Cummins/Onan KTA19 Generator Set

⚠ Do not break or remove the lockwire.

⚠ Do not use the ST-1224 if stop crank adjustment is required.

Tools: ST-1224 Tachometer drive adapter (2:1 ratio), tachometer, 1/16 inch hex allen wrench

1. Remove the tachometer drive adapter.
2. Install the ST-1224 in place of the standard drive adapter; connect the tachometer and overspeed stop switch to the ST-1224.
3. Start the engine and warm to operating temperature.
4. Set the engine speed to the appropriate overspeed switch set speed in Table 1-3 as indicated by the tachometer.
5. Remove the round head dust cover screw marked 2 from the top of the switch.
6. Insert a 1/16 inch hex allen wrench into the adjusting screw located just below the surface of the cover.
7. Turn the adjusting screw counterclockwise to lower the engine shut off speed; clockwise to raise it.
8. Replace the dust cover screw.
9. Reset the switch by pushing the reset button on top of the switch.
10. Replace the ST-1224 with the original drive adapter and reconnect the cables.

⚠ 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.

⚠ Use only proper engine barring techniques; do not attempt to rotate the engine by pulling or prying on the fan.

Tools: Snap-On Model TQ12B or equivalent in-lb torque wrench, screwdriver adapter, ST-669 Adapter

1. Turn the crankshaft in direction of rotation until the No. 1 'VS' mark appears; verify both intake and exhaust valves are closed for cylinder No. 1.
2. Tighten the injector hold-down capscrew to 30 to 35 ft-lbs [41 to 47 N·m].
3. Turn the adjusting screw down until the plunger contacts the cup and advance an additional 15 degrees to squeeze the oil from the cup.
4. Loosen the adjusting screw one turn; tighten with an in-lb torque wrench and screwdriver adapter to the cold-setting value.
5. Hold the adjusting screw and tighten the locknut to the specified torque.
6. Turn the crankshaft to the next 'VS' mark per firing order and repeat.

⚠ Be sure the injector and valve set markings are in proper alignment with the indicator mark.

Tools: feeler gauge

1. Loosen the locknut and back off the adjusting screw.
2. Insert a feeler gauge between the rocker lever and the top of the crosshead.
3. Turn the screw down until the lever just touches the gauge.
4. Lock the adjusting screw in this position with the locknut and torque to specification.

⚠ 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.

Tools: dial indicator, feeler gauge, long capscrew

1. Remove the exhaust and intake piping from the turbocharger to expose the ends of the rotor assembly.
2. Remove one capscrew from the front plate and replace it with a long capscrew; attach an indicator and register the point on the end of the rotor shaft.
3. Push the shaft from end-to-end and note the total indicator reading.
4. Check the radial clearance on the compressor wheel only by pushing the wheel toward the side of the bore and using a feeler gauge between the wheel vane tips and the bore.
5. If end clearances exceed the limits, remove the turbocharger and replace it with a new or rebuilt unit.
6. Install the exhaust and intake piping to the turbocharger.

⚠ Parts originally supplied must not be deviated from without qualifying agency approval (Underwriters Laboratory / Factory Mutual Research).

1. Contact operating personnel responsible for the fire protection system and obtain approval.
2. Close all cooling system drains.
3. Remove the heat exchanger cap; check or fill engine coolant supply; open the water filter inlet and outlet valves.
4. Prelubricate the engine with API Class CD or CC oil, SAE 15W40 or 20W40; on turbocharged engines add 2 to 3 oz. [60 cc] oil to the turbocharger oil inlet line.
5. Check the crankcase oil level and fill to the high mark on the dipstick.
6. Remove the fuel pump solenoid wire and crank the engine through two cranking cycles using the fire pump controller.
7. Turn the governor idle adjusting screw counterclockwise 6 turns to permit near idle speed at initial start-up.
8. Verify the lube oil system is under pressure.
9. Operate the engine for 8-10 minutes and look for leaks, unusual noises or other indications of improper operation.
10. Set the overspeed stop switch.
11. Stop the engine and check the engine oil and expansion tank coolant levels; top off if necessary; clean the raw water strainer.
12. Start the engine and bring it to the fire pump required operating speed; adjust the raw water pressure regulator and readjust speed if necessary.
13. Lock the governor lever (naturally aspirated) or max speed screw (turbocharged) in position.
14. Shut off the engine; notify operating personnel and obtain authorized signature of acceptance.

⚠ 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.

⚠ Mechanical tightening will distort or crack the filter head.

1. Close the shut-off valves on the inlet and drain lines.
2. Unscrew the element and discard.
3. Apply a light even coat of lubricating oil to the gasket sealing surface prior to installing the filter.
4. Install a new element and tighten until the seal touches the filter head, then an additional one-half to three-fourths turn.
5. Open the shut-off valves.