Cummins KT19, KTA19 and KTTA19 (K19 series) Diesel Engines Diagnostic and Repair Manual (cummins-K19)

Illustrated factory Diagnostic and Repair Manual for Cummins Diesel Engines Models KT19, KTA19 and KTTA19.

This manual will assist you in diagnosing, troubleshooting, assembling, disassembling, and repairing for your diesel engine.
You can use a Windows, Mac, or Android device to view this manual. You only need to have a PDF reader installed.

Covered Models:
   KT19
   KTA19
   KTTA19

Format: PDF, 713 pages
Language: English
Publication Date: 01 Jan 2005
Table of Contents:
   SECTION I - INTRODUCTION
      ABOUT THE MANUAL
      HOW TO USE THE MANUAL
      SYMBOLS
      SIMBOLOS
      SYMBOLE
      SYMBOLES
      ILLUSTRATIONS
      GENERAL SAFETY INSTRUCTIONS
      GENERAL REPAIR INSTRUCTIONS
      GENERAL CLEANING INSTRUCTIONS
      DEFINITION OF TERMS
   SECTION E - ENGINE AND COMPONENT IDENTIFICATION
      ENGINE IDENTIFICATION
      GENERAL SPECIFICATIONS
      EXTERNAL ENGINE COMPONENTS
   SECTION T - TROUBLESHOOTING
      PROCEDURES AND TECHNIQUES
      TROUBLESHOOTING CHARTS (ALPHABETICAL LISTING)
      TROUBLESHOOTING CHARTS (BY SYSTEM)
      COOLANT TEMPERATURE ABOVE NORMAL
      COOLANT TEMPERATURE BELOW NORMAL
      COOLANT LOSS
      FUEL IN COOLANT
      LUBRICATING OIL PRESSURE LOW
      LUBRICATING OIL PRESSURE HIGH
      LUBRICATING OIL TEMPERATURE ABOVE NORMAL
      LUBRICATING OR HYDRAULIC OIL IN THE COOLANT
      LUBRICATING OIL CONSUMPTION EXCESSIVE
      LUBRICATING OIL SLUDGE IN THE ENGINE CRANKCASE EXCESSIVE
      COOLANT IN THE LUBRICATING OIL
      FUEL IN THE LUBRICATING OIL
      TURBOCHARGER NOISE
      TURBOCHARGER BOOST PRESSURE LOW
      TURBOCHARGER LEAKS (ENGINE OIL OR FUEL)
      AIR COMPRESSOR SLOW AIR PRESSURE RISE
      AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE (NOT PUMPING CONTINUOUSLY)
      AIR COMPRESSOR PUMPING EXCESSIVE LUBRICATING OIL
      AIR COMPRESSOR WILL NOT PUMP
      AIR COMPRESSOR WILL NOT STOP PUMPING
      AIR COMPRESSOR NOISE EXCESSIVE
      ENGINE CRANKS BUT WILL NOT START (NO SMOKE FROM EXHAUST)
      ENGINE HARD TO START OR WILL NOT START (EXHAUST SMOKE PRESENT)
      ENGINE STARTS BUT WILL NOT KEEP RUNNING
      ENGINE RUNS ROUGH OR MISFIRES (WARM ENGINE)
      IDLE ROUGH
      ENGINE SURGES AT LOW IDLE
      ENGINE WILL NOT REACH RATED RPM WHEN LOADED
      ENGINE POWER OUTPUT LOW
      PERFORMANCE MEASUREMENT
      EXHAUST SMOKE EXCESSIVE UNDER LOAD
      ENGINE WILL NOT SHUT OFF
      ENGINE DECELERATES POORLY
      ENGINE SURGES UNDER LOAD
      ENGINE SURGES AT HIGH IDLE
      THROTTLE RESPONSE SLOW (ENGINE DIES GOING DOWN HILL)
      FUEL CONSUMPTION EXCESSIVE
      ENGINE WILL NOT CRANK OR CRANKS SLOWLY (AIR STARTER)
