Cummins/Onan KTA-50G3 Generator Set

⚠ The injector plunger is under spring tension. Do NOT allow the tool to slip.

Tools: 3822575 adjustment kit, 3822574 rocker lever actuator, ST-669 adapter

1. Install injector and valve adjustment kit, Part No. 3822575.
2. Adjust indicator tip to touch top of injector plunger.
3. Lower indicator 12.25 mm [0.5 inch] and lock support.
4. Depress rocker lever until injector bottoms two or three times.
5. Hold plunger bottomed and set indicator to ZERO.
6. Turn adjusting screw until indicator reads specified travel.
7. Tighten locknut; verify setting.

⚠ Use the correct chart for the engine or the parts will be damaged.

⚠ Crosshead adjustment must always be made before adjusting the valves.

Tools: 3376592 inch pound torque wrench, 3822575 injector and valve adjustment kit, 3822574 rocker lever actuator, ST-669 torque wrench adapter

1. Steam clean engine before removing rocker lever covers.
2. Remove rocker lever covers and related components.
3. Align valve set (VS) mark on damper or flywheel with pointer.
4. Determine cylinder in position; crossheads and valves ready when all valves closed.
5. Adjust crossheads before adjusting valves.
6. Adjust valves to lash specification with feeler gauge.
7. Adjust injectors per PT (type D) or STC/HVT method.
8. Tighten locknuts and reinstall rocker lever covers.

⚠ Do not use caustic cleaners; aluminum components will be damaged.

⚠ Wait until temperature is below 50 C [120 F] before removing the pressure cap.

1. Drain the cooling system; do not allow it to dry out.
2. Add Fleetguard RESTORE or RESTORE PLUS (1 U.S. gallon per 38-57 liters capacity).
3. Fill system with plain water.
4. Operate engine at normal temperature (at least 85 C [185 F]) for 1 to 1.5 hours.
5. Shut off and drain the system.
6. Fill with clean water and operate at high idle 5 minutes above 85 C.
7. Shut off and drain; repeat flush if water is still dirty.
8. Refill with new heavy duty coolant and SCA.

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

Tools: 8-point socket, breaker bar

1. Remove the back side idler end of the shock absorber, control rod, or turnbuckle.
2. Loosen upper capscrew and remove lower capscrew.
3. Relieve idler spring tension with an 8-point socket and breaker bar.
4. Remove the fan belt.
5. Install the belt on crankshaft and fan hub pulley, aligning grooves with pulley ribs.
6. Rotate idler against spring and install lock washer and capscrew; torque 45 Nm.
7. Install control rod or shock absorber and tighten capscrews to 60-90 Nm.

Tools: 3375049 filter wrench

1. Clean area around the fuel filter head.
2. Remove the fuel filter with filter wrench, Part No. 3375049.
3. Clean the filter head gasket surface with a lint-free towel.
4. Apply a light film of clean engine oil to the filter gasket.
5. Fill the filter with clean fuel and install on the head.
6. Tighten until gasket contacts head, then per filter manufacturer.

⚠ Do not overtighten the valve. Overtightening can damage the threads.

1. Shut off the engine.
2. Open the drain valve by hand, turning counterclockwise 1-1/2 to 2 turns.
3. Drain the filter sump until clear fuel is visible.
4. Turn the valve clockwise 1-1/2 to 2 turns to close.

⚠ Avoid direct contact of hot oil with your skin.

⚠ Fill oil filters with clean lubricating oil; lack of lubrication is harmful.

Tools: 3375049 oil filter wrench

1. Operate engine until coolant reaches 60 C [140 F]; shut off.
2. Remove oil drain plug and drain oil immediately.
3. Clean filter head and gasket surface; remove o-ring if stuck.
4. Remove and discard full flow and bypass filters.
5. Fill new filters with clean lubricating oil and lubricate gaskets.
6. Install filters; tighten per filter manufacturer.
7. Install and tighten oil drain plug to 100 Nm [75 ft-lb].
8. Fill engine with clean oil to correct level.

1. Disconnect the electrical wire from the fuel pump solenoid valve.
2. Rotate the crankshaft with the starting motor until oil pressure appears.
3. Connect the electrical wire to the fuel pump solenoid valve.
4. Start the engine.

Tools: ST-537 dial depth gauge, dial indicator, feeler gauge

1. Remove air intake and exhaust piping.
2. Look for damaged or cracked compressor or turbine blades.
3. Check that the turbocharger shaft spins freely.
4. Measure axial clearance (end play) and compare to specification.
5. Measure radial clearance (side to side).
6. Rebuild or replace if out of specification.

⚠ Do not repair or balance a viscous damper in the field.

Tools: paint solvent, fine emery cloth, micrometer

1. Clean the exterior of the damper with solvent.
2. Inspect mounting flange for cracks.
3. Inspect housing for dents, bulges, or leaks.
4. Remove paint and measure thickness at four locations, 90 degrees apart.
5. Replace damper if damaged or thickness exceeds specification.
6. Replace damper after 24,000 hours regardless of measurement.

⚠ Do not operate a diesel engine where there are or can be combustible vapors.

1. Disengage the driven unit or put the transmission in neutral.
2. Start the engine with the throttle in the idle position.
3. Do not engage starting motor more than 30 seconds; wait 2 minutes between attempts.
4. Oil pressure must be indicated within 15 seconds after starting; shut off if not.
5. Idle 3 to 5 minutes at approximately 1,000 RPM before applying load.

⚠ Do NOT use a wooden tool to push the injector on the seat.

⚠ Do not let the tappet fall out of the HVT injector.

Tools: 3376497 injector puller (STC/HVT), 3376000 or 3376497 injector puller (standard), 1-1/4 inch or 27 mm socket

1. Identify o-rings: 3010510 red dot, 205216 no marking, 193736 green dot.
2. Lubricate o-rings with vegetable oil and install on injector.
3. Install the proper size seal ring.
4. Position injector so screen points toward hold down capscrew hole.
5. For STC/HVT, align hole in top stop screw with oil supply hole.
6. Use a 1-1/4 inch or 27 mm socket to seat the injector with a quick hard push.
7. Install hold down clamp; tighten capscrews alternately to 16 Nm [146 in-lb].
8. Install jumper tube with o-ring and copper washers; tighten screw to 25 Nm [20 ft-lb].