TOUCHSTONE General Contracting,

Engineering Consultancy and Project

Management L.L.C.,
Apt. No. 14, Building (18/609)
Street (14), Ramadan, Al-Mansour,
Baghdad, Iraq

To: SAKR Ref.: M0015K-AMEC-SAK-0000-T-0049

P. O. Box 98 - Jbeil Issue Date: 31-Dec-14
Return Date: -

DOCUMENT TRANSMITTAL NOTE

Distributees
Company Names Position Issuance Code Comment (if any)
SAKR Mr. Georges Daccache Project Manager IFR/IFA
TOUCHSTONE Mr. Peter Prentice Engineering Manager IFI
TOUCHSTONE Mr. Mahmoud Slayhi Project Engineer IFI
TOUCHSTONE Mr. Janusz Makrocki Lead Mechanical Engineer IFI
TOUCHSTONE Mr. Anil Shenoy Lead Instrument Engineer IFI
TOUCHSTONE Mr. Baha-Aldin Ismail Lead Civil/Structural Engineer IFI
TOUCHSTONE Mr. Shekhar Dhuri Process Engineer IFI

Item No. TOUCHSTONE Document No. Other Document No. Revision Code Title/Description
Installation & Operation and Maintenance Manual
1 2014-04-092-M03-0001 N/A R1
for Engine, Alternator and Genset.

PREPARED BY: SAKR ISSUED BY: IBRAHIM KHALEEL

CHECKED BY: NAVEEN KUMAR

REVIEWED BY: NAVEEN KUMAR

Issuance Codes Revision Codes

ICH - Issued For Construction with Holds
ICR - Issued For Construction Record
IFA - Issued For Approval/Action
IFB - Issued For Bid
IFC - Issued For Construction
IFD - Issued For Design
IFE - Issued For Estimate
IFH - Issued For HAZOP
IFI - Issued For Information
IFR - Issued For Review/Comments
IFU - Issued For Use
IFX - Issued For Void/Cancelled
IFP - Issued For Purchase/Procurement
IFQ - Issued For Quotation
IFS - Issued For Squad Check - Regional
IFT - Issued For Tender
IPT - Issued For Permit
RLM - Red Line Mark-up
RTS - Return To Supplier
SFR - Supplier Issued For Review - Regional
SFS - Supplier Issued for Squad Check - Regional
P - Preliminary / Draft
R - Issued for Comment
I - Information
A - Approved for Use/ Design / ITT/ITB
B - Approved for Purchase
C - Approved for Construction

Notes:
Please acknowledge the receipt.
Comments to be returned to DCC (DCC.SIBA@amec.com).

M0015K-0000-CD10-FRM-0001
  

Operation and Maintenance Manual

Above 500KVA

 
Introduction

Thank you for purchasing this generating set from

Sakr Power Systems S.A.L.; We hope you will be
satisfied with this product and that it meets
your power supply needs.

To fully benefit from the longevity and reliability built into this generating
set, please ensure that it is operated and maintained properly.
Sakr Power Generation (SPG) branded genset comprises of a complete
system that incorporates cutting edge engineering concepts which, like
all products manufactured by Sakr Power Systems, adhere to the latest
standards.

Persons responsible for the operation and maintenance of this generating

set should review the relevant sections in this manual in order to become
familiarized with this type of generating set and its components prior to
attempting to operate the unit.

This manual provides an operational guide for Sakr Power Generation (SPG)
generating sets ranging from 500 KVA to 2000 KVA rating.
Its purpose is to provide the information and instructions necessary for the
proper operation of this unit in order to sustain a reliable power source.

Sakr Power Generation Gensets are manufactured to a stringent quality-

control system that is registered under ISO 9001-2000 and BS 8528 that are
specifically tailored to the generating set industry. This unit and its control
system are manufactured under a registered quality-control structure that
allows you to fulfil your power requirements.

The performance of this product is subject to the care it receives and the
conditions under which it has to operate.

1
Table of Contents

Section One: Safety & Handling

1.1 General Safety Precautions..................................................................................................................... P.5
1.2 Specific Safety Precautions..................................................................................................................... P.6
1.2.a Radiator Pressure Release..................................................................................................................... P.6
1.2.b Fire and Explosion................................................................................................................................... P.7
1.2.c Rotating Parts.......................................................................................................................................... P.7
1.2.d Hot Surfaces............................................................................................................................................ P.7
1.2.e Toxic and Irritating Substances........................................................................................................... P.7
1.2.f Electrical Shock....................................................................................................................................... P.7
1.2.g Lifting, Handling and Transportation (when applicable).............................................................. P.7
Warranty & Product Registration............................................................................................................. P.8

Section Two: General Description of Equipment

2.1 Introduction................................................................................................................................................ P.11
2.2 Description of the Genset Package....................................................................................................... P.11
2.3 Engine........................................................................................................................................................... P.12
2.4 Air Filtration............................................................................................................................................... P.12
2.5 Governing System..................................................................................................................................... P.12
2.6 Cooling System.......................................................................................................................................... P.12
2.7 Fuel System................................................................................................................................................. P.13
2.8 Exhaust System.......................................................................................................................................... P.13
2.9 Anti-Vibration Mounting System........................................................................................................... P.13
2.10 Starting System........................................................................................................................................ P.13
2.11 Lubricating System.................................................................................................................................. P.13
2.12 Alternator................................................................................................................................................... P.14
2.13 Voltage Regulator..................................................................................................................................... P.14
2.14 Control System Power Supplies........................................................................................................... P.14
2.15 Main Circuit Breaker............................................................................................................................... P.14
2.16 Control Panel............................................................................................................................................ P.15
2.17 Deif Control Module............................................................................................................................... P.15
2.18 Sound Proof Canopy............................................................................................................................... P.15

Section Three: Installation

3.1 Base and Foundation................................................................................................................................ P.16
3.2 Cooling and Ventilation........................................................................................................................... P.17
3.3 Exhaust System.......................................................................................................................................... P.17
3.4 Fuel System................................................................................................................................................. P.18

Section Four: Maintenance

4.1 Introduction................................................................................................................................................ P.19
4.2 Routine Maintenance............................................................................................................................... P.20
4.3 Maintenance Program.............................................................................................................................. P.20
4.4 Genset Maintenance Schedule............................................................................................................... P.23

Section Five: Troubleshooting

5.1 Alternator Troubleshooting..................................................................................................................... P.24
5.2 Engine Troubleshooting........................................................................................................................... P.24

Appendices
A.1 Fuel, Lubricant and Coolant Specifications......................................................................................... P.27
A.2 Batteries....................................................................................................................................................... P.32

3
1.Safety & Handling

1.1 General Safety Precautions:

The responsibility for safe operation rests on two major points:

Verification that all safety protections are in proper operating conditions.
Following the safety precautions as illustrated below.

If the following safety precautions are followed, the possibility of accidents will be minimized:
This diesel generating set should be handled only by trained and qualified personnel. Failure to follow safety will increase the
possibility of accidents and injuries to the operator and nearby personnel.
Always refer to this manual before conducting any work on the generating set.
Be sure to follow local and state regulations when operating this generating set. Some items only apply to specific
applications.
The use of this generating set in any capacity other than its intended purpose will pose a safety hazards and result in the
cancellation of its warranty.
Do not smoke or allow sparks, flames or any other incendiary device near this unit when you are refueling the genset tank.
Be sure to clean all spilled diesel before starting the generating set.
Materials which have been contaminated by fuel must be moved to a safe distance.
Do not pour fuel in the daily tank while the engine is running (unless it is absolutely necessary).
Do not clean, add lubricating oil, or adjust the engine while it is running.
Do not make any adjustments to components with which you have no experience.
Ensure that the generating set does not run in a location where it can accumulate a concentration of toxic emissions.
Only technicians should be near the generating set while it is in operation.
Loose clothing or long hair should not be in the vicinity of moving parts.
Keep away from moving parts while the generating set is operating.
Attention: Some moving parts cannot be seen clearly while the generating set is running.
Do not operate the unit if safety guards have been removed.
Do not remove the filler cap of the cooling system while the engine is warm-hot coolant can be discharged under pressure.
Do not attempt to service the engine while it is operating.
Before servicing, allow the engine to cool down.
Do not allow sparks or flame near the batteries (especially when the batteries are being charged): fuel and vapors are explosive.
Hydrogen gas generated by charging batteries is also explosive. The battery fluid is hazardous to the skin and especially the
eyes.
Disconnect the battery terminals and apply the emergency button before any repairs are made on the system.
Ensure that the generating set is operated by a dedicated skilled technician.
Ensure that the generating set is operated from the control panel or from control room.
If your skin comes in contact with high-pressure fuel, get medical assistance immediately.
Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin. Protect your hands by wearing gloves or a
special solution to protect your skin.
Do not wear clothing that is contaminated by lubricating oil. Do not put oil-contaminated material in your pockets.
To prevent contamination dispose of used lubricating oil in accordance with your local and state laws.
Fit only genuine parts.

5
 1.Safety & Handling

1.2 Specific Safety Precautions:

Before you attempt any adjustment on the generating set, always make sure you are wearing protective equipment such as gloves and
safety shoes.

1.2.a Radiator Pressure Release:

If you want to check the coolant level or add coolant to the radiator, never remove the radiator cap while the engine is hot.
Wait until the coolant temperature is below 50ºC before removing the pressure cap.
Failure to do so will result in personal injury from heated coolant spray or steam.

1.2.b Fire and Explosion:

To prevent fire, it is important to keep flammable liquids such as fuel and oil away from hot surfaces.

A number of precautions must be taken:

Always clean up spilled fuel, oil, battery electrolyte or coolant.
Smoking is prohibited when adding fuel, oil, or battery electrolyte.
Turn off the battery charger before breaking the connections to the battery. Always disconnect the ground (negative) connection
prior to the positive one.
Keep electrical wiring in good condition and terminals clean and tight.
Do not operate the generating set with any known leaks in the fuel system. Repair damage in the fuel system immediately.
Fully charged BC and ABC fire extinguishers should be kept on hand at all times. Personnel must know how to operate them.
Never use water to extinguish fires.

1.2.c Rotating Parts:

Keep hands, arms, feet, long hair, loose clothing and jewelry away from pulleys, belts and other moving parts.
Do not operate the generating set with any guards removed.
Adjustments to the engine should ONLY be done when the emergency stop button is depressed. After adjusting ensure the
adjustments were successful.
Keep hands, feet, floor, and walking surfaces clean and free of fuel, oil, and any other liquid to minimize the possibility of
slipping.

1.2.d Hot Surfaces:

Avoid contact with hot oil, hot coolant, hot exhaust gases and hot surfaces (mainly exhaust pipes).
Keep a first-aid kit handy nearby and do not ignore small cuts and burns because they may lead to infection.

1.2.e Toxic and Irritating Substances:

Operate the generating set in open or well-ventilated areas.
Wear an acid-resistant apron and face shield or goggles when servicing the battery.
Discharge exhaust fumes outside the plant room, and ensure that the fumes do not re-circulate back into the plant room.
Do not swallow or allow skin contact with fuel, oil, coolant, lubricants or battery electrolyte. If swallowed, seek medical treatment
immediately. Do not induce vomiting if fuel is swallowed. With skin contact, wash with soap and water.
Do not waste oil, coolant or fuel directly on the ground, down a drain or into any water source.

6
1.Safety & Handling

1.2.f Electrical Shock:

The generating set should be shutdown with the negative (-) terminal disconnected prior to attempting to connect or disconnect
load connections.
Remove any metal or gold accessories from your body before working with electricity.
Do not touch electrically energized parts of the generating set and or interconnecting cables or conductors with any part of the
body or with any non-insulated conductive objects.
Replace any wiring whose insulation is cracked, cut, abraded or otherwise degraded.
Do not work with the generating set while standing on a wet surface.
Stop the engine, isolate the battery charger, disconnect the battery cables, and turn off all the circuit breakers before making
electrical connections to the generating set.
Keep all body parts, hand tools, and other conductive objects away from live parts in the genset electrical system.
Close and lock all the access doors off the electric panels.
Use only Class BC or Class ABC extinguishers on electrical fires.

1.2.g Lifting, Handling and Transportation:

The engine, alternator, base frame, and canopy are provided with lifting points.

When lifting the generating set, the following instructions should be taken into consideration:
Never lift the generating set from the engine or alternator lifting lugs.
Ensure the lift rigging and supporting structure is in good condition and is suitably rated.
The generating set should be lifted from the lifting points.
Use guide ropes to prevent the generating set from twisting or swinging once it is lifted.
Do not lift in high winds.
Drain fuel from the daily tank before lifting and transportation
Do not lift the generating set while the engine is running.
Keep all personnel away from the generating set when it is suspended.
Place the generating set on level surfaces capable of supporting its weight.
Whenever the generating set is suspended, ensure it is under constant supervision.

Do not open radiator Keep Away

Hot Surface Fuel Oil Filling Oil Dip Slack Earth Point Lifting Point Electric Danger
cup before it cools down Risk from rotating parts

7
 Warranty

Sakr Power Generation Warranty

This is a warranty which applies to all Sakr Power Generation (SPG) industrial Generating Sets and associated Switches,
Switchgear(s), and Accessories (hereafter referred to as “Products”).
SPS guarantees to the client (original purchaser) that its Products are free from defects in material and workmanship for
a period of twelve (12) months (unlimited running hours) from the date delivery to the same client (first user), provided
that the spare parts used for maintenance and repair are genuine parts, regular maintenance is performed to specified
schedule and lube oil meets engine manufacturer specifications.

1. SPS’ Responsibilities
If a defect in material or workmanship arises during the warranty period, SPS will repair or replace the defective parts, at its own
discretion and at a location of its choice. The method of delivery of any replacement parts shall be at SPS’ sole discretion.
Repair or replacement parts under warranty are warranted for the remainder of the product warranty period.
Any defective goods or parts therefore replaced by SPS shall become its property.

2. Client’s Responsibilities
The Client is responsible for:
Returning the Warranty Registration Card signed by the client (original purchaser) to SPS within one month of delivery date.
Proper installation and commissioning, in case done by other than SPS.
Operating and maintaining the product in accordance with the recommendations published by SPS, including, without limitation,
operating within power rating designation as set within the power rating* section in this document.
Periodic parts replacement and service of all mechanical devices.
The notification of the defect to SPS or to an authorized SPS distributor promptly – within 15 days of the discovery of the
warrantable failure - and in any event prior to the expiry of the warranty period.
Accepting SPS’ judgment as to whether the faulty part is defective in material or workmanship.
Rental equipment used to replace the equipment being repaired, other downtime expenses and all business costs and losses.
The premium costs for overtime labor requested by the client.
Any other consequential damages or incidental losses, arising statute whatsoever.

If the client (original purchaser) fails to fulfill the said obligations, the present warranty is considered as non applicable and
void.

3. Limitations
This Warranty does not cover any damage caused by any of the following:
Generating set Overload or Operation beyond the rated capacity
Misuse, Abuse, Negligence or Improper Application
Lack of Maintenance or use of non-genuine spare parts
Natural Disaster, Fire, Earthquake, Lightning, War or any other Force Majeure event.
Product having been subjected to any sort of disassembly and/or repair, control settings having been altered and/or fuel pump
or seals having been altered by other parties, without prior written approval from SPS or their approved distributors.

8
Warranty

This warranty neither covers:

Consumable parts, or maintenance items (such as oil, filter elements, belts, and hoses),
Expenses incurred by the customer for the transportation of the products to SPS approved service facilities.
Repairs where normal use has exhausted the life of a part or product (such as filters, belts…) - “normal wear and tear” -
Consequential damages.
Any other indemnities that are not explicitly stated in this policy.

* Power Ratings – SPG generating Sets must be used within the following rating designations:
A. Standby Power Rating: The standby power rating is applicable for supplying emergency power for the duration of normal power interruption. No
sustained overload capability is available for this rating. This rating is applicable to installations served by a reliable normal utility source. This rating
is only applicable to variable loads with an average load factor of 80% of the standby rating for a maximum of 200 hours of operation per year.

B. Prime Power Rating: The prime power rating is applicable for supplying electric power in lieu of commercially purchased power. The number of
allowable operating hours per year is unlimited for variable load applications. However the permissible average power output during a 24 hours period
shall not exceed 75% of the max power stated.
The total operating time at 100% prime power shall not exceed 500 hours per year. A 110 % overload capability is available for a period of 1 hour
within a 12 hours period of operation. Total operating time at the 10% overload power shall not exceed 250 hours per year.

C. Continuous Power Rating: The continuous power rating is applicable for supplying power continuously to a load of up to 100% of the continuous
rating for an unlimited number of hours per year, between the stated maintenance intervals and under stated ambient conditions. No overload
capacity is available at this rating.

THIS WARRANTY IS THE ONLY WARRANTY APPLICABLE TO SAKR POWER GENERATION PRODUCTS AND NO PERSON IS AUTHORIZED
TO GIVE ANY OTHER WARRANTY, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. SPS SHALL NOT BE LIABLE FOR ANY INCIDENTAL LOSSES AND/OR CONSEQUENTIAL DAMAGES AND/OR
ARISING STATUTE WHATSOEVER AS DESCRIBED ABOVE.

* For countries covered by our “Export Warranty”, additional conditions apply. Please ask for the “Export Warranty” from
our Sales representative.

4. Warranty Registration Card:

Please find hereafter the Warranty registration Card to sign and return to SPS within one month of delivery date.

9
 Warranty Registration Card

Complete and return this form to register your product for warranty.

LEBANON UAE KSA QATAR IRAQ IRAN EGYPT NIGERIA SUDAN

Sakr Power Systems s.a.l
P.O.Box 98 Jbeil, Lebanon - lebanon@sakr.com
Halat T +961 9 442 000 - F +961 9 445 444, Tripoli T +961 9 442 000 - F +961 9 445 444
Hazmieh T +961 5 952 555 - F +961 5 952 666, Khaldeh T +961 5 808086 - F +961 5 812 530

10
2.General description of equipment

2.1 Introduction:

Your new SAKR POWER GENERATION generating set is a complete system that incorporates advanced engineering
concepts. With years of experience SPG generating set are designed to provide you with superior performance backed by
manufacturing expertise, reliability and quality focused team.

Your generating set:

Will respond to your emergency standby or prime power needs.
Is fitted with an alternator that produces the correct voltage with optimum wave form, fast response and precise voltage
regulation.

2.2 Description of the Genset Package:

This Sakr Power Generation generating set has been designed as a complete package to provide superior quality, reliability, and
performance. The figure below identifies the major components which comprise the unit. However, each generating set differs
slightly due to size and configuration of major components. The full technical details of each unit’s main parts are included in the
manufacturer’s manuals found in the generator set’s manuals pouch.

2
.

3
5

1 4 1

11 10 12 13
8 6

1. Radiator. 2. Muffler. 3. Flexible.

4. Alternator 5. Control Panel. 6. A.V.M.
7. Fuel Filters. 8. Base Frame. 9. Main Circuit Breaker.
10. Oil Sump. 11. Starter. 12. Charging Alternator.
13. Belts.

11
 2.General description of equipment

2.3 Engine:

Your Sakr Power Generation generating set is powered by a heavy-duty industrial type diesel engine. The engine is reliable and
specifically designed in conjunction with the generating set’s alternator.
The engine is equipped with all necessary accessories to provide a reliable power source. For the purpose of protecting the engine,
sensors are mounted on the unit to provide signals for oil pressure, water temperature and battery-charging current with the
default shown on the control panel displayed. In addition, in the event the engine functions abnormally, these sensors send a
signal to the control card to protect your generating set against damage.
All engine details including the serial number are stamped on the engine identification data plate affixed on the engine.
The engine’s general specifications are found in the included technical specifications sheets.

2.4 Air Filtration:

The air filtration system consists of the following parts:

The cartridge container (Optional).
The cartridge.
The hose Line from the Cleaner to the Air Inlet.
The Cleaner Status Gauge (Optional).

2.5 Governing System:

Electronic engine governing is provided for optimum performance.

Additional details concerning governors will be discussed in later sections.

2.6 Cooling System:

This generating set is water-cooled by a cooling system which is comprised of a radiator, a pusher fan and a thermostat.
The cooling system radiator is a heavy duty tropical site rated industrial type unit.
Cooling-System protection liquids (anti-corrosion, anti-cavitations, and anti-freeze) will be added to the coolant and should be
re-filled in the cooling system of the generating set.
The engine cooling system has engine protection sensors such as high coolant temperature switch sensor and low water level
sensor. The radiator is mounted in front of the engine.
Air circulates from the generating set side through the engine area and then directly through the radiator.
In case of an enclosed canopy,air enters the canopy from the rear filter (alternator side) through the canopy interior to cool the
environment of the generator set and then exits through the radiator inlets out the front filters.

12
2.General description of equipment

2.7 Fuel System:

The fuel system consists of the following main components: the pre-cleaner element, feedpump, primary and secondary fuel
filters (optional) with replaceable cartridges, main distribution pump, injectors, to include supply and return lines. There are two
possible ways to operate the generating set. The first is from the internal base fuel tank and the second from the external fuel
tank. If there is a canopy the external fuel lines are fed through the fuel connectors on the canopy.

2.8 Exhaust System:

The purpose of the exhaust system is to direct the engine exhaust outside to a location and height above the generating set where
the fumes and odors will not become a hazard, as well as to reduce noise.
The exhaust gases are discharged to the atmosphere at a point located above the generating set. If there is a canopy the discharge
will be above the roof of the canopy

Each discharge is completed through connecting ducts consisting of:

One expansion compensator (Flexible Bellow).
One exhaust silencer and connecting flanges (in open-set configuration).

Jacketing is placed over the pipe in the engine compartment to prevent accidental burning. The engine exhaust for all indoor
generating set should meet local and state codes.

2.9 Anti Vibration Mounting System:

Vibration isolators are designed to reduce the vibration produced by the engine and alternator mass. Anti Vibration Mounts (AVM)
are selected based on weight and load and distributed equally between the engine and alternator bases. The AVM's are then
secured to the base frame for a stable long-running generating set.

2.10 Starting System:

The starting system is represented by the cranking motor (starter) that was selected to produce sufficient torque to crank the
engine. The cranking signal is controlled by the control panel.

The standard set of batteries are mounted with the generating set to provide the necessary starting current, and are sized
according to the generating set’s rating.

2.11 Lubricating System:

The lubricating system lubricates moving parts, provides internal cooling and keeps the engine interior clean. Its main parts consist
of an oil pump, oil high pressure relief valve, oil pressure regulator assembly, full-flow filter and by-pass filter (optional).

13
 2.General description of equipment

2.12 Alternator:

Alternators are brushless single bearing, revolving field, Four-pole, drip proof, screen protected, and class H Insulated. With four
pole, brushless features, it utilizes a 2/3 pitch winding to minimize harmonic distortion and facilitate parallel operation.
They are Heavy duty bearing (minimum life of 100,000 hours) close coupled engine/alternator for perfect alignment.

All Alternators:
Are 12 lead re-connectable and provide voltage and phase flexibility.
Have 4 bars for load connection.
Meet NEMA MG1-32, BS5000, CSA C22.2, AS1359, VDE0530 and IEC 34-1 requirements.

The Alternator general characteristics are found in the technical specifications sheet attached.

2.13 Voltage Regulator:

The main function of the voltage regulator is to sense the voltage of the alternator and adjust the excitation current of the
alternator stator to maintain the voltage constant as load varies.

2.14 Control System Power Supplies (Batteries):

Each generating set is provided with lead acid batteries or maintenance free batteries. The batteries are mounted on the base
frame in a durable tray, with sizing to provide multi-starting attempts.
Engine-driven alternators are provided on all models to charge the batteries.
A 24 Volts DC power supply powers the DC components in the electric panel such as the DC relays, senders, control module, etc.
The same 24 Volts DC power supply system powers the engine starter system.

The 24 Volts batteries can be recharged through the following two methods:
1- An on-board battery charger which is located beneath the control panel and supplied from the Auxiliary Supply (optional).
2- A charging alternator located on the engine, and connected to the engine shaft via a belt.

In case the Optional Battery Charger is installed the Primary charging source is the alternator.

2.15 Main Circuit Breaker:

Load isolation and over-current protection are provided by circuit breaker with a trip unit. In the event of an overcurrent the
breaker thermal and magnetic elements trigger a latching device to trip the breaker switch.

14
2.General description of equipment

2.16 Control Panel:

An essential part of the generating set is the control panel. The control panel consists of electrical items such as meters for
monitoring oil pressure, water temperature, alternator voltage and driven output current on each phase, output frequency and
battery charging current. The function of the control panel is to protect the engine in the event of a sensor failure.

2.17 DEIF Control Module:

Within the control panel is the Controller Unit. It contains the controls necessary for start/stop procedures and protection for the
engine and the alternator. Please refer to the attached manual for operation instructions.

2.18 Sound and Weather Proof Container (Optional):

The weather-proof Containers are manufactured to the following specifications:

Material: Black mild steel thickness 3mm for the body with corrugated sheets. The skeleton is manufactured with hollow 80x80
tubes of 3mm thickness. The base frame is made with HEA channels.
Paint: All the doors’ parts and louvers are treated through a three-stage pre-treatment tunnel (degreasing, phosphating and
passivating).
Paint will be electro-static powder coating thickness 60-80 microns.
The skeleton is sand blasted, treated with solvents, painted with three liquid coats (primer, intermediate and top coat).
The base frame is treated the same way as the frame.
The color of all interior and exterior parts will be according to the customer’s requirements.
All doors are fitted with steel hinges and steel locks, and are equipped with internal releases in case of emergency.
The container is fitted with a window to enable the operator to see the control panel and a special opening for power cables.
The oil-drainage system can be extended to exterior of the container.
All maintenance operations can be carried out easily.
Hot exhaust gases will be directed vertically by providing an exhaust flap.
A non-flammable mineral fiber (density 60Kg/m3) is secured to the inside of the canopy.
The roof is designed to prevent the accumulation of rain water.
The base is equipped with four lifting points which are based on the unit’s total weight (Canopy & Genset).
Additional mufflers can be added for sound-attenuation purposes.

15
 3.Installation

3.1 Base and Foundation:

The generating set with its base frame can be placed directly Fig.3.1
on a horizontal concrete floor, but for a permanent installation,
it is recommended that a base concrete foundation support the
generating set weight.

The major functions of a foundation include:

To support the weight of the generating set
To isolate vibrations from generating set set from the 
surrounding structures.
To protect against any water flow in the plant room.
To compensate of any abnormality in the floor. Fig.3.2

The foundation, for more stability, is made under the floor limits
(Cf. fig. 3.1). The pad is made of anti-vibration materials, and
the main block is of concrete material (cement, sand, ballast,
and metal bars). It is recommended that the generating set be
installed at least 20 cm from the outer edges to avoid fractures
in the concrete due to vibration.

The foundation could also be placed above ground level (Cf. fig.