      ENGINE WILL NOT CRANK OR CRANKS SLOWLY (ELECTRIC STARTER)
      ALTERNATOR MALFUNCTIONING
      CRANKCASE GASES (BLOWBY) EXCESSIVE
      ENGINE VIBRATION EXCESSIVE
      ENGINE NOISE - DIAGNOSTIC PROCEDURES
      ENGINE NOISE EXCESSIVE
      EXHAUST SMOKE (WHITE) AT IDLE EXCESSIVE (WARM ENGINE)
   SECTION 1 - COOLING SYSTEM
      SERVICE TOOLS (01-00)
      GENERAL INFORMATION (01-01)
      COOLING SYSTEM SPECIFICATIONS (01-02)
      COOLING SYSTEM FLOW CHARTS (01-03)
      COOLING SYSTEM VENTING (01-04)
      COOLING SYSTEM - MAINTENANCE (01-05)
      COOLING SYSTEM - DRAIN (01-06)
      COOLING SYSTEM - FILL (01-07)
      COOLANT FILTER - REPLACE (01-08)
      DIESEL COOLANT ADDITIVES (DCA4) (01-09)
      COOLING SYSTEM - CLEAN (01-10)
      COOLING SYSTEM - TEST FOR AIR OR COMBUSTION GASES (01-11)
      CRACKED OR POROUS CYLINDER LINER
      DEFECTIVE AIR CONTROL VALVE
      AIR COMPRESSOR CHECK
      COOLING SYSTEM - PRESSURE TEST (01-12)
      HOSES - CHECK (01-13)
      COOLANT TEMPERATURE GAUGE - CHECK (01-14)
      RADIATOR PRESSURE CAP - CHECK (01-15)
      RADIATOR FINS - INSPECT (01-16)
      RADIATOR BAFFLE LEAKAGE - CHECK (01-17)
      RADIATOR - CHECK FOR REVERSE FLOW (01-18)
      RADIATOR - CHECK FOR OBSTRUCTION (01-19)
      SHUTTER OPERATION - CHECK (01-20)
      FAN, AND FAN SHROUD - INSPECT (01-21)
      FAN - REPLACE (01-22)
      FAN DRIVE BELT - REPLACE (01-23)
      FAN CLUTCH - CHECK OPERATION (01-24)
      FAN RPM - CHECK (01-25)
      FAN HUB (BELT DRIVEN) - REPLACE (01-26)
      FAN HUB (GEAR DRIVEN) - REPLACE (01-27)
      FAN HUB IDLER AND SHOCK ABSORBER (OR TURNBUCKLE) - REPLACE (01-28)
      WATER PUMP BLOCK PRESSURE - CHECK (01-29)
      WATER PUMP - REPLACE (01-30)
      WATER PUMP - CHECK FOR REUSE (01-31)
      THERMOSTAT - TEST (THERMOSTAT IN CHASSIS) (01-32)
      THERMOSTAT - REPLACE (01-33)
      THERMOSTAT - CHECK OPERATING TEMPERATURE (01-34)
      THERMOSTAT HOUSING - REPLACE (01-35)
      CHECK FOR COOLANT LEAKS AT COUNTERBORE (01-36)
   SECTION 2 - LUBRICATION OIL SYSTEM
      SERVICE TOOLS (01-00)
      GENERAL INFORMATION (02-01)
      SPECIFICATIONS (02-02)
      FLOW DIAGRAMS (02-03)
      INTERNAL ENGINE DAMAGE - CHECK (02-04)
      OIL LEAKS (EXTERNAL) - CHECKS (02-05)
      OIL SYSTEM - LEAK CHECK USING DYE (02-06)
      OIL PRESSURE GAUGE - CHECK (02-07)
      OIL TEMPERATURE GAUGE - CHECK (02-08)
      DRAIN OIL (02-09)
      OIL PAN - FILL (02-10)
      OIL FILTERS (FULL FLOW AND BYPASS) - REPLACE (02-11)
      OIL FILTER (FULL FLOW) - MEASURE PRESSURE DROP (02-12)
      CRANKCASE BREATHER AND TUBE - REPLACE (02-13)
      DIPSTICK TUBE - REPLACE (02-14)
      DIPSTICK - CALIBRATE (02-15)
      OIL PAN - REPLACE (02-16)
      OIL PAN ADAPTER - REPLACE (02-17)
