Cummins K19 Series Engine

Operation & Maintenance Introduction of Cummins

TI\ 1\

• Long History
• Independency
• Profession
• Multinational
• High Tech
• Systemization
• Integral Technical Service
Cummins Inc., Training
2

Strong Global Position

Supply
Operations Distribution Service
Chain

Identification of
Cummins Engine
❑ Operations
❑ Components
❑ Technical Centers 131 Countries
❑ Regional Parts Distribution 500 Distributor Locations
O Sales and Service 5,000 Independent Dealers
❑ International Distributors 5,847 Service Locations

3 4

ngine Identification
Main Information on Data-plate:
= Maximum Brake
Horsepower • Engine Model
= Application Code
A = Agricultural
• Engine Serial Number (E.S.N.) (8 digitals)
=Displacement C = Construction • Control Parts List (CPL)
in Liters D =Generator Drive
=Engine is Aftercooled F =Fire Pump • Horsepower and RPM rating __@
G =Generator Set
=Engine has two L =Locomotive • Valves Clearance
Turbochargers M =Marine
P =Power Unit
• Injector Adjustment Parameter (PT engine)
=Engine is Turbocharged
R =Railcar • Etc.
=Series (Family of Engines) T =Tactical Military
5 6

Training


!:-1.1
Engine Identification L General Specifications
• Engine Speed Refer to the fuel pump
CPL --- calibration data for optional speed rating.
Control Parts List • Displacement 18.7 liters[1150 C.I.D.]
• Bore and stroke 158.75 mm[6.25 in x 6.25 in]
Injector Camshaft • Engine Weight
Turbocharger Piston Dry 1720 kg [3800 Ib]
Cylinder Head Timing Code
Wet 1800 kg [3965 Ib]
Exhaust Manifold Type Aftercooler
• Firing Order 1-5-3-6-2-4
7 8

‘
General Specifications General Specifications
Valve and injector settings
• Compression Ratio . Intake valve adjustment 0.36 mm [0.014 in]
KT 15.5:1 • Intake valve limits 0.28 to 0.43 mm [0.011 to 0.017 in]
. Exhaust valve adjustment 0.69 mm[0.027 in]
KTA 14.5:1 or 15.5:1 • Exhaust valve Iimits 0.60 to 0.76 mm [0.24 to 0.030 in]
KTA-C(700) 13.8 :1 . PTD Non-Top Stop injector travel adjustment 7.72 mm [0.304 in]
. PTD Non-Top Stop injector travel limits 7.67 to 7.77 mm [0.302 to 0.306 in]
KTTA 13.8:1 or 13.9:1 • HVT Non-Top Stop injector travel adjustment 10.24 mm [0.403 in]
HVT Non-To Stop injector travel limits..10.18 to 10.29 mm [0.401 to 0.405 in]
• Crankshaft Rotation (Viewed from the front Wci.adñ
STC Top Stop injector OBC Method adjustment (in engine). 10 Nm [90 in-Ib]
of the engine) Clockwise
77.
• STC Top Stop injector travel limit (total travel in engine) 10.18 to 10.29 mm
[0.401 to 0.405 in]
With high lift cam and injectors _12.47 to 12.57 mm [0.491 to 0.495 in]
9 10

irs
General Engine Data General Engine Data
K19 Engine Locatfon
Air Induction System
• Cylinder location
• Maximum Allowable Intake Restriction (at rated speed and
and Firing Order: load)
1-5-3-6-2-4 With Clean Filter Element 380 mm H20 [15 in H 2 0]
With Dirty Filter Element 635 mm H20 [25 in H 2 0]
Lubricating Oil System
Intake • Oil Pressure, Main Oil Rifle (15W40 Oil at 107°C [225 °F]):
Exhaust
• Intake and Exhaust
Odie) RPM 138 to 483 kPa [20 to 75 psi]
Valve locations
(Rated) RPM 345 to 517 kPa [50 to 75 psi]
• Oil Temperature — Maximum 120 °C [250 "F]
• Oil Pan Capacity Refer to Section V
12