3.2). In this case the generator set’s base frame should be at
least 40 cm from the edges of the main block to ensure the unit
is in a stable position.

When calculating the foundation size, make sure that the

weight of the foundation’s main block is at least, 1.5 times
greater than the weight of the generating set.

The depth of the foundation’s main block is calculated using

the following formula: 

W = weight of the genset (Tons)

Density of concrete = 2.2 Tons/m³

Another alternative when mounting a generating set on a floor

or a simple concrete pad is to use vibration isolators inserted
directly between the sub-base and the floor.

16
3.Installation

3.2 Cooling and Ventilation:

The main purpose of the cooling system is to dissipate the heat away from the engine’s cylinder block. The cooling process
consists on a water circuit between the engine and the radiator. Water takes the engine’s heat when it circulates through the
cylinder block through multiple vertical passages, and sheds it while flowing through the radiator.
Special precautions should be reviewed when installing the generating set’s canopy with regards to air flow. There should be no
obstacles in front of the engine’s cooling fan for a distance of at least three meters.
Proper ventilation measures must be taken when placing a generating set in a closed room because the heat produced will
overheat the enclosed plant room. Ducting must be installed in the plant room such that the incoming air reaches the engine
while allowing heat from the engine to depart through the exit ducting.
The inlet duct to the plant room should be at least 1.5 times the size of the radiator air outlet duct.

3.3 Exhaust System:

It is recommended that the ventilation for the exhaust piping be directed away from the generating set. Under no circumstances
should the exhaust gases be allowed to return to the engine room.

Exhaust system sizing:

The diameter of the exhaust system pipes should take into consideration back pressure, which should never exceed the limit
specified in the engine data sheet (normally around 0.1bar).

The diameter of the exhaust pipes is based upon the following parameters:
Exhaust gas flow
Maximum allowable back-pressure
Length of straight pipe
Number of bends
Resistance through the silencer
Linear velocity through the silencer

The exhaust system in the generating set is well calculated, and in case it should be extended for any reason, some precautions
should be taken in consideration:
For any additional distance (exhaust extension outside the room), special calculations should be made to specify correct pipe
sizing.
To insure that condensation does not run back to the engine, horizontal pipes should slope downwards away from the engine.
To avoid rain water from remaining in the exhaust system, drain points should be made at the base of vertical pipes.
Pipes passing through roofs, walls, or partitions should be protected with metal sleeves and closing plates insulated with mineral
wool.
When a silencer or sections of pipes are to be installed in the plant room, they should be fully insulated with 5cm of mineral
wool and sheathed in aluminum foil in order to reduce heat dissipation into the plant room.
o
The inner radius of a 90 bend should be three times the diameter of the pipe.
A long exhaust system may need a terminal silencer to reduce any regenerated noise that may occur in the pipe after the
primary silencer.
The end of the exhaust system should be positioned vertically, a rain cap must be installed or a bend with a horizontal pipe
introduced in order to avoid water ingression toward the engine.
When installing exhaust-system piping on a building or structure, anti-vibration mounts must be installed. The pipes should be at least
20 cm away from concrete walls or structures to avoid fissures in concrete due to heat from the exhaust.
Expansion joints must be installed at each change of direction to compensate the heat expansion in the pipe during operation.
Also some flexible sections may be required to absorb the pipes’ expansion due to heat.

17
 3.Installation

3.4 Fuel System:

Some precautions must be taken regarding the following points:

The feed connection on the fuel tank should be at a level to accommodate the fuel pump’s suction capabilities. The lowest
possible fuel level in the fuel tank should be no lower than 1 meter below the fuel-pump inlet.
The return connection on the fuel tank should not be higher than suction lift capability of the fuel pump.
Supply and return fuel lines must be capable of withstanding 17 bars peak pressure and 0.65 bars vacuum.
Never run a fuel return line directly back to the engine supply line. The fuel will over heat and break down. Also, for multiple
engine installations, each generating set must have a separate fuel return line.
Never add fuel to the daily tank while the engine is running.

18
4.Maintenance

4.1 Introduction:

To ensure maximum reliability and performance from a generating set it is important that all components are inspected periodically,
and where necessary, the prescribed maintenance carried out.
The principle behind an organized maintenance plan is to regularly carry out inspections of listed items.
Before and after each scheduled or unscheduled servicing, precautionary measures should be taken.

4.1.1 Preventive Maintenance:

Unauthorized maintenance could lead to unsafe operation and render the warranty invalid.
Always remain alert to avoid contact with any hot surfaces, such as the engine block, the exhaust manifold and piping, etc...
Any test or normal operation of the generating set should be done with protection guards installed.
All electrical power sources, from mains to battery, should be isolated.
In the event the protection panels on electrical or revolving parts are removed, extra caution should be considered. Make sure to
depress the ES Stop button.
The genset may be supplied with anti-starting devices that should be used in case of maintenance. However,in the event these are
not provided, warning signs should be posted to prevent accidental start-ups.

4.1.2 Prior-to-Maintenance Precautions in the case of a Running Genset:

This maintenance should only be carried out on parts which require the generating set to be running. In any other case the generating
set should be shut-down.
Extra precaution should be taken in this case, with particular care taken to avoid dangereous components such as live electrical
components, revolving parts, extreme temperatures, etc.)
Appropriate protective attire should be worn without allowing loose clothing, jewellery or long hair to be caught in a revolving
mechanism.
Warning signs indicating that “Maintenance Work is in Progress” should be clearly posted.

4.1.3 Post-Maintenance Verification Tasks:

This maintenance should only be carried out on parts which require the generating set to be running. In any other case the generating
set should be shut-down.
Extra precaution should be taken in this case, with particular care taken to avoid dangereous components such as live electrical
components, revolving parts, extreme temperatures, etc...)
Appropriate protective attire should be worn without allowing loose clothing, jewellery or long hair to be caught in a revolving
mechanism.
Warning signs indicating that “Maintenance Work is in Progress” should be clearly posted.
a. Oil level
b. Coolant level
c. Loose or damaged parts
d. Worn or damaged belts
e. Leaks

19
 4.Maintenance

4.2 Routine Maintenance:

Replacement of oil, anti-freeze and filter is usually determined by the relevant manufacturer’s recommendations based on the
cumulative number of hours the engine was operated.
Battery replacement is determined by the condition of the electrolyte.

4.3 Maintenance Program:

It is recommended that the person responsible for maintaining the components of generating set parts formulates a timetable, or
schedule, of inspection and maintenance, grouping together the component at intervals, as follows:

Maintenance Record

Genset Type Genset S/N

Engine Type Engine S/N
Alternator Type Alternator S/N

Date Hours or Time Oil Oil Filter Fuel Filter Water Filter Air Filter Others Performed By
Intervals Change Change Change Change Change

The engine manufacturer’s maintenance interval recommendations are based on clean and dry conditions in the generating set’s
housing. Otherwise maintenance should be carried out more frequently.

The maintenance program is divided into the following intervals.

20
4.Maintenance

4.3.1 Daily Maintenance:

Before starting the generating set you should inspect the following:
Conduct a visual inspection of the entire generating set. Watch for signs of potential leaks from the engine fuel system, cooling
system or lubricating system.
Check the alternator for obstructions in the cooling screen.
Check the fuel level in the daily fuel tank integrated in the base frame.
Check the coolant level in the radiator.
Check the engine oil level.
Check the condition of the fan belt and ensure there is tension.
Dispose of any unnecessary items in the vicinity of the generating set that may inhibit operation or pose a risk of injury.
Drain water/sediments from the fuel-water separator if installed.
Clean the air pre-cleaner jar and dry-type air cleaner dust pan when fitted. Check the dial gauge indicator for filter status if
available.
Note: In dusty environments, primary filters should be cleaned regularly.
Start the generating set only after all checks have been made, and check the following:
a. Control panel check for indications of abnormal operation.
b. For any noise or vibration.
c. For fluid leakage or high temperature.

Maintenance Procedures:
Engine oil level:
After stopping the engine for more than five minutes to allow the oil to drain to the sump, remove the dipstick and check the oil
level. If necessary add oil to the recommended level.

- The oil level should be strictly between the High and Low marks, not exceeding the maximum
nor falling below the minimum recommended levels.
- Oil type should comply with the recommended grade.

Gauges functions:
All monitoring gauges should be working properly.
1. While the engine is running, check the oil-pressure gauge-it should indicate between 40 psi and 80 psi
2. After a while the coolant temperature should stabilize between 85˚C and 95˚C.
3. The voltage and frequency gauges should be within normal required working conditions.
4. The fuel gauge should indicate a logical level in comparison with tank content.
5. The control unit is not showing any alarms indicators.

21
 4.Maintenance

4.3.2 Weekly Maintenance:

Weekly maintenance is more thorough and comprehensive, and would normally include a test run for stand-by operation.

It includes the following checkpoints:

The level of the electrolyte in the battery should be ¼” above the top of the separators. Top up with distilled water if necessary.
Never add acid. Check to ensure the battery is not gassing excessively.
The coolant levels are normal and no dirt of foreign materials is collected in the air ducts, louvers or ventilation grills. Also check
the radiator fluids. Add only distillate water if needed.
Check the alternator and control box for heavy accumulation of dust and dirt. Clean any heavy accumulations as electrical
hazards as well as cooling problems could arise.
Check whether the air filter is clean and in good shape. Replace if necessary.
Drain water and sediments from the fuel tank and fuel filters.
Check all hose connections and hose conditions for cooling and air indication systems.
All driving belts should be inspected for tension, wear and tear:
a. Coolant pump.
b. Alternator.
c. Radiator fan.
Note: No guard should be removed.

The optimal check is while the generating set is running. As you start/run the generating set, the engine cranking should be fast
with no sluggish signs of fatigue, if there are signs of fatigue the batteries may be in poor condition.
Note: A diesel engine should never run for more than ten minutes with no load.

During the first 30 minutes of operation ensure that there are no abnormalities:
a. Objects in the path of moving parts
b. Fuel, Coolant, and lubricating oil leakage
c. Exhaust fumes are normal
d. Exhaust smoke should not be black
e. Check for excessive vibration or noise around the generating set
f. Alternator frequency, voltage and current on each phase.
g. Charging voltage should be at 27 volts for 24 volts system

After completing the above test stop the generating set and make sure it shuts down.

4.3.3 Monthly Maintenance:

During the monthly maintenance, inspect the following items:

The drain traps in the exhaust system, if equipped. Check for exhaust leakage.
Check for items such as starter, batteries, and other components which naturally deteriorate progressively with time.
Check, clean or replace all manner of filters (fuel, oil, water, etc…)
Load run test should consider full working temperature, pressure, voltage, etc...
Greasing of the radiator fan rotating system through the fitting grease is recommended (where applicable).

22
4.Maintenance

4.3.4 Yearly Maintenance:

The yearly maintenance schedule involves the monthly undertakings with the following points added:
Clean the battery and terminals (use petroleum jellies to clean the terminals. NEVER ATTEMPT TO USE GREASE. Also make sure
the terminals are tightly secured.
Cut all battery power to the control panel by removing the terminals. Clean the interior with a vacuum cleaner and a lint-free
cloth. Vacuum out any cable ducts.
Make sure all nuts, bolts and screws are tightly secured and check all connections for signs of corrosions. Connections should be
cleaned and given a smear of petroleum jelly.
Inspecting the control panel. Make sure the fuse holders are tightly secured.
After inspection and repairs, close the control-panel door and reconnect the power supply.
Check and tighten all exhaust connections, electrical connections, and mounting bolts.
Grease all bearings.
Check all safety sensors by electrically simulating a fault to ensure that all systems will function properly in the event of a
default.
Check and adjust the valves and injectors.
Check the crank case breather.
Change the anti-corrosion additive, and check DCA concentration (if applicable).
Check all belts for fraying and tension.
Steam cleaning of the engine is recommended.
Check crankshaft end clearances.
Also refer to the diesel engine and alternator manufacturer’s maintenance booklets to ensure a proper maintenance schedule
as illustrated in the table below.

4.4 Genset Maintenance Schedule:

Equipment No. Engine S/N

Maintenance Record
Daily
Check Engine Oil Level and
Coolant Level
Visually Inspect engine for
damage, leaks, loose or frayed
belts, and listen for unusual
noise.
Drain water / sediment
from fuel tanks and fuel
filters.
Check / Clean air cleaner
precleaner and dust pan.
Clean raw water strainer.
Check engine monitor
system
Hours Calendar
Check Performed By
Weekly Monthly
Repeat Daily Checks. Repeat (Daily / Weekly
Check air cleaner piping checks)
houses, clamps, and the Change filters of oil full flow,
restriction indicator oil by-pass, fuel filter, and
Also clean the Air cleaner the water filter if fitted.
element. Change oil filters every 200
Drain air tanks. hours.
Change engine oil every 100 Change fuel filters every two
hours. months or every 400 hours.
Check the battery electrolyte Change Air filters every 3
level. months or every 750 hours
for clean aspiration...
Greasing the radiator fan
rotating system every 6
months or every 500 hours.
Date
Yearly
Repeat previous intervals Repeat previous intervals
Adjust valves and injectors. Replace hoses as required.
Change anti-corrosion Check batteries.
additive every 3000 hours or Steam clean engine.
one-year. Tighten mounting bolts.
Clean / Change the crank Check crankshaft ends
case breather. clearance.
Check all belts.
Check the electrical con-
nection.
Grease all bearings.
Check DCA concentration.

* Based on eight hours operation per day.

Also, follow other manufacturer’s recommendations for any special applications.

23

5.1 Alternator Troubleshooting:
Trouble
The alternator will not energize (No load
voltage below 10% of rated voltage)
The alternator will not energize (no load
voltage 20%-30% of rated voltage. Voltage
insensitive to AVR Potentiometer rotation.)
Voltage lower than rated (Output voltage
between 50 and 70 %)
Voltage too high
Unstable voltage.
5.1 Engine Troubleshooting:
Trouble
Engine will not crank or cranks slowly
Engine hard to start or will not start
(exhaust smoke present)
24
Possible Cause
a. Loose connections.
b. Rotating Diodes or surge suppressor
broken.
c. Excitation circuit shorted or interrupted.
a. Fuse (on AVR Supply line) blown.
b. Connection cut on the exciter stator.
c. Incorrect connection on exciter stator.
a. Speed less than rated.
b. Voltage potentiometer unset.
c. Fuse blown.
d. Faulty regulator.
a. Potentiometer V unset
b. Faulty regulator
a. Diesel engine rpm variations
b. Stability potentiometer unset
c. Faulty regulator
Possible Cause
a. Incorrect oil
b. Battery rating too low
c. External or internal conditions affecting
engine crankshaft
d. Battery connection broken, loose or
corroded
e. Battery charge low
f. Starting circuit component malfunction
a. Engine cranking speed low
b. Engine driven unit engaged
c. Fuel filter plugged
d. Air in fuel filter
e. Fuel section line restricted
f. Intake Air system restricted
g. Fuel contaminated
5.Troubleshooting
Remedy
(always to be performed with the machine switched off)
a. Check and Repair
b. Check the diodes and change in case they are open or
short-circuited.
c. Check the continuity and repair.
a. Replace the fuse with the spare. If the Fuse blows
again then check if the exciter stator is short-circuited. If
everything is correct then change the AVR.
b. Check the continuity and repair.
c. Reverse the two wires from the exciter stator.
a. Check rpm (frequency)
b. Rotate the potentiometer until the voltage reaches the
rated value.
c. Replace the fuse with spare
d. Disconnect the AVR and replace it
a. Rotate the potentiometer until the voltage reaches the
rated value.
b. Replace AVR
a. Check rpm uniformly. Check the diesel engine governor.
b. Act on AVR’s stability potentiometer.
c. Replace the AVR.
Remedy
a. Change oil and filters. Use recommended type.
b. Replace with correct rating
c. Check engine for case of crankshaft rotation
d. Check battery connections
e. Check electrolyte level and specific gravity
f. Check starting circuit components
a. Check engine cranking rpm
b. Disengage engine driven unit
c. Replace fuel filter
d. Check for air in fuel, tighten fuel connections and filter,
and check fuel tank.
e. Check fuel line for restrictions
f. Check intake air system for restrictions
Verify by operating the engine from a temporary supply
tank
5.Troubleshooting
Engine cranks but will not start ( No smoke
from exhaust)
Engine starts but will not keep running
Engine will not shut off
Lubricating oil pressure low
Filter plugging - low oil pressure light On
Coolant temperature above normal
Coolant temperature below normal
Exhaust smoke excessive under load
a. No fuel in tank
b. No fuel to injectors
c. Fuel connection loose on suction side of
fuel pump
d. Fuel filter plugged or suction line restricted
e. No fuel in pump
f. Intake or exhaust system restricted
a. Air in the fuel system
b. Engine driven unit engaged
c. Fuel filter pluged.
d. Fuel suction line restricted
e. Fuel contaminated
a. Fuel pump override open
b. Fuel tank vents plugged
Fuel drainline restricted
d. Engine running on fumes drawn into air
intake
a. Incorrect oil level
b. Oil pressure gauge malfunctioning
c. Oil diluted with fuel
d. Incorrect oil specification.
a. Oil level incorrect
b. Oil filter restricted
c. Oil dilution or inproper viscocity oil
d. Electrical short in Low/High oil pressure
filter alarm
a. Low coolant level
b. Radiator fins damaged or obstructed with
debris
c. Collapsed or restricted radiator hose
d. Loose fan drive belt
e. Incorrect oil level
f. Cooling fan shroud damaged or missing
g. Cooling fan shroud damaged or missing.
h. Incorrect or malfunctioning radiator cap.
i. Temperature gauge malfunctioning.
j. Radiator shutters are not opening
completely .
a. Radiator shutters stuck in open position or
are openning early
b. Temperature gauge malfunctioning
a. Intake air system restricted.
b. Fuel specifications wrong
c. Fuel drain line restricted
a. Add fuel
b. Loosen fuel supply line between fuel pump and cylinder
head while cranking engine check for fuel.
c. Tighten all filter fittings and connections from fuel tank
to fuel pump
d. Replace fuel filter. Inspect fuel hose for restriction.
e. Prime fuel pump.
Check intake and exhaust system for restrictions.
a. Check air in fuel, tighten fuel connections, tighten filter,
check fuel tank standpipe.
b. Disengage engine driven unit
c. Replace fuel filter
d. Inspect fuel line for restriction.
e. Verify by operating the engine from temporary supply
tank.
a. Check to make sure manual override screw is out to
maximum travel.
b. Remove, clean, or replace vents.
c. Check fuel drain line for loops, crimps, or clamped
points.
d. Locate or isolate the source of fumes.
a. Check for oil leaks. Add or drain engine oil. Check
Dipstick calibration.
b. Check oil pressure gauge
c. Change oil. If oil becomes diluted again then contact
authorized repair facility.
d. Check oil and check oil specifications.
a. Oil level must be between the high marks. Check
dipstick calibration.
b. Check oil pressure. If within specifications , change oil
and find source of dilution
c. Check wiring to light
a. Add coolant
b. Inspect radiator fins, clean repair it necessary
c. Inspect hoses , replace it if necessary
d. Check belt tensions and tighten it if necessary.
e. Add or drain engine oil
f. Check dipstick calibration
Inspect shroud, repair, replace, or install.
h. Check the radiator cap. Replace if necessary.
i. Test the gauge for repair or change.
j. Inspect the shutters for repair or change.
a. Inspect the shutters. Repair or replace.
b. Test the gauge for repair or change.
a. Check intake air system for restrictions
b. Check fuel specifications
c. Check / Adjust valves or injectors.
d. Inspect fuel return system for loops, crimps, or clamped
points.
25

Engine power output low
Engine will not reach rated speed when
loaded
White smoke temperature
26
a. Excessive load for engine horsepower
rating
b. Fuel suction line or fuel filter restricted
c. Lubricating oil level too high, throttle
linkage adjustment wrong
d. Intake or exhaust system restricted
e. Fuel drain line restricted or fuel tank vents
plugged
f. Valves or injectors incorrect, or poor fuel
quality
a. Excessive load to engine horse power
rating
b. Tachometer has a malfunction
c. Throttle linkage adjustment wrong
d. Fuel section line restricted
a. Low coolant temperature
b. Fuel quality poor
5.Troubleshooting
a. Reduce the load.
b. Check fuel for restriction. Replace fuel filter.
c. Check dipstick calibration and the oil pan capacity.
d. Check them for restrictions.
e. Check fuel drains line for loop crimps or clamped
points. Remove, clean, or replace vents.
f. Check / Adjust valves or injectors.
a. Reduce load
b. Check with external tachometer
c. Check for full throttle travel
d. Check fuel inlet for restriction
a. Refer to the coolant temperature below normal
b. Verify by operating the engine from a temporary tank
that contains good fuel.
Appendices

A.1 Fuel, Lubricant and Coolant Specification:

The life of any diesel engine is seriously affected by the quality of the fluids used. There are three different types of fluids:
fuel oil, lubricating oil and coolant fluids.

The sections below will detail each of the three fluids along with their technical specifications:

A1.1 Fuel oil:

Use only good quality ASTM No.2-0 or No.2-D diesel fuel. In extreme cold temperatures, a winter blend of fuel should be used to
prevent “waxing” in the fuel filters.

Avoid using contaminated fuel; fuel that is contaminated by water or dirt can cause severe damage to the engine fuel system.
Proper maintenance of fuel filters and the supply tank is essential.

Proper maintenance of fuel storage tanks are essential. Storage tanks that are contaminated with water will promote the growth
of “foreign material.” Foreign materials form “slime” that will clog filters and lines.

Fuel Grade Diesel #2

ASTM number D975
Cetane number 40 Min.
Sulphur 0.3 to 0.7% max by volume
Viscosity 1.25 to 9.5 CST at 20 ºC
Water & Sediment 0.1%
Pour point min. 5.5 ºC
Ash 0.02% max
Alkali or mineral acid Neutral (ph7)

For common use, it is recommended to select fuel based on a 40 minimum Cetane number, and maximum 1.0% sulfur.

When inspecting or cleaning the fuel system, care should be taken with regards to the following points:
Check the fuel filter (fuel-water separator) daily for water. Drain as needed.
Change the filters at least every six months (when engine is not running).
Use clean fuel equipment (tanks, pipes, etc...).
Clear dirt away from the filler cap.
Storage tanks should have a pitched roof for water drainage.
Always keep daily tank topped up (to avoid water condensation).

27
 Appendices

A1.2 Lubricant oil:

The lifetime of each moving part inside the engine is related to the lubricant oil used. Not all lubricants are produced to the same
specifications, and the use of a quality brand is recommended.

The following chart represents laboratory and field test results on new NTC-400 engine.

Laboratory and Field Test Results

10
Pre-1980
9
CD oils
8
Relative oil consumption

7 SAE 15W-40
commercial
6 CD oils
5
Premium oil
4
CE oils
3
2
1
0
0 50 100 150 200 250 300 350 400 450
test hours

Oil specifications are important. The oil performance is optimum when the viscosity is matched to local ambient
temperatures.

Turbocharged heavy duty diesel engines need CE oil. CC/CD or CD/SF oils can be used in areas where CE is not yet available.
Sulfated ash content must be 1.0 mass percent minimum to a maximum of 1.85 mass percent. Experience has shown that oils
with high ash content may produce deposits on valves that can lead to guttering and valve burning.

Do not use special “break –in” lubricating oils for new or rebuilt engines. Use the lubricating oils specified for normal engine
operation.

The use of multi-viscosity (15W-40) oils allows the lubricant to reach the surfaces of the bearings quicker after start-up than
straight 40 weight oils.

28
 Appendices

Heat and movement inside the engine cause oil specifications to change progressively, particularly viscosity, and oil will not be
able to adequately lubricate moving components, and must be therefore changed.
The following chart shows the effect of oil change intervals to the average hours to first rebuild, and eventually the engine’s life-
time.

General Effect of Oil Change Intervals

14
Increased oil change interval
will decrease engine life and
12 increase oil consumption
Average hours to first rebuild (x1000)

10

0
0 100 200 300 400 500 600 700 800 900
Oil change intervals (hours)

Care should be taken regarding the following points:

Running a dry shaft on dry bearings will result in damage to the bearings. Fill the filters during the oil change to ensure
immediate lubrication to the bearing.
Clean around all openings to the lubricating oil system such as the filter caps, dipsticks, line connections, etc...
Oil tanks as well as hose nozzles and containers are to be kept clean. Ring and bearing failure can be caused by dirt introduced
during oil-change intervals.

29
 Appendices

Oil consumption is usually a good yardstick of useful engine life before a need for repairs.
The following chart shows oil consumption with time.

Fast or cold starts:

Main bearing damage or failure usually occurs when an engine is started at any room temperature and immediately allowed to
accelerate to high RPM. The delay in oil flow to the main bearings and high bearings will cause permanent bearing damage.

During fast starts, one, two, or three main bearings can be starved for oil and overheat to the point at which the bearing liner
melts.

Damage to the bearing at this time varies in degree and total failure will not occur for some time.
In temperatures below -1ºC SAE30 weight or a heavier oil becomes extremely viscous and at -18ºC it is not pumpable. Refer to
the lubricating oil viscosity requirements table.

In order to prevent bearing damage from fast and cold start use 15W-40 in ambient from -26ºC to 50ºC.

30
Appendices

Lubricating oil viscosity requirements

API CE/SF lubricants

Stable TBS HT/HS
Min Max Cold stability
Oil viscosity Pour point Viscosity
Temperature ºC Temperature ºC Temperature ºC
Temperature ºC CP,M/sec.min

Arctic
5W-30* -30 10 <-40 -34
5W-40- -27 10 <-40 -32
Winter
10W-30** -25 10 <-35 -32 2.9-3.7
10W-40** -20 25 <-30 -29 3.7-4.5
15W-40 -18 50 <-30 -2 3.7-4.5
All season
15W-40 -18 50 <-30 -26 3.7-4.5
15W-50 -10 50 -25 4.5-5.7
20W-50 -10 50 <-20 -23 4.5-5.7
10W -25 10 <-35 -34 4.5-5.7
20W -10 25 <-25 -26 2.4-2.9
30 5 40 <-20 -15 2.9-3.7
40 30 50 -5 3.7-4.5

* Must be fully synthetic base oils

** Do not exceed maximum temperatures.

Stable Pour Point is the temperature at which the oil will pour (semi hard).
Cold Stability is the temperature at which the oil will pump.

A1.3 Coolant

Use a 50% antifreeze and 50% water mixture. Maintain the supplemental coolant additive (SCA) levels between 0.3
to 0.8 per liter. It is recommended that a heavy-duty coolant be used for coolant make-up purposes to protect against
under concentrations of SCA through dilution. Heavy duty coolant consists of low silicate antifreeze, water, and SCA’s.
Antifreeze concentrations are not to exceed 60% or fall below 40%.

