Cummins Inc.

Worldwide
HHP Technical Training
Center
Salt Lake City, Utah
Welcome to QSK19 CM850/2150
MCRS Classroom Training
QSK19 Tier III

Production began February 2005

Manuals available on QSOL

Virtual College available in HHP CVC Library

#4091843

Qualification Training available world wide: Salt

Lake City, Daventry ,Singapore, South Africa,
Australia, South America, Western Canada, Russia
Environmental Protection Agency
(EPA)

The engine has been redesigned to meet legislated Tier 3 emission levels
for both the U.S. and European regulations.

The U.S. Tier 3 off-highway emission level is effective January 1, 2005 for
ratings 224 to 560 kW (300 to 751 hp)

The European Tier 3 off-highway emission level is effective January 1,

2006 for ratings 130 to 560 kW (174 to 751 hp).

Refer to GCE for latest QSK19 CM850 MCRS Tier II and Tier III ratings
and specifications.

Refer to AEB 10.114 QSK19-C Tier 2/3 Industrial Technical Package

updated March 10, 2008. This document is Cummins Confidential.
Improving Air Quality:
EPA Tier 3 MOH 302-751 hp
US EPA M obile
Off Highway 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

302 - 602 HP T ier 1 T ier 2 T ier 3 T ier 4

603 - 751 HP T ier 1 T ier 2 T ier 3 T ier 4

> 751 HP T ier 1 T ier 2 T ier 4

European Union 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

302 - 602 HP Stage I Stage II Stage IIIA Stage IIIB

603 - 751 HP Stage I Stage II Stage IIIA Stage IIIB

> 751HP No Regulations in Effect

Tier 2 Tier 3 Reduction

NOx + HC 6.4 NOx + HC 4.0 38%
CO 3.5 CO 3.5 --
PM 0.20 PM 0.20 --

Regulated in grams per kW hour (g/kW-hr)

General Engine Data

Configuration D193101CX03
Number of Cylinders Inline 6
Displacement 19.0 L (1,159 in3)
Bore 158.75mm (6.25 in)
Stroke 158.75mm (6.25 in)
Compression Ratio 15.8:1 Tier III, 15:1 Tier II MCRS
Aspiration Turbocharged and Charge Air Cooled
Approximate Engine weight (wet) 1,973 kg (4,350 lbs)
Maximum overspeed capacity 2,450 RPM
Maximum allowable installed engine power angle 6 deg
Maximum allowable installed engine tilt angle 6 deg
QSK19 CM850/2150 MCRS
Engine Dataplate

• Located on the right side of the block, above the oil cooler housing
• Will be called “QSK19” on Production Dataplate
• Serial Number stamped on Lube Pump Housing Flange
• Uses Round Nose Rocker Levers
instead of Elephant Foot

Different Valve Clearance Adjustment

What do you call it ??????
Three NAMES ! ! ! !

QSK19 -- Marketing Name

QSK19 Tier III --Technical Name (AEBs)
QSK19 CM850/2150 MCRS -- INSITE Name
QSK19 CM850/2150 MCRS- Electronic Service Manuals
QSK19 --- Base Engine Manual, with procedures referencing type of
component, (electronically or mechanically actuated injectors) etc: which means
you need to know your engine to know which procedure to use.

QSK19 CM850 MCRS -- Virtual College Name

Left Side/ Intake Side

Significantly Different
Right Side/ Exhaust Side

“Almost” Identical

Changes
 Major Changes to the QSK19 Tier III Engine

New Turbo New Valve Cover

New Injectors

Modified Exhaust Manifold

FCD Pistons

Modified Block
Modified K Cylinder Head with
Modified Crank
new Valve Guides and Stem
w/tone wheel
Seals

D R Glackin – 19 Nov. 03
Major Changes to the QSK19 Tier III Engine

Modified Intake Manifold

New Breather
New Cam & Follower
Modified K Rocker Shafts – removed
Housing and Exhaust injector lever
Lever – removed injector
lever

New Fuel Supply

and Drain Plumbing

New ECM and Cooling Plate

New Wiring Harness

New Engine Position

New Fuel Pump and Drive & Speed Sensing
New Fuel Filter Head for
Stage II Filters
 Cylinder Block
• Existing QSK19 Block has been modified to accommodate the following:
- Crankshaft Speed Sensor
- New Fuel Filter Head Assembly
- Fuel Pump Support Bracket

Sensor Boss
 Crankshaft

• Modified QSK19 Crankshaft includes a

Tone Wheel for the additional, new
Engine Speed Sensor. It has a 60+1 teeth
arrangement.