Training 2


General Engine Data [4<'\

General Engine Data
Cooling System
Fuel System
• Coolant Capacity (Engine Only) 30 Liters [32 U.S. Quarts]
80 to 90°C [175 to 195 °F] Note: For performance and fuel rate values, refer to the
• Standard Thermostat Range
50 kPa [7 psi] engine data sheet, or the fuel pump code for the particular
• Coolant Pressure Cap (Minimum)
model involved.
o an Temperature
Minimum Top Tank 70 °C [160 °F] • Maximum Allowable Restriction to Pump (at rated power):
Maximum Top Tank 95 °C [203 °F] With Clean Filter 100 mm Hg [4 in Hg]
With Dirty Filter 200 mm Hg [8 in Hg]
• Back Pressure – Maximum (at rated speed and load)
75mm-Hg [3 in-Hg] • Maximum Allowable Return Line Restriction without check
. Exhaust Pipe Size ( Normally Acceptable inside Diameter) values 63 mm Hg [2.5 in Hg]
KTTA 152 mm [6 inch] • Maximum Allowable Return Line Restriction with check
KTA 127 mm [5 inch] values and/or Overhead Tanks 165 mm Hg [6.5 in Hg]
KT 127mm[5inch,]3 14

' Le, h

',, 1

Y>>5

E^ General Engine Data External Engine Components

Electrical System
• Minimum Recommended Battery Capacity
System Ambient Temperatures
Voltage -18°C [O °F]
Cold Reserve Cold Reserve
Cranking Capacity * Cranking Capacity*
Amperes Amperes Amperes Amperes
12 Volt ** 1800 640 1280 480
24 Volt*** 900 320 640 240
* Note: The number of plates within a given battery size determines
reserve capacity. Reserve capacity is the length of time sustained
cranking can occur.
** Note: Not Recommended for K19 Engines.
*** Note: CCA ratings are based on two 12 Volt batteries in series. 15

KG

G4

1
External Engine Components External Engine Components
• Exhaust Side Turbocharger • Fuel Pump Side
– KTA19 – KTTA19
Coolant Outlet
s
3 Thermostat
Engine Oil Cooler Housing
Assembly
Fan Hub f 9STC Oil Control Valve
Flywheel Housing s (Belt Driven) STC
3 Bypass Oil Filter Supply
8 STC Fuel Pressure Switch
Vibration T STC
Damper Dipstick
Starting Motor
10

Fuel Pump Fuel Filters 18

Training 3


oF

External Engine Components Coolant System Flow Diagram

L L41;1
Coolant System Flow Diagram Lubricating System Flow Diagram
Vent to Radiator Top Tank Oil Cooler Elements

13 1t 11

Coolant Bypass Coolant Before Thermostat 21 Lubricating Oil Pump Regulator Lubricating Oil Pump 22

Lubricating System Flow Diagram Lubricating System Flow Diagram

1
Rocker Lever

3 Oil Before Filter

Cam Follower
2 Filter Bypass Valve

Main Oil Rifle

Oil Supply to
Main Bearings
23 24

Training 4


Lubricating System Flow Diagram Lubricating System Flow Diagram

Oil Supply to Gear Driven Fan Hub
2 • Front of
Engine

Oil Supply to Camshaft

Oil Supply to Idler Gear

and Hydraulic Pump Drive
Oil Supply to Air
Compressor and Fuel
Pump Drive
Oil After Filter 7
4
Piston Cooling Pistan Co r
Oil Rifle Control Valve 25 Oil Supply to Main Bearing and Idler 26

r
Combustion Air System Flow Diagram Combustion Air System Flow Diagram
Intake Air Inlet to Turbocharger Air Turbocharger Exhaust Outlet
Turbocharger to Aftercooler Aftercooler • Exhaust
2 3 System

Intake Manifold

Intake Valve Ports

• Intake
System
s
Exhaust Manifold
27 28

IL:<W'.
Fuel Systems Flow Diagram Fuel Systems Flow Diagram
3 Injector
1. Oil Supply to Oil Control
Valve
E 2. Oil Filler Head
Injector Fuel Gear Pump
- i= 3 Oil Control Valve
Drain Return 4 C9 oolant Drain
nIt.t a,
4. Pressure Relief Valve
Fuel Rail 2
ca Fuel Pressure Less than 53 psi (365 kPa)
Pressure Lien Oil Pressure More than 10 psi (69 kPa)
011 Drain
5. Fuel Supply lo Injectors

LLo
AFC Cavil Drain,
Fuel Return 6. Fuel Pressure Switch
to Tank
7 Oil Manifold
I O
H 8 STC Tappet
u)
Fuel Inlet Supply._ 9. Oil Transfer Connection
•
• T
Note: When Fuel Pressure .- 3 is lower than 365 kPa, Fuel Pressure
Tachometer Drive ,o e Switch^^)^ will close, while Oil Control Valve ,._' will open. Oil will run
Fuel Fuel Tank . Injection Timing is advanced.
29
from'2 to :! y 30
Pump Filler Breather

Training


Notice During Starting & Shut-down

. Disengage the driven unit, or if equipped, put the
transmission in neutral.
Cummins Engine • Start the engine with the throttle in the idie position.

• Engines equipped with Air Starters require a minimum

Operation & Maintenance of 480 kPa compressed air pressure.
• To prevent damage to the starter, do not engage the
starting motor more than 30 seconds.
• Wait two minutes between each attempt to start
(electrical starting motors only).

31 32

rii.l
L
Notice During Starting & Shut-down Engine Maintenance
• Engine oil pressure must be indicated on the gauge within 15 seconds
after starting. If oil pressure is not registered within 15 seconds, shut • Please refer to the Operation & Maintenance
off the engine immediately. Manual. Engine maintenance period is
determined by operation condition and time.
• Idle the engine three to five minutes at approximately 1,000 RPM
before operating with a load. • Maintenance periods of K19 series could be
divided into daily, every 250 hours or 6
• When starting a cold engine, increase the engine speed slowly to months, every 1500 hours or 1 year and
provide adequate lubrication to the bearings, and to allow the oil every 6000 hours or 2 year.
pressure to stabilize.
• Do not idle engine for more than ten minutes. • For detailed maintenance procedures, please
• Allow the engine to idle three to five minutes after a full load operation refer to Operation & Maintenance Manual.
before shutting it off.
33 34

Daily Maintenance Fuel Recommendations 1 Specification

• Check
• Cetane Number aboye 40
– Engine Operation Report
–Oil Level • Fuel Viscosity > 1.3 cSt
—Coolant Level • Waterless
—Belts
– Fuel-Water Separator • Pure

35 36

Training


Lubricating Oil
Recommendations 1 Specification Coolant Recommendations 1 Specification

American Petroleum Institute (API) • 50% Qual ity Water : 50 %Antifreeze

performance classification: Antifreeze Ingredient:
Ethylene Glycol or Propylene Glycol
• Ambient temperature aboye -5°C Antifreeze Concentration:
SAE 15W-40 CF4, or aboye 40 % -68%

• Ambient temperature lower than -5°C • DCA4

SAE 10W-30 CF4 Concentration: 0.320.79 Units 1 Liter
or: 1.23 Units 1 Gallon

37 38

CC2602M
3-Way Heavy duty coolant test kit
Technical Materials
6o';', 33%, 40% 50ti„
Cooling System
• Operation and Maintenance Manual
-5 -10 ..20 -30 -45 -BO
1. Sampling $(,A UNETS PER GA
Bulletin: 3666013-02
3,113,7 ! 4,1 4.9 5.71
2.10 ` -55°C • Troubleshooting and Repair Manual
4.3 5.1 1
3. Remove excessive Bulletin: 3666372
4.4
4. Wait 45 sec • Shop Manual
5. Read in 75 sec Bulletin: 3666533
6. Compare color • Alternative Repair Manual
7. Do proper action Bulletin: 3667004

48

Training 7