31
 Appendices

SCAs will deplete over time without experiencing coolant loss due to leakage. Failure to replace the SCAs will lead to pitting
damage to liners and the engine block. Water filters should be replaced with every oil filter change. Water filters contain solid SCA
which will dissolve totally in the cooling system one hour after engine running.

A majority of cooling system problems is caused by the

addition of untreated coolant that quickly dilutes the SCA
SCA protect the
concentration and results in liner pitting (see photo).
liner by forming
Add heavy-duty coolant to the cooling system regularly.
an invisisble
tough oxide
NB: Failure to abide by the proposed quality of fuel, oil, film on the liner
and coolant will lead to premature damage in the engine surface.
caused by the use of non-appropriate elements.

A.2 Batteries

A.2.1 Dry charged batteries delivered without acid:

The dry-charged starting batteries are built with pre-charged plates, dried and protected against oxidation with a patented
chemical treatment. These batteries have never been filled and are totally free of acid, thus allowing a hazard–free shipment,
particularly by boat or plane.
Compliance with this process ensures the longevity of dry-charged batteries (several years in normal conditions). Nevertheless, it
is further advised to avoid excessively damp storage areas as this could render the starting procedure more difficult. Longetivity
can be maximiozed by storing Dry-cell batteries in cool and dry premises. The effect of high temperatures is more damaging on
already-filled batteries.
Contrary to ready-to-work batteries (already filled), the dry-charged batteries only start to live when they receive their electrolyte;
there is thus neither aging nor wear, an unavoidable phenomenon in the case of ready-to-work batteries (even the “maintenance-
free” type).
If storage is to be extended and in unfavorable conditions, the plates’ protection may be altered and may require an initial charge
(described hereafter). Except in the case of extreme humidity, the battery will recover its performance.

A.2.2 Maintenance – Free Batteries:

The standards (DIN and NF, for example) define the so-called “maintenance-free” batteries. They are batteries used to start
rental cars, trucks, tractors, etc..., designed to prevent the need for topping up the electrolyte and from carrying out periodic
recharging.
It must be pointed out that this goal is fully realized when operating conditions comply with standards; however, there remain
specific applications or conditions in which maintenance cannot be completely suppressed, but rather simply reduced.
Water consumption and self-discharge are linked phenomena which occur in parallel.

Then two main parameters are overcharge and temperature. In fact, a lead battery is only perfectly charged after an overcharge
phase during which a part of the water disappears (by electrolysis) proportionally to the overcharge ampere-hour. On the other
hand, self-discharge increases exponentially with temperature doubling every 10ºC, that is 8 times more at 40ºC.
The most difficult cases are when the battery’s operating temperature is high or when the battery is exposed either to overcharge,
to frequent recharging or to permanent charge.
In diesel vehicles, for example, the battery is very close to the engine, and consequently frequent recharging is always required
(radio power, etc...)
In the case of generating sets start-up or safety or alarm circuits battery power supply, we find that most of the time a permanent
charge, which even if very low, presents an overcharge with water consumption.

32
Appendices

A.2.3 Putting the battery into service:

The “setting into service” or “activation” operation consists of filling the battery cells with battery solution.

If the solution is not supplied, sulfuric acid of the “accumulator” type is to be bought, having a density complying with:
1.28 kg/1 in temperate climates
1.23 kg/1 in tropical climates

Density can, of course, be checked with a densimeter or acidometer. When more concentrated acid must be diluted to obtain the
required concentration, use de-ionized or distilled water.

PRECAUTIONS WHEN PREPARING BATTERY SOLUTION FROM CONCENTRATED ACID:

Always pour slowly acid into water, and not the other way round, stirring up thoroughly. In fact, the mixture heats up a lot.
After removing the plugs (stoppers or strips), fill the batteries up to the marks at the bottom of the filling ducts, i.e. roughly 1cm
above the plates or the partitions. Do not overfill as this does not bring about any advantages but rather exposes the battery to
corrosive spillages. Excess acid can be removed using the densimeter or acidometer syringe.

Sulfuric acid is very corrosive, especially on clothes. Treat immediately by washing in water added with a slightly
alkaline solution such as bicarbonate of soda or ammonia to neutralize the acid.

The main hazard to the operator is acid getting into the eyes. In such an event, immediately rinse in running
BEWARE water for 5 minutes, and then consult physician. It is crucial to wear safety glasses while filling the battery or
batteries.
Dry-charged battery activation is automatic; the acid penetrates the porous active matter that makes up the
plates and partitions. It is therefore important to wait around 20 minutes for imbibitions to be correct.
In very cold weather, activation is greatly reduced and, although the chemical protection given to the plates is higher than that
of physical protective devices, make sure the electrolyte temperature is not lower than 10˚C. In emergency cases, even if the
battery is under 0˚C, simply heat up a bit the solution.

To gain time when replacing a used battery with a dry-charged battery, adhere to the following in order:
Fill the dry battery
Remove the used battery
Thoroughly clean the terminals (very important), the securing devices and the battery support.
Check the acid level which must be equal in each cell
Secure the new battery
Connect all the connectors, which must be protected with grease or thick oil
After this operation, there is no need to wait any longer and the starting procedure can take place

After extended storage or storage in unfavorable condition (humidity) or again in very cold weather, the battery may not have
the required starting power. Give it an activation charge before another attempt to start the unit. This partial charge is generally
a normal charge at an intensity of 1/10 or 1/20 of the battery capacity over a few hours. It is also possible to attain a quicker
but shorter charge, taking care that battery-solution gassing does not become excessive.
Note that the stoppers and plugs are designed to allow recharging; it is advised to leave them in place to avoid acid bubble
projections, releasing them a little if required.

33
 Appendices

If the equipment is not to be used just after the battery has been put into service, it is also advised to complete a short charge
(one to three hours) at 1/10 of the capacity, this would improve the preservation conditions while awaiting further utilization.
This recommendation more specifically applies in the case of batteries designed to be used with generating sets. Recharging is
generally very short and can be halted whenever the acidometer indicates that the battery is charged.
In the case of improper preservation conditions (several years, humidity) a more-or-less superficial sulfurization of the plates may
have occurred, due to overheating and reduced recharging current. Recharge the battery at the lowest possible rating for 12 to 24
hours. Even in these extreme cases, it is possible to activate a battery without causing damage when used further.

SAFETY INSTRUCTIONS RELATIVE TO THE BATTERY BEING PUT INTO SERVICE

Sulfuric acid is very corrosive; avoid spills on clothes and especially into the eyes. It is highly recommended to wear safety
goggles.
The gases produced during charging are explosive; avoid sparks or heat sources. For further details refer to the safety instructions
related to battery recharging.
Concentrated acid dilution; refer above (pour acid into water).

A.2.4 Maintenance and Servicing:

CHARGE PRESERVATION
On the N.F. or D.I.N. standard «maintenance-free» batteries, charge preservation is very good. A new and well-charged battery is
still capable of starting after a year of storage at moderate temperatures (under 20˚C). It must be kept in mind that self-discharge
doubles when the temperatures increase. But this applies to open-circuit batteries (not connected to electrical circuits) and one
must take into account current loss and permanent consumption in cases such clocks, etc.
Therefore, in the case of seasonal usage such as yachting, the battery must be fully recharged and thoroughly cleaned and stored
in a cool and dry spot. A recharge before use or every six months will, of course, improve the battery’s longevity.
The use of permanent recharging systems (discharge «compensators» or voltage regulated charges) causes an oxidation of the
grids and a premature wear in case of year-long service. With the «maintenance-free» batteries, is advised to recharge periodically
instead of permanent charging.

WATER CONSUMPTION
As indicated above, water consumption, which is linked to overcharge and temperature, has been considerably reduced in
«maintenance-free» batteries. The user no longer has to check the levels, except in specific cases studied below. Nevertheless,
level checking helps detect possible misadjustments of the voltage regulator, a more frequent malfunction than one may think.

SPECIFIC SERVICE CONDITIONS

1- Tropical climates: water consumption and self-discharge, though greatly reduced, imply checking every three or six months and possibly
topping up with de-ionized water. The removable plugs provided on the batteries are designed to allow checking for level and density as
well as topping up water.
2- Generating sets in which the battery is exposed to very high temperatures over 60˚C are common, and levels must be checked
and topped up at regular intervals: These batteries, when thus maintained, have increased longevity compared to traditional
«maintenance-free-plug-free» batteries.
3- Cyclical service: besides the fact that starting batteries are not designed to undergo important and repeated discharges and
recharges, recharging implies loss of water by electrolysis.Maintenance therefore becomes necessary.

34
Appendices

A.2.5 Rules relative to battery recharging:

Battery recharging is optimal when the charge current ranges between 1/10 and 1/20 of the battery capacity. For example, 10 to
20 amperes for a 200 Ah battery.
The charging duration is between 12 to 24 hours. Recharging can be done more quickly, but keep in mind this will greatly reduce
rating after charging (temperature must not exceed 55˚C).
Charge completion is indicated by heavy gassing and solution-density stabilization, as well as the charge completion voltage.
To reach a recharge level of 100%, the charge (ideal at the 1/20 of capacity) must be maintained for two hours after charge
completion is indicated.

PRECAUTIONS DURING CHARGING:

Leave stoppers and plugs in position (they can be released).
Charge completion causes gassing with hydrogen and oxygen degasifying; this mixture is explosive in the presence of sparks;
avoid flames, hot spots and/or heat sources. Do not smoke and remember that connecting a battery can cause sparks. There
might be a risk of a battery burst with hazardous spray of acid fragments.
In the case of a voltage-regulated charge, this hazard is almost non-existent.
When reconnecting the batteries, beware of sparks and short-circuits. First connect the positive terminal and finish with the
negative terminal to earth (should the key used to tighten the positive clamp come into contact with the earth, a short-circuit
would occur if the latter was already connected; many explosions occur in this manner.
It is always advised to allow the battery to rest for an one hour after a full charge, removing the plugs to allow gases to
escape.
Follow the charger manufacturer’s instructions (switch the unit on only after the battery is connected. Cut the power supply
before disconnecting the battery, etc...)
Make sure the charging premises are well ventilated.

35
 c Operation and
Maintenance Manual
K38 and K50
. Engine Series

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Copyright© 1993 Bulletin No. 3810497-02

Cummins Engine Company, Inc. Printed USA 924
All Rights Reserved
 Foreword
This manual contains information for the correct operation and maintenance of your Cummins engine. It also
includes important safety information, engine and systems specifications, troubleshooting guidelines, and listings
of Cummins Authorized Repair Locations and component manufacturers.
Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner.
The information, specifications, and recommended maintenance guidelines in this manual are based on infor-
mation in effect at the time of printing. Cummins Engine Company, Inc. reserves the right to make changes at
any time without obligation. If you find differences between your engine and the information in this manual, contact
your local Cummins Authorized Repair Location.
The latest technology and the highest quality components were used to produce this engine. When replacement
parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts can be
identified by the following trademarks:

CC
Pre.niu.ln <!!)

[HDL5ET) .,.Blue
®
PfI
Note: Warranty information is located in Section W. Make sure you are familiar with the
warranty or warranties applicable to your engine.
 Important Reference Numbers
Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever
service. or maintenance is required.

Engine Model
Engine Serial Number
Engine Specification Number (Control
Parts List)
Fuel Pump Part Number
Filter Part Numbers:
• Air Cleaner Element
• Oil (Full-Flow)
• Oil (Bypass)

• Fuel
• Fuel Water Separator (Marine)
Belt Part Numbers

Clutch or Marine Gear

• Model
• Serial Number
• Part Number
• Oil Type
Raw Water Pump

• Model
• Part Number
 Table of Contents
Sectl(

Introduction ...................................................................................................................................

Engine Identification..................................................... ......................... ........................................ E

Operating Instructions ............................... ....................................................................................

Maintenance Guidelines ...................... ........................................................................... ..... .......... 2

Dally Maintenance Guidelines................... .............. ............................................................ .......... 3

Weekly Maintenance Guidelines ............... ......................... ........................................................... 4

Maintenance Procedures Every 250 Hours or 6 Months .......... ...... ...... .......... ...................... ........ 5

Maintenance Procedures Every 1500 Hours or 1 Year ...................................... ........................... 6

Maintenance Procedures Every 6000 Hours or 2 Years ................................................................ 7

Other Maintenance Procedures..... ...................... ............... ...................... ....................... .............. 8

System ·Diagrams ..................................... :.. :.: .. ;.......... :.... :................................................. ............ D

Troubleshooting.... ......................................................................................................................... T

Adjustment, Repair, and Replacement ..... ......................... .......... ................................................. A

Specifications and. Torque Values ................................................................................................ V

Service Assistance.. ........................................ ................................................ ........ .......... ............ S

Component Manufaaturers............................................................................................................ C

warranty......................................................................................................................................... W

Additional Service Literature............... ........ ....................................... ...... ......................... ............ L

Index .............................................................................................................................................. X

CAP Program .. ..................................................................................,. ... ....... ......... ... ..... ................ M

section I - Introduction
K38 and K50 Page i

Section i-Introduction
Section Contents
Pac
About the Manual .... c••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
Definition of Terms ............................................................................................................................................
General Safety Instructions ...............................................................................................................................
Important Safety Notice ....................................................................................................................................
How to Use the Manual ..... .................................................................................................................................
Illustrations ......... ................................................................................................................................................
Symbols .............................................................................................................................................................
To the Owner and Operator ...............................................................................................................................
 To the Owner and Operator Section i-Introduction
Page i-2 K38 and K50

To the Owner and Operator

Preventative maintenance is the easiest and least expensive type of maintenance. Follow the maintenance
schedule recommendations outlined in Maintenance Guidelines (Section 2).
Keep records of regularly scheduled maintenance.
Use the correct fuel, oil, and coolant in your engine as specified in Engine Specifications, Section V.
Cummins uses the latest technology and the highest quality components to produce its engines. Cummins
recommends using only genuine Cummins parts and ReCon® exchange parts.
Personnel at Cummins authorized repair locations have been trained to provide expert service and parts support.
If you have a problem that can not be resolved by a Cummins authorized repair location, follow the steps outlined
in the Cummins Service Assistance section of this manual (Section S).
About the Manual
This manual contains information needed to correctly operate and maintain your engine as recommended by
Cummins Engine Company, Inc. Additional service literature (Shop Manual, Troubleshooting and Repair Manual,
etc.) can be ordered by filling out and mailing the Literature Order Form located in Additional Service Literature,
Section L.
This manual does not cover vehicle or equipment maintenance procedures. Consult the vehicle or equipment
manufacturer for specific maintenance recommendations.
Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the
U.S. customary in brackets.
Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to page i-3
for a complete listing of symbols and their definitions.

How to Use the Manual

This manual is organized according to the maintenance intervals that are to be performed. A table that states the
required intervals and the checks to be made Is located in Section 2. Locate the maintenance interval that you
are performing and follow all the procedure steps given in that section. In addition, all the previous maintenance
interval procedures must also be performed.
"" Keep"a record of all the checks and inspections made. A record form for recording date, mileage/kilometer or hours,
and what maintenance checks were performed is located in Section 2.
Refer to Section T for a troubleshooting guide to your engine. Follow the Troubleshooting Section Contents for
locating and correcting engine problems.
Refer to Section V for specifications recommended by Cummins Engine Company, Inc., for your engine. Spec-
ifications and torque values for each engine system are given in that section.
Section i-Introduction Symbol,
K38 and K50 Page 1-:

Symbols
The following symbols have been used in this manual to help communicate the intent of the instructions. Wher
one of the symbols appears, it conveys the meaning defined below:

WARNING - Serious personal injury or extensive property damage can result if the warnin!
instructions are not followed. - -

CAUTION - Minor personal injury can result or a part, an assembly, orthe engine can be damage(
if the caution instructions are not followed.

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

@ INSPECTION is required.

~ CLEAN the part or assembly.

q) PERFORM a mechanical or time MEASUREMENT.

[5] LUBRICATE the part or assembly.

~
Indicates that a WRENCH or TOOL SIZE will be given.

~
TIGHTEN 10 a specific torque.

@l PERFORM an electrical MEASUREMENT.

Refer to another location in this manual or another publication for additional information.

The component weighs 23 kg [50 Ib] or more. To avoid personal injury, use a hoist or gel
assistance to lift the component.
Symbols Section i-Introduction
Page i-4 K38 and K50

Simbolos
Los simbolos siguientes son usados en este manual para clarificar el proceso de las instrucciones. Cuando
aparece uno de estos simbolos, su significado se especifica en la parte inferior.

ADVERTENCIA· Serios danos person ales 0 dano ala propiedad puede resultar si las instrucciones
de Advertencia no se consideran.

PRECAUCION - Danos menores pueden resultar, 0 de piezas del conjunto 0 el motor puede
averiarse si las instrucciones de Precaucion no se siguen.

Indica un paso de REMOCION 0 DESMONTAJE.

Indica un paso de INSTALACION 0 MONTAJE.

® Se requiere INSPECCION.

~
LlMPIESE la pieza 0 el montaje.

t1) EJECUTESE una MEDICI ON mecanica 0 del tiempo.

F.l LUBRIQUESE la pieza 0 el montaje.

~
Indica que se dara una LLAVE DE TUERCAS 0 el TAMANO DE HERRAMIENTA.

® APRIETESE hasta un par torsor especifico.

@l EJECUTESE una MEDICION elect rica.

Para informacion adicional refierase a otro emplazamiento de este manual 0 a otra publicacion
anterior.

EI componente pesa 23 kg [50 Ib] 0 mas. Para evitar dano corporal empleen una cabria u obtengan
ayuda para elevar el componente.
Section i-Introduction Symbc
K38 and K50 Page i

Symbole
In diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. 0
Symbole haben folgende Bedeutung:

WARNUNG - Wird die Warnung nicht beachtet, dann besteht erhbhte Unfall- ur
Beschadigungsgefahr.

VORSICHT - Werden die Vorsichtsmassnahmen nicht beachtet, dann besteht Unfall- ur

A Beschadigungsgefahr.

EE~ AUSBAU bzw. ZERLEGEN.

~ EINBAU bzw. ZUSAMMENBAU.

~
@ INSPEKTION erforderlich.

~
Teil oder Baugruppe REINIGEN.

Cl) DIMENSION - oder ZEITMESSUNG.

EJ Teil oder Baugruppe OLEN.

~
WERKZEUGGROSSE wird angegeben.

® ANZUG auf vorgeschriebenes Drehmoment erforderlich.

l~l.
Elektrische MESSUNG DURCHFUHREN.

~ Weitere Informationen an anderer Stelle bzw. in anderen Handbiichern.

Das..teil weigt 23 kg [50 Ib] oder mehr. Zur vermeidung von koerperverletzung winde benutze
oder hilfe beim he ben des teils in anspruch nehmen.
Symbols Section i-Introduction
Page 1-6 K38 and K50

Symboles
Les symboles suivants sont utilises dans ce manuel pour aider lot communiquer Ie but d.es instructions. Quand I' un
de ces symboles apparalt, iI evoque Ie sens defini ci-dessous:

AVERTISSEMENT - De graves lesions corpore lies ou des dommages materiels considerables

peuvent survenir si les instructions donnees so us les rubriques "Avertissement" ne sont pas
suivies.

ATTENTION - De petites lesions corporelles peuvent survenir, ou bien une piece, un ensemble
ou Ie moteur peuvenl etre endommages si les instructions donnees so us les rubriques "Atten-
tion" ne sont pas suivies.
Indique une operation de DEPOSE.

Indique une operation de MONTAGE.

L'INSPECTION est necessaire.

NETTOYER la piece ou I'ensemble.

EFFECTUER une MESURE mecanique ou de temps.

Indique qu'une DIMENSION DE CLE ou D'OUTIL sera don nee.

SERRER lot un couple specifique.

EFFECTUER une MESURE electrique.

Se reporter lot un autre endroi! dans ce manuel ou lot une autre publication pour obtenir des
informations plus completes.

Le composant pese 23 kg [50 Ib] ou davantage. Pour eviter toute blessure, employer un appariel
de levage ou demander de I'aide pour Ie soulever.
Section i-Introduction lIIustratiol
K38 and K50 Page i

Illustrations
The illustrations used in the "Repair Sections" of this
manual are intended to give an example of a problem,
and to show what to look for and where the problem can
be found. Some of the illustrations are "generic" and
might not look exactly like the engine or parts used in
your application. The illustrations can contain symbols
to indicate an action required, and an acceptable or not
acceptable condition.

The illustrations are intended to show repair or replace-

ment procedures. The illustration can differ from your
application, but the procedure given will be the same.

cll6vagc
General Safety Instructions Section i • Introduction
Page i·8 K38 and KSO

General Safety Instructions

Important Safety Notice

A WARNING A
Read and understand all of the safety precautions and warnings before performing any repair. This list contains
the general safety precautions that must be followed to provide personal safety. Special safety precautions are
included in the procedures when they apply.
o Make sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist.
o Always wear protective glasses and protective shoes when working.
o Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
o Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air
starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in the operator's
compartment or on the controls.
o Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate
the engine by pulling or prying on the fan. This practice can cause serious personal injury, property damage,
or damage to the fan blade(s) causing premature fan failure.
• If an-engine~has-b,ren~ op~erating and the coolant is hot, allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling system.
• Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product ~bef(jrejierfOrming any' seriiiceWork.-~'"' "~-
o Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are
n:"':nf')V~0 0f ("r~!""(l.""i'"'l.p.{":~or. P<=· ~lo-'" ff~ 1/"<::,,,;>--10 " .. ::; .... r ' , . . - t,~~ _r-"_~"._._ . . .-.I~,-,.-~ ~-, .. -'.- .. :.- - ,. c' -- r- • • -'-_. ':'-;;;::.

utilizes pressure. Do not check for pressure leaks with your hand. High pressure o'il or fuel can cause personal
injury.
o To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon)
lines in a well ventilated area.
o To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 Ib] or
more. Make sure all lifting devices such as chains, hooks. or slings are in good condition and are of the correct
capacity. Make sute"l100ks'arErpOs1!ioned·'correctIY. Always use a spreader bar when necessary. The~lifting
hooks must not be side-loaded.
• Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact
~~ ,,_II/ith skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case
of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY
CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
o Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH
OF CHILDREN.
o To avoid burns, be alert for hot parts on products that have just been turned OFF. and hot fluids in lines, tubes,
and compartments.
o Always use tools that are in good condition. Make sure you understand how to use them before performing
any service work. Use ONLY genuine Cummins or Cummins Recon® replacement parts.
o Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener
of lessor quality if replacements are necessary.
Section i-Introduction Definition of Tern
K3!! and K50 Page i

Definition of Terms

AFC Air Fuel Control kg Kilograms

API American Petroleum Institute km Kilometers
ASA Air Signal Attenuator kmll Kilometers per Liter
ASTM American Society of Testing and Materials kPa Kilopascal
A.C. Alternating Current I Liter
C Celsius Ib Pounds
CCA Cold Cranking Amps Ibf Pounds Force
CFM Cubic Fleet Per Minute LTA Low Temperature Aftercooling
CARB California Air Resources Board m Meter
C.C. Cubic Centimeter mm Millimeter
C.1. Cubic Inch MPa Megapascal
C.!.D. Cubic Inch Displacement MPH Miles Per Hour
Cm Centimeter MPQ Miles Per Quart
CPL Control Parts List N Newton
cSt Centistokes Nom Newton-meter
DCA Diesel Coolant Additive NPTF National Pipe Thread Fine
D.C. Direct' Current ··00" Outside Diameter
E.C.S. Emission Control System OEM Original Equipment Manufacturer
EPA Environmental Protection Agency ppm Parts Per Million
E.S.N. Engine Serial Number psi Pounds Per Square Inch
F Fahrenheit PTD PT (type D)@) (Pressure Timed (type D) Ir
ft-Ib Foot Pound PTG Pressure Time Governing
GVW Gross Vehicle Weight RPM Revolutions Per Minute
Hg Mercury S.A.E. Society of Automotive Engineers
'~-" <,- ... -~- --~~- .>~.

HP Horsepower ST Service Tools

HVT Hydraulic Variable Timing S,C Step Timing Control
H2 O Water TDC Top Dead Center
10 Inside Diameter V Volts
In Inch VS Valve Set
in-Ib Inch Pound
Section E - Engine and Component Identification
K38 and K50 Page E·

Section E - Engine and Component Identification

Section Contents
Pag
Engine Diagram - KT38 .................... ............................ ......... .............. ......... ................... ............. .......... ........... E
Left Bank View ............................................................................................................................... :............... E·
Rear and Front View................. ....................................... ............... .................. ...... ......... .......... .......... ......... E-1
Right Bank View ............................................................................................................................................. E-
Top View ...................................................................................................................................................... E-1
Engine Diagram - KTA38 Center Mount Aftercooler (K50 Similar) ................................................................ E-1
Rear and Front View..................................................................................................................................... E-1
Top View ...................................................................................................................................................... E-1
Engine Diagram - KTA3S Center Mount Aftercooler (KTA50 Similar) ........................................................... E-1
Left Bank View ............................................................................................................................................. E-1
Right Bank View ........................................................................................................................................... E-1
Engine Diagram - KTA38 Outboard Aftercoolers (KTA50 Similar) ................................................................ E-2
Left Bank View ............................................................................................................................................. E-2
Rear and Front View..................................................................................................................................... E-2·
Right Bank View ........................................................................................................................................... E-2·
Top View ...................................................................................................................................................... E-2.
Engine Diagram - K'fTA:38 (KTTA:5lISlmilar).................................................................................................. E-1
Left Bank View ............................................................................................................................................. E-1'
Rear and Front View. ................. ............ ..... ........... ... ... .... ..................... ............... ........ ... ................... ....... .... E-1'
~~~h~~0~. ~~~~ ::~::~::::::::: :::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::~::: :::::::::::::::::::::::::: :::: ::~~:: ~: :;:::;::::: .t~:
Engine Identification... .................. ... ......... .... .............. ............................. ........ ...... ............. ................. ... ....... ... E-:
Cummins Engine Nomenclature ..................................................................................................................... E-:
Engine Dataplate ... ,............................................................... ' .......... .......... .......... ....... ............................ ....... E-:
Fuel Pump Dataplate ...................................................................................................................................... E-:
Engine Weight................................................................................................................................................... E-'
General Specifications...................................................................................................................................... E-:
Air Induction System....................................................................................................................................... E-!
Cooling System .............................................................................................................................................. E-!
~~~!~~~Is~~f!~~::::::::::::: :::: ::::: ::.::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: :::::::::::::::::::: :::::::::::::~::::~:7:;::::~ ;:~;. -
Fuel System ...................................., .... ,.............................................................................................................. E-I
t:
Lubricating Oil System.................................................................................................................................... E-!
Engine Identification Section E - Engine and Component Identification
Page E-2 K38 and K50

Engine Identification
Cummins Engine Nomenclature
The model name provides the following data:
K T T A 38 or 50 - (_)

L
U L -l,~oo,
=
'" u,~
= Engine is Aftercooled
Engine has Four Turbochargers
= Maximum Brake Horsepower
= Application Codes:
C = Construction
D = Generator Drive
F
G
= Fire Pump
= Generator Set
= Engine is Turbocharged L = Locomotive
= Series (Family of Engines) M = Marine
P = Power Unit
R = Railcar

Engine Dataplate
The engine dataplate shows specific information about
your engine. The engine serial number (E.S.N.) (1), Con-
trol Parts list (CPl)·(2) .. Mode~(3),and Horsepower and
RPM rating provide information for ordering parts and
service needs.
I~-v i"a::: -I ne engine dalaplaie nlust not-be changeo unless
approved by Cummins Engine Company, Inc.
The engine dataplate for the older K38 and K50 engines
is located on the rear, right bank side of the engine. The
engine dataplate on the present K38 and K50 engines is
located on the left bank side of the front gear cover. Refer
to Engine Diagrams in this section.