Note: Never place the Crankshaft on

the Tone Wheel Teeth, it will Damage
the teeth.
 Crankshaft

Tone Wheel (60+1 Teeth)

Capscrews x 6

Counter Weights
Camshaft

• Modified K19 Camshaft

• Injector Lobes no longer required due to Electronic Injectors
• Injector Lobes now machined circular
• Circular Injector Lobes pilots Camshaft during Assembly
Cam Followers

• Modified K19 Cam Followers

• Center Injector Follower has been removed
• Spacer has been added instead
• The shaft is unique to this engine – no injector follower oil hole
Pistons

• Ferrous Cast Ductile Iron (FCD)

• Single Piece
• Compression Ratio 16:1
• FCD is common on all other HHP Engines
Pistons - continued

Ceramic Coated Top Ring (CKS)

• Increases Fatigue Strength
• Reduces Scuffing

Positive Twist Second Compression Ring

• Has a top inside groove cut in it

Gas Nitrided and Plateau Honed Liner

• Improves Durability

Single Jet Targeted Piston Cooling Nozzle

• Prevent coking under bowl
• Reduces piston temperature
Cylinder Head
• Modified K19 Cylinder Head
• Accommodates new Injectors, valve guides, valve stem seals
and fuel drain lines
• Requires three less drillings: Two used for mounting the fuel rail
and the third for fuel drain
• One fuel drilling retained but machined to accept metric banjo fittings
utilized by the fuel drain
• Cast iron valve guides and new stem seals
• Metric threaded hole for Injector hold-down
Rocker Levers
• K19 Rocker Levers have been used

• Push rods and Rocker Levers associated with Injection have

been removed

• Injection Rocker Levers replaced by spacers

Rocker Levers

Spacers
Cooling System

Maintains 1-pump, 1-loop system that requires a radiator

and air-to-air charge air cooler (CAC)

Heat rejection reduced due to lower intake air temperature

and increased air flow

Service interval of corrosion filter is 250 hours

No change in coolant flow from other QSK or K19 engines

QSK19 CM850/2150 MCRS
Coolant Flow

T-Stats: 180 – 202 Degrees F

Max Top Tank Temp: 212

Degrees F

Block Pressure: 35 PSI

Min Pressure Cap: 7 PSI

Air-to-Air Charge Air Cooler
(CAC)
The CAC must be designed to
meet the new intake manifold
temperature target of 49 °C
(120°F) on a 25°C (77°F)
ambient day.
Air Intake

Air mass flow increased due to the new Turbocharger

Maximum allowable air temperature rise from air inlet to

turbo compressor inlet unchanged

Intake air restriction unchanged

 Turbocharger
• An all new Holset HX83 Turbocharger
• Larger compressor to provide higher air flows to meet emissions
• Extended compressor inlet, called a “Map Width Enhanced” compressor
inlet, to provide improved turbo stability by reducing air flow restrictions
• Increased compressor inlet length by 40mm (1.57 in.)
• Compressor cover material changed from Aluminum to Cast Iron, thus it is heavier
and caution should be taken when handled (Total Turbo weight approximately 90 lbs)
• Compressor wheel material changed from Aluminum to Titanium
• Has a water cooled bearing housing
• Turbo Speed Sensor incorporated into its design

Old New
HX83 Turbocharger
 Turbocharger
Coolant Return
Oil Supply

Manifold flange
matched to turbo.

Coolant Supply

Oil Return
Turbocharger
Turbocharger - Bracket
Turbocharger
Coolant Flow
Exhaust Piping
Exhaust Pipe size increased from 6 to 8 inches due to
increase in exhaust gas flow
Note: Compressor outlet remains at a 6 inch diameter
Lubrication System
Two Venturi Combo Filters (LF9001) for improved filtration
Engine oil and filter service intervals remain at 250 hours
Remote mount oil filter head option available
Lubrication Flow
Essentially unchanged
Lubrication Flow

6 1. Pan ( 3 options )
2. Suction Tube
8 5 3. Pressure Regulator
9 4. Lube Pump (Gear Driven)
5. Coolant Cavity
6. Turbo oil supply
7. Oil Cooler (in parallel)
8. Turbo oil drain
9. To other side of engine

