Cummins/Onan K 19 Generator Set

⚠ 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.

⚠ 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.

⚠ 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.

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.

⚠ 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.

⚠ 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 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].

⚠ 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.