Cummins/Onan KTAA19-G12 Engine

⚠ The lower jam nut has left-hand threads.

1. Loosen alternator and adjusting link mounting capscrews.
2. Loosen jam nuts on adjusting screw.
3. Turn adjusting screw clockwise to tighten belt tension.
4. Tighten jam nuts to 55 Nm [40 ft-lb].
5. Tighten adjusting link and alternator mounting capscrews to 55 Nm [40 ft-lb].
6. Check belt tension again.

⚠ Dipstick will break if scribe mark is too deep.

Tools: Scribe

1. Drain oil from oil pan.
2. Install dipstick in dipstick tube housing.
3. Fill oil pan to specified low level with clean 15W-40 oil.
4. Remove dipstick and scribe mark at oil level; mark low with L.
5. Install dipstick tube.
6. Add oil to specified full level.
7. Remove dipstick and scribe mark at oil level; mark high with H.

⚠ Injector plunger is under spring tension. Do not allow tool to slip.

Tools: 3822575 Injector and Valve Adjustment Kit, 3822574 Rocker Lever Actuator, 3376592 Inch Pound Torque Wrench, ST-669 Torque Wrench Adapter

1. Steam clean engine.
2. Remove rocker lever covers.
3. Rotate engine to A mark alignment.
4. Determine cylinder with valves closed.
5. Adjust crossheads before valves.
6. Adjust intake valve to 0.36 mm and exhaust valve to 0.69 mm.
7. Adjust PT (type D) injector travel to 7.72 mm using dial indicator.
8. Tighten locknuts to specified torque.
9. Repeat for all cylinders per firing order.

⚠ Do not use a clicker-type torque wrench for OBC method.

Tools: Dial type torque wrench with 0.28 Nm resolution and 17 to 23 Nm range, ST-669 Torque Wrench Adapter

1. Steam clean engine.
2. Run engine in retard mode before setting OBC method.
3. Disable STC oil control valve.
4. Operate engine at high idle 5 minutes in normal timing mode.
5. Remove rocker lever covers.
6. Rotate engine to set marks.
7. Adjust crossheads, then valves.
8. Tighten injector adjusting screw to 10 Nm [90 in-lb] using OBC method.
9. Tighten locknuts to specified torque.
10. Install rocker lever cover.

⚠ Pull cover and element straight out to avoid damage.

1. Remove wing nut securing bottom cover; remove cover.
2. Pull element down from center bolt.
3. Remove gasket from outlet end of housing.
4. Install new element.
5. Ensure gasket washer is in place under wing nut before tightening.

⚠ Do not remove radiator cap from a hot engine.

⚠ Do not allow oil to get in the filter; it will adversely affect DCA.

1. Warning: Do not remove radiator cap from hot engine.
2. Remove coolant system pressure cap and close shutoff valve(s), if equipped.
3. Turn valve on filter head to OFF position.
4. Remove and discard coolant filter.
5. Use engine oil to lubricate seal on new filter.
6. Install new coolant filter until seal touches head, then turn additional 1/2 to 3/4 turn.
7. Turn valve to ON position.

⚠ The fan belt idler is under tension. Do not allow hands between idler and belt or fan hub.

Tools: 8-point socket, breaker bar or large wrench

1. Hold idler in position against spring tension and remove capscrew using 8-point socket and breaker bar.
2. Slowly turn wrench until spring tension is relieved.
3. Remove fan belt.
4. Visually check belt for cracks, glazing, tears or cuts.
5. Install belt.
6. Rotate idler against spring tension until capscrew holes align.
7. Install capscrew and tighten to 45 Nm [35 ft-lb].

Tools: 3375049 Oil Filter Wrench

1. Clean area around fuel filter head.
2. Remove fuel filter using filter wrench Part No. 3375049.
3. Clean filter head gasket surface with clean lint-free towel.
4. Apply light film of clean engine oil to filter gasket.
5. Fill filter with clean fuel.
6. Install filter until gasket contacts head, then tighten 1/2 to 3/4 turn.

⚠ Avoid direct contact of hot oil with skin.

⚠ Fill oil filters with clean lubricating oil.

⚠ Mechanical overtightening can distort threads or damage filter element seal.

Tools: 3375049 Oil Filter Wrench

1. Operate engine until water temperature reaches 60°C [140°F]. Shut off engine.
2. Remove oil drain plug and drain oil immediately.
3. Clean area around oil filter head and gasket surface.
4. Remove full flow and bypass filters using oil filter wrench Part No. 3375049.
5. Fill new filters with clean lubricating oil.
6. Apply light film of oil to gasket sealing surface.
7. Install filters as specified by filter manufacturer.
8. Clean and install oil drain plug; Torque 100 Nm [75 ft-lb].
9. Fill engine with clean oil to correct level.
10. Operate engine at idle and inspect for leaks.
11. Shut off engine, wait 5 minutes, check oil level.

1. Allow engine to idle three to five minutes after full load operation before shut-off.
2. Turn ignition key switch to OFF position.
3. If engine fails to stop, rotate manual fuel shutoff thumb screw counterclockwise to ensure valve is not held open.

⚠ Do not operate a diesel engine where combustible vapors are present.

1. Disengage the driven unit, or put transmission in neutral.
2. Start engine with throttle in idle position.
3. Air starters require minimum 480 kPa [70 psi] compressed air.
4. Do not engage starting motor more than 30 seconds.
5. Wait two minutes between each start attempt (electric starters only).
6. Engine oil pressure must be indicated within 15 seconds after starting.
7. If no oil pressure in 15 seconds, shut off engine immediately.
8. Idle three to five minutes at approximately 1,000 RPM before loading.

1. Disconnect electrical wire from fuel pump solenoid valve.
2. Rotate crankshaft using starting motor until oil pressure appears or warning light goes out.
3. Connect electrical wire to fuel pump solenoid valve.
4. Start engine per normal starting procedures.