3 4
1 2
Lubrication Flow
Lubrication Flow

1. Filter bypass valve 43 +/-8 psi

2. Filter Head
3. Filter Media
4. Oil from coolers
5. 25 psi Pressure Regulator
6. Piston Cooling Rifle
7. Piston Cooling Nozzle
8. Main Oil Rifle
Oil Pressure Ports
Filtered Oil
• The plugs on top of the filter head are all clean filtered oil going to the main oil rifle.
• Dirty oil going into the filter is on the back side of the filter head with same size plug.
Piston Cooling Nozzle

Engine must be in
correct position to
remove nozzle.
Nozzle must be
rotated.
“O” ring is not
reusable.
Lubrication Flow

Max Oil Temp: 250 Degrees F

Oil Pressure Regulator:

50 – 70 PSI @ Rated
Min 20 PSI @ Idle
Dump to Sump
Lubrication Flow
 Lubrication Flow
1. Oil supply to main bearing and idler
2. Oil supply to water pump and drive
3. Oil supply to turbocharger
4. Oil supply to camshaft bushing
5. Main oil rifle
6. Oil supply to idler gear and hydraulic pump
drive
7. Oil supply to air compressor, fuel pump
drive, and fuel pump
Lubrication Flow

Fuel Pump is oil lubricated

Screen catches debris incase of failure

Fuel System - MCRS
Totally different
New Terminology

Fuel Pump Pressurizing Assembly (FPPA)

Electric Lift Pump for Engine Fuel Supply
Mechanical Dump Valve (MDV)
Gerotor (Fuel Delivery Pump)
Fuel Delivery Pressure Sensor
Injector Metering Rail 1 Pressure Sensor
Stage I and Stage II Fuel Filters
Fuel System
Specifications
Stage I Fuel Filter: 7 Micron
Stage II Fuel Filter: 3 Micron
Electric Lift Pump: 3-5 BAR, Runs 2 Minutes After Key-on or 200
BAR Rail Pressure when Engine Cranking
Gerotor (Fuel Delivery Pump): 5-7 BAR. 7 BAR Regulator and 12
BAR High Pressure Dump Valve.
FPPA: Normally Open EFC Valve
Air Bleed Valve: Maintains 5 BAR Backpressure / 2.5 Liters per
Minute Flow
MDV: Opens at 1950 BAR
WIF Sensor: Stage I Fuel Filter, 83K ohm Resistor
Injectors: 48 VDC, Two Injector Drivers, 1-2-3 / 4-5-6
Rail Pressure
Specifications
300 BAR While Cranking, Minimum
650 BAR Nominal @ Idle
1200 BAR Nominal @ High Idle
1600 BAR Nominal @ Rated Transient
1950 BAR MDV Opens
900 BAR Nominal Maximum with MDV Open
Fuel Flow Logic
Update
 Fuel Pump Notes

•The Q19 pump is called a 2 X 2 that is, 2 pumping plungers and a 2 lobe cam. .
•The pump has retracting plungers unlike the Pegasus pump that has floating
plungers.
•The pumping plungers are not ceramic rather, they are metal with a 3 micron wear
resistant coating. The coating process is quite common to other Bosch components.
•The Gerotor drive shaft is a spline drive. It is lubricated by fuel. There are back to
back oil and fuel seals with a weep hole between them, like we have done on the PT
fuel pump.
Fuel Filters
Stage 1 Stage 2
Industrial Pro New Filter FF 5644
FS 19763 StrataPore StrataPore
7 Micron 3 Micron
Water Drain
DO NOT PRE-FILL!
WIF Sensor with Resistor
WIF Sensor & Water Drain Locations

WIF Sensor

Water Drain
Fuel Flow

Filtered Fuel Out

Of Stage I Fuel
Filter

From Tank to 7 Micron

Stage I Fuel Filter
Fuel Flow
From Lift Pump

Check
Valve

To Lift Pump
Lift Pump

• Supplier: Airtex
• Power: 24 Volts
• Produces 3-5 BAR Pressure
•Runs for 120 Seconds @ Key-on
•Shuts off @ 200 BAR Rail Pressure
• Mounting: 2 Bracket w/ Vibration
Isolators
• Connector: Deutsch 2 pin
•Mounted on Stage I Fuel Filter Head
Fuel Flow
M14 STOR Fitting, Install #3824844
Compuchek Fitting to Measure From Stage I
Inlet Restriction Fuel Filter

