Cummins/Onan KTA19-G2 Engine

⚠ The injector plunger is under spring tension. Do not allow the tool to slip. Personal injury can result.

Tools: Injector and Valve Adjustment Kit Part No. 3375004, Dial Indicator Extension Part No. 3376870, Rocker Lever Actuator Part No. 3376869, Torque Wrench Adapter Part No. ST-669, Inch Pound Torque Wrench Part No. 3376592

1. On engines with STC, remove the wire from the terminal on the oil control valve. Operate engine at high idle for 5 minutes, then shut off.
2. Remove the rocker lever cover and related components (Procedure 07-04).
3. Turn the barring device until the 'A' mark on the pulley aligns with the mark cast into the accessory drive seal boss.
4. Determine the cylinder in position for valve set: if mark A check cylinders 2,5; if B check 3,4; if C check 1,6. Set valves on the cylinder where both levers feel loose.
5. Adjust the crossheads first (loosen locknuts, turn adjusting screw out one turn, hold crosshead down, turn screw in until it touches the valve stem top).
6. Tighten the crosshead lock nut to 35/40 N·m as applicable.
7. Adjust the valves using a feeler gauge: Intake 0.36 mm [0.014 in], Exhaust 0.69 mm [0.027 in].
8. Tighten the locknut to 45 N·m [35 ft-lb] with adapter ST-669 or 60 N·m [45 ft-lb] without adapter.
9. Adjust the injector using the injector and valve adjustment kit Part No. 3375004.
10. Reset to the specified travel: 7.72 mm [0.304 in] less STC; 10.24 mm [0.403 in] with STC.
11. Tighten the locknut to 45 N·m [35 ft-lb] with adapter or 60 N·m [45 ft-lb] without adapter.
12. Rotate the engine, align the next mark, and adjust the appropriate valves and injectors until all are correct.

⚠ Ignition of explosive battery gases can cause severe personal injury. Do not smoke or allow arc-producing devices around the battery area.

⚠ Do not disconnect battery cables while the generator set is cranking or running.

1. Use two 12-volt batteries for a normal installation.
2. Connect the batteries in series: negative post of the first battery to the positive post of the second battery.
3. Connect the negative (-) battery cable last to reduce the risk of arcing.
4. If an automatic transfer switch is not used or has no built-in charge circuit, connect a float charger to the batteries.

1. Check ventilation and exhaust systems.
2. Check all mechanical connections.
3. Fill the coolant, lubrication and fuel systems.
4. Prime the lubrication and fuel systems.
5. Check the fuel system for leaks.
6. Check the lubrication system for leaks.
7. Verify all electrical connections are secure and wiring is complete.
8. Check load cables are properly connected to transfer switch or circuit breaker panel.

1. Place the isolators on the genset support structure.
2. Shim or grout isolators so all isolator bases are within 0.25 inch (6 mm) elevation of each other; surface must be flat.
3. Loosen the side snubber lock nuts so the top plate is free to move vertically and horizontally.
4. Place the genset onto the isolators, aligning the skid's mounting with the threaded isolator hole.
5. Insert the leveling bolt through the skid and into the isolator; lock nut threaded up toward the bolt head.
6. Adjust the leveling bolt for a nominal clearance of 0.25 inch (6 mm) or greater between top plate and base.
7. Adjust leveling bolts until the set is level and sufficient clearance remains; lock leveling bolt with lock nut.
8. Snubber nuts may remain loose to provide better isolation.

1. Turn the valve on the filter head to the OFF position.
2. Remove the coolant filter.
3. Use engine oil and lubricate the seal on the filter.
4. Install the coolant filter. Turn until the seal touches the filter head, then an additional half to three-fourths of a turn.
5. Turn the valve to the ON position.

⚠ Wait until the temperature is below 50°C before removing the coolant system pressure cap. Failure to do so can cause personal injury from heated coolant spray.

1. Position the vehicle on level ground. Wait until coolant temperature is below 50°C before removing the pressure cap.
2. Remove the radiator cap after the engine is cool.
3. Open the radiator draincock.
4. Remove the lower radiator hose(s).
5. Open the water pump draincock.
6. Open the oil cooler draincock.

⚠ Check the coolant level only when the engine is stopped. Wait until the temperature is below 50°C [120°F] before removing the pressure cap.

⚠ Do not add cold coolant to a hot engine. Allow the engine to cool to below 50°C [120°F] before adding coolant.