FUEL PUMP DATAPLATE Fuel Pump Dataplate

The fuel pump dataplate is located on the top of the. fuel.
pump. It provides information for fuel pump calibration.

Service Pump Production

Part No. Part No.
IpBplga
Section E - Engine and Component Identification General Specificatil
K38 and K50 Page

General Specifications
Metric [U.S. Customa
Valve and Injector Settings:
Intake Valve Adjustment .................................................................................................0.36 mm [0.014
Exhaust Valve Adjustment ..............................................................................................0.69 mm [0.027
PTD Non-Top Stop Injector Travel Adjustment. ...............................................................7.82 mm [0.308
HVT Non-Top Stop Injector Travel Adjustment ............................................................ 10.234 mm [0.403
STC Top Stop Injector Adjustment (in engine) ...................................................0.6 to 0.7 Nom [5 to 6 in·
Premium K STC Injector Adjustment (in engine) ................................................0.6 to 0.7 Nom [5 to 6 in'

Specifications - K38 General Engine

Aspiration:
KT = One Stage Turbocharged
KTA One Stage Turbocharged and Aftercooled
KTTA Two Stage Turbocharged and Aftercooled
Bore and Stroke: 159 mm x 159 mm [6.25 in x 6.25 in]
Compression Ratio: KTTA-GS/GC 14.5:1
KTTA 13.5:1
KTA-P(1350) 13.5:1
KTA-G3 13.9:1
KTA 14.5:1 or 15.5:1 or 13.8:1
KT 15.5:1
Displacement: 38 Liters [2300 cu in]
Firing Order: 1R-6L-5R.2L-3R-4L·6R-l L-2R-5L-4R-3L
Type: 4 Cycle, 60 Degree Vee, 12 Cylinder
Weight: Refer to the Engine Weight in this section
Crankshaft Rotation
(Viewed from the
front of the engine): Clockwise
General Specifications Section E • Engine and Component Identification
Page E-4 K38 and K50

Cylinder Numbering Sequence:

r RB = Right Bank of Cylinders

r-
LB = Left Bank of Cylinders
~ ®®®@@@ f-

!
La ®®®®®® f-
'--

ee601Q8

Intake and Exhaust Valve locations.

o Intake 9 Exhaust
- r-
RB @@@@@@
oe oe oe oe oe r-
00

1 ----

LB @@@@@@
. oo
.
GO @o eo eo 80
-
c-
~ ~

ee601gb

Specifications - K50 General Engine

Aspiration: KTA = One. Stage Turbocharged lind Aftercooled
KTTA = Two Stage Turbocharged and Aftercooled
Bore and Stroke: 159 mm x 159 mm [6.25 in x 6.25 in]
Compression Ratio: KTTA 13.5:1 or 13.8:1 or 13.9:1
KTA 13.8:1 or 13.9:1 or 14.5:1 or 15.5:1
Displacement: 50 Liters [3067 cu in]
Firing Order (original standard): 1R-1 L-3R-3L-7R-7L-5R-5L-8R-8L-6R-6L-2R-2L-4R-4L
Note: Some KTTA50 engines manufactured after September. 1986. and
KTA50-G3 and G4. will have a different firing order. These engines have
decals on the rocker lever covers that stipulate the REVISED FIRING
ORDER. They also have REVISED FIRING ORDER on the engine Dataplate.
Revised Firing Order: 1R-1 L-3R-3L-2R-2L-5R-4L-8R-8L-6R-6L-7R-7L-4R-5L
Type: 4 Cycle. 60 Degree Vee. 16 Cylinder
Weight: Refer to the Engine Weight in this section.
Crankshaft Rotation
(Viewed from the front
of the engine): Clockwise
 Section E - Engine and Component Identification General SpecificaU
K38 and K50 Page

Cylinder Numbering Sequence:

RB = Right Bank of Cylinders
LB = Left Bank of Cylinders
RB @)@@@®®@@

l
LB @@®®®®®®
....,
Intake and Exhaust Valve locations. o Intake
• Exhaust

RB @@@@@@@@
oe o. oa oa o. o. 00 O.

LB @@@@@@@@
eo eo eo eo eo
00 00.

ee601{

Air Induction System

Maximum Allowable Intake Restriction:
~ With Clean Filter Element .....................................................................................380 mm H2 0 [15 in H,
• With Dirty Filter Elemen!.. .....................................................................................635 mm H2 0 [25 in H,
Lubricating Oil System
Oil Pressure, Main Oil Rifle (15W oil at 107°C [225°F]:
- Maximum at Rated RPM: 483 kPa [70 psi]
- Minimum at Rated RPM: 310 kPa [45 psi]
- Minimum at Idle RPM: 138 kPa [20 psi]
Oil Temperature - Maximum .......................................................................................................1200C [250°
Oil Pan Capacity ...................................................................................................................Refer to Section
Cooling System
Coolant Capacity (Engine ONLY) KT38 104 Liters [110 Quarts]
Standard Thermostat Modulating Range 80°C to 90°C [175°F to 195°F]
LTA Modulating Thermostat 74°C to 86°C [165°F to 187°F]
Coolant Pressure Cap - Minimum 48 kPa [7 psi]
Coolant Temperature - Minimum Top Tank 70°C [160°F]
- Maximum Top Tank 95°C [203°F]

\
I !
General Specifications Section E - Engine and Component Identification
Page E-6 K38 and KSO

Exhaust System
Back Pressure - Maximum (at rated speed and load) ..........................................................75 mm Hg [3 in Hg]
Exhaust Pipe Size (Normally Acceptable Inside Diameter)
• KT38 ....................................................................................... ~ ............................................ 127 mm [5 in]
• KTA38 ..................................................................................................................................127 mm [5 in]
• KTTA38 ................................................................................................................................152 mm [6 in]
• KTA50 ..................................................................................................................................152mm [6 in]
• KTTA50 ................................................................................................................................203 mm [8 hi]

Fuel System
NOTE: For performance and fuel rate values, refer to the engine data sheet, or the fuel pump code for the particular
model involved.
Maximum Allowable Restriction to Pump (at rated power):
• With Clean Filter .......................................................................................................100 mm Hg [4 in Hg]
• With Dirty Filter .........................................................................................................200 mm Hg [8 in Hg]
Maximum Allowable Return Line Restriction ....................................................................63 mm Hg [2.5 in Hg]
Maximum Allowable Return Line Restriction
with Check Valves and/or Overhead Tanks ................................................................165 mm Hg [6.5 in Hg]

Electrical System
Minimum Recommended Battery Capacity

r~ _~-,I"

Engine Temperature System Cranking Ampere Reserve

Model Range Voltage Ampere Hours Capacity
K38 -1 B to O°C [0 to 32°F] 24 1800 400 640
32 1560 340 550
K38 O°C [32°F] 24 1280 260 480
--_ ..-.-- .... ~ ~~-.- -- .. -- .. --.. -~-

32 1040 240 390

K50 All 24 1800 400 640
32 1560 340 550

NOTE: The number of plates within a given battery size determines reserve capacity. Reserve capacity is the length
of time sustained cranking can occur.
NOTE: CCA ratings are based on two 12 volt batteries in series.
Section E - Engine and Component Identification Engine Weigl
K38 and K50 Page E·
Batteries (Specific Gravity)
Battery State Specific Gravity
of Charge @ 27°C [80°F]

100% 1.260-1.280
75% 1.230-1.250
50% 1 .200-1.220
25% 1.170-1.190
Discharged 1.110-1.130
l.IaBOOka

Engine Weight

Dry Weight
Model and Package kg [Ibs]
KTTA38 with-AI~minum Oil PaR-MaptsF 4,200 [9,260J
KITA50 with Aluminum Oil Pan Adapter 5,200 [11,465]
KTA38-M with Heat Exchanger, Front PTO, and Base Rails 5,143 [11,430]
KTT A50-MwithJ:leiltJ;x:~I]<lnger, Front PTOdV)d. El.ase Jlejl.. 6,1.8~ [13,640]
KTA38-M on Base Rails with Marine Gear and Front PTO 7,018 [15,475]
KTTA3B-P on Base Rails with Radiator and Heavy Duty Air Cleaner 5,753 [12,685]
KTTA50·P on Base Rails with Radiator and Heavy Duty Air Cleaner 6,753 [14,890]
KTT A38-GS/GC on Base Rails with Generator 7,864 [17,340]
KTTA50-GS/GC on Base Rails with Generator 9,016 [19,880]
Typical KTA38 Electric Drive Truck Module 7,978 [17,600]
Typical KTA50 Electric Drive Truck Module 9,066 [20,000]

Lift Capacity, Engine Lifting Fixture, Part No. 3375109 5,443 [12,000]
Engine Diagram - KT38 Section E - Engine and Component Identification
Page E-8 K38 and K50

Engine Diagram - KT38

Right Bank View

1. Housing, Air Transfer 11 . Adapter, Oil Pan

2. Turbocharger 12. Plate, Oil Pan Adapter Cover
3. Connection, Air Crossover 13. Pan, Oil
4. Cover, Rocker Lever 14. Connection, Water Inlet
5. Bracket, Lifting 15. Pump, Water
6. Connection, Air Intake 16. Drive, Water Pump
7. Manifold, Intake 17. Tube, Water Bypass
8. Cover, Cam Follower 18. Pulley, Fan Belt Idler
9. Housing, Flywheel 19. Breather, Crankcase
10. Cover, Hand Hole 20. Idler Assembly, Fan Belt
21. Housing, Thermostat
22. Connootien, Water Ol;ft~et-
Section E - Engine and Component Identification . Engine Diagram - KT:
K38 and K50 Page E

Engine Diagram - KT38

Left Bank View
1. Turbocharger 13. Filter, Full-Flow Lubricating Oil (4 shown)
2. Support, Thermostat Housing 14. Breather, Crankcase
3. Housing, Thermostat 15. Gauge, Oil Level
4. Support, Fan Hub 16. Tube, Oil Fill
5. Cover, Front Gear 17. Head, Lubricating Oil Filter
6. Housing, Front Gear 18. Housing,. Flywheel
7. Oataplate, Engine 19. Cover, Cam Follower
8. Drive, Air Compressor 20. Manifold, Intake
9. Compressor, Air 21. Bracket, Lifting
10. Pump, Fuel 22. Manifold, Exhaust
11. Head, Fuel Filter 23. Housing, Air Transfer
12. Filter, Fuel (2 shown)
Engine Diagram· KT38 Section E • Engine and Component Identification
Page E·10 K38 and K50

Engine Diagram - KT38

Top View

1. Alternator 11. Cover, Rocker Lever

2. Outlet, Right Bank Water 12. Housing, Air Transfer
3. Housing, Right Bank Thermostat 13. Manifold, Intake
4. Bracket, Fan Hub 14. Tube, Water Transfer
5. Shaft, Fan Hub 15. Manifold, Right Bank Exhaust
6. Support, Thermostat Housing 16. Housing, Rear Gear
7. Housing, Left Bank Thermostat 17. Housing, Flywheel
8. Outlet, Left Bank Water 18. Housing, Rocker Lever
9. Turbocharger 19. Crossover, Air
10. Manifold, Left Bank Exhaust
Section E - Engine and Component Identification Engine Diagram - KT3;
K38 and K50 Page E-1

Engine Diagram - KT38

Rear and Front View
1. Housing, Air Transfer 17. Pulley, Alternator Drive
2. Turbocharger 18. Pulley, Fan Idler
3. Crossover, Air 19. Pulley, Crankshaft
4. Passage, Water Outlet 20. Damper, Vibration
5. Cover, Rocker Lever 21. Direction of Rotation
6. Housing, Rocker Lever 22. Pulley, Accessory Drive
7. Head, Cylinder 23. Cover, Front Gear
8. Manifold, Fuel 24. Pulley, Fan
9. Block, Cylinder 25. Hub, Fan
10. Cooler, Oil 26. Head, Water Filter
11. Housing, Flywheel 27. Housing, Left Bank Thermostat
12. Flywheel 28. Outlet, Left Bank Water
13. Adapter, Oil Pan 29. Outlet, Right Bank Water
14. Pan, Oil 30. Housing, Right Bank Thermostat
15. Manifold, Right Bank Exhaust 31. Filter, Water (4 required)
16. Manifold, Left Bank Exhaust

REAR VIEW
FRONT VIEW
Engine Diagram - KTA38 Center Mount Aftercooler Section E - Engine and Component Identification
Palle E-12 K38 and K50

Engine Diagram - KTA38 Center Mount Aftercooler (KTA50 Similar)

Right Bank View

1. Assembly, Aftercooler 13. Pan, Oil

2. Turbocharger 14. Connection, Water Inlet
3. Connection, Air Crossover 15. Pump, Water
4. Cover, Rocker Lever 16. Drive, Water Pump
5. Bracket, Lifting 17. Tube, Water Bypass
6. Connection, Air Intake 18. Pulley, Fan Belt Idler
7. Manifold, Intake 19. Breather, Crankcase
B. Cover, Cam Follower 20. Assembly, Fan Belt Idler
9. Housing, Flywheel 21. Housing, Thermostat
10. Cover, Hand Hole 22. Connection, Water Outlet
11. Adapter, Oil Pan 23. Tube, Aftercooler Water Inlet
12. Cover, Oil Pan Adapter 24. Tube, Aftercooler Water Outlet
Section E - Engine and Component Identification Engine Diagram - KTA38 Center Mount Aftercool
K38 and K50 Page E-

Engine Diagram - KTA38 Center Mount Aftercooler (KTA50 Similar)

Left Bank View

1. Turbocharger 14. Filter, Fuel (2 shown)

2. Outlet, Aftercooler Water 15. Filter, Full·Flow Lubricating Oil (4 shown)
3. Inlet, Aftercooler Water 16. Breather, Crankcase
4. Support, Thermostat Housing 17. Gauge, Oil Level
5. Housing, Thermostat 18. Tube, Oil Fill
6. Support, Fan Hub 19. Head, Lubricating Oil Filter
7. Cover, Front Gear 20. Housing, Flywheel
8. Housing, Rear Gear 21. Cover, Cam Follower
9. Dataplate, Engine 22. Manifold, Intake
10. Drive, Air Compressor 23. Bracket, Lifting
11. Compressor, Air 24. Manifold, Exhaust
12. Pump, Fuel 25. Assembly, Aftercooler
13. Head, Fuel Filter
Engine Diagram - KTA38 Center Mount Aftercooler Section E - Engine and Component Identification
Page E-14 K38 and K50

Engine Diagram - KTA38 Center Mount Aftercooler (K50 Similar)

Top View
1. Assembly, Aftercooler 12. Manifold, Left Bank Exhaust
2. Tube, Aftercooler Water Outlet 13. Cover, Rocker Lever
3. Alternator 14. Manifold, Intake
4. Outlet, Right Bank Water 15. Tube, Water
5. Housing, Right Bank Thermostat 16. Manifold, Right Bank Exhaust
6. Support, Fan Hub 17. Plate, Oil Cooler
7. Shaft, Fan Hub 18. Housing, Rear Gear
8. Support, Thermostat Housing 19. Housing, Flywheel
9. Housing, Left Bank Thermostat 20. Housing, Rocker Lever
10. Outlet, Left Bank Water 21. Crossover, Air
11. Turbocharger 22. Connection, Air Intake
Section E • Engine and Component Identification Engine Diagram· KTA38 Center Mount Aftercool
K38 and K50 Page E·'

Engine Diagram - KTA38 Center Mount Aftercooler (1<50 Similar)

Rear and Front View

1. Assembly, Aftercooler 18. Pulley, Alternator Drive

2. Turbocharger 19. Pulley, Fan Idler
3. Tube, Aftercooler Water Inlet 20. Pulley, Crankshaft
4. Plate, Oil Cooler 21. Damper, Vibration
5. Crossover, Air 22. Direction of Rotation
6. Passage, Water Outlet 23. Pulley, Accessory Drive
7. Cover, Rocker Lever 24. Cover, Front Gear
8. Housing, Rocker Lever 25. Pulley, Fan
9. Manifold, Fuel 26. Hub, Fan
10. Head, Cylinder 27. Head, Water Filter
11. Block, Cylinder 28. Housing, Left Bank Thermostat
12. Housing, Flywheel 29. Outlet, Left Bank Water
13. Flexplate 30. Outlet, Aftercooler Water
14. Adapter, Oil Pan 31. Outlet, Right Bank Water
15. Pan, Oil 32. Housing, Right Bank Thermostat
16. Manifold, Left Bank Exhaust 33. Filter, Water (4 required)
17. Manifold, Right Bank Exhaust

FRONT VIEW
Engine Diagram - KTTA38 Section E - Engine and Component Identification
Page E-16 K38 and K50

Engine Diagram - KTTA3S (KTTA50 Similar)

Right Bank View

1. Turbocharger, High Stage 13. Adapter, Oil Pan

2. Turbocharger, Low Stage 14. Plate, Oil Pan Cover
3. Connection, Air Crossover 15. Pan, Oil
4. Pipe, Exhaust Outlet 16. Connection, Water Inlet
5. Support, Turbocharger 17. Breather, Crankcase
6. Cover, Rocker Lever 18. Pump, Water
7. Tube, Aftercooler Water Outlet 19. Tube, Water Bypass
8. Assembly, Aftercooler 20. Drive, Water Pump
9. Tube, Aftercooler Water Inlet 21. Pulley, Fan Belt Idler
10. Cover, Cam Follower 22. Assembly, Fan Belt Idler Arm
11. Housing, Flywheel 23. Housng, Right Bank Thermostat
12. Cover, Hand Hole ".
"::'"T". Outlet, Right Bank Water
Section E - Engine and Component Identification Engine Diagram - KTTA
K38 and K50 Page E-

Engine Diagram - KTTA3B (KTTA50 Similar)

Left Bank View

1. Turbocharger, High Stage 15. Drive, Air Compressor

2. Turbocharger, Low Stage 16. Compressor, Air
3. Connection, Air Crossover 17. Cover, Front Gear
4. Pipe, Exhaust Outlet 18. Pump, Fuel
5. Support, Turbocharger 19. Head, Fuel Riter
6. Outlet, Left Bank Water 20. Filter, Fuel (2 shown)
7. Support, Thermostat Housing 21. Adapter, Oil Pan
8. Housing, Left Bank Thermostat 22. Filter, Full-Flow Lubricating Oil (4 shown)
9. Tube, Aftercooler Water Outlet 23. Breather, Crankcase
10. Assembly, Aftercooler 24. Gauge, Oil Level
11. Tube, Aftercooler Water Inlet 25. Head, Lubricating Oil Filter
12. Cover, Cam Follower 26. Port, Oil Fill
13. Dataplate, Engine 27. Housing, Flywheel
14. Housing, Front Gear 28. Cover, Rocker Lever
Engine Diagram - KTTA38 Section E - Engine and Component Identification
Page E-18 K38 and K50

Engine Diagram - KTT A38 (KTTA50 Similar)

Top View

1. Connection, Air Crossover 12. Support, Thermostat Housing

2. Turbocharger, High Stage
3. Connection, Ai r
4. Assembly, Aftercooler
5. Tube, Water Transfer
6. Bracket, Lifting
7. Cover, Rocker Lever
8. Turbocharger, Low Stage
9. Tube, Aftercooler Water Outlet
10. Housing, Right Bank Thermostat
11. Outlet, Right Bank Water
13. Support, Fan Hub
14. Shaft, Fan Hub
15. Housing, Left Bank Thermostat
16. Outlet, Left Bank Water
17. Support, Turbocharger
18. Pipe, Exhaust Outlet
19. Housing, Rear Seal
20. Housing, Flywheel
21. Housing, Rocker Lever
Section E • Engine and Component Identification Engine Diagram· KTTA:
K38 and K50 Page E·'

Engine Diagram - KTTA38 (KTTA50 Similar)

Rear and Front View

1. Turbocharger, Low Stage 16. Pulley, Fan Idler

2. Turbocharger, High Stage 17. Pulley, Crankshaft
3. Manifold, Exhaust 18. Damper, Vibration
4. Support, Turbocharger 19. Direction of Rotation
5. Cover, Rocker Lever 20. Pulley, Accessory Drive
6. Housing, Rocker Lever 21. Cover, Front Gear
7. Head, Cylinder 22. Pulley, Fan
8. Manifold, STC Oil 23. Hub, Fan
9. Manifold, Fuel 24. Filter, Water (4 required)
10. Block, Cylinder 25. Head, Water Filter
11. Housing, Flywheel 26. Housing, Left Bank Thermostat
12. Flexplate 27. Outlet, Left Bank Water
13. Adapter, Oil Pan 28. Outlet, Right Bank Water
14. Pan, Oil 29. Housing, Right Bank Thermostat
15. Pulley, Alternator-Drive

REAR VIEW .....'

FRONT VIEW
Engine Diagram. KTA38 Outboard Aftercoolers Section E • Engine and Component Identification
Page E·20 K38 and K50

Engine Diagram - KTA38 Outboard Aftercoolers (KTA50 Similar)

Right Bank View

1. Turbocharger 13. Pan, Oil

2. Connection, Air Crossover 14. Plate, Oil Jumper
3. Connection, Air 15. Connection, Water Inlet
4. Assembly, Aftercooler 16. Breather, Cran kcase
5. Cover, Rocker Lever 17. Tube, Water Bypass
6. Tube, Aftercooler Water Outlet 18. Pump, Water
7. Tube, Aftercooler Water Inlet 19. Drive, Water Pump
8. Cover, Cam Follower 20. Alternator
9. Cover, Hand Hole 21. Pulley, Fan Belt Idler
10. Housing, Flywheel 22. Assembly, Fan Belt Idler
11. Adapter, Oil Pan 23. Housing, Right Bank Thermostat
12. Plate, Oil-Pan Adapter 24. Outlet, Right Bank T-trermostat
Section E - Engine and Component Identification Engine Diagram - KT A38 Outboard Aftercoolel
K38 and K50 Page E-2

Engine Diagram - KTA38 Outboard Aftercoolers (KTA50 Similar)

Left Bank View

1. Turbocharger 14. Drive, Air Compressor

2. Connection, Air 15. Compressor, Air
3. Connection, Air Crossover 16. Dataplate, Engine
4. Assembly, Aftercooler 17. Pump, Fuel
5. Cover, Rocker Lever 18. Head, Fuel Filter
6. Tube, Aftercooler Water Outlet 19. Filter, Fuel (2 shown)
7. Outlet, Left Bank Water 20. Filter, Full-Flow Lubricating Oil (4 shown)
8. Support, Thermostat Housing 21. Breather, Crankcase
9. Housing, Thermostat 22. Gauge, Oil Level
10. Tube, Aftercooler Water Inlet 23. Head, Lubricating Oil Filter
11. Cover, Cam Follower 24. Port, Oil Fill
12. Housing, Front Gear 25. Housing, Flywheel
13. Cover, Front Gear
Engine Diagram· KTA38 Outboard Aftercoolers Section E . Engine mnd Component Identification
Page E·22 K38 and K50

Engine Diagram - KTA38 Outboard Aftercoolers (KTA50 Similar)

Top View

1. Turbocharger 9. Outlet, Right Bank Water

2. Conneciion, Air Crossover 10. Support, Thermostat Housing
3. Assembly, Aftercooler 11. Support, Fan Hub
4. Tube, Water 12. Shaft, Fan Hub
5. Manifold, Exhaust 13. Housing, Left Bank Thermostat
6. Cover, Rocker Lever 14. Outlet, Left Bank Water
7. Tube, Aftercooler Water Outlet 15. Housing, Flywheel
8. Housing, Right Bank Thermostat 16. Plate, Oil Cooler Cover

.----<16)

--
Section E - Engine and Component Identification Engine Diagram - KTA38 Outboard Aftercoolel
K38 and K50 Page E-2

Engine Diagram - KTA3S Outboard Aftercoolers (KTA50 Similar)

Rear and Front View

1. Plate, Oil Cooler Cover 16. Pulley, Fan Idler

2. Turbocharger 17. Pulley, Crankshaft
3. Manifold, Exhaust 18. Damper, Vibration
4. Cover, Rocker Lever 19. Direction of Engine Rotation
5. Housing, Rocker Lever 20. Pulley, Accessory Drive
6. Head, Cylinder 21. Cover, Front Gear
7. Connection, Air Crossover 22. Pulley, Fan Hub
8. Manifold, STC (HVT) 23. Hub, Fan
9. Manifold, Fuel 24. Filter, Water (4 required)
10. Block, Cylinder 25. Head, Water Filter
11. Housing, Flywheel 26. Housing, Left Bank Thermostat
12. Flexplate 27. Outlet, Left Bank Water
13. Adapter, Oil Pan 28. Outlet, Right Bank Thermostat
14. Pan, Oil 29. Housing, Right Bank Thermostat
15. Pulley, Alternator Drive

REAR VIEW
Section 1 • Operating Instructions
K38 and K50 Page 1-1

Section 1 - Operating Instructions

Section Contents
Page
Cold Weather Engine Operation ....................................................................................................................... 1-5
Cold Weather Starting ....................................................................................................................................... 1-4
Using Starting Fluid With Mechanical or Electrical Metering Equipment.......................................................... 1-4
Using Starting Fluid Without Metering Equipment........................................................................................... 1-5
Cold Weather Starting Aids .......... ........... ....................... ....... ............. ........ ...... .... ...... ................ ....... ... .... .... .... 1-6
Electrically Operated Ether Valve.................................................................................................................... 1-7
Ether Starting Aids ........... ............. ...... ... ... ...... ............ ........... ....... ............ ...... .......... ................ ... .... ............ ... 1-6
Installation Recommendations......................................................................................................................... 1-7
Manually Operated Ether Valve ....................................................................................................................... 1-7
Engine Operating Range .... ........... ........ .......................... ....... ................. ....... ... ........... ............... ....... ... .......... 1-10
Engine Shut-down ......... .............. ...... ....................... ............ .............. ........ .......... ................. ...... ........... ...... ... 1-11
Fuel Control Valve - Single Bank .................................................................................................................... 1-13
General Information .... ..... ............. ........ ..... ................... ....... ...... ......... ..... ......... ... .... ... .... ......... ............. ........ .... 1-2
Normal Starting Procedure (Above DoC [32°F]) ............................................................................................... 1-2
Operating the Engine ........................................................................................................................................ 1-9
Power Takeoff Application with Variable Speed Controls ............................................................................ 1-11
Starting Procedure .• After 'Extended -5hutdownor Oil· Ghange ............ ,..................................................." ....... ~ 1-8
Step Timing Control (STC)...... ...... ............. ....... ........... ........ .............. .................. .... .......... ............ ....... .......... 1-11
General Information Section 1 - Operating Instructions
Page 1-2 K38 and K50

General Information
Correct care of your engine will result in longer life, better
performance and more economical operation.
• Follow the daily maintenance checks listed in Main-
tenance Guidelines, Section 2.

o1801vu

• Check the oil pressure indicators, temperature in-

dicators, warning lights and other gauges daily to
make sure they are operational.