To Gerotor
(Fuel Delivery Pump)
Fuel Pump

Accumulator

FPPA

Gerotor
(Fuel Delivery Pump)
Fuel Pump
Weight: 76 Pounds US
Fuel Pump
*Do Not Remove These Bolts
Fuel Pump Pressurizing
Assembly (FPPA)
 Fuel Pump

Injector Metering Rail 1

Pressure Sensor
(Bosch Sensor)
Gerotor (FDP)
** DO NOT attempt to remove the Gerotor.
- Some internal parts of the Gerotor are
serviceable, but not the Gerotor as a unit.
Fuel Pump Rear Bracket
Fuel Pump Bracket
• Made of three separate parts
• Part 1 must be installed on the pump & the 2 bolts
torqued before inserting pump into place. When
removing the pump, part 1 should stay on the pump and
only parts 2 & 3 should be disassembled.
1
2
2

1
3

3
Fuel Pump Bracket
•Finger tighten the bolts on bracket #3.
•Finger tighten the bolts on bracket #2.
•Torque all bolts to specifications found on QSOL.

2
2

1
3

3
 Fuel Pump Bracket

Stay with
pump

remove

remove
 Fuel Pump
Identification
To identify a the fuel pump, you need to record the following:

1. Serial Number
2. Date Code - This is a number like 587 for July 2005, the year is the 5, the month is 80 +month, so 87 for July
3. Cummins part number
Fuel Flow

Fuel Out of Gerotor

To ECM Cooling Plate

Fuel from Stage I

Filter to Gerotor
Fuel Flow

From ECM Cooling Plate

To Stage II Filters
(2 Filters in Parallel, 3 Micron)
Stage II Fuel Filters

DO NOT PRE-FILL
 Stage II Filter Head

Fuel Delivery Pressure Sensor

(Pressure After Stage I Filter,
Before Stage II Filters)
Stage II Filter Head

Engine Fuel
Temperature
Sensor 1
(After Stage II
Filters)
Fuel Flow
Fuel Out of Stage II Filters
To Fuel Pump
Fuel Flow

Recirculation Line
(Fuel Bypassed From Gerotor Regulator, Flows to
Gerotor Inlet)
Fuel Flow
Air Bleed Valve

Air Bleed Line.

Maintains 5 BAR
Backpressure.
2.5 Liters / Minute
Fuel Flow
Mechanical Dump Valve

Opens at 1950 BAR,

Sends Fuel to Return if Open.
Normally Closed, 2 Stage Valve.
Fuel Flow
Fuel to #1 Injector
Fuel Flow
Common Fuel Supply to Accumulator of Each Injector,
Injectors are in Parallel, Modular Common Rail
System (MCRS).
Fuel Flow,
Injector Accumulator

Accumulator
Fuel Flow,
Injector Accumulator

Accumulator
Fuel Flow,
Injector Accumulator
Fuel Flow
End of the Line Plug at #6 Injector.
Special Plug.
End of Line Plug

•M24 x 1.5 with 27mm Hex head

•0.799” x 0.103” viton o-ring

• Not just any Nut!

• Has a conical shaped end to

seal against Injector
High Pressure Fuel
Lines
High Pressure Fuel Line,
Pump to #1 Injector
HP Line From Pump to Injector #1

• Tube route
• M24 x 1.5 nut w/ 27mm hex head
• 0.799” x 0.103” viton o-ring
• Separate cap and grommet to seal outer tube
to nut
High Pressure Fuel Line,
Between Injectors
HP Line Between Injectors

•2’nd Nut with a Vibra Seal

•Used to aid in troubleshooting

• M24 x 1.5 nut w/ 27mm hex head

• 0.799” x 0.103” viton o-ring
• Separate cap and grommet to seal
outer tube to nut
• Low natural frequency (~190Hz)
HP Line Between Injectors

5 1

1. Outerwall Pipe
2. Vibralock Nut
3. Seal
8 4. Connector Fitting
3 5. O-Ring Groove
6. Sealing Cone
4
7. Innerwall Pipe
7 8. Pressurized Fuel

2
6
HP Line Between Injectors
T-connector

•Double walled pipe threads into T-

connector.
•3.5mm I.D.
•Green – fuel drain line
•Yellow – fuel inlet path
•When removing fuel line, (before
complete detachment) if some
Pressure still in line, fuel will go thru
drain path (Green)

