Cummins/Onan QSM1i Generator Set

⚠ Do not roll a belt over the pulley or pry it on with a tool.

Tools: ST-1293

1. Loosen the adjusting screw.
2. Loosen the adjustment link locking capscrew.
3. Loosen the pivot capscrew and nut.
4. Measure belt tension with gauge ST-1293.
5. Turn adjusting screw clockwise to tighten belt to specification.
6. Tighten adjusting screw locknut.
7. Tighten adjustment link locking capscrew to 80 N·m.
8. Tighten pivot capscrew and nut to 47 N·m.

⚠ All valve and injector adjustments must be made when the engine is cold (below 60°C).

Tools: 3376592, ST-669, feeler gauges

1. Remove crankcase breather tube and rocker lever cover.
2. Rotate accessory drive to the A valve set mark aligned with pointer.
3. Loosen injector adjusting screw locknut; bottom the plunger 3 or 4 times.
4. Back out adjusting screw two flats (120 degrees); tighten locknut to 61 N·m.
5. Loosen intake and exhaust valve adjusting screw locknuts.
6. Insert correct feeler gauge between crosshead and rocker lever pad.
7. Tighten adjusting screw (torque wrench method 1 N·m) and hold.
8. Tighten valve locknut to 61 N·m (47 N·m with adapter); recheck feeler gauge.

⚠ Do not remove pressure cap from a hot engine; coolant can leak when servicing filter.

Tools: 3398145

1. Remove cooling system pressure cap.
2. Turn coolant filter head valve to OFF position.
3. Remove and discard coolant filter.
4. Clean coolant filter head gasket surface.
5. Apply thin film of clean engine oil to new gasket.
6. Install new filter until gasket contacts head, tighten 3/4 to 1 turn.
7. Turn valve to ON position and install pressure cap.
8. Operate engine, check for leaks and coolant level.

⚠ Do not remove pressure cap from a hot engine; coolant is toxic.

Tools: CC-2800 refractometer

1. Drain the cooling system; do not allow it to dry out.
2. Do not remove the coolant filter.
3. Add 3.8 liters Fleetguard RESTORE per 38 to 57 liters capacity; fill with clean water.
4. Operate engine at normal temperature (at least 85°C) for 1 to 1-1/2 hours.
5. Shut off, cool to 50°C and drain.
6. Fill with clean water and operate 5 minutes above 85°C.
7. Drain; repeat flushing until drained water is clean.
8. Fill with 50/50 fully formulated coolant; install pressure cap and check for leaks.

⚠ Mechanical overtightening can distort threads and damage the fuel filter seal.

Tools: 3376807

1. Clean area around fuel filter and filter head.
2. Remove fuel filter with filter wrench 3376807.
3. Remove the thread adapter sealing ring.
4. Clean the gasket surface on the filter head.
5. Lubricate new filter gasket with clean engine oil; fill filter with clean diesel fuel.
6. Install new thread adapter sealing ring.
7. Install filter until gasket contacts head, tighten 1/2 to 3/4 turn by hand.

⚠ Used engine oil can be carcinogenic; avoid inhalation, ingestion, and prolonged contact.

Tools: 3375049

1. Operate engine until coolant reaches 60°C; shut off.
2. Remove oil drain plug from bottom of oil pan.
3. Remove oil filter(s) with filter wrench 3375049.
4. Clean gasket surface of the oil filter head.
5. Coat new oil filter gasket with clean engine oil; fill filter with clean oil.
6. Install new filter; tighten 1/2 to 3/4 turn after gasket contacts.
7. Install and tighten oil drain plug to 88 N·m.
8. Fill engine with clean oil to H mark; run engine and recheck level.

⚠ Do not use Teflon tape or pipe sealant on the threads; it will insulate the zinc anode.

1. Shut off the sea water inlet valve on the vessel hull.
2. Remove the zinc plug(s).
3. Measure length of zinc plug(s) removed.
4. Replace any zinc plug 50 percent or more eroded.
5. Install and tighten the zinc plug(s) to 44 N·m.

⚠ A restricted or clogged sea water strainer can result in overheated engine coolant and marine gear oil temperatures.

1. Loosen and remove the sea water strainer wing nut(s).
2. Remove the sea water strainer assembly; retain and inspect o-ring.
3. Remove the strainer basket and empty all debris.
4. Clean the sea water strainer.
5. Prime with clean water.
6. Install strainer; replace o-ring if damaged and seat properly.
7. Install and tighten the wing nut(s).
8. Open the sea water inlet valves.

⚠ Coolant is toxic; dispose of in accordance with regulations.

1. Remove pressure cap when engine is cool.
2. Drain cooling system; remove lower radiator hose.
3. Remove upper coolant hose from thermostat housing.
4. Loosen coolant bypass hose clamps.
5. Remove four thermostat housing mounting capscrews and housing.
6. Remove thermostat from housing.
7. Install thermostat in housing with new o-ring seal.
8. Install housing (capscrews 54 N·m); fill and check for leaks.

⚠ Batteries can emit explosive gases; ventilate the compartment before servicing.

1. Disconnect battery electrical connections (negative cable first).
2. Tag and remove electrical connections from starting motor.
3. Remove three capscrews and the starting motor.
4. Install starting motor and three mounting capscrews; tighten to 90 N·m.
5. Install and tighten the electrical connections to starting motor.
6. Install and tighten battery electrical connections (negative cable last).

1. Remove intake and exhaust pipes from turbocharger.
2. Remove oil supply line and oil drain line.
3. If water-cooled, drain cooling system and remove water lines.
4. Loosen aftercooler air inlet hose clamps.
5. Remove four turbocharger mounting nuts, turbocharger and gasket.
6. Apply anti-seize 3824879 to mounting studs; use new gasket.
7. Install turbocharger, tighten mounting nuts to 61 N·m; tighten hose clamps to 8 N·m.
8. Install oil drain line (27 N·m) and supply line (20 N·m); pour 50-60 cc oil in supply fitting.

⚠ Do not remove pressure cap from a hot engine.

Tools: ST-647, 3377401, 3376326

1. Drain cooling system; remove lower radiator hose.
2. Remove alternator drive belt and alternator.
3. Remove water pump pulley retaining capscrew and pulley (puller ST-647).
4. Remove dust seal, oil seal capscrews, clamping ring, oil seal and gasket.
5. Remove thermostat housing and water transfer connection.
6. Remove water pump.
7. Install new o-rings, gasket and oil seal; install water pump (capscrews 47 N·m).
8. Install transfer connection (25 N·m) and thermostat housing (54 N·m); fill and check for leaks.