, I / ",- 1./
" /
-~-- -~--
/ I '-, ./ I '-.

I I egBgasj

Warning: DO NOT OPERATE A DIESEL ENGINE WHERE

THERE ARE OR CAN BE COMBUSTIBLE VAPORS_ These
vapors can be sucked through the air int,ake s,ystem and
cause engine acceleration and over-speeding, which can
result in a fire, an explosion and extensive property
damage. Numerous safety devices are available, such as
air intake shutoff devices, to minimize the risk of over-
speeding where all engine, due to Its application, might
operate in a combustible environment, such as due to a
fuel spill or gas leak. Remember, Cummins has no way
of knowing the use you have for your engine. THE EQUIP-
MENT OWNER AND OPERATOR ARE RESPONSIBLE FOR
SAFE OPERATION IN A HOSTILE ENVIRONMENT. CON-
SULT YOUR CUMMINS AUTHORIZED REPAIR LOCATION
FOR FURTHER INFORMATION.

Normal Starting Procedure (Above ooe

[32°F])
• Disengage the driven unit, or if equipped, put the
transmission in neutral.
• Start the engine with the throttle in the idle pOSition.
Engines equipped with air starters require a minimum of
480 kPa [70 psi] compressed air pressure.
To prevent damage to the starter, do not engage the
starting motor more than 30 seconds. Wait two (2) min-
utes between each attempt to start (electrical starting
motors only).
Section 1 Operating Instructions
0 Normal Starting Procedure (Above O·C [32°F
K38 and K50 Page 1·

Caution: When using jumper cables to start the engine,

make sure to connect the cables in parallel: positive ( + )
to positive (+) and negative (-) to negative (0). When
using an external electrical source to start the engine,
turn the disconnect switch to the OFF position. Remove
the key before attaching the jumper cables.
The accompanying illustration shows a typical parallel
battery connection. This arrangement doubles the crank·
ing amperage.

Parallel
Connection sbOcoga

This illustration shows a typical series battery connec·

tion. This arrangement, positive to negative, doubles the
voltage.

Series
Connection sb8cogb

. ' .. Engine oil pressure must be indicated on the gauge

within 15 seconds after starting. If oil pressure is not
registered within 15 seconds, shut off the engine
immediately to avoid engine damage. Confirm the
correct oillevelintlieoil pan. .~.

eg8gask

• Idle the engine three (3) to five (5) minutes at ap·

proximately 1,000 RPM before operating with a load.

3 to 5 minutes
oiBOOV02
Cold Weather Starting Section 1 - Operating Instructions
Page 1-4 K38 and K50

• When starting a cold engine, increase the engine

speed (RPM) slowly to provide adequate lubrication
to the bearings, and to allow the oil pressure to
stabilize.

Do not idle the engine for excessively long periods. Long

periods of idling, more than 10 minutes, can damage an
engine because combustion chamber temperatures drop
so low the fuel will not burn completely. This will cause
carbon to clog the injector spray holes and piston rings,
and=n~ cause_the valves~ to stick.

III 1'1''''11\1 I

If the engine coolant temperature becomes too low, 60 0 e

[140°F], raw fuel will wash the lubricating oil off the cyl-
inder walls and dilute the crankcase oil; therefore, all
moving parts of thee engine will not receive-ths--correct
amount of lubrication.

Cold Weather Starting

Using Starting Fluid With Mechanical or
Electrical Metering Equipment
• Set the throttle at idle.
• Disengage the driven unit, or if equipped, put the
transmission in neutral.
• Activate the switch to open the fuel pump shutoff
valve.

oiB00v03
 Section 1 - Operating Instructions Cold Weather Engine Operatic
K38 and K50 Page 1·

• While cranking the engine, inject a metered amount

of starting fluid.
• Engine oil pressure must be indicated on the gauge @
within 15 seconds after starting. \0'

Using Starting Fluid Without Metering F"L ~

Equipment
i'
~,,~
Warning: Do not use volatile cold starting aids in un- A
derground mine ortunnel operations dueto the potential ...
of an explosion. Check with the local U.S. Bureau of
Mines Inspector for instructions. Star1ing
Fluid
Caution: Do not use excessive amounts of starting fluid A
_ when starting an engine. The use of too much starting ~
fluid will cause eng'ine damage:' .. .
Due to increased safety hazards and potential for engine
damage, Cummins Engine Company, Inc. does NOT rec-
ommend the use of starting fluid without metering
'" "'" oi800qe

equipment.

Cold Weather Engine Operation

. Satisfactory performance o!.a..diesel engine operating in low ambient tempemture condition!?.r·equjr~,!u!u?.pifigatipr
of the engine, surrounding equipment, operating practices and maintenance procedures. The colder the tem
-~."- peratur-es'-encountered,-1Ae-greater the amount of'modifieation required and yet with the modifications ,applied
the engines must still be capable of operation in warmer climates without extensive changes. The followin(
information is provIge<;i, !Q eog,ine ownel~, operators andlTlaintenance personnel on how the modifications can bE
applied to get satisfactory performance from their diesel engines: .. .. , "
There are three basic objectives to be accomplished:
1. Reasonable starting characteristics followed by practical and dependable warm-up of the engine and equipment.
2. A unit or installation which is as independent as possible from external influences.
3. Modifications which maintain satisfactory operating temperatures with a minimum increase in maintenance 0'
the equipment and accessories.
If satisfactory engine temperature is not maintained, higher maintenance cost will result due to the increasec
engine wear, poor performance and formation of excessive carbon, varnish and other deposits. Special provision~
to overcome low temperatures are definitely necessary, whereas a change to warmer climate normally require~
only a minimum of revision. Most of the accessories will be designed in such a way that they can be disconnectec
so there is little effect on the engine when they are not in use.
 Cold Weather Starting Aids Section 1 - Operating Instructions
Page 1-6 K38 and KSO

The two most commonly used terms associated with preparation of equipment for low temperature operation are
Winterization and Arctic Specifications.
Winterization of the engine and/or components so starting and operation are possible in the lowest temperature
to be encountered requires:
1. Use of correct materials.
2. Proper lubrication, low temperature lubricating oils. Refer to Lubricating Oil Specifications, Section V.
3. Protection from the low temperature air. The metal temperature does not change, but the rate of heat dissipation
is affected.
4. Fuel of the proper grade for the lowest temperature.
50. Heating to be provided to increase the engine block and component temperature to a minimum of -32°C [-25°Fj
for starting in lower temperatures.
6. Proper external heating source available.
7. Electrical equipment capable of operating in the lowest expected temperature.
Arctic specifications refer to the design material and specifications of the components necessary for satisfactory
engine operation in extreme low temperatures -54°C [-65°Fj. Contact Cummins Engine Company, Inc. or the
equipment manufacturer to obtain the special items required.
For additional information on cold weather operation, obtain Service Bulletin No. 3379009, Engine Operation in
Cold Weather, from the nearest Cummins Distributor or dealer.
__ JUs _possible.lQ _operate diesel engines in extremely cold environments if they are properly prepared and main-
tained. The correct lubricants, fuels and coolant must be used for the cold weather range for which the vehicle
is being operated. Refer to the chart below for recommendations in different operating ranges.
- -...- - - . - ..-- .. --~ .. "'-- .. - . - - ..---..-----.---.--..._--._-_.-----_.... _._----..... ---- ...-_.
vvlmenze - Wmtenze Anic ::.peciticauons
0° to -23°C -23° to -32°C -32° to -54°C
[32° to -10°F] [-10° to -25°F] [-25° to -65°F]
Use ethylene glycol antifreeze to Use 50 percent ethylene glycol an- Use 60 percent ethylene glycol an-
protect to -29°C [-20 0 Fj tifreeze, 50 percent water mixture. tifreeze, 40 percent water mixture.
Use multi viscosity oils meeting Use T1]ult! visc:.o.sitY.CllLmeeting API Use_p.rtig oil meeti[lg API G.Eor._.
-API, CE or CF4 specificaiions. -- CE or CF4 specifications. CF4 specifications.
Fuel to have maximum cloucriliid Fuel to have maximum cloud and Fuel to have maximum clouif and
pour points 6°C [10 0 Fjlower than pour points 6°C [10 0 Fjlower than pour points 6°C [10 0 Fjlower than
ambient. temperature.in which..en-..._ . ambienUemperatures-in which en- . __ ambient. temperature in which en-... __ .
gine operates. gine operates. gine operates.

Cold Weather Starting Aids

~
Ether Starting Aids
Warning: Starting fluid contains ether and Is extremely

~ 3 At\ flammable. Misuse or mishandling can cause an explo-

sion. NEVER handle starting fluid near an open flame.
NEVER use starting fluid with a preheater, glow plug,
® .~ flame thrower or other type of electrical starting eqUip-
ment. Do NOT breathe the fumes as serious injury to the
(D-- human respiratory system will result. Fuel 011 or volatile
fuel cold starting aids are NOT to be used In under-
ct8vagb ground mine or tunnel operations.
Caution: Using too much starting fluid will cause ex-
1::.. tremely high pressures and detonation in the engine
cylinders, resulting in damage to the cylinder parts and
bearings. Too much starting fluid can also cause dam-
age from engine overspeed_
 Section 1 - Operating Instructions Cold Weather Starting Ai
K38 and K50 Page 1

Manually Operated Ether Valve

The manually operated ether valve includes the valve
body assembly (5), clamp (2), and nylon tube (3). The fuel
cylinder (1), atomizer fitting (4) and pull control (6) must
be ordered separately.
Standard pull or throttle control cables can be used to
actuate the manual valve, if desired.

Electrically Operated Ether Valve

~
The electrically operated ether valve includes the valve
body (7), 90 degree elbow (5), clamp (2), push button
switch (6), and nylon tube (3). A thermostat is mounted to
the cylinder block or coolant passage and stops electrical 3
power to the atomizer~solen6id-when the-engine is warm. ~
See the Parts Catalog for fuel cylinder (1) and fuel at-
omizer fittings (4). These fittings must be ordered sep- ® .~
arately, as required.

cs8vagb

Installation Recommendations

t~;-;·:b~
The atomizer fittings must be mounted in the engine air
intake manifold to provide an equal distribution of starting
"fUe1lO each ~cylillaer':The-atoffirzefiloles 'arlHSOaegrees ~
aPM!!nq rnullt!2!'l m9l!!!!!ll;t lelO the spr~y ilLLl1iE3£!ed thE!~_~ -. ----~~, _.- ---
long way of the manifold. If incorrectly installed, the spray

[~{~~III.~~f~J~~-1~~®~:
goes crosswise of the manifold.

...,. Im'Nb
Starting Procedure - After Extended Shutdown or Oil Change Section 1 - Operating Instructions
Page 1-8 K38 and KSO

The following cold weather operating aids are required for cold weather situations:

Cold Weather Operating Aids

Under-
Temperature Starting Coolanl 011 hood Fuel Battery Radiator Engine Winter Therl1lltlc
Aid Heater Heater Air Hell.r HealtH' ShuHers Enero.ure Fronl Fan

60 to 32° F
10 to 0 0 C

-------- - - - - - - - - - - -r---- - -
32 to ·tO O F

';';'" +~ ---~tf--- ----1- -r-- -,-

Ota_23 6 C

-10 to _25 0 F
-23 to -32" C Required
Required
----1----
-25 to -65° F
-32 to .54 0 C

If, ))
I-~

Starting Procedure - After Extended

Shutdown or Oil Change
Complete the following -steps after each oil change, or --
after the engine has been shut off for more than five (5)
days to make sure the engine receives the correct oil flow
tfiro-iighUliflutiricatiiig"oil system:
• Disconnect the electrical wire from the fuel pump
solenoid valve_
• Rotate the crankshaft, using the starting motor, until
oil pressure appears on the gauge or the warning
light goes out.
Section 1 - Operating Instructions Operating the Engin
K38 and K50 Page 1·

• Connect the electrical wire to the fuel pump sole-

noid valve.
• Start the engine. Refer to Normal Starting Proce-
dures in this section.

Iv2swka

Operating the Engine

• Allow the engine to idle three (3) to five (5) minutes
before shutting it off after a full load operation. This
allows adequate cool down of pistons, cylinder lin-
ers, bearings and turbocharger components.

3 TO 5 MINUTES
of800vOS

NOTE: Continuous operation with low coolant temperature,

below 60°C [140°F), or high coolant temperature, above
100°C [212° F), can damage the engine .
... -. Monitot""the Oil pressore aM' coolant -temperature'
gaugesfrequen~. Refer to Lubricating Oil System
@
~
- -.. SpeCificaiions'or-Cooling System Specifications,
Section V, for recommended operating pressures
. and-temperatures. Shut off the engine if any pres-
sure or temperature does nol meet the
specifications.

• If an overheating condition starts to occur, reduce

the power output of the engine by releasing the ~
throttle pressure or shifting the transmission to a ~
lower gear or both until the temperature returns to
normal operating range. If engine temperature does
not return to normal, shutoff the engine and refer to
Troubleshooting, Section T, or contact a Cummins
Authorized Repair Location.

eg8gasm
80 -----+- 7G
Engine Operating Range Section 1 • Operating Instructions
Page 1·10 K38 and K50

• Most failures give an early warning. Look and listen

for changes in performance, sound or engine ap-
pearance that can indicate service or engine repair
Performance is needed. Some changes to look for are as follOWS:
Engine misfires
Vibration
? Sound Service Unusual engine noises
Sudden changes in engine operating tempera-
ture or pressure
- Excessive smoke
? Engine
Appearance - Loss of power
- An increase in oil consumption
ol800kOI - An increase in fuel consumption
- Fuel, oil or coolant leaks

Engine Operating Range

~~ Rated
Torque
Peak
® Rated
Excessive full throttle operation below peak torque RPM
(lugging) will shorten engine life to overhaul, can cause
serious engine damage and is considered engine abuse.
Cummins engines are designed te operate SUGcessfully
at full throttle under transient conditions down to peak
torque engine speed.

Full Throttle Full Throttle oiSOObf

Operation of the engine below peak torque RPM can

Torque occur during gear shifting due to the difference of ratios
Peak . ,?~tvy~_e.~.t!.i!~smI!3s!()I]_g.e!lrs,.p'",t engine ()PE!ration mus~_
not be sustained more than 30 seconds at full throttle
below_peak.lorque Rf>M.

Full Throttle ,180000

Caution: Operating the engine beyond high idle speed

can cause severe engine damage. The engine speed
. MUST NOT exceed 2,400 RPM under any circumstances.
When descending a sleep grade, use a combination of
transmission gears or vehicle braking systems to control
the vehicle and engine speed.
 Section 1 - Operating Instructions Engine Shut-do
K38 and K50 Page 1·

Engine Shut-down
• Allow the engine to idle three (3) to five (5) minutes
after a full load operation before shutting it off. This
allows the engine to cool gradually and uniformly.
• Turn the ignition key switch to the OFF position. If
the engine fails to stop running. rotate the manual
fuel shutoff thumb screw counterclockwise to make
sure the valve is not being held open by the manual
override screw.
-k
OFF~

Power Takeoff Application with

Variable Speed Controls
The variable speed governor on power takeoff applica-
tions is used to control engine speed at the desired RPM.
To engage the~ variable-speed-govemorwittothe enyine
idling on standard throttle:
• Put the variable speed control lever (2) in the idle
~ position.

• Lock the standard throttle lever (1) in the full open

position.
• Adjust the ~ variable speed control lever (2) to the
speed desired.

To return to standard throttle operation:

• Return the standard throttle lever (1) to the idle
position.
- .;"

• Lock the variable speed control lever (2) in the max-

imum speed position.

1161vvd

Step Timing Control (STC)

Some engine models are equipped with step timing con- STC
trol (STC). formerly called HVT (Hydraulic· Variable Tim-
ing). STC allows the engine to operate in advanced in-
Advanced Normal
jection timing immediately after start-up and light duty Starting and High Load
engine load conditions. and to return to normal timing Light Load
during medium and high engine load conditions.
Benefits include:
• Improved cold weather idling characteristics.
• Reduced cold weather white smoke.
• Improved light load fuel economy.
Step Timing Control (STC) Section 1 • Operating Instructions
Page 1·12 K38 and K50

Do not attempt to bypass or otherwise tamper with the

CAUTION o o o STC oil control valve or plumbing. This will result in the
DO NOT TAMPER 1~.....O.f
loss of both fuel economy and engine durability. Correct
valve operation is necessary to maintain acceptable cyl-
OR READJUST ~~~~~__________~:I inder pressures and temperatures, and to yield optimal
fuel economy during high-load operation. Correct oper-
ation is also necessary to control white smoke at idle.

o
bpSvaub

When operating in the advanced mode, a light ticking

noise can be noted at the overhead. This sound is normal,
and is caused by the actuation of the STC hydraulic
tappets during each injection cycle.

For optimal white smoke control on STC-equipped en-

gines, do not increase engine speed above idle during
engine start-up until sufficient oil pressure reaches the
STC tappets to shift all injectors into the advanced timing
mode.
Section 1 - Operating Instructions Fuel Control Valve - Single BI
K38 and K50 Page 1

Fuel Control Valve - Single Bank

Some engine models are equipped with a fuel control single bank idle valve. These engines will not be equip~
with step timing control (STC). The single bank idle valve allows the engine to only operate on the right ban~
cylinders during start-up and idle conditions and to return the engine to all cylinder operation during normal load
conditions. Engine idle operation on one bank of cylinders ensures that the firing cylinders are at a tempera\!
sufficient for proper combustion.
Benefits include:
• Improved cold weather idling characteristics.
• Reduced cold weather white smoke.
• Improved idle fuel consumption.
• Reduced injector carboning.
~ The single bank idle valve is adjusted with internal shims. Refer to the K38 and K50 Engine Seri
Troubleshooting and Repair Manual Procedure Nos. 05·38 and 05-39, Bulletin No. 381 0432, for the pro~
procedures.

-_. -_. < '. ,. ~- - ,-. -

Section 2 - Maintenance Guidelines
K38 and K50 Page 2·

Section 2 - Maintenance Guidelines

Section Contents
Pag
Engine Maintenance Schedule......... ................................................................................................................. 2-
Page References for Maintenance Instructions ............................................................................................... 2-
General Information ............................." ........................................................................................................... 2-
Tool Requirements.. ............................... ................................... ........................................................................ 2-
General Inform at/on Section 2 - Maintenance Guidelines
Page 2-2 K38 and K50

General Information
Cummins Engine Company, Inc. recommends that the engine be maintained according to the Maintenance
Schedule on page 2-3.
If the engine is operating in ambient temperatures consistently below -18' C [0' F) or above 38 °c [1 OO'F), perform
maintenance at shorter intervals. Shorter .maintenance intervals are also required if the engine is operated in a
dusty environment or if frequent stops are made. See your Cummins Authorized Repair Location for recommended
intervals.
NOTE: Some of these maintenance procedures require special tools or must be done by qualified personnel. These
procedures are outlined in the specifiC manuals as follows:

Procedure Bulletin No. Description

• Adjust the Valves and Injectors 3810304 K38 and K50 Shop Manual .
3810432 K38 and K50 Troubleshooting & Repair Manual
• Clean and Calibrate the Injectors 3379071 Injector PT Rebuild Manual
3810313 PT (type D) STC Injector Shop Manual
• Clean and Calibrate the Fuel Pump 3379084 Fuel Pump (PT type G) Rebuild and Calibrate
• Repair and Rebuild Components* 3810304 K38 and K50 Shop Manual

*If your engine is equipped with a component or an accessory not manufactured by Cummins Engine Company,
Inc., refer to the component manufacturer's maintenance recommendations. A listing of suppliers' addresses and
telephone numbers Is provided in Component ManufactUrers, SectiorrC:-· .

Tool Requirements
Most of the maintenance operations described in this manual can be performed with common hand tools (S.A.E.
wrenches, sockets, and screwdrivers).
The following is a list of special service tools required for·some maintenance operations:

Tool Part No_ Description

3375049 Oil Filter Wrench
3376592 Inch Pound Torque Wrench
3376807 Water/Fuel Filter Wrench
3822524 Belt Tension Gauge (Click-Type)
3822525 Belt Tension Gauge (Click-Type)
3822648/3823348 Top Stop Tappet Setting Tool (STC
equipped engines only)
ST-1293 Belt Tension Gauge (v-belts)
ST-1274 Belt Tension Gauge (Kriket)

Refer to the appropriate sections for a description of the tools and how to use them.

Contact your nearest Cummins Authorized Repair Location for the required service tools.
Section 2 • Maintenance Guidelines Engine Maintenance SChed.
K38 and K50 Page:

Engine Maintenance Schedule

Maintenance Schedule Equipment No.

Mechanic
TlmeSpenl
Engine Serfal No,
HoufS, Calendar.
Check Performed
Parts Order No. Dale

K3B and K50 Series Cummins Diesel Engines

Check eaoh operation as peJformed.

250 Hours 1500 Hours 6000 Hours

or or or
Dally Weekly 6 Mos. 1 Yellr 2 Years Other
(Section 3) (Section 4) (Section 5) (Section 6) (Section 7) (Section 8)
Repeat Dally Check Repeal (Dally/Weekly) Repeat Previous Repeat Previous
Intervals Intervals

o Check operator's re- D Check air cleaner: o "'Change engine oil o Steam clean engine o Clean and calibrate o + Alternator
port • Check piping, injectors and fuel
hoses, and clamps o Change filters o **Adjust valves and pump o +Generator
o Check engine: II Oil full flow injectors
• Oil Level
• Check restriction
indicator • onby-~s o Adjust Fan Idler o Inspect the following o +Starter
• Coolant level • Replace air cleaner • Fuel fi er assemblies: D + Air compressor
Qf make-up cooI- • Water filter Pulley Tensloner • Turbocharget
element as re- (Non-Cummins)
ant is required, qulred • Air compressor air D Check engina protec- • Vibration damper
OCA4 concentra- cleaner element lion system • Water pump D + Electrical connec-
tion must be D Drain air tanks
checked.) o Check/Clean DGrease o Clean and flush cooI- tlons

o Visually check en-

• Crankcase
breather tube/hose
• Fan Idler piVot arm Ing system o +Batteries
gina for damage, • Air compressor air
• Front englna sup-
port
o Calibrate engine pro- D + Fan Shaft_Searing
leaks, loose or frayed filter tection system
belts and listen for D o Rebuild o + Clutch or Marine
unusual noises o Cheokbe~ Check/replace hoses
as required • Fan hub o
Gear
+ Freon compressor
o Drain water/sediment o Check belt tension o Check cold start aids • Fan idler pulley
o +Hydraulic
• Air compressor
from fuel tanks and
fUEifnlters o System
Check Cooli~ (seasonal) govemor

o
Addit 'lEIS o Check batteries + On these components
CheckfCfean air o Cheok all be~, follow the manufaGtur·
. cleaner precleaner
and dust pan o Check cooling fan o Tighten mounting er's recommended
bol" maintenance prace-
condition
D Clean caw water dure
strainer o eI~ct crankshaft
clearance
o Check Engine Moni-
o Check heat ex-
tor System
changer zinc plugs
annuallfr or as re-
quired marine only)
o Clean/replace
Crankcase breather
element

Note: Under circumstances where hours of operation are not accumulated at a fast rate, use calendar time. In other words, use hours, or calendar time, which·
ever comes first.
~-

·Cummlns engine Company, Inc., recommends 1he use of dry1ype air cleaners.

* Refer to Section V for alternate method of determining safe oil drain intelVals.
** Cummins has found that engines in most applications will not experience significant valve/injector train wef
after an initial adjustment is made at 1500 hours. After this adjustment, it is recommended that the valves an
injectors not be adjusted again previous to injector calibration at the 6000 hour or 2 year intelVal. Becaus
injector train hardware is typically mixed between cylinders during injector replacement, it is recommende,
to adjust valves and injectors 1500 hours after all injector replacements.
Engine Maintenance Schedule Section 2 - Maintenance Guidelines
Page 2-4 K38 and K50

Page References for Maintenance Instructions

F or your convenience, listed below are the page numbers that contain specific instructions for performing the
maintenance checks listed in the maintenance schedule.
Section
Daily ..................................................................................................................; ...~..•••..••••.••...•...• 3
• Air Cleaner Precleaner and Dust Pan - Checking/Cleaning ............................................................. 3-4
• Coolant Level - Checking ................................................................................................................ 3-3
• Engine Monitor System - Checking ................................................................................................. 3-5
• Engine Operation Report ................................................................................................................ 3·2
• Fuel-Water Separator ...................................................................................................................... 3·2 ~
• Oil Level - Checking ....................................................................................................................... 3·3
• Raw Water Strainer· Cleaning ........................................................................................................ 3·4
• Unusual Engine Noise· Checking ................................................................................................... 3·2
Weekly ........................................................................................................................................ 4
• Air Cleaner Element· Replacement ................................................................................................ 4-4
• Air Intake Hoses, Pipes, and Clamps· Inspection ........................................................................... 4·6
• Drain Air Tanks ............................................................................................................................... 4·6
• Inlet Air Restriction Indicators· MechanicalNacuum ....................................................................... 4·2
Every 250 Hours or 6 Months ........................................................................................................ 5
• Air Compressor Air Cleaner Element· Replacement ..................................................................... 5·10
~ ~ .~
Belt Tension . Checking ................................................................................................................ 5·11
• Belts· Checking ........................................................................................................................... 5·11
• Bendix-Westinghouse Paper Element· Replacement .................................................................... 5·10
A Pn.--.di"":-\Jd!?_,,:tin:::,"'-."<:'._~. c:n'"''l!""'r:;. ~!--:;,....,Pl!~ .. Dr.:-"":'!~""'?0"p.r")t __ . . .... . < • • _ ••• , • , h-1n
• Coolant Filter - Replacement ........................................................................................................... 5-8
• Cooling Fan· Checking ................................................................................................................ 5·11
• Crankcase Breather Tube/Hose • Checking/CI~aning ...................................................................... 5·6
• Cummins Two Cylinder Only· Replacement ................................................................................. 5·10
• Cooling System Additives· Checking .............................................................................................. 5·6
• Fuel Filter· Replacement ................................................................................................................ 5·2
• Lubricating Oil and Oil Filter· Changing/Replacement .................................................................... 5·3
Every 1500 Hours or 1 Year .............................. , ............................................................................ 6
• Batteries· Checking ...................................................................................................................... 6·22
• Cold Start Aids· Checking ............................................................................................................ 6·23
• Crankshaft End Clearance - Inspection ..... ;................................................................................... 6-21
• Engine Mounting Bolts - Checking ................................................................................................ 6·24
• Engine Protection System· General Information ........................................................................... 6·23
• Fan Idler Pivot Arm ....................................................................................................................... 6·20
• Fan Idler Pulley Tensioner - Adjustment ........................................................................................ 6-20
• Front Engine Support .................................................................................................................... 6·24
• Heat Exchanger Zinc Plugs (Marine Only) - Checking ................................................................... 6-21
• Hoses - Checking/Replacement .................................................................................................... 6·20
• Steam Clean Engine ....................................................................................................................... 6-2
• Valves and Injectors· Adjustment/Checking ................................................................................... 6·2
Section 2 • Maintenance Guidelines Engine Maintenance Schedu
K38 and K50 Page 2·

Every 6000 Hours or Two Years ......................................................................................................

• Air Compressor - Checking ........................................................................................................... 7-~
• Cooling System - Cleaning System and Changing Antifreeze ........................................................ 7-1
• Engine Protection System - Calibration ......................................................................................... 7-~
• Fan Hub - Inspection .................................................................................................................... 7-1
• Fan Idler Pulley Assembly - Rebuild/Replacement ........................................................................ 7-1
• Fuel Pump - Cleaning/lnstallation/Removal/Calibration ................................................................... 7·
• Injectors - Cleaning/Calibration/Checking/lnstallation/Removal ........................................................ 7·
• Thermostats and Seals - Replacement .......................................................................................... 7-1
• Throttle Travel/Throttle Air Cylinder - Checking ............................................................................... 7·
• Turbocharger - Inspection ............................................................................................................. 7-2
• Vibration Damper -Inspection ....................................................................................................... 7-2
• Water Pump - Inspection ............................................................................................................... 7-1
Other ...........................................................................................................................................
• + Air Compressor (non-Cummins) .............................. :.................................................................. 8·
• + Alternator .................................................................................................................................. 8·
• + Batteries .................................................................................................................................... 8-
• + Clutch and Marine Gear ............................................................................................................ 8-
• + Electrical Connections ............................................................................................................... 8-
• + Fan Shaft Bearings .................................................................................................................... 8-
• + Freon CompressQr ..................................................................................................................... 8-
• + Generator .................................................................................................................................. 8-
• + Hydraulic Governor .................................................................................................................... 8-
e + Starter ....................................................................................................................................... 8-
+ Follow the manufacturer's recommended maintenance procedures on these components. Refer to Secton C
Component Manufacturers.
Maintenance Record Form Section 2 - Maintenance Guidelines
Page 2-6 K38 and KSO

Maintenance Record
Engine Serial No. _ _ _-'-_ _ _ _ _ _ __ Engine Model _ _ _ _ _ _ _ _ _ _ _ __
Owner's Name Equipment Name/Number

Km [Miles], Actual Maintenance Check

Date Hours or Km [Miles] Check Performed Comments
Time Interval or Hours Performed By

- . . .. ------- - --,- .

, ... o _.r ....... -.. -- .- --<~ •••• - - •• . .,~~. ...... , -.-,- .- . .. - ---- ..... - ...
.

-- ~--. - - --. ~.-- .. . . .

Section 3 • Daily Maintenance Procedures
K36 and K50 Page 3

Section 3 - Daily Maintenance Procedures

Section Contents
Pal
Air Cleaner Pre·Cleaner and Dust Pan ............................................................................................................ 3
Checking/Cleaning ........ ... ......... ............. ... ..... ... ...... .... ... ... ......... ......... ..... ......... .............. ......... ...... ... ........ ..... 3
Coolant Level............. .... ..... .............. ....... ......... ............................ ...... ... .......... .... ... .......... .... ... ......... .......... ...... 3
Checking ........................................................................................................................................................ 3
Engine Monitor System .... ..... ..... ..... ...................... ................... ... ........ ............. .... ...... ....... ..... ..................... ...... 3
Checking ........................................................................................................................................................ 3
Engine Operation Report ........... ....... .......................... ......... ............. ...... ... ..... ........ ... ... ............. ........... ....... ..... 3
Fuel·Water Separator ........................................................................................................................................ 3·
General Information ................. .................. .......... ....... ...... ........... ......... ............. ............. .............. .................... 3·
Oil Level .............................................................................................................:............................................... 3·
Checking .............................................................................. ,.,", ....... " ........... " ...... ,.. ,............ ,.. ,.. ,..... ,........ ,., 3,
Raw Water Strainer ..... ,........ "., ,.,",' .,., ,., ...... ,.. ,... ,., ..... ,.," .""" ,., .. ,............... .... ............... .... ................ ....... ....... 3·
Cleaning ,......... ,.... ,........................ ,............................... ,., ........... " .. ,........................... ,............... ,.................. 3·
Unusual Engine Noise ......... ,"""""""'''''''' ..................................................... ,"""",,,,,,, ............................. ,.... 3·
Checking ................................... ,......................... ,................... "................................. ................................... 3·
General Information Section 3 - Dally Maintenance Procedures
Page 3-2 K38 and K50

General Information
Preventative maintenance begins with day-to-day awareness of the condition of the engine and its systems.
Before starting the engine, check the oil and coolant levels. Look for:
• Leaks
• Loose or damaged parts
• Worn or damaged belts
• Any change in engine appearance
Engine Operation Report
The engine must be maintained in top mechanical condition if the operator is to get optimum satisfaction from
its use. The maintenance department needs daily running reports from the operator to make necessary adjust-
ments in the time allotted and to make provisions for more extensive maintenance work as the reports indicate
the necessity.
Comparison and intelligent interpretation of the daily report along with a practical follow-up action will eliminate
most failures and emergency repairs.
Report to the Maintenance Department any of the following conditions:
• Low iubricating oil pressure
• Low power
• Abnormal water or oil temperature
• Unusual engine noise
• Excessive smoke
• Excessive use of coolant, fuel or lubricating oil
,,--,- ~·,~l ,--_ ......, __ I-:~~~. - J •• I.-~,.::-.,..~:~:::- ,,'; f--::-;":-

Unusual Engine Noise

Checking
During the daily maintenance check, listen for any un-
usual engine noise which can indicate that service is
required. .

Fuel-Water Separator
I I If the engine is equipped with a fuel-water separator,
drain the water and sediment from the separator daily.
Shut off the engine. Use your hand to open the drain
valve. Turn the valve counterclockwise approximately
,",,=-. ,",,=-.~ 1- 1/2 to 2 turns until draining occurs. Drain the filter sump
I I I I of water until clear fuel is visible.
Caution: Do not overtighten the valve. Overtightening
~ can damage the threads.

clJ ...,,' Turn the valve clockwise approximately 1-112 to 2 turns

to close the drain valve.
 Section 3 - Dally Maintenance Procedures Oil LeVI
K38 and K50 Page 3-

Oil Level
Checking
Check the oil level daily.
Never operate the engine with the oil level below the L
(Low) mark or above the H (High) mark. Wait at least 5
minutes after shutting off the engine to check the oil. This
allows time for the oil to drain to the oil pan.
The vehicle must be level when checking the oil level to
make sure the measurement is correct.

With a fill to the high oil level, oil will just start to flow from
the pipe plug near the center of the pan adapter.

Coolant Level
Checking
. .... Warning: Do not remove the radiator cap from· a hot it.
engine. Wait until the temperature is below sooe [120°F) . .
before removing'the pressure cap. Failure to do so can
result in persona! injury from heated coolant spray or
- steam. Remove thefiller..cap.slowly ..tQ relieve coolant.
system prassure.
Never use a sealing addilive to stop leaks in the cooling
system. This can result in the cooling system plugging
and inadequate ·coolant flow.
~
The coolant level must be checked daily. ~

Cummins Engine Co., Inc. does not recommend the use

of water and DCA without anti·freeze.
Refer to Coolant Recommendations/Specifications in ~
Section V for anti-freeze, water, and DCA specifications. ,.,
Air Cleaner Pre-Cleaner and Dust Pan Section 3 • Oaily Maintenance Procedures
Page 3-4 K38 and KSO

Caution: Do NOT add cold coolant to a hot engine. En-

gine castings can be damaged. Allow the engine to cool
to below SO·C [120°F] BEFORE adding coolant.

Fill the cooling system with coolant to the bottom of the

fill neck in the radiator fill or expansion tank.
NOTE: Some radiators have two fill necks, both of which
must be filled when the cooling system is drained.
Caution: Any time a significant amount of coolant is
added, the Diesel Coolant Additive concentration MUST
be checked. If the concentration is low, engine damage
/ .~ will resu It. . .. .... .... - ....... ..

~
II 'J I
g!BOOwS
.
J

Air Cleaner Pre-Cleaner and Dust Pan

Checking/Cleaning
Under extremely dirty conditions an air pre·cleaner can
be used. Clean the pre-cleaner jar and dry·type air cleaner
dust pans daily or more often, as necessary, depending
on operating conditions.

Raw Water Strainer

Cleaning
This picture illustrates a typical raw water strainer.
Depending on the operating environment, clean the raw
water strainer daily or as required. Some units can be
operated up to, but no longer than 6 months, before
cleaning.
Section 3 - Daily Maintenance Procedures Engine Monitor Systel
K38 and K50 Page 3·

Caution: A restricted or clogged strainer will result in

hotter than normal, or over heated, engine coolant and
marine gear oil temperatures.

wf811el

Engine Monitor System

Checking
Check the Engine Monitor System daily (push button to ~
test) per the manufacturer's recommendation to verify
proper operation.
Section 4 - Weekly Maintenance Procedures
K38 and K5D Page 4-'

Section 4 - Weekly Maintenance Procedures

Section Contents
PagE
Air Cleaner Element - Replacement.................................................................................................................. 4-:
Cartridge Type Element - Cleaning ................... ...................... ............... .......... .............. ...... ......... ...... ........... 4-1
Dual - Heavy Duty Dry-Type Element - Replacement ............................................................................... ...... 4-'
Single - Heavy Duty Dry-Type Element - Replacement ................................................................................... 4-1
Air Intake Hoses, Pipes, and Clamps .............. .................. ................ ................................ ........................ ...... 4-1
Checking ............. ..................... ..................................... ............. ..................... ............................. ................. 4-1
Air Tanks.. ....... ...................... ............................ ............................. .............................. ..................................... 4-1
General Information ................ ... ......... ... ......... ... ..... .... ....... ................ ...... ... ....... ......................... .... ...... ........... 4-~

Inlet Air Restriction Indicators ....................................................................................... _, .. ' .................. ",..... ... 4-~
Mechanical Indicator ............................................................ '" ..... ............. ... ....... ............. ............ .... ...... .... .... 4-~
Vacuum Indicator ........................................................................................................................................... 4-~
General Information Section 4 - Weekly Maintenance Procedures
Page 4-2 K38 and K50

General Information
All checks or inspections listed under the daily mainte-
nance interval must also be performed at this time in
addition to those listed under this maintenance interval.

oi801vU

Inlet Air Restriction Indicators

Mechanical Indicator
A mechanical restriction indicator is available to indicate
excessive air restriction through a dry-type air cleaner.
This instrument can be mounted in the air cleaner outlet
or on the vehicle instrument panel. The red flag (1) in the
window gradually rises as the cartridge loads with dirt.
After changing or replacing the cartridge, reset the indi-
2 cator by pushing the reset button (2).
Restriction or vacuum ind!cators are to he installed as
close as possible 10 the turoocharger air Inlet in order to
obtain a true indication of restrictions.
NOTE: Never remove the felt washer from the indicator. The
felt washer absorbs moisture.

Vacuum Indicator
Vacuum·switches actuate a' warning -light on the instru-
. @) ment panel when .--.
"-
the air restriction
-: ..
~,.-
becomes excessive.
.--~-

Air restriction on turbocharged engines must not exceed

635 mm [25 inches] or 46 mm [1.8 inches] of water under
fUlr power conditions. . --" - - - - . .. ..
 Section 4 • Weekly Maintenance Procedures Air Cleaner Element· Replacemen
K38 and K50 Page 4·:

Air Cleaner Element - Replacement

NOTE: The illustrations in this section show typical dry type
air cleaner parts. The particular engine parts can vary.
Replace the element if the inlet restriction or vacuum at
full power is found to exceed 25 inches of water. Chang-
ing filters or breaking the seal on the intake system more
than necessary will result in excess dirt in the engine and
must be avoided.

8c4elga

NOTE: Cummins Engine Co., Inc. does not recommend f\:"l

cleaning paper type air cleaner elements. ~

Elements that have been cleaned will clog and air flow to
the engine will be restricted.
Caution: Holes, loose end seals, dented sealing sur· A
faces and other forms of damage render the cleaner .L.l.
inoperative and require immediate element replacement.

ac4etgb

Remove the wing nut (1) that secures the bottom cover
(2) to the cleaner housing (3). Remove the cover.
Pull the element (6) down from the center bolt (4).
Caution: Pull the cover and the element straight out
. when removing them from the housing to avoid damage
to the element.
Remove the gasket (5) from the outlet end (7) of the
housing. inspect the gasket. Replace the gasket if nec-
essary. Assemble the bottom cover to the cleaner housing.

ae4e'gB

Single - Heavy Duty Dry-Type Element·

Replacement
Heavy duty air cleaners combine centrifugal cleaning
with element filtering before air enters the engines.
Before disassembly, wipe dirt from the cover and the
upper portion of the air cleaner.
Loosen the wing bolt, remove the band clamp securing
the dust pan (1).
Air Cleaner Element - Replace Section 4 - Weekly Maintenance Procedures
Page 4-4 K36 and K50
Loosen the wing nut (2). Remove the dust shield (3) from
EE~ the dust pan (1). Clean the dust pan and shield.
Remove the wing nut (5) that secures the air cleaner

~ primary element in the air cleaner housing. Inspect the

rubber sealing washer under the wing nut (4). Remove

~-
the dirty cleaner element.
•• Install the new primary element.
Make sure the rubber sealing washer is in place underthe
wing nut before tightening.
ac-4elgb
~
•• Assemble the dust shield and dust pan again. Position
them to the air cleaner housing and secure with the band
clamp.

Dual - Heavy Duty Dry-Type Element -

Replacement
Heavy duty air cleaners combine centrifugal cleaning
with element filtering before air enters the engines.
Before disassembly, wipe dirt from the cover and the
upper portion of the air cleaner.
Loosen the wing nut (3), remove the band clamp (1)se·
--curingthe-dust pan (2);--- ------------ -------

Loosen the wing nut (3). Remove the dust shield (4) from
the dust pan (2). Clean the dust pan and shield.
I'lernpve the vyingl)llt (9) _tl:l?lL.seQures the air cleafler
primary element (6) in the air cleaner housing. Inspect the
rubber sealing washer on the wing nut.

ac4etgc

Remove the dirty primary cleaner element (6). If the inner

safety element (8) is being replaced based on high intake
restriction, remove the wing nut (7) and replace the inner
safety element.

rffh, Install the inner safety element (8) and secure with the
wing nut (7). Check the seals.
~
Install the dust plan (2) and band clamp (1). Operate the
engine at rated speed and power and record the intake
restriction.

aC4t1lgc
 Section 4 - Weekly Maintenance Procedures Air Cleaner Element - ReplaCE
K38 and K50 Page 4-5

Cartridge Type Element - Cleaning

Loosen the wing nuts (4) on the air cleaner housing (5) to LS(q)
remove the pre-cleaner panel with the dust bin (6). To \l5
remove the pre-cleaner panel (2) equipped with an ex-
haust aspirator, loosen the U bolt clamp securing the
pre-cleaner to the aspirator tubing.
Remove the dirty Pamic cartridge (3), by inserting your
fingers in the cartridge opening (loosen all four corners
of the cartridge, one at a time) and pulling it straight out.
With the larger cartridge, it can be necessary to break the
seal along the edges of the cartridge. After the seal has
been broken, pull the cartridge straight out and slightly up
so the cartridge will clear the sealing frame and edges of
the air cleaner housing.

Cleaning and Inspection

Clean the pre-cleaner openings (2) of all soot, oil film and fS:l
any other objects that can become lodged in the open- iIiIi
ings. Remove any dust or dirt in the lower portion of the
pre-cleaner and aspirator tubing. Inspect the inside of the
air cleaner housing for foreign material.
Inspect the dirty cartridge for soot or oil. If there is soot ~
inside the Pamic tubes, check for leaks in the engine ~
.. "exhaust system,- exhaust blow-back into the air intake'
and exhaust from other equipment. If the cartridge ap-
pears oily, check for fumes escaping from the crankcase
breather. Excessive oil mist shortens the life of any dry-
.... type cartridge. Troubleshooting allhis point can appre-
Ciably lengthen new cartridge life.

It is not recommended to clean and reuse the cartridge.

When returned to service, life expectancy of a cleaned
cartridge will be only a fraction of the original service life.
, . - Inspect 'clamps al'idflexible hose 'Ol tubing to'make sure". --.~.'
..'.' '"
all fittings are air tight on cleaners with exhaust aspira- ~
tors. ... ,.. - - . ...~- .. ...
~

Toe PlEl"cleaner .dust (6)pjn is s,."lf-cleaning.,

Assembly
5
Inspect the new filter cartridge for shipping damage be-
fore installing.
rf8fu
~
To install a new cartridge, hold the cartridge (3) in the
same manner as when removing it from the housing.
Insert the clean cartridge into the housing, avoiding hit-
ting the cartridge tubes against the sealing flange on the
edges of the air cleaner housing.
Air Intake Hoses, Pipes, and Clamps Section 4 - Weekly Maintenance Procedures
Page 4-6 K38 and K50

As the cleaner requires no separate gaskets for seals,

~
\'@ care must be taken when inserting the cartridge to insure
a proper seat within the cleaner housing. Firmly press all
edges and corners of the cartridge with your fingers to
effect a positive air seal against the sealing flange of the
housing. The cartridge must not be pounded or pressed
in the center to seal.
Replace the pre-cleaner panel (2) and tighten the wing
nuts (4) by hand. For final tightness turn the wing nuts 1
to 1 1/2 turns with a small adjustable wrench. Do not
tighten too much. On a pre-cleaner with an exhaust as-
pirator, assemble the aspirator tube to the pre-cleaner
panel and tighten the U bolt.
Care must be taken to keep the cleaner face
unobstructed.

Air Intake Hoses, Pipes, and Clamps

Checking
~ Inspect the intake piping for cracked hoses, loose clamps,
~ or punctures which can damage the engine.

EB
~ Tighten or replace parts as necessary to make sure the
~ air intake system does not leak.
_. _~ __••• _. -0- ___ •• ___ • ~ ______ • ____ _

Check for corrosion of the intake system piping under the

clamps and hoses. Corrosion can allow corrosive prod-
uct~ and dirt to enter- the intAke s\'stem_ Oisas::-:emble 2nd

~ rp6~sa j clean as required.

All hoses on the intake piping must be dOUble clamped
or use t-bolt type clamps.

Air Tanks
Drain the moisture. from .the.•air system wet.tank .weekly....... .
Section 5 • Maintenance Procedures Every 250 Hours or 6 Months
K38 and K50 Page 5·1

Section 5 - Maintenance Procedures Every 250 Hours or 6

Months
Section Contents
Page
Air Com pressor Air Cleaner Element ......... ,... ......... ... ....... .......... ...... .......... .......... .......... .... ... ... .......... ... ... ...... 5-10
Bendix-We~tinghouse Paper Element - Replacement .................................................................................... 5-10
Bendix-Westinghouse Sponge Element - Replacement ................................................................................. 5-10
Cummins Two-Cylinder Only - Replacement. ................................................................................................. 5-10
Belt Tension .................................................................................................................................................,.. 5-11
Checking... , ... ...... ...... .... ... ... ......... ...... ......... ....... ...... ...... .......... ..... ........... .... .... ...... ......... ........... ... .... ... ... ...... 5-11
Belts ................................................................................................................................................................. 5-11
Checking... , ....... ............ ... .............. ........ ......... ......... .... ...... ................... ... ... .................... .............. ....... ...... ... 5-11
Coolant Filter..... ... ...... ........... ...... .... ..... ......... ...... ... ....... ......... ...... ........ ...... .......... .... .......... ...... ...... ... ... .......... ... 5-8
Replacement............................................... ............... ............................ ............................. ... ......................... 5-8
Cooling Fan ..................................................................................................................................................... 5-11
Checking....................................................................................................................................................... 5-11
Cooling System Additives ......... ... ............ ............... ....... ... .... ...... ....... ..... ..... ..... ... ... ... .......... ... ...... ... ... ....... ... ... 5-6
Checking .................................. ,. ...... .......... ...... ... ... .......... ... ....... ........... ...... .... ... ... ...... ... .... ...... ... ... ... ....... ...... 5-6
Crankcase Breather Tube/Hose .................................................................................,................ ...... ... ... .... ... ... 5-6
Checking/Cleaning·......... .... ... ..... .... .......... ...... ...... ... ......... .... .... .............. .... ...... ... ... ... ... ............. ... ... ...... ....... ... 5-6
Fuel Fllter(s)· .~. :.~:... :.".: .. ::~.:: .. :..... :";;;":...... :.:.. :...... ; ..... :;;~;;::.;";..-......: ..::;::.::.C c. ;.;.;;:: ••••......••.••.......•.•: ......................=:." "5-2-
Replacement ................................................................................................................................................... 5-2
General Information .................................. .......... ............... ............................................................................... 5-2
Lubricating Oil and Oil Filter ............................................................................................................................. 5-3
Changing/Replacement.. ......................................... ................................... ........................................... .......... 5-3
General Information Section 5 - Maintenance Procedures Every 250 Hours or 6 Months
page 5-2 . K38 and K50

General Information
All checks or inspections listed under the previous main-
tenance intervals must also be performed at this time in
addition to those listed under this maintenance interval.

olB01vu

Fuel Filter(s)
Replacement
Every 250 hours or 6 months clean the area around the
fuel filter he_ad and replaceJl:Je_fueL filter(s).
NOTE: The illustrations in this section show typical parts.
The parts on your engine can look slightly different but the
instructions.given will apply. ---
Use a filter wrench, Part No. 3375049, to remove the fuel
filter.
j J'--

Use a clean, lint-free towel and clean the filter head

gasket surface.
Use the correct filters for your engine. -.... - ... -" ..... _.........
Fuel Filter
Cummins Part No. 3315844 (without draincock)
Cummins Part No. 3315847 (with draincock)
Ffeetguard® Part No. FF1!iSD (with draincock)
Fleetguard® Part No. FF105 (without draincock)

Apply a light film of clean engine oil to the filter gasket

I~ surface.
Fill the filter with clean fuel.

.....b
 Section 5 • Maintenance Procedures Every 250 Hours or 6 Months Lubricating 011 and 011 Fllte
K38 and K50 Page 5·;

Install the filter on the filter head. Tighten the filter until
the gasket contacts the filter head surface.
Tighten the filter perthefilter manufacturer's instructions.

+ 1f2 to 3A Turn
ffBlJlhJ

Lubricating Oil and Oil Filter

Changing/Replacement
Caution: Avoid direct contact of hot oil with your skin. it. ."
Hot 011 can cause personal Injury. .Llr.
Charrge1tTelubricating oil and oil filters at every ali change M
interval. IIMi
Operate the engine until the water temperature reaches
60°C [140°Fj. Shut cifffhe engine. Remove the oil drain· ... ~.
EB
plug. Drain the oil immediately to make sure all the oil and
suspended contaminates are removed from the engine.
........
The external appearance of the full flow (1) and the by-
pass (2) filters is the same. The accompanying picture
identifies the difference between the two filters.
-NOTE: "Fhe1ull flow filter contains 1-1/2 16 inch threads. The
bypass filter contains 1-3/8 16 inch threads.
Lubricating Oil and 011 Filter Section 5 - Maintenance Procedures Every 250 Hours or 6 Months
Page 5-4 K38 and K50

The following illustrations show the full flow oil filter. Use
the same procedure when changing the bypass oil filters.
Clean the area around the lubricating oil filter head. Clean
the gasket surface of the filter head.
NOTE: The a-ring can stick on the filter head. Make sure the
o-ring is removed.
Cut all the way around the top of a full flow filter using a
pipe cutter or hack saw. Inspect the pleated paper ele-
mentfor metal debris. Metal debris in the filter can reveal
impending engine failure. If debris is found, find the rea-
\\-
1!8hdwa
son for the debris and make the needed repairs.
Use an oil filter wrench, Part No. 3375049, or equivalent.
Remove the full flow oil filters.
Discard the filters if they are not needed for a failure
analysis.

Use the correct oil filter for your engine.

Full Flow Filter
K38 (4 required)
Cummins Part No. 3313279
Fleetguard® LF-670
o • ""'K5{>-(S'requiredj .--
Cummins Part No. 3313287
Fleetguard® LF-3325
Bypass filter

116"m, I K38 and K50 (2 required)

Cummins Part No. 3313283
Fleetguard® P art No. LF-777

Caution: Fill the oil filters with clean lubricating oil. The
. 'Iack--of 1Ubrtclitlondllrlttg'tlfe"delay until the filtlml a~
pullle.ed full o.foills harmful to the engine.
Apply a light film of lubricating oil to the gasket sealing
surface before installing the new filters.
Section 5 - Maintenance Procedures Every 250 Hours or 6 Months Lubricating Oil and Oil FiliI
K38 and K50 Page 5·

Caution: Mechanical overtightening can distort the

threads or damage the filter element seal. A.
Install the filter as specified by the filter manufacturer.
The tightening instructions are normally printed on the ~
outside of. the filter. ~

+ 3fi1 to I Turn
ff6eth[

Check and clean the oil drain plug threads and the seal
surface.
Install and tighten the oil drain plug.
Torque Value: 100 Nem [75 ft-Ibs]

op6pxwa

NOTE: Use a high quality 15W-40 multi·viscosity oil such as

Cummins Premium Blue, or its equivalent in Cummins en-
gines. Choose the correct oil for your operating climate as
·outlined in Section V-of this manual. . .~.

pJ800gb

Fill the engine with clean oil to the correct level. Total
system capacity including filters is listed in Section V of
this manual. H
H

ol80lvw
Crankcase Breather Tube/Hose Section 5 • Maintenance Procedures Every 250 Hours or 6 Months
Page 5·6 K38 and K50

Caution: Before starting the engine, complete the steps

given In Starting Procedure After Extended Shutdown in
Section 1 to make sure the engine receives correct lu.
brlcatlon. Lack of lubrication will damage the engine.
Operate the engine at idle speed to inspect for leaks at
the filters and the drain plug.

Shut off the engine. Wait approximately 5 minutes to let

the oil drain from the upper parts of the engine. Check the
oil level again.
H . H
Add oil as necessary to bring the oil level to the high mark
(H) on the dipstick.

LJ L
I Hili i /1/ 1111'''01~ I

~
H =GI~~eiil~i~
,. i .- _____ __ ,Checking/Cleaning
Crankcase Breather
, Tube/Hose
I l."
-
I
~ I,r'fii"" -'
J/I
/11 ,- ,. '"
~
Every 250 hours.or 6 months, check and clean the crank-
case breather tube/hose.
o , __. ,. o}.: E ,_ r- __ - r--=- _ The tube/hose is to be Iemoved and checked internally
.....J for obstructions or sludge buildup.
~<!J If the tube/hose is blocked, It Is to be cleaned or replaced
'\J:!} to prevent excess crankcase pressure buildup.
k 0 oj

Cooling System Additives

£r .
Checking
-,- --
Large Plastic
r r' Cup

-- -- --
"""'- Check the DCA4 concentration level whenever coolant is
A B -...t""_ ... i )
.....J"_a _"'f.....
·· . added to the cooling system between filter changes.

~,-·Jl
~f.~ Use Fleetguard® coolant test kit, CC2626, to check the
Test Strip ;. ') concentration level. Instructions are included with the
test kit.
Bonles
Bottle
~1.;;m.w·'!1P Small Plastic
Container
Syringe o1803vu
Section 5 - Maintenance Procedures Every 250 Hours or 6 Months Cooling System Additivo
K38 and K50 Page 5

Warning: Check the coolant level ONLY when the en-

gine Is stopped. Wait until the coolant temperature Is
below 50°C [120°F] BEFORE removing the pressure
cap. Failure to do so can cause personal Injury from
heated coolant spray.
Operate the engine and check for coolant leaks.
After the air has been purged from the system, check the
coolant level again.

COOling system additives (DCA4 or equivalent) are used

to prevent the buildup of corrosion and scale deposits in
the cooling system.

- .. - ... ~~

~ ta600we

Caution: Under-concentration of coolant additives can

result In liner pitting and system corrosion. Over-
concentration can result In water pump seal leakage.
The'l'eCommended'concentration level of sUpplemental' ,. ,.......
coolant additives is 1.5 per U.S. ~lIon of coolant. The
additiilelevel must neverarop berovn ~2 uniis or exceed
3 units per gallon of coolant. .... Ii ""-~ ..............
. I' '.

1:'-';;;;::::;:>-<..::::--;::::11.5 Units DCA4 3+Unlts DCA

NOTE: DCM is compatible with all permanent-type anti-

freeze except Methoxy Propanol. If Methoxy Propanol an-
tifreeze is used, reduce the amount of DCA4 by one-third.
This will prevent inhibitor loss due to precipitation, caused
by chemical incompatibility.

Full 2/3 Full

DCA4 DCA4
ra800vl
Coolant Filter Section 5 • Maintenance Procedures Every 250 Hours or 6 Months
Page 5-8 K38 and K50

When changing the coolant, the initial DCA4 (or equiv-

alent) concentration must be between 1.5 and3 units per
3.8 liters [1 U.S. galionJ of coolant (initial charge).
NOTE: The cooling system must be clean before adding
~ OCM (or equivalent).
Refer to Section V for cleaning instructions.
If coolant is added between drain intervals, additional
OCA4 (or equivalent) will be required unless the added
coolant is precharged with additives as described in this
3 Units DCA4 section.
raGOOva

Coolant Filter
Use the correct Fleetguard® coolant filter to maintain the
correct DCA4 concentration in the system.
Maintain the correct concentration by changing the ser-
vice coolant filter at each oil drain interval.
/
/ ,,
===~ ~ Refer to Coolant Recommendations/Specifications in
. / ______ ",1 __ _ Section V fOithe Fleetguard® Coolant Filter listing.

r250 ~'ours I
1._- .~ ___ ~_. __

wr~etya

Replacement
Change the service coolant filter at every oil and filter
.
·changeinterval~···

The correct service coolant filter to be used is determined

by the total cooling system capacity and other operational
factors.
~ Refer to the DCA4 Maintenance Guide in Section V for
the correct filter selection.

cl800vf

Warning: Do NOT remove the radiator cap from a hot

engine. Hot steam will cause serious personal Injury.
Remove the coolant system pressure cap and close the
shutoff valve(s), If equipped, before removing the cool-
ant filter. Failure to do so can result In personal Injury
from heated coolant spray.
Section 5 - Maintenance Procedures Every 250 Hours or 6 Months Coolant Filtel
K3B and K50 Page 5·~

Push in the knob on the filter head or close the gate valve
(1) if so equipped,

Use engine oil and lubricate the seal on the new filter.
NOTE: Do not allow oil to get in the filter, it will adversely
affect the DCA.

wfflS6W8

Install the new coolant filter. Turn. the filter until the seal .~
touches the filter head. Turn the filter an additional 1/2 to ~
3/4 of a turn after contact.
.< ~ __ ~·-i.

Pull the knob on the filter head out or open the gate valve
(1).
Air Compressor Air Cleaner Element Section 5 • Maintenance Procedures Every 250 Hours or 6 Months
Page 5-10 K38 and K50

Air Compressor Air Cleaner Element

NOTE: If the air compressor inlet is plumbed to the engine
intake air system downstream of engine intake air filter, an
air compressor air cleaner element will not be present.
Cummins Two-Cylinder Only - Replacement
Every 250 hours or 6 months replace the air compressor
air cleaner element. Remove the wing nut, the cover, the
housing, and the element. Clean the cover and the hous-
ing with a clean cloth. Inspect the rubber gasket on the
center bolt. Replace if damaged.
ac8elga
Install a new element, Fleetguard® Part No. AF-251 or
Cummins Part No. 256837, in tne front cover and as-
semble over the center bolt. Use your fingers to instali
and tighten the wing nut.

Bendix-Westinghouse Paper Element -

1 Replacement
Remove the breather cover and element. Clean by re-
verse flushing with compressed_air. Assemble on the
compressor. Discard the element if it is damaged or can
not be cleaned.

I\
Bendix-Westinghouse Sponge Element -
Replacement
Remove the breather from the air compressor. Disas.
semble the breather, wash all metal parts in solvent and
blow dry with compressed air. Wash the element in sol-
vent. Remove all solvent from the element. Dip the ele-
ment in clean engine oil and squeeze excess oil from the
element.
~ NOTE: If other compressors are used, follow the manufac-
turer's service requirements.
 Section 5 • Maintenance Procedures Every 250 Hours or 6 Months BI
K38 and K50 Page 5

Belts
Checking
Visually check the belts every 250 hours or 6 months. .~
Replace the belts that are cracked or frayed. Adjust belts ~
that have a glazed or shiny surface which indicates belt
slippage. Correctly installed and tensioned belts will show
even pulley and belt wear.
Belt damage can be caused by:
• Incorrect tension
• Incorrect size or length
• Pulley misalignment
• Incorrect installation
• Severe operating environment
• Oil or grease on the belts

Belt Tension
Checking
Measure the belttension in the center span olthe pulleys.
Refer tothe manufacturer's recommendations for the use
of the belt tension gauge. Refer to Section V in this
manual for the gauge and tension information .
. ...Refer to the Drive BeJtT.ension,.Section V, fortheconecL ~.I~J;ll;;j~~~~e~
gauge and tension value for the belt width used. I
The tension of the fan belt on an engine with a fan idler
pulley (refer to Section E, page 11) need not be mea-
sured. The spring loaded idler used on this design main-
tains the correct belt tension.
An engine with a two pulley fan drive (one which does not
have an idler pulley) must have the fan belt tension
measured.

. Cooling Fan
Checking
Warning: Personal Injury can result from a fan blade
--ra:llure:Nevet pull <wpry onlhiffiill;This tan damage the
fan blade(s) and cause fan failure.
NOTE: Rotate the crankshaft by using the engine barring
gear only.
Check the eooling fan every 250 hours or 6 months.
Check fo'r cracks, loose rivets, and bent or loose blades.
Check the fan to make sure it is securely mounted. Tighten
the capscrews if necessary. Replace any fan that is dam-
aged.
Refer to Section A, Fan Belt, of this manual for adjust-
ment procedures.
Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year
K38 and K50 Page

Section 6 - Maintenance Procedures Every 1500 Hours

Section Contents
p
Batteries ..........................................................................................................................................................
Checking .................................... :............... :..................................................................................................
Cold Start Aids .......... ................................... .............................. ......... ................. ...... .................. ................... I
Checking....................................................................................................................................................... I
Crankshaft End Clearance.......................................... ...................................................... ................. .............. I
Inspection ................................................. .................................. ...... ............................. ...... ................... ...... f
Engine Mounting Bolts and Nuts ...................... .............................................................................................. f
Checking....................................................................................................................................................... f
Engine Protection System................. ................... ...................... ..................................................................... f
General Information................... .............................. .......................... ............................ .......... ....... .............. f
Fan Idler Pivot Arm ........................... ...................... ........................................................................................ e
Fan Idler Pulley Tensioner Adjustment .......................................................................................................... 6
Engines With Control Rod Spring.... ................... ........................................................................................... 6
Engines With Shock Absorber .................................................. ................... ......... ....................... .................. 6
Engines With Solid Control Rod... ....... ...... ......... ............. ...... ............. ............ ...... .......... ....................... ........ 6
Front Engine Support ...................................................................................................................................... 6
General Information ..........................................................................................................................................
Heat Exchanger Zinc piiigs(Marine Orily) ........ : .. ::.~.::.~ ... ~.:....·.:·:.:.: ...... :·..:: .... :.~.. :::........................... :.........: ... 6
Checking ....................................................................................................................................................... 6
Hoses ............................................................................................................................................................... 6
CheckingJRepiacement ................ ................................................................................................................. 6·
Steam Clean the Engine................ ............ ............... .................... ................ ............... .......... ...... ................. ..... I

Valves and Injectors.................................. ....... ................................................................................................. I

General information - Checking and Adjustment ............................................................................................. I
PT (type DJ Injector and Valve ~et Procedures ............................................................................................... I
STC or HVT OBC Valve and Injector Set Procedure ..................................................................................... 6·
 General Information Section 6 • Maintenance Procedures Every 1500 Hours or 1 Year
Page 6·2 K38 and K50

General Information
All checks or inspections listed under the previous maintenance intervals must also be performed at this time in
addition to thos,e listed under this maintenance interval.

Steam Clean the Engine

Caution: Cover all engine openings and electrical equip.
ment to prevent water damage.
Steam clean the engine before conducting any 1500
hour maintenance. Steam is the best method of cleaning
a dirty engine or a piece of equipment. If steam is not
available, use a solvent to wash the engine.
Protect all electrical components, openings, and wiring
from the full force of the cleaner spray nozzle.

Valvesal'ld Injesters
General Information - Checking and Adjustment
"" .. "-Valveltandinjectors must be correctly adjusted for the engine to operate efficiently:-Valve and injector adjustment
must be performed using the values listed in this section.
Ct!'l1mins enaines in most Boo!!cat.ions will not experience sioniflG8'1t vahte and/or ini~ctortra!n \1,f9Rr aft~r an initial
aOjustmem IS mace at 1 bUU nours. Arler HilS adjUStment, Cummins recommends the valves and injectors not be
adjusted again until the 6000 hour or 2 year injector calibration interval. Because injectorlrain hardware is typically
mixed between cylinders during injector replacement, Cummins recommends to adjust valves and injectors 1500
hours after all injector replacements.

1. Engine firing order:

K38 1R-6L-5R-2L-3R-4L-6R·1 L-2R-5L-4R-3L
K50 Standard 1R-1 L-3R-3L·7R-7L-5R·5L-BR-BL-6R·6L·2R·2L4R-4L
K50 Revised 1R·1 L-3R-3L·2R-2L·5R-4L·8R.8L·6R.6L-7R·"ZL.4R-SL

". _..... 2. Cylinders are nUlT!bered from the front gear cover end of the engine. To determine the right and left banks on
a K38 and K50 engine, stand at the rear of the engine and face the front. (The left bank of these engines is the
fuel pump side.)
3. Two crankshaft revolutions are required to adjust all of the valves and the injectors.
4. Each cylinder has three rocker levers. On the left bank (fuel pump side of the engine), the lever nearest to the
rear of the engine is the intake lever. On the right bank, the exhaust valve is nearest to the rear. The center lever
is the injector lever.
5. One pair of valves and one injector are adjusted at each pulley index mark before rotating the engine to the next
index mark.
6. There are two methods for adjusting the injectors on K3B and K50 engines. "the engine has STC (Stepped Timing
Control) or HVT injectors, the outer base circle (OBC) method is used. If the engine has PT (type 0) injectors,
the injectors are set by adjusting the travel.
7. If the engine contains PT (type 0) injectors, the valves and injectors on the same cylinder are adjusted at the
same index mark.
8. All KTTA38 and 50 engines have STC injectors. Some KTA38 and 50 engines have STC injectors.
9. All KT38 and most KTA38 and 50 engines have PT (type 0) injectors.
10. The KTA38-G3, KTA50-G3, KTA50-G4, and KTTA50·G2 all use Premium K STC Injectors. Premium K STC
injectors are similar in appearance to Full Top Stop STC injectors, but the total plunger travel is different. Both
the Premium K STC injector and the Full Top Stop STC injector are adjusted by the OBC Injector set method.
11. Instructions for adjusting both types of injectors (PT (type D) and STC or HVT) are included in the Injector, Adjust
Section 6 • Maintenance Procedures Every 1500 Hours or 1 Year Valves and Injectol
K38 and K50 Page 6·

fi4bdWb

PT (type OJ Injector Early STC/HVT Injector

Full Top Stop STC Inlector

(Premium K rn/ector rs similar.)
Valves and Injectors Section 6 • Maintenance Procedures Every 1500 Hours or 1 Year
Page 6-4 K38 and K50

PT (type 0) Injector and Valve Set Proce-

dures
~ If you have not previously cleaned the engine, steam
clean the engine now to prevent dirt from entering the
engine when the valve covers are removed. Refer to
Steam C-Iean the Engine in this section of the rrianual.

Remove the rocker lever covers and all related

components.

~ K38 and K50 engines have valve and injector adjustment

~ marks in three locations.
Valve and injector adjustment marks are onthe vibration
dampe~,_,!he m~!:.~~_,lI1ust
be aligned with the pointer,

ItGlaga
!

For valve and injector adjustment marks on the flywheel

/ @ with the engine barring device located on the right bank:

t
/
I -'-I The starter bore cover must be removed to see the marks.

A II A
Caution: When using this Index mark, the marks on the
flywheelthat begin with anA must be used or the valves
.I'
',/ and Injectors will not be adjusted correctly, causing dam·
age to the push rods.

r~< A
I
rrn I tt6iagb
 Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Valves and (njecta
K38and K50 PageS

For valve and injector adjustment marks on the flywheel ~

with the engine barring device located on the left bank: .~
The starter bore cover must be removedto see the marks.
Caution: When using this Index mark, the marks on the
flywheel that begin with a C must be used or the valves
and Injectors will not be adjusted correctly, causing dam-
age to the push rods.
This illustration also shows the engine barring device. To
use the device, remove the Clip and push the device shaft
toward the flywheel. The barring device must be rotated
counterclockwise to turn the flywheel and crankshaft in it61agc
the direction of normal rotation.

This artwork displays the Firing Order for ALL K38

engines.
K38 Firing Order

1 R-6L-SR-2L-3R-4L-,
I
L6R-1 L-2 R-SL-4R-3L

olaOOwa

This artwork displays the standard Firing Order for all K50
engines which use PT (type D) injectors.
KSO Firing Order

1 R-1 L-3R-3L-7R-7L-SR-SL
J
LSR-SL-6R-6L-2R-2L-4R-4L

o!600wb

Direction of normal rotation for K38 and K50 engines is

clockwise when viewing the front of the engine.
@
~
........
VS represents the valve set. Ignore any Te (top center)
marks while setting the valves and injectors.
Determine the Cylinder In Position for Valve Set
The crossheads and valves are ready to be adjusted on
the cylinder that has all the valves closed.
Check the two cylinders shown on the VS mark.

) -
it600wa
Valves and Injectors Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year
Page 6-6 K38 and K50

If the rocker lever assemblies have been removed, use

this step to determine the cylinder to set.
All adjusting screws must be loose on all cylinders, and
the push rod must remain in alignment. '
NOTE: Perform this step on both cylinders to be checked.
Hold both rocker levers against the cross heads. Turn the
adjusting screws until they touch the push rods. Turn the
locknuts until they touch the levers.
The cylinder with the adjusting screws that are nearly the
same height Ontake screw can be upto two threads above
the exhaust) is ready for valve adjustment. The second
cylinder that is not ready for adjustment will have the
adjusting screw for the exhaust valves more than five
threads above the intake screw.
The push rods will be close to the same height above the
top of the rocker lever housing on the cylinder ready for
valve adjustment.
If the rocker levers have not been removed, wiggle the
valve rocker levers on the two cylinders in question. The
crossheads and valves on the cylinder where both levers
feel loose are ready to adjust.
Caution: Use the cprrect chart forlhe engine belng'se'r; .
viced or the parts will be damaged.
tt~ -, ... l.rL~"'''--'-'f"~''r-:'< 'I-~o f",\,H...,rl-,.. ,,.i+r- +1..,....., '-'~~'/~.- P--:':.-"-<-"':C' ~c

adjusted, use tlie following charts for the sequence. The

procedure and specifications for adjusting the cross-
heads, valves and injectors are after the charts.
The following charts give the crosshead, valve and in-
jector adjustment sequence.
NOTE: Adjustment can begin on any valve set mark. In our
example, assliitiEfthe1R-6R anR·SR marks are aligned
and the acljusting.~c;rew height forthe valves on the cylinder
No. 1 right bank are closed and ready to adjust.
Section 6 • Maintenance Procedures Every 1S00 Hours or 1 Year Valves and Injecto
K38 and KSO PageS

K38 PT (type D) Valve and Injector Adjustment Chart

VALVES CLOSED ADJUST VALVES AND INJECTORS
VS MARK ON CYLINDER NUMBER ON CYLINDER NUMBER
1R-6R VS 1 RB 1 RB
6L-1L VS 6 LB 6 LB
SR-2R VS 5RB 5RB
2L-SL VS 2 LB 2 LB
3R-4R VS 3 RB 3RB
4L-3L VS 4 LB 4 LB
1R-6R VS 6RB 6RB
6L-1L VS HB 1 LB
5R-2R VS 2 RB 2RB
2L-5L VS 5 LB 5 LB
3R-4R VS 4 RB 4RB
4L-3L VS 3 LB 3 LB

KSO PT (type D) Valve and Injector Adjustment Chart

VALVES CLOSED ADJUST VALVES AND INJ£CT_OBS
VS MARK ON CYLINDER NUMBER ON CYLINDER NUMBER
1R-BR VS 1 RB 1 RB
1L-BL VS HB 1 LB
3R-6RVS "3 RB 3"RB" .. 0 -

3L-6L VS 3 LB 3 LB
2R-7R VS 7 RB 7RB
2L-7L VS 7LB 7 LB
4R-5R VS 5RB 5RB
4L-5L VS 5 LB 5 LB
1R-8R VS BRB aRB
1L-BL VS aLB aLB
3R-6R VS 6RB 6RB
3L-6L VS 6LB 6LB
2R-7R VS 2RB 2RB
2L-7L VS ·2 LB 2LB
4R-5R VS 4RB 4RB
4L-5L VS 4LB !UB
Valves and Injectors Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year
Page 6-8 K3!! and K50

Crossheads - Adjustment
NOTE: Crosshead adjustment must always be made
before attempting to adjust the valves.
Adjustthe crossheads on the cylinder that has both valves
closed~.

Loosen the crosshead adjusting screw locknuts on the

intake and exhaust valve crossheads.

Use the following procedure to adjust both the intake and

the exhaust cross heads.
Turn the adjusting screw out at least one turn.
Hold the crosshead down against its guide.
Turn the adjusting screw in until it touches the top of the
valve stem but does not raise the crosshead.

Hold the adjusting screw in this position. The adjusting

screw must not turn when the lock nut is tightened to its
torque value. Tighten the lock nut. The following torque
values are -given with arid without Part No. ST-669 Torque
Wrench AdapteC{:I):

__Tor_que .valu~ __~

N.m ft-Ib
With Adapter 35 25
Less Adapter 40 30

Valves - Adjustment

Valve Adjustment (Initial Set)

mm In
0.69 Exhaust 0.027
0.36 Intake 0.014
Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Valves and Injecte
K38 and K50 Page E

Select a feeler gauge for the correct valve lash specifi- ~~.
cation. I nsert the gauge (2) between the rocker lever and '\..Y
the crosshead.

)
Two different methods for establishing valve lash clear-
ance are described below. Either method can be used;
however, the torque wrench method has proven to be the
most consistent.
a. Torque Wrench Method: Use Part No. 3376592
Inch Pound Torque Wrench and tighten the ad-
justing screw to 0.68 Nem [6 in-Ib] torque.
b. Feel Method: Use a screwdriver and turn the ad-
. justing screw· ONtY until the lever .touches the
feeler gauge.

rhGtol

The adjusting screw must not turn when the locknut is

tightened.
Tighten the locknut to the value indicated below.
With Torque Wrench
Adapter. Part No.
ST -669 (1) 45 Nem [35 ft-Ib]
Without Adapter 60 Nem [45 ft-Ib]
o
The feeler gauge must slide backward and forward with
only a slight drag.
Attempt to insert a feeler gauge that is 0.03 mm [0.001
inch] thicker. The valve lash is not correct when the
thicker gauge will fit.
Repeat the adjustment process until the clearance is
correct on both the intake and the exhaust valves on the
cylinder being adjusted.
Valves and Injectors Section 6 • Maintenance Procedures Every 1500 Hours or 1 Year
Page 6·10 K38 and K50

PT In/ector (type D) • Adjustment

NOTE: All KT38 and some KTA38 and 50 engines have PT
(type D) injectors. To determine if the engine being serviced
contains PTD injectors, refer to the engine dataplate. The
Injector Travel section will specify 0.3075 inch.
1. Assemble the parts of an injector and valve adjust·
~
ment kit (3), Part No. 3822575, or equivalent. Install
the adjustment kit on the cylinder to be adjusted as
~ shown.
2. Adjust the indicator so that the tip is touching the top
of the injector plunger.
3. Lower the indicator 12.25 mm [0.5 inch] to allow for
travel. Lock the indicator support to the post.

Caution: The Injector plunger is under spring tension.

Do NOT allow the tool to Slip. Personalln/ury can result.
NOTE: Prevent damage to the indicator by allowing the lever
to return slowly.
4. Use a rocker lever actuator, Part No. 3822574, or
equivalent. Depress the lever until the injector bot-
toms two or three times. This will remove fuel from the
cup.

Check Existing Setting

1. Hold the lever with the injector plunger firmly bot-
tomed in the cup. Set the indicator to ZERO.
Raise and lower the lever a few times to confirm the
ZERO.

2. Slowly release the lever and observe the travel of the

gauge. Press down or tap lightly on the adjusting
P1D INJECTOR TRAVEL screw to confirm the reading.
VERIFICATION SPECIFICATION

mm pn]
7.80 MIN [0.307]

7.82 MAX [0.308]

IteOOnb
Section 6 • Maintenance Procedures Every 1500 Hours or 1 Year Valves and Inlecton
K38 and K50 Page 6·11

Reset
1. Turn the adjusting screw until the indicator reads the ~
specified travel. W
PT (type D) Injector Travel Specifications
mm Model in
7.81 0.308

NOTE: The adjusting screw must not turn when the locknut
is tightened.
2. Tighten the locknut to the value indicated below:
With Torque Wrench ~
Adapter, Part No. ST-669 (1) 45 Nem [35 ft-Ib] '-Y
Without Adapter 60 Nem [45 ft-Ib]

Check New Setting

Caution: The Injector plunger Is under spring tension.
Do NOT allow the tool to Slip. Personal InJury can result.
. .-._.'
NOTE: Prevent damage tothe indicator by allowing the lever
to return slowly.
1. Check the injector adjustment. Use the rocker lever
. actuator: Bottom the injector plunger. Confirm the
ZERO on the indicator.

2. Allow the rocker lever to return slowly. Check the

injector setting. Repeat the adjustment process if it is
@
-;;r;;
......-
not within specification.
Pm INJECTOR lRAVEL

3. Rotate the engine. Align the next mark. Adjust the VERIRCATION SPECIRCATlON
appropriate valves and injectors. Repeat the process
to adjust all of the valves and the injectors correctly. ~ mm pn]
Refer to Adjust the Valves in this section. [0.307]
7.80 MIN
If the barring device was used, allow the spring to push
the shaft and clear the ring gear. Install the clip. 7.82 MAX [0.308]

ItBOOnb
Valves and Injectors Section 6 • Maintenance Procedures Every 1500 Hours or 1 Year
Page 6·12 K38and K50

STC or HVT OBC Valve and Injector Set

[ , Procedure
Run the engine in the retard mode before setting the
OBC method. This removes oil from the tappets which
can cause an improper set.
-- --

K38 and K50 engines are equipped with a

hydromechanical STC valve. Remove the oil supply hose
from the oil control valve. Plug the hose and cap the
fitting. This prevents the engine from going into advance
timing.

Operate the engine at high idle for 5 minutes (in retard

timing mode). This will allow all of the oU to pump out of
the injector tappets so a correct injector adjustment can
be made.
Shut the engine off.

I.· . j ew600va )

If you have nol previously cleaned the engine, steam

~ clean the engine now to prevent dirt from entering the
engine when the r5lcker lever covers are removed. _

Et;<!1 Remove the rocker lever covers. Discard the gasket.

 Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Valves and I nject(
K38 and K50 Page 6·

K38 and K50 engines have valve and injector adjustment ~

marks on the vibration damper and on both sides of the IQl
flywheel housing.
Valve and injector adjustment marks are on the vibration
damper. The marks must be aligned with the pointer.

It61agl

For valve and injector adjustment marks on the flywheel

with the engine barring device located on the right bank: @ / _.
~.
The starter bore cover must be removed to see the marks.
Il
Caution: When using this Index mark, the marks on the
flywheel that begin with an A must be used or the valves
and InJectorswill not be adjusted correctly, causing dam-
A. -;/
age to the push rods.

/1
A (if) II 1t61agh

For valve and injector adjustment marks on the flywheel ~

with the engine barring device located on the left bank: IQl
The starter bore cover m usl be removedlo see the marks .
. Caution: When using this Index mark, the marks on th~····~ .•. ·~t~;)lI~mj!ll
flywheel that begin with a C must be used or·the valves· ·4
and Injectors will not be adjusted correctly, causing dam- ~
ag~ to the push !od.s.

This illustration also shows the engine barring device. To

use the device, remove the clip and push the device shaft
toward the flywheel. The barring device must be rotated
counterclockwise to turn the flywheel and crankshaft in i1Blagc
the direction of normal rotation.

Caution: Not all K50 en glnes have the same firing order.
Some K50englnes manufactured after September, 1986,
have a revised firing order. These engines have decals
K50 REVISED Firing Order
on the rocker lever covers and the engine data plate Is
stamped with the words REVISED FIRING ORDER.
1R-1 L-3R-3L-2R-2L-SR-4L J
LSR-SL-SR-SL-7R-7L-4R-SL
Valves and Injectors Section 6 • Maintenance Procedures Every 1500 Hours or 1 Year
Page 6-14 K38 and K50

Direction of normal rotation for K38 and K50 engines is

/ -- clockwise when viewing the front of the engine.
VS represents the valve set. Ignore any TC (top center)
marks while setting the valves and injectors.
Determine Cylinder in Position for Valve Sel
The crossheads and valves are ready to be adjusted on
the cylinder that has all the valves closed.
Check the two cylinders shown on the VS mark.

If the rocker lever assemblies have been removed, use

this step to determine the cylinder to set.
All adjusting screws must be loose on all cylinders, and
the push rod must remain in alignment.
NOTE: Perform this step-on both cylinders-to be checked.
Hold both rocker levers against the crossheads. Turn the
adjusting screws until they touch the push rods. Turn the
lock nuts untll-they toucfnne-Ieviirs. - - -.. .
The cylinder with the adjusting screws that are neaily the
::-~-.'~ ~~ ~r ....._ht. (;""'~~"-'-,.'" <;--'-'rn'" c-" b,.-' , ..- c ... ~\--"!':>"" th~ ...... ~_""!-
above the exhaust) is ready for valve adjustment. The
second cylinder that is not ready for adjustment will have
the adjusting screw for the exhaust valves more than five
threads above the intake screw.

The push rods will be close to the same height above the
top of the rocker lever housing on the cylinder ready for
valve adjustment: ---, - _.
NOTE: K200@Eand K18ooEenginescontain a unique cam- -
a
shaft that creates noticeable difference in the height of the
valve <!cJi!!sting_ scr!1W§., W[1!l!J_ the_ valves are properly ?d-
justed on these engines, the exhaust valve adjusting screw
will have approximately one thread visible above the top of
the tightened locknut. The intake valve adjusting screw will
have approximately three threads visible above the top of
the tightened locknut.
Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Valves and I nJect(
K3S and K50 Page 6-

If the rocker levers have not been removed, wiggle the

valve rocker levers on the two cylinders in question. The
crossheads and valves on the cylinder where both levers
feel loose are ready to adjust.
After identifying the cylinder with the valves ready to be A.
adjusted, use the following chart for the sequence. The .Ll.
procedure and specifications for adjusting the cross-
heads, valves and injectors are shown after the charts.
The following charts give the cross head, valve and in.
jector adjustment sequence.
NOTE: Adjustment can begin on any valve set mark. I n our
example, assume the 1R-SR marks are aligned and the
adjusting screw height for the valves on the cylinder no. 1
right bank are closed and ready to adjust.

K3S OUTER BASE CIRCLE SET PROCEDURE

With STC Valve and Injector Adjustment Chart
VALVES CLOSED ON ADJUST VALVES ON -·ADJUST INJECTORS ON
VS MARK CYLINDER NUMBER CYLINDER NUMBER CYLINDER NUMBER
1R-6R VS 1R 1R 2R
6L-1L VS 6L 6L 5L
5R-2R VS 5R 5R 4R
2L-5L VS 2L 2L 3L
3R-4R VS 3R 3R 1R
4L~L VS 4L 4L 6L
1R-6R VS 6R 6R 5R
6L-1L VS ·1L --. '''1-1::-'' --,""- 2L
5R-2R VS 2R
. .... - - - 2R 3R
2L-5L VS 5L
".-".~".-~-- -.~,~.~'

'-~5L 41'
3R-4R VS 4R 4R 6R
4L~L VS 3L 3(. 1L
Valves and Injectors Section 6 • Maintenance Procedures Every 1500 Hours or 1 Year
Page 6·16 K38 and K50

Caution: For K50 engines, It Is Important to know If the engine has the Standard Firing Order or the REVISED
FIRING ORDER. Do NOT use the Standard Firing Order sequence for uprate engines manufactured after Sep.
tember, 1986 that have REVISED FIRING ORDER. All engines that have the REVISED FIRING ORDER have STC
Injectors and are Identified as Revised on the engine dataplate. These engines also have decals on the rocker
lever covers.

K50 OUTER BASE CIRCLE SET PROCEDURE· REVISED FIRING ORDER

With STC 01' HVT Valve and Injector Adjustment Chart
VALVES CLOSED ON ADJUST VALVES ON ADJUST INJECTORS ON
VS MARK CYLINDER NUMBER CYLINDER NUMBER CYLINDER NUMBER
1R-8R VS 1R 1R 6R
1L·8L VS 1L 1L 6L
3R-6R VS 3R 3R 7R
3L-6L VS 3L 3L 7L
2R-7RVS 2R 2R 4R
2L·7L VS 2L 2L 5L
4R·5RVS 5R 5R 1R
4L-5L VS 4L 4L 1L
1R-8R VS 8R 8R 3R
1L-8L VS 8L 8L 3L
3R-6R VS 6R 6R - . -. -- . -",
2R
3L-6L VS 6L 6L 2L
2R-7RVS 7R 7R 5R
,.." """. " ......

4R-5R VS 4R 4R 8R
4L-5L VS 5L 5L 8L

K50 OUTER BASE CIRCLE SET PROCEDURE· STANDARD FIRING ORDER

.. -"--WftflSTC or HVT Valve and Injector Adjustment'Chart
VALVES CLOSED.ON . ADJUS:L.Y.ALVES ON ADJUST INJECTORS ON
VS MARK CYLINDER NUMBER CYLINDER NUMBER CYLINDER NUMBER
1R-8R VS 18 .1R " .... _.- 6E1
1L-8L VS 1L 1L 6L
3R-6R VS 3R 3R 2R
3L-6L VS 3L 3L 2L
2R-7R VS 7R 7R 4R
2L-7L VS 7L 7L 4L
4R-5R VS 5R 5R 1R
4L-5L VS 5L 5L 1L
1R-8R VS 8R 8R 3R
1L-8L VS 8L 8L 3L
3R-6R VS 6R 6R 7R
3L-6L VS 6L 6L 7L
2R-7R VS 2R 2R 5R
2L-7L VS 2L 2L 5L
4R-5R VS 4R 4R 8R
4L-5L VS 4L 4L 8L
Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Valves and InJecto
K38 and K50 Page 6-1

Crossheads - Adjustment
NOTE: Crosshead adjustment must always be made be-
fore attempting to adjust the valves.
Adjust the crossheads on the cylinder that has both valves
closed.
Loosen the crosshead adjusting screw lock nuts on the
intake and exhaust valve crossheads.

Use the following procedure to adjust both the intake and

the exhaust crossheads.
Turn the adjusting screw out at least one turn.
Hold the cross head down against its guide.
Turn thaadj1Jstingscr~w in until it touches the top of the
valve stem but does not raise the crosshead.

Hold the adjusting screw in this position. The adjusting

screw must not turn when the lock nut is tightened to its
torque value. Tighten the lock nut. The following torque
values ar.e giveHl withilndwit.hQI,l\ Pal:tr~:t9 ..ST-669, Torque
Wrench Adapter (1):

Torque Values
·N.m ft-Ib
:(S)
With 35 25
Adapter
Without 40 30
Adapter

Valves - Adjustment
VALVE ADJUSTMENT· RECHECK UMITS
If valve and injector adjustment is checked during trou-
bleshooting or before the recommended maintenance
interval, adjustment Is not required if measurements are OBC
within the recheck limits.
mm Onl
0.28 MIN [0.0111
INTAKE VALVE MAX
0.43 [0.0171

0.06 MIN [0.0241

EXHAUST VALVE 0.76 MAX [0.0301

"""'"
Valves and Injectors Section 6 • Maintenance Procedures Every 1500 Hours or 1 Year
Page 6·18 K38and K50

Valve Adjustment (Initial Set)

mm In
0.69 Exhaust 0.027
0.36 Intake 0.014

Select a feeler gauge for the correct valve lash specifi-

:~ cation. Insert the gauge (2) between the rocker lever and
the crosshead.

)
Two different methods for establishing valve lash clear-

1
ance are described below. Either method can be used;
however, the torque wrench method has proven to be the
most consistent.
. a. Torque Wrench Method: Use Part No. 3376592,
Inch Pound Torque Wrench, and tighten the ad-
justing·screwloO.68 Nem [6in-lb)torque.
b. Feel Method: Use a screwdriver and turn the ad-
justing-screw ONLY until the lever touches' the-
feeler gauge.

The adjusting screw must not turn when the lock nut is
tightened.
Tighten the ·Iock nut to the value indicated below.
:~ WITH Torque Wrench Adapter
Part No. ST·669:45 Nem [35 ft-Ib]
WITHOUT Adapter
Part No. ST·669:60 Nem [45 ft-Ib
The feeler gauge must slide backward and forward with
i(l) only a slight drag.
Attempt to insert a feeler gauge that is 0.03 mm [0.001 in]
thicker. The valve lash is not correct when the thicker
gauge will fit.
Repeat the adjustment process until the clearance is
correct on both the intake and the exhaust valves on the
cylinder being adjusted.
 Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Valves and Injecton
K38 and K50 Page 6-1!

Caution: Valves and Injectors ona cylinder are NOT

adjusted at the same engine position. Incorrect adjust-
ment by the sequence or procedure will result In engine
damage.
Check the valve and injector adjustment chart to deter-
mine which injector is in position to adjust.
Use a dial type torque wrench and 7/16 inch socket to
tighten the injector rocker lever adjusting screw. If the
screw causes chattering during setting, repair the screw
and lever as required.
Hold the torque wrench in a position that allows you to
look in a direct line at the dial. This is to make sure the
dial will be read accurately.

Tighten the adjusting screw to 11 Nem [100 in-Ib] to make '.~

sure the parts are in alignment and to squeeze the oil out '\.Y
of the valve train.
Loosen the adjusting screw at least one turn.
Tighten the adjusting screw to 10 Nem [90 in-Ib].
The torque wrench must be calibrated, have a resolution
of 0.28 Nem [2.5 in-Ib], and have a range of 17 to 23 Nem
.~ ... ___ [150 tg 2QO .in-Ib]. Do 110t use aclickElf=-tyfJ? torque wrench.

rh610tb

The adjusting screw must not turn when the lock nut is
tightened.
Tighten the lock nut to the following values: :~
WITH Torque WTenclrAdapter --.
Part No: ST -669:45 Nem [35 ft-~]
WITHOUT Adapter
........, _Part N~. ST -669_:6Q.f'Jei11.J4Sft-lb _____ .
3. Rotate the engine. Align the next mark. Adjust the
appropriate valves and injectors. Repeat the process
to adjust all of the valves and the injectors correctly.
Refer to Adjust the Valves in this section.
lithe barring device was used, allow the spring to push
the shaft and clear the ring gear. Install the clip.

If the barring device was used, allow the spring to push

the shaft and gear outward to clear the ring gear. Install
the clip.
:~
Install the rocker lever covers and all related compo-
nents.
Torque Value: 40 Nem [30 ft-Ib]
'\.Y Q IJ
~ d"
.I I

~-
Hoses Section 6 - Maintenance Procedures Every 1500 Hours or 1 Yel
Page 6-20 K38and K50

Hoses
Checking/Replacement
Annually inspect the bypass oil filter and cooling systel
hoses and hose connections for leaks or deterioratiOi
Particles of deteriorated hose can be carried through the
cooling system or lubricating system and restrict or clan
small passages, especially radiator core, and lubricatin
oil cooler, and partially stop circulation. Replace a_
necessary.

Water line hoses can balloon when a remote, high

mounted radiator is used. The maximum permitted radi-
ator height is 18.3 m [60 ftl above the cranksha'
centerline.
Water hoses do not normally collapse, but this can occur
if the radiator tubes become ciogged with scale or debriS

'~I

Fan Idler Pivot Arm

Use. waterpu.!TIE !yp.e grease.listed below, _or it~eq!*.
alent, to lubncate tlie Pivot arm assembly. Lubncate the
pi\fQ! amUIll.tU grease. appearsJrom undenhe cap.

Supplier Compound
Amoco Oil Company Rykon Premium No.2
Rykon Premium No.2 EP
Chevron U.S.A., Inc.. SRI
Exxon Company, U.S.A. Unirex N2
Shell Oil Company Dolium R
Texaco Inc. Premium RS

Fan Idler Pulley Tensioner Adjustment

Engines With Solid Control Rod
The fan belt must be installed and under the tension 01
the fan idler arm spring to adjust the control rod. The fan
belt and a portion of the flat washer is not shown for
clarity.
Turn the adjusting screw (10) until the end of the slot on
the lower control rod end (9) is touching the spacer (1).
NOTE: One of the nuts has left-hand threads.
Hold the adjusting screw and tighten the two jam nuts
(11).
 Section 6 • Maintenance Procedures Every 1500 Hours or 1 Year Heat Exchanger Zinc Plugs (Marine Only'
K38 and K50 Page 6·21

Engines With Control Rod Spring

Caution: Do not tighten the Inner Jam nut excessively. it..
If the Jam nut Is too tight, the spring retainer will bend, .Ll.
causing the control rod to fail.
Turn the inner jam nut until the spring retainer washer
(24) touches the cylinder on the lower control rod end
(27). Holdthe Inner jam nut and tighten the outer jam nut.

Engines With Shock Absorber

There is no adjustment required for engines with a shock
absorber.

Heat Exchanger Zinc Plugs (Marine

Only)
Checking . .
.Check the length of all zinc plug~in the he.at ex.ch<!fl9!lL
and change if they are 50 percent eroded. Frequency of
change depends upon the chemical reaction of raw water
"circulated through the"heat exchanger. - _.-

Erosion Limits
REPLACE NEW
A = Approximately 19 mm [0.75 in] 51 mm [2 in]
B = ApproximateJy 6.4 mm [0.25 in] 16 mm [0.625 in]

Crankshaft End Clearance

Inspection
Measure the crankshaft end clearance with a dial indi-
cator. Measure the clearance.

Crankshaft End Clearance

mm In
0.13 MIN 0.005
0.51 MAX 0.020
Batteries Section 6 - Maintenance Procedures Every 1500 Hours or 1 Yea
Page 6-2? K38 and K50

The check can be made by attaching an indicator to res

against the damper or pulley, while prying against th(
front cover and inner par.! of the pulley or damper. End
clearance must be present with the engine mounted ir
. the unit and assembled to the transmission or convener
caution: Extreme care MUST be used In prying against
the viscous damper. Sharp pry bars can damage thl!'
damper casing, resulting In a leak of the viscous fluio
and ultimate failure of the damper.
If the clearance is not within specifications, contact your
Cummins Repair Location.

Batteries
Checking
If conventional batteries are used, remove the cell caps
or covers and check the electrolyte (water and sulfuric
acid solution) level.
M aintenance·free batteries are sealed and do not require·
the addition of water.
~ Fill each battery celf with distilled water. Refer to the
.~ manufacturer's specifications.

Use the Fleetguard® refractometer, Part No. CC-2800, to

check the condition of the battery.
Refer to the battery fluid column in the refractometer to
determine the state·of·charge of each battery cell.

Use battery tester, Part No. 3377193, to test the state·

of·charge of maintenance·free batteries.
If the state·of-charge is low, use a battery charger to
~ charge the battery. Refer to the manufacturers instruc-
tions. Refer to Section A for battery connection informa·
tion.
Replace the battery if it will not charge to the manufac·
turer's specifications or will not maintain a charge.
 Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year Engine Protection Syste
K38 and K50 Page 6-:

Engine Protection System r;=g........IIC Plclc:up

General Information Ro.
B"
If an Engine Protection System is present, it must be
checked every 1500 hours or yearly. Follow the manu-
facturer's recommended maintenance procedures.
If the Compusave unit is in use, refer to the Operations
and Maintenance Manual for the Flight Systems 9560
Test Set.
If the Flight Systems Engine Saver is in use, refer to the
Engine Saver Level 7 Manual, Flight Systems, Bulletin 1t800we
No. 57-ASSO-26. For more information, call Flight Sys-
tems 1-800-333-1194.

Cold Start Aids

Checking k5I
• Oii pan heater
Check for proper operation. If operating properly, tbeoil .~ ~"~
pan will be warm. Inspect for loose connections, frayed \:=:./ ...;;
wires, and oil leaks. Repair or replace as needed.

eJ600la

• Engine Coolant Preheater

Check for proper operation. Check for loose connections, ~
_ fr.ayed Jllires, ."lnp coolant.lElal5!l. Cle<;lJJ .. thll. J!1~ali and .~_. ~~~~~~:;" 1.j:-:-1lJ;=1§F"'~
sludge from the unit. I'"
. Check the liries which take coolaiii from tne cooiant heater . . . 'l':'1=;I~'
~~~~;:::
to the engine block to determine that they are flexible..JJ ~~~~~~~~~
These line5-flormally consist of steel tubing GOOnectoo---~ ~ =--
with silicone hose.
Do not replace the silicone hose with normal radiator
hose as it becomes too brittle and breaks.
NOTE: The outlet connection from the coolant heater will ch6etva
experience a large number of thermal cycles and thus must
be of high quality with specific operating capabilities.
Replacement hose material forthe coolant heater to the
block hose connection must be a polyester reinforced
silicone rubber material, capable of 120°C [250°F] tem-
peratures and a minimum working pressure rating of 689
kPa [100 psi].
Front Engine Support Section 6 - Maintenance Procedures Every 1500 Hours or 1 Year
Page 6-24 K38and K50

Front Engine Support

Use water pump type grease, Chevron SRI grease or its
equivalent, to lubricate the front engine support. Lubri-
cate the support until grease appears at the outside of the
support.

Engine Mounting Bolts and Nuts

Checking
Check the torque on the nuts and bolts annually. Tighten
any that are loose. Inspect the rubber for deterioration
and age hardening. Replace any broken or lost bolts,
capscrews or damaged rubber.
. Capscrew. size and grade vary with the flywheel. housif.lg. .
~ and mounting arrangement. Determine the size and grade .
of the mounting bolts. Refer to the capscrew torque val-
~
'!e;'<:' ;r_ ~-"""'f.fr--' ,! r-,.t: fl-;ir-. .......,"'n.I'"O;I,

amSgrsa
 Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years
K38 and K50 Page 7·

Section 7 - Maintenance Procedures Every 6,000 Hours

or 2 Years
Section Contents
Pag
Air Compressor ............................................................................................................................................... 7-2
Air Compressor Discharge-Checking ............................................................................................................. 7-2
Air Compressor Intake·Checking ........................... ........................................................................ ................ 7-2
Checking..........................................................................................................................:............................ 7-2
Cooling System ............................................................................................................................................... 7-1
Cleaning System and Changing Antifreeze ................................................................................................... 7-1
Engine Protection System.................................................................... ........................................................... 7-2
Calibration .................................................................................................................................................... 7-2
Fan Hub .......................................................................................................................................................... 7-1'
Inspection .................................................................................................................................................... 7-1'
Fan Idler Pulley Assembly ............................................................................................................................. 7-1·
Installation .................................................................................................................................................... 7-1:
Rebuild ......................................................................................................................................................... 7-1:
Rebuild/Replacement ................................................................................................................................... 7·1:
Fuel Pump .... ............................................................ ........................................................................................ 7-:
Calibration ....................... :.............................................................................................................................. 7-
Checking ........................................................................................................................................................ 7-
Installation ....~, ....-.... n.-.~' ....... ~ ••••• .." • .-. •••• ,. ,f, •••••••• , .-•••• .-... ~ •.-....T.-.lnn . . . .-.............. ..-•••••••••••••• ~ ••••• ,; •••••••••• n.-. • ..-00 ••••••••••-h ••••- •••• ,. 7-l
Removal ............................................................................................................, ............................................ 7-:
General Information ......................................................................................................................................... 7-:
Injectors... ...... ............................................ ........................................................................................................ 7-!
Calibration .................................................................................................................................................... 7-1:
Checking....................................................................................................................................................... 7-1'
Installation .................................................................................................................................................... 7-1:
Removal ......................................................................................................................................................... 7-1
Thermostats and Seals.................................................................................................................................... 7-11
Replacement ................................................................................................................................................. 7-11
- ,,_ • • _ "," ___ ... " ••• • ,r<_ • • _~,~~_.~ ... ,.-{>~ •• _~ .•• _ ••• ,.,0. _ . _ _, _
Throttle Travel/Throttle Air Cylinder ................................................................................................................ 7,,(
Checking .............................................................................. ~........................................................................ 7,,(
Variable Speed (VS) Throttle Linkage Adjustment ................... ........................................................................ 7-1
. Turbocharger ...................... , .................., ..............,' ......... "' .........' .•..::.•.',.....~,' ..............'..., ..................".,................... 7-2·
Inspection..................................................................................................................................................... 7-2'
Vibration Damper............................................................................................................................................. 7-21
Checking....................................................................................................................................................... 7-21
Damper leakage Detection ........................................................................................................................... 7-2!
Thickness Measurement .......................... .-.................................................................................................... 7-21
Water Pump ..................................................................................................................................................... 7-1!
RebuildlReplacement .................................................................................................................................... 7-1!
General Information Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-2 K38 and K50

General Information
All checks or inspections listed under the previous main-
tenance intervals musl also be performed at this time in
addition to those listed under this maintenance interval.

o!fl01Vu

Fuel Pump
..
Every 6,000 Hours or 2 years clean and calibrate the fuel
r ~ pump.
Refer to Calibration in this section for calibration
~ information .

. .,
..•
.c

1":11:1 .:
!
I "
.. '~:=crr,-.~~~ '"w'"

Removal
Disconnect the (-J negative battery cable first, then dis-
connect the (+ ) positive cable.

Clean the fuel pump and the surrounding area before

removing it from the engine.
 Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years Fuel Pu
K38 and K50 Page

Disconnect the wires to the fuel shutoff valves.

Disconnect the linkage from the throttle lever.

On engines with the throttle air cylinders mounted on a

bracket on the fuel pump, remove the throttle cylinder air
inlet (2), the braking cylinder air inlet (3), the vent line (4)
and bracket mounting capscrews (5).
The throttle cylinder assembly is removed with the fuel LS(~
pump as a unit. Q3

The newer engines will have the air throttle cylinders

mounted to the cam follower covers. Inspect the throttle
cylinders for shaft wear and seal leakage. If there is
. _.. signifiggnLWe<lL.Dr leakage, refer to the K38 and K50
Shop Manual, Bulletin No. 3810304, or contact your
Cummins Distributor for repair.

Disconnect the fuel tubing and air hose.

• Gear pump cooling drain (2)
• Gear pump suction line (3)
• AFC fuel drain (4)
• Fuel supply to injectors (5)
• AFC air hose (6)
• Tachometer cable (7)
Fuel Pump Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-4 K38 and K50

ffi Remove the four mounting capscrews and the fuel pum p.
'\b'<iJ Remove the drive coupling (23). Remove and discard the
gasket.

Checking
Clean the fuel pump and the air compressor or accessory
drive mounting surfaces.
Inspect the mounting surfaces for damage. Replace if
cracked or distorted.

Visually inspectthe spider coupling for damage. Replace

if cracked or distorted.

-
Calibration
~ Calibrate the fuel pump. The procedure m usl be done at
a Cummins Authorized Repair location. Refer to the PT
Fuel Pump Rebuild and Calibrate Manual, Bulletin No.
3379084.

fpBOlul
 Section 7 • Maintenance Procedures Every 6,000 Hours or 2 Years Fuel Pur
K38and K50 . Page i

Installation
All K38 and K50 engines use a white nylon or light green
fuel pump drive coupling.
Install the drive coupling (23), gasket, fuel pump, and four
caps crews. Tighten the capscrews to 45 Nem [35 ft-Ib].

Connect the fuel tubing and air hose.

e Fuel drain (1)
e Gear pump cooling drain (2)
e AFC air hose (4)
e Fuel supply to injectors (5)
e AFC fueldmin (6)
e Tachometer cable (7)

On engines equipped with throttle air cylinders mounted

on a bracket on the fuel pump:
t{il&
~
Install the bracket mounting capscrew (5).
-' -. ,
Install throttle cylinder (2) and brake cylinder (3) air lines.
Install vent ifne (4).
J'lefeL tQ Throttle JravelfThrottle Air Cylinder in this sec,
tion for more information.
The newer engines will have the air throttle cylinders
mounted to the cam follower covers.

Connect the electric wires to the fuel shutoff valve.

t{il&
NOTE: The wire connection nut and the ground post nut ~
must be clean and tight.
install the linkage to the throttle lever.
. 'T:hr,ottle, Travel/Throttle Air Cylinder Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-6 K38 and K50

I ~ Connect the (+ ) positive battery cable first,. then connect

~ 'W ,he (-, "'oro'" ~bl,. _ _

Operate the engine to normal operating temperature and

check for leaks,

'-----" I
ew601wb

Throttle Travel/Throttle Air Cylinder

Checking._
Throttle Lever Breakover ~ ~hecklng

• Make sure the throttle linkage is adjusted so the

throttle lever breaks over 3 to 6 mm [0,125 to 0.250]
(1/8 to 1/4 inch) when the lever is In the full throttle
position.
• The throttle lever stop must contact the rear throttle
stop screw.

Variable Speed (VS) Throttle Linkage Adjust-

ment
• Remove the throttle linkage from the VS throttle
lever.
• Hold the VS lever In the idle position. Move the
linkage to the idle position.
• With the VS lever in idle poSition, adjust the linkage,
Section 7 - Maintenance Procedures Every 6,000' Hours or 2 Years Throttle Travel/Throttle Air Cylln,
K38 and K50 Page'

• Move the VS lever and linkage to the maximum

speed position.
@
~
""""
• If the lever and the linkage are not aligned, adjust
the linkage.
NOTE: Throttle travel on a VS lever is not adjustable. The
pump may be recalibrated with a stiffer VS Governor spring
to reduce throttle travel.

• Install the linkage on the lever.

~
'J@

This section applies only to air cylinder equipped en- ~

~~ '~