      OIL FILTER HEAD - REPLACE (02-18)
      OIL COOLER - MEASURE PRESSURE DROP (02-19)
      OIL COOLER COVER - REPLACE (02-20)
      TORQUE CONVERTER COOLER - REPLACE (02-21)
      OIL COOLER CORE - REPLACE (02-22)
      OIL COOLER CORE - CHECK FOR REUSE (02-23)
      TORQUE CONVERTER COOLER - PRESSURE TEST (02-24)
      OIL COOLER HOUSING - REPLACE (02-25)
      MAIN OIL PRESSURE REGULATOR - REPLACE (02-26)
      OIL PUMP - REPLACE (02-27)
      LUBRICATING OIL PUMP - CHECK FOR REUSE (02-28)
   SECTION 3 - COMBUSTION AIR SYSTEM
      GENERAL INFORMATION (03-01)
      SPECIFICATIONS (03-02)
      FLOW DIAGRAMS (03-03)
      SERVICE TOOLS (03-04)
      TURBOCHARGER TURBINE SEAL LEAKS - CHECK (03-05)
      COMPRESSOR SEAL LEAKAGE - CHECK (03-06)
      CORRECT TURBOCHARGER INSTALLED - CHECK (03-07)
      INTAKE AIR RESTRICTION - CHECK (03-08)
      EXHAUST RESTRICTION - CHECK (03-09)
      AIR LEAKS - CHECK (03-10)
      TURBOCHARGER BLADE DAMAGE - CHECK (03-11)
      TURBOCHARGER AXIAL AND RADIAL CLEARANCE - CHECK (03-12)
      TURBOCHARGER - REPLACE (03-13)
      SERIES TURBOCHARGER - REPLACE (03-14)
      EXHAUST MANIFOLD - REPLACE (03-15)
      EXHAUST MANIFOLD - CHECK (03-16)
      AFTERCOOLER - REPLACE (03-17)
      AFTERCOOLER ELEMENT - REPLACE (03-18)
      AFTERCOOLER ELEMENT - TEST (03-19)
      INTAKE MANIFOLD PRESSURE - CHECK (03-20)
   SECTION 4 - COMPRESSED AIR SYSTEM
      GENERAL INFORMATION (04-01)
      SPECIFICATIONS (04-02)
      FLOW DIAGRAMS (04-03)
      SERVICE TOOLS (04-04)
      CARBON BUILDUP, AIR COMPRESSOR - CHECK (04-05)
      GASKET LEAKS, AIR COMPRESSOR - CHECK (04-06)
      AIR GOVERNOR - CHECK (AIR COMPRESSOR NOT PUMPING) (04-07)
      AIR GOVERNOR - CHECK (AIR COMPRESSOR PUMPS CONTINUOUSLY) (04-08)
      LUBRICATING OIL USAGE, AIR COMPRESSOR - CHECK (04-09)
      UNLOADER VALVE, AIR COMPRESSOR - REPLACE (04-10)
      UNLOADER VALVE - CHECK (04-11)
      INTAKE/EXHAUST VALVES, AIR COMPRESSOR - CHECK (04-12)
      CYLINDER HEAD, AIR COMPRESSOR - REBUILD ON ENGINE (04-13)
      CYLINDER HEAD, AIR COMPRESSOR - REPLACE (04-14)
      AIR COMPRESSOR (SINGLE CYLINDER) - REPLACE (04-15)
      AIR COMPRESSOR (TWO CYLINDER) - REPLACE (04-16)
      AIR COMPRESSOR - CHECK FOR REUSE (04-17)
   SECTION 5 - FUEL SYSTEM
      GENERAL INFORMATION (05-01)
      SPECIFICATIONS 05-02)
      FLOW DIAGRAMS (05-03)
      SERVICE TOOLS (05-04)
      IDLE SPEED - CHECK AND ADJUST (05-05)
      HORSEPOWER - MEASURE ENGINE PERFORMANCE (05-06)
      FUEL RATE - ADJUST (05-07)
      AFC NO-AIR VALVE SETTING - CHECK AND ADJUST (05-08)
      INJECTORS - REPLACE (05-09)
      INJECTORS - CLEAN EXTERIOR FOR REUSE (05-10)
      FUEL PUMP - REPLACE (05-11)
      THROTTLE TRAVEL - CHECK (05-12)
      FUEL SYSTEM MAINTENANCE (05-13)