1. Close the radiator draincock.
2. Install the lower radiator hose(s). Tighten the hose clamps to 5 N·m [40 in-lb].
3. Close the engine draincock.
4. Close the oil cooler draincock.
5. Fill with a mixture of 50 percent ethylene glycol antifreeze and 50 percent water to the bottom of the fill neck in the radiator fill tank.
6. Install the radiator or fill cap.
7. Operate the engine until coolant reaches 70°C [160°F] and check for leaks.
8. Shut the engine off and allow it to cool; check the coolant level and add if necessary.

⚠ The fan belt idler is under tension. Do not allow your hands to get between the idler and the belt, or the fan hub. Personal injury can result.

⚠ Be sure the fan idler spring tension is released.

Tools: 8-point socket, breaker bar

1. Use an 8-point socket and breaker bar or large wrench. Hold the idler in position against the spring tension and remove the capscrew.
2. Slowly turn the wrench until the spring tension is relieved.
3. Remove the fan belt.
4. Visually inspect the belt for cracks, glazing, tears or cuts.
5. Install the belt.
6. Rotate the idler against the spring tension until the capscrew holes are aligned. Install the capscrew.
7. Tighten the capscrew to 45 N·m [35 ft-lb].
8. Slowly turn the wrench until the idler is against the belt.

⚠ Diesel injection system tolerances are precise; keep fuel clean and free of water to avoid damage to injection pump and nozzles.

1. Remove each fuel filter and fill with clean fuel.
2. Put a light coat of fuel on the sealing gasket.
3. Install and tighten by hand until the gasket just touches the filter head.
4. Tighten the filter an additional one-half to three-fourths turn.

Tools: hand or motor driven priming pump with pressure gauge, torque wrench

1. Remove oil inlet line from turbocharger housing; fill bearing housing with clean engine lubricating oil; replace line and secure.
2. Fill crankcase to L (low) mark on dipstick.
3. Connect a hand or motor driven priming pump with pressure gauge from clean oil source to the plug boss in the filter housing.
4. Prime until a 30 psi (207 kPa) pressure is obtained.
5. Disconnect wire from fuel solenoid valve.
6. On the engine control panel, depress the RUN switch to crank the engine, maintaining 15 psi (103 kPa) oil priming pressure for 15 seconds at the filter head priming port.
7. Stop engine cranking, remove external priming equipment, reinstall plug in filter housing and torque to 15 to 20 ft lb (20 to 27 N·m).
8. Reconnect wire to fuel solenoid valve.
9. Complete oil fill to H (high) mark on dipstick.

⚠ Do not use Fleetguard No. LF 3325 filters on K19 engines. The cannister seam will touch the head before the seal touches the sealing surface. An oil leak will result.

Tools: Oil Filter Wrench Part No. 3375049

1. Use an oil filter wrench, Part No. 3375049, or equivalent. Remove the full flow oil filters.
2. Discard the filters if they are not needed for a failure analysis.
3. Clean the oil filter head surface.
4. Use engine oil to lubricate the gasket surface of the filters.
5. Fill the filters with clean 15W-40 oil. Install the filters on the oil filter head.
6. Turn the filter until the seal contacts the head. Turn an additional three-fourths of a turn to one turn.
7. Operate the engine and check for leaks.

Tools: Seal driver Part No. 3375411, mallet

1. Open the draincock and remove the lower radiator hose to drain the cooling system.
2. Remove both upper radiator hoses and the vent line from the thermostat housing.
3. Remove by-pass tube clamp. Loosen both hose clamps and remove the by-pass tube.
4. Remove the (5) long capscrews and (1) short capscrew.
5. Remove the thermostat housing and gasket.
6. Remove the thermostats and seals.
7. Use a mallet and seal driver Part No. 3375411 to install the seal (no more than 0.51 mm [0.020] below the top of the cast edge).
8. Install the thermostat by pushing on the outer rim.
9. Install a new gasket, thermostat housing and capscrews; tighten to 45 N·m [35 ft-lb].
10. Install the by-pass tube, retainer and capscrew; tighten to 45 N·m [35 ft-lb] and hose clamps to 5.6 N·m [50 in-lb].
11. Install the two upper radiator hoses and tighten clamps to 5.6 N·m [50 in-lb].
12. Fill the cooling system and operate the engine to 70°C [160°F]; check for leaks.