O-ring
HP Line Between Injectors

•Double walled pipe threads into T-

connector.
•3.5mm I.D.
•Green – fuel drain path
•Yellow – high pressure fuel inlet path
•When removing fuel line, (before
complete detachment) if some
Pressure still in line, fuel will go thru
drain path (Green)
High Pressure Fuel
Line Parts
Warning! Use Fuel System Clean Care
Procedures. This is Critical! Visit
QSOL for Latest Procedures.
Keep it Clean!
Vent Line for Double Wall –
Injector Fuel Line Leaks

Flexible hose (Nitrile / Polychloroprene)

Swivel type elbow
 Vent Line
Will Only Have Fuel Out of the Vent Line if a High Pressure
Fuel Line or Fitting is Leaking
Fuel Flow
Return Fuel from Injectors, 15-18% of Fuel to Injectors
Manifold Tube for Injector Drain

• ∅8 O.D. x 1mm wall tube

• M12 banjo fittings
• Nat. freq. mode 1 @ 1680Hz
Fuel Flow

Return Banjo Fitting

Drain Line from Injectors
to Drain Block

• ∅8 O.D. x 1mm wall tube

• M12 banjo fittings
• Nat. freq. mode 1 @ 324Hz
 Fuel Flow

Drain
Line

Drain
Manifold

Return Line
To Tank
 Fuel Flow,
Drain Manifold
Injector Drain

Air Bleed Line

MDV Line

Return Fuel to Tank

Fuel Injectors
Warning! Use Fuel System Clean Care
Procedures. This is Critical! Visit
QSOL for Latest Procedures.
Keep it Clean!
Fuel Injectors
 Fuel Injectors
Identification
To Identify a unique individual injector, you need to record the following:

1. Serial number
2. Date Code - This is a number like 587 for July 2005, the year is the 5, the month is 80 +month, so 87 for July
3. Cummins part number
 Fuel Injectors
How do they operate?
• The injection nozzle is being opened and closed by movements of a nozzle needle.
• The needle is balanced by pressures at the nozzle seat and at the needle control
chamber, at the opposite end of the needle.
• When the solenoid valve is energized by the ECM, it opens the chamber to the
return fuel line.
• The pressure in the needle control chamber drops, the needle is lifted, the nozzle opens
and the injection begins.
• When the current in the solenoid valve drops to zero, the control valve returns to
its seat.
• The pressure in the needle control chamber increases and becomes equal to the
pressure at the nozzle seat.
• The needle closes due to a nozzle spring force and stops the injection.
• Optimal control of the system is achieved by calibrating several orifices in the hydraulic
assembly of the injector
• A flow limiter (Check ball, seat, and spring) is used to prevent large volumes of fuel
from entering the cylinder, thus providing engine protection.
Flow Limiter
Flow Limiter
Fuel Injectors
• What makes fuel inject is not the High Pressure
Fuel Pump Plunger, but the accumulated pressure
inside the accumulator. The fuel actually compresses
by about 7%.
This is a cutout view of what the injector Flow Limiter looks like
Fuel enters the Flow Limiter region of the injector
Fuel fills up the area above the flow limiter’s check ball
Fuel flow pushes down on the check ball compressing the spring slightly
Fuel flow pushes down on the check ball compressing the spring slightly
Fuel then enters the “accumulator” section of the injector
Fuel then enters the “accumulator” section of the injector
Fuel Flow,
Injector Accumulator

Accumulator
Fuel fills up the “accumulator” section of the injector
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Injector
Injector
Injector
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

The needle is balanced by pressures at the

nozzle seat and at the needle control
chamber, at the opposite end of the needle.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

When the solenoid valve is energized by the

ECM, it opens the chamber to the
return fuel line.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

The pressure in the needle control chamber

drops, the needle is lifted, the nozzle opens and
the injection begins.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

The pressure in the needle control chamber

drops, the needle is lifted, the nozzle opens and
the injection begins.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

The pressure in the needle control chamber

drops, the needle is lifted, the nozzle opens and
the injection begins.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

When the current in the solenoid valve

drops to zero, the control valve returns to
its seat.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

The pressure in the needle control chamber

increases and becomes equal to the
pressure at the nozzle seat. The needle closes
due to a nozzle spring force and stops the
injection.
 Flow Limiter
The flow limiter (Check ball, seat, and spring) is used to prevent large volumes of fuel
from entering the cylinder, thus providing engine protection. If large volumes above
normal are suddenly demanded due to an injector malfunction, the check ball
compresses the spring to a point where it seals against the seat, thus cutting fuel
supply to the injector.
Injector Connectors
Injector Connector

Bosch
Connector
Service Connection Location
SAE J1939 Service Port Connector
Service Connection
SAE J1939 Service Port Connector
OEM Connectors Location

31 Pin

23 Pin

16 Pin
OEM Connector

•Three OEM connections are now required since the power, ground,
and key switch inputs have been broken out separately

•Power Connector
Deutsch HD36-24-16SE-059 (OEM Side)
Sixteen 12 Gauge (AWG) Contacts, 100 AMP Capacity
•Signal Connector #1
Deutsch HD36-24-23PE-059 (OEM Side)
Twenty Three 16 Gauge Contacts
•Signal Connector #2
Deutsch HD36-24-31SE-059 (OEM Side)
Thirty One 16 Gauge Contacts
Turbocharger 1 Speed
Sensor Connection Point
Real Time Clock Backup
Battery
Sensors
Turbocharger 1 Speed
Sensor
Intake Manifold
Intake Manifold 1 Temperature Sensor
Intake Manifold 1 Pressure Sensor
Temperature Pressure
Barometric Pressure Sensor
Engine Camshaft Speed/Position
Sensor
Engine Coolant Temperature 1
Sensor

- Located on the Thermostat Housing

Engine Crankshaft Speed/Position
Sensor
J1939 OEM Connection and
Terminating Resistor
J1939 Terminating Resistor

•Used to filter out noise on

the data link.
Fuel Sensors
Engine Fuel Temperature 1 Sensor
Fuel Delivery Pressure Sensor
Engine Oil Rifle
Pressure
1 Sensor
WIF Sensor
Water in Fuel Indicator Sensor
WIF Sensor with
83K ohm Resistor
Injector Metering Rail 1
Pressure Sensor
Engine Barring Device
 Lifting Hooks

• Lifting Hooks (Part Number 3163091) must be used on the QSK19

CM850 Engine.

• Provide clearance between rocker housings

• Have increased load carrying capability

**Previous K 19 and QSK 19 lifting hooks part numbers ST 1286 and

3823210 should not be used**
Service Literature
Available on QSOL and Printed Versions:

Bulletin Number Title of Publication

4021497-01 Wiring Diagram, QSK19 CM850 Control Module
4915516 Operation and Maintenance Manual, QSK19 Series Engines
4021493 QSK19 CM850 MCRS Electronic Control T&R Manual
4021592 QSK19 & QSK19 CM850 MCRS Service Manual
3379001 Fuel for Cummins Engines
3810340 Cummins Engine Oil Recommendations
3666132 Coolant Requirements and Maintenance
3379000 Air for Your Engines
3387622 Cold Weather Operation
3666257 HHP Engine Warranty Failure Code Manual
3810333 Standard Repair Times, K19 & QSK19 Series Engines
Service Tools

Electronic Service Tool

INSITE is the Cummins computer-based electronic service tool for this

engine. INSITE Version 6.3a, or later, is required for this engine. It is capable
of performing the following functions:

- Read fault codes

- Monitor and log engine operating parameters
- Adjust features and parameters
- Update engine calibrations
- Run diagnostic tests
- Manage work orders

Cummins distributors provide security for INSITE. Different levels of

functionality are available, depending on the needs of users.
Service Tools
Injector Removal and Installation Tool (4918218)
Used to remove and install the electronic injectors.

Fuel Pump Removal and Installation Tool (4918227)

To aid in the removal and installation of the fuel pump on engines with electronically
actuated injectors.
Service Tools

#4918227

#4918218
Service Tools
Wiring Harness Repair Kit (4918309)
Contains additional components to repair the engine wiring harness.

Valve Guide and Seal Installer (4918258)

Used to install both the valve guide (7) to the proper height and install the valve
stem seals as well.
Service Tools
Cylinder Head Protective Cover (4918282)
Used to prevent debris from entering the injector push rod hole when
servicing the overhead.
Service Tools
Fuel air bleed oriffice
Used to create fuel flow through first stage filter that is equal to full load
rated rpm flow. The fuel filter restriction is one use for this tool.
The test is done at idle. The center hole is bigger.

Tool Standard fitting

Injector Alignment
Tool
Injector Alignment
Tool Installed
Dyno Controller
#4918767 Plug Kit
Cylinder Leakage
Tool
Cylinder Leakage
Tool Installed
Questions ?