      GEAR PUMP CHECK VALVE - REPLACE (05-14)
      VARIABLE SPEED (VS) GOVERNOR LEAKING FUEL (05-15)
      FUEL SHUTOFF VALVE - CHECK (05-16)
      FUEL PUMP - FLOW CHECK AND PRIME (05-17)
      FUEL PUMP ROTATION CHECK (05-18)
      AIR LEAKS (05-19)
      AFC - CHECK FOR AIR LEAK (05-20)
      CYLINDER MISFIRE (05-21)
      ENGINE OIL DILUTION BY FUEL (05-22)
      FUEL LINE RESTRICTION (SUCTION) - CHECK (05-23)
      FUEL DRAIN RESTRICTION - CHECK (05-24)
      STC OIL CONTROL VALVE - CHECK (05-25)
      STC FUEL PRESSURE SWITCH - CHECK (05-26)
      STC WIRING HARNESS - CHECK FOR REUSE (05-27)
      STC OIL CONTROL VALVE - REPLACE (05-28)
      STC WIRING HARNESS - REPLACE (05-29)
      FUEL CONSUMPTION CHECK (05-30)
      LOW POWER CHECK (05-31)
      ENGINE STALL SPEED AND TIME CHECK (05-32)
      FUEL MANIFOLD - REPLACE (05-33)
      STC OIL MANIFOLD - REPLACE (05-34)
      STALL SPEED CHECK LIST (05-35)
      DRIVEABILITY - LOW POWER CHECK LIST (05-36)
      FUEL CONSUMPTION CHECK LIST (05-37)
   SECTION 6 - ELECTRICALSYSTEM
      GENERAL INFORMATION (06-01)
      SPECIFICATIONS (06-02)
      SERVICE TOOLS (06-03)
      BATTERY TERMINAL CONNECTIONS - CHECK (06-04)
      BATTERIES - CHECK (06-05)
      STARTING CIRCUIT - CHECK (06-06)
      ALTERNATOR BELT - ADJUST (06-07)
      ALTERNATOR - OUTPUT TEST (06-08)
      ALTERNATOR - REPLACE (06-09)
      ACCESSORY/ALTERNATOR DRIVE PULLEY - CHECK FOR REUSE (06-10)
      STARTING MOTOR - REPLACE (06-11)
      STARTER MOTOR - CHECK FOR REUSE (06-12)
   SECTION 7 - BASE ENGINE COMPONENTS
      SERVICE TOOLS (07-01)
      GENERAL INFORMATION (07-02)
      CRANKCASE GAS (BLOWBY) - CHECK (07-03)
      ROCKER LEVER COVER - REPLACE (07-04)
      CHECK/ADJUST VALVES AND INJECTORS (07-05)
      JACOBS ENGINE BRAKE - ADJUST (07-06)
      JACOBS ENGINE BRAKE - REPLACE (07-07)
      PUSH ROD - REPLACE (07-08)
      ROCKER LEVER ASSEMBLY - REPLACE (07-09)
      ROCKER LEVER ASSEMBLY - CLEAN AND CHECK FOR REUSE (07-10)
      ROCKER LEVER HOUSING - REPLACE (07-11)
      CHECK CYLINDER HEAD GASKET FOR COMBUSTION, COOLANT, OR OIL LEAK (07-12)
      POWER CYLINDER - LOCATE FAILED CYLINDER (07-13)
      CYLINDER HEAD GASKET - REPLACE (07-14)
      CYLINDER HEAD - CLEAN AND CHECK FOR REUSE (07-15)
      PRESSURE TEST CYLINDER HEAD - HEAD REMOVED (07-16)
      CAM FOLLOWER ASSEMBLY - REPLACE (07-17)
      CAM FOLLOWER ASSEMBLY - CLEAN AND CHECK FOR REUSE (07-18)
      INJECTION TIMING - GENERAL INFORMATION (07-19)
      MEASURE THE INJECTION TIMING (07-20)
      PISTON COOLING NOZZLE - REPLACE (07-21)
      MAIN CRANKSHAFT BEARING - REPLACE (07-22)
      CONNECTING ROD BEARING - REPLACE (07-23)
      PISTON AND ROD ASSEMBLY - REPLACE (07-24)
      PISTON - CLEAN AND CHECK FOR REUSE (07-25)
      CYLINDER LINER - REMOVE (07-26)
      CHECK LINER PROTRUSION (07-27)
      ACCESSORY DRIVE PULLEY - REPLACE (07-28)
      WEAR SLEEVE, ACCESSORY DRIVE PULLEY - REPLACE (07-29)
      ACCESSORY DRIVE SEAL - REPLACE (07-30)
      ACCESSORY DRIVE ASSEMBLY - REPLACE (07-31)
      FUEL PUMP/COMPRESSOR DRIVE - CLEAN AND CHECK FOR REUSE (07-32)
      VIBRATION DAMPER - REPLACE (07-33)
      VISCOUS VIBRATION DAMPER - CLEAN AND CHECK FOR REUSE (07-34)
      RUBBER VIBRATION DAMPER - CLEAN AND CHECK FOR REUSE (07-35)
      CRANKSHAFT FRONT SEAL - REPLACE (07-36)
      WATER PUMP DRIVE - REPLACE (07-37)
      WATER PUMP DRIVE - CLEAN AND CHECK FOR REUSE (07-38)
      GEAR COVER (ONE PIECE) - REPLACE (07-39)
      CAMSHAFT GEAR - REPLACE (CAMSHAFT INSTALLED) (07-40)
      GEAR COVER PLATE (SPACER PLATE) - REPLACE (07-41)
      GEAR COVER (TWO PIECE) - REPLACE (07-42)
      GEAR HOUSING (TWO PIECE DESIGN) - REPLACE (07-43)
      CHECK GEAR TRAIN BACKLASH (07-44)
      IDLER SHAFT (PRESS-IN) - REPLACE (07-45)
      FRONT ENGINE SUPPORT - REPLACE (07-46)
      CRANKSHAFT GEAR - REMOVE AND INSTALL (07-47)
      CAMSHAFT - REPLACE (07-48)
      CAMSHAFT GEAR - REMOVE AND INSTALL (07-49)
      CYLINDER BLOCK - REPLACE CAMSHAFT BUSHINGS (07-50)
      CAMSHAFT REAR COVER - REPLACE (07-51)
      FLYWHEEL - REPLACE (07-52)
      CRANKSHAFT SEAL, REAR - REPLACE (07-53)
      FLYWHEEL HOUSING - REPLACE (07-54)
      FLYWHEEL HOUSING REDOWEL TO CYLINDER BLOCK (07-55)
      PIPE PLUGS AND CUP PLUGS - REPLACE (07-56)
   SECTION 8 - ENGINE TESTING ("IN-CHASSIS")
      SPECIFICATIONS AND PROCEDURES (08-01)
      GENERAL ENGINE TEST PROCEDURES (08-01)
      CHASSIS DYNAMOMETER OPERATION (08-02)
      ENGINE RUN-IN PROCEDURE (CHASSIS DYNAMOMETER) (08-03)
      ENGINE RUN-IN PROCEDURE "IN-CHASSIS" (ON AND OFF-HIGHWAY VEHICLES) (08-04)
      ENGINE CONFIGURATIONS AND MODELS (08-05)
   SECTION 9 - ENGINE REMOVE AND INSTALL
      GENERAL INFORMATION (09-01)
      SERVICE TOOLS (09-02)
      ENGINE - REMOVE (09-03)
      ENGINE MOUNT - INSPECT (09-04)
      ENGINE - INSTALL (09-05)
   SECTION 10 - ENGINE COMPONENT SPECIFICATIONS
      GENERAL INFORMATION (10-01)
      CONVERSION FACTORS (10-02)
      PIPE PLUG TORQUE VALUES (10-03)
      CAPSCREW MARKINGS AND TORQUE VALUES (10-04)
      DECIMAL AND METRIC EQUIVALENTS (10-05)
      COOLING SYSTEM (10-06)
      LUBRICATING OIL SYSTEM (10-07)
      COMBUSTION AIR SYSTEM (10-08)
      COMPRESSED AIR SYSTEM (10-09)
      FUEL SYSTEM (10-10)
      ELECTRICAL SYSTEM (10-11)
      BASE ENGINE COMPONENTS (10-12)
   SECTION 11 - INDEX - TROUBLESHOOTING AND REPAIR
   SECTION 12 - SERVICE LITERATURE
      SERVICE LITERATURE ORDERING LOCATION
      SERVICE LITERATURE ORDER FORM
   SECTION 13 - COMPONENT MANUFACTURERS