Cummins K19 Diesel Engine Troubleshooting & Repair Manual – 1986 (P/N 3810307-00)

The Cummins Troubleshooting and Repair Manual — K19 Engines, P/N 3810307-00, printed September 1986, covers in-chassis troubleshooting and repair for KT19, KTA19, and KTTA19 configurations.

PDF Search, Bookmarks and Page Details

Search and illustrated detail: Text search is available in the introduction, troubleshooting charts, and specification tables, but many illustrated repair pages are not searchable. Embedded bookmarks link to system sections and individual procedures. Small terminal numbers in the STC wiring illustrations are readable with zooming.

One printable 713-page PDF includes the original cover, 10 notes pages, and one repeated thermostat-service page bearing printed page number 1-61.

K19 System Diagnosis and In-Chassis Repair

The following selected repair areas show the manual’s scope. Further topics include vibration-damper inspection and pipe-plug and cup-plug replacement.

• Cooling system: Pressure and combustion-gas testing, water-pump replacement, thermostat testing, fan-drive checks, and coolant-leak diagnosis.

• Lubrication system: Oil-pressure diagnosis, filter and cooler pressure-drop tests, oil-pump inspection, pressure-regulator replacement, and dipstick calibration.

• Turbochargers and aftercoolers: Seal-leak and clearance checks, single and series turbocharger replacement, intake/exhaust restriction testing, and aftercooler pressure testing.

• Compressed air: Compressor fault diagnosis, unloader-valve checks, on-engine compressor-head rebuilding, and single- and two-cylinder compressor replacement.

• Fuel and STC systems: Fuel-rate and AFC checks, suction and drain restriction tests, injector replacement, and Step Timing Control diagnosis.

• Electrical system: Battery checks, starter-switch and solenoid diagnosis, starting-circuit tests, alternator-output testing, and starter and alternator replacement.

• Base engine: Valve, injector, and Jacobs brake adjustment; injection-timing measurement; cylinder-head, piston, liner, bearing, camshaft, and gear-train service.

Written for service technicians, this manual assumes familiarity with engine repair practices and the special tools specified for individual procedures.

Engine Identification and Troubleshooting Charts

Engine identification uses the Engine Serial Number (ESN), Control Parts List (CPL), model, horsepower, and rated RPM. The fuel-pump dataplate supplies calibration information.

Configuration tables cover automotive, construction, stationary power, agricultural, military, locomotive, marine, and generator applications. They identify variable-timing builds and distinguish one-piece aluminum from two-piece cast-iron front covers.

The 44 troubleshooting logic charts connect symptoms and probable causes to repair-procedure references. That organization lets a technician follow an engine complaint into the relevant checks before selecting a repair.

Cooling and lubrication charts address coolant loss, cross-contamination, temperature problems, and high or low oil pressure. Performance charts cover no-start conditions, rough running, misfire, surging, low power, excessive fuel consumption, and white smoke.

Other charts address turbocharger noise and low boost, air-compressor faults, excessive blowby, vibration, alternator faults, and slow cranking with air or electric starters.

Cooling, Lubrication and Air-System Detail

The Cooling System Flow Charts and Lubricating Oil System Flow Diagrams trace circulation through the engine and its associated components. The cooling procedures include separate checks for combustion gases, air-compressor leakage, and liner-counterbore leakage.

The pressure-test instructions warn that excessive test pressure can damage the water-pump seal. Fan-speed checks identify optical tachometer P/N 3377462.

Lubrication coverage extends to oil analysis and filter inspection for internal damage, external leak tracing, and material-specific oil-cooler service. Torque-converter cooler procedures distinguish aluminum and cast-iron assemblies.

The KTTA Intake and KTTA Exhaust diagrams show the series-turbocharger arrangement. Turbocharger inspection references the ST-537 dial depth gauge for axial-motion measurement, alongside radial-clearance and blade-damage checks.

PT Fuel, Injector and STC Diagnosis

The PT (Type G) AFC Connection and Adjustment Locations views identify pump connections and adjustment points. STC flow diagrams explain advanced and normal timing, with separate checks for the oil-control valve, fuel-pressure switch, wiring harness, and harness diode.

Fuel-system testing references the ST-998 sight glass for suction-side air checks and P/N 3375140 for AFC no-air adjustment. Low-power, driveability, fuel-consumption, and dynamometer recording sheets support diagnosis across different applications.

The overhead-tank fuel-system instructions warn that missing or incorrectly used check valves can fill a cylinder with fuel and cause hydraulic lock.

Injector service limits: Precision-fit plungers and barrels require trained handling; sealing-ring thickness determines injector protrusion. Injector rebuilding and calibration require the separate Injector Rebuild Manual and an injector test stand.

Internal Components, Testing and Engine Handling

Step-by-step procedures cover cylinder-head removal and installation, failed-cylinder isolation, piston and liner service, bearing replacement, liner-protrusion measurement, camshaft work, gear backlash, and flywheel-housing alignment.

The component sections distinguish liner-counterbore designs, head-capscrew lengths, main-bearing-cap hardware, and camshaft-bushing designs by serial break. These distinctions help match parts and inspection procedures to the engine’s actual build and modification history.

Torque references include separate black and silver cylinder-head capscrews, main-bearing-cap fasteners, and system-specific hardware. Head service includes staged tightening sequences.

Engine-testing coverage includes chassis-dynamometer operation and run-in procedures for on-highway, off-highway, and power-generation applications. Engine removal and installation reference ST-1258 or P/N 3822512 lifting fixtures.

Before repair work, follow the manual’s requirements for battery isolation, pressure release, hot coolant, rotating components, and lifting. Components weighing 23 kg [50 lb] or more are marked for hoist or assisted handling.

Rebuild scope: Component and assembly rebuilding belongs in the separate K19 Shop Manual, Bulletin 3810258. Related publications include Fuel Pump Rebuild Manual 3379084, Injector Rebuild Manual 3379071, and T18A and HC-5A turbocharger rebuild manuals. These publications are referenced rather than supplied as additional manuals. Vehicle and equipment repairs require the relevant manufacturer’s instructions.

Selected Bore and Oil-Pan Reference Data

The general engine specifications list a bore and stroke of 158.75 × 158.75 mm [6.25 × 6.25 in]. The component sections supplement these dimensions with inspection limits, liner-protrusion data, and gear and bearing clearances.

Oil-pan tables identify capacities by part number: pan P/N 3008538 has a 32-liter low mark and a 38-liter high mark. For the rear gear-train option, the lubrication specifications add 7.6 liters [2 U.S. gal] to the listed oil-pan capacity.