORMATION.......................................557
SERVICE LITERATURE....................................................559
	ADDITIONAL SERVICE LITERATURE.....................................560
	LITERATURE ORDER FORM.............................................562
	SERVICE LITERATURE ORDERING LOCATION..............................561
COMPONENT MANUFACTURERS...............................................564
	COMPONENT MANUFACTURERS' ADDRESSES................................565
		AIR COMPRESSORS...............................................565
		AIR CYLINDERS.................................................565
		AIR HEATERS...................................................565
		AIR STARTING MOTORS...........................................565
		ALTERNATORS...................................................565
		AUXILIARY BRAKES..............................................565
		BELTS.........................................................565
		CATALYTIC CONVERTERS..........................................565
		CLUTCHES......................................................565
		COOLANT HEATERS ..............................................566
		COOLANT LEVEL SWITCHES........................................565
		DRIVE PLATES..................................................566
		ELECTRIC STARTING MOTORS......................................566
		ELECTRONIC SWITCHES...........................................566
		ENGINE PROTECTION CONTROLS....................................566
		FAN CLUTCHES..................................................566
		FANS..........................................................566
		FAULT LAMPS...................................................566
		FILTERS.......................................................566
		FLEXPLATES....................................................566
		FUEL COOLERS..................................................566
		FUEL WARMERS..................................................566
		GAUGES........................................................566
		GOVERNORS.....................................................567
		HEAT SLEEVES..................................................567
		HYDRAULIC AND POWER STEERING PUMPS............................567
		IN-LINE CONNECTORS............................................567
		OIL HEATERS...................................................567
		PRELUBRICATIONS SYSTEMS.......................................567
		RADIATORS.....................................................567
		THROTTLE ASSEMBLIES...........................................567
		TORQUE CONVERTERS.............................................567
SPECIFICATIONS........................................................569
	AIR INTAKE SYSTEM - SPECIFICATIONS................................612
		AFTERCOOLER ASSEMBLY..........................................612
		TURBOCHARGER, WATER-COOLED....................................612
	AIR INTAKE SYSTEM - TORQUE VALUES.................................613
		AFTERCOOLER ASSEMBLY..........................................613
		TURBOCHARGER HEAT SHIELD......................................613
	CAM FOLLOWERS/TAPPETS - SPECIFICATIONS............................594
		CAM FOLLOWER ASSEMBLY.........................................594
	CAPSCREW MARKINGS AND TORQUE VALUES...............................618
		CAPSCREW MARKINGS AND TORQUE VALUES  - METRIC.................619
		CAPSCREW MARKINGS AND TORQUE VALUES - U.S. CUSTOMARY..........620
	COMPLETE ENGINE - SPECIFICATIONS..................................571
		ENGINE ASSEMBLY...............................................571
	COMPLETE ENGINE - TORQUE VALUES...................................573
		ENGINE ASSEMBLY...............................................573
		ENGINE DISASSEMBLY............................................573
	COOLING SYSTEM - SPECIFICATIONS...................................601
		FAN DRIVE IDLER PULLEY ASSEMBLY...............................601
		FAN HUB, BELT DRIVEN..........................................601
		TORQUE CONVERTER COOLER.......................................601
		WATER PUMP....................................................601
		WATER PUMP BEARINGS...........................................602
	COOLING SYSTEM - TORQUE VALUES....................................603
		COOLANT THERMOSTAT............................................603
		FAN HUB, BELT DRIVEN..........................................603
		TORQUE CONVERTER COOLER.......................................604
		WATER PUMP....................................................604
	CYLINDER BLOCK - SPECIFICATIONS...................................583
		BEARINGS, MAIN................................................583
		CAMSHAFT......................................................583
		CAMSHAFT BUSHINGS.............................................583
		CAMSHAFT GEAR (CAMSHAFT REMOVED)..............................583
		CONNECTING ROD................................................584
		CRANKSHAFT....................................................585
		CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED).................585
		CRANKSHAFT PULLEY.............................................585
		CYLINDER BLOCK................................................585
		CYLINDER BLOCK AND LINER SEATS................................585
		CYLINDER BLOCK COUNTERBORE....................................588
		CYLINDER LINER................................................586
		GEAR COVER ACCESSORY DRIVE BUSHING............................588
		GEAR COVER, FRONT.............................................587
		GEAR COVER SPACER PLATE.......................................587
		IDLER GEAR, CAMSHAFT..........................................587
		MEASURE THE CONNECTING ROD BEND (BORE ALIGHNMENT).............584
		MEASURE THE CONNECTING ROD TWIST..............................585
		PISTON........................................................587
	CYLINDER BLOCK - TORQUE VALUES....................................589
		CONNECTING ROD................................................589
		CRANKSHAFT PULLEY.............................................589
		CYLINDER BLOCK................................................589
		CYLINDER BLOCK COUNTERBORE....................................589
	CYLINDER HEAD - SPECIFICATIONS....................................590
		CYLINDER HEAD ................................................590
		CYLINDER HEAD INJECTOR BORE...................................590
		VALVE, CYLINDER HEAD..........................................591
		VALVE GUIDE, CYLINDER HEAD....................................590
		VALVE SEAT BORE...............................................591
		VALVE SEAT INSERT, CYLINDER HEAD..............................591
	DRIVE BELT TENSION................................................617
	DRIVE UNITS - SPECIFICATIONS......................................605
		FUEL PUMP DRIVE...............................................605
		FUEL PUMP DRIVE GEAR AND SHAFT................................606
		HYDRAULIC PUMP DRIVE..........................................606
		HYDRAULIC PUMP SUPPORT BUSHING................................609
		OUTER HYDRAULIC PUMP SUPPORT DRIVE............................608
		REAR GEAR DRIVE (LOWER ASSEMBLY)..............................606
		REAR GEAR DRIVE (UPPER ASSEMBLY)..............................607
		WATER PUMP DRIVE..............................................608
	DRIVE UNITS - TORQUE VALUES.......................................610
		OUTER HYDRUALIC PUMP SUPPORT DRIVE............................611
		REAR GEAR DRIVE (LOWER ASSEMBLY)..............................610
		REAR GEAR DRIVE (UPPER ASSEMBLY)..............................610
	ELECTRICAL EQUIPMENT - SPECIFICATIONS.............................615
		DRIVE BELT, ALTERNATOR........................................615
	ENGINE TESTING - SPECIFICATIONS...................................616
		ENGINE TESTING (CHASSIS DYNAMOMETER)..........................616
		ENGINE TESTING (ENGINE DYNAMOMETER)...........................616
	EXHAUST SYSTEM - SPECIFICATIONS...................................614
		EXHAUST MANIFOLD, DRY.........................................614
	FRACTION, DECIMAL, MILLIMETER CONVERSIONS.........................621
	FUEL SYSTEM - TORQUE VALUES.......................................595
		FUEL SHUTOFF VALVE (FSOV).....................................595
	INJECTORS AND FUEL LINES - TORQUE VALUES..........................596
		FUEL MANIFOLD(SUPPLY).........................................596
	LUBRICATING OIL SYSTEM - SPECIFICATIONS...........................597
		LUBRICATING OIL FITER HEAD....................................597
		LUBRICATING OIL FILTER HEAD (LF670)...........................597
		LUBRICATING OIL FILTER HEAD (REMOTE-MOUNTED)..................597
		LUBRICATING OIL PAN...........................................597
		LUBRICATING OIL PUMP..........................................597
		OIL TRANSFER CONNECTION.......................................598
	LUBRICATING OIL SYSTEM - TORQUE VALUES............................599
		LUBRICATING OIL COOLER........................................599
		LUBRICATING OIL FILTER HEAD...................................599
		LUBRICATING OIL FILTER HEAD (REMOTE-MOUNTED)..................599
		LUBRICATING OIL PUMP..........................................599
		OIL TRANSFER CONNECTION.......................................600
	NEWTON-METER TO FOOT-POUND CONVERSION CHART.......................622
	PIPE PLUG TORQUE VALUES...........................................623
	ROCKER LEVERS - SPECIFICATIONS....................................593
		ROCKER LEVER..................................................593
		ROCKER LEVER ASSEMBLY.........................................593
		ROCKER LEVER BUSHINGS.........................................593
	TAP-DRILL CHART - U.S. CUSTOMARY AND METRIC.......................624
	WEIGHTS AND MEASURES - CONVERSION FACTORS.........................625
INDEX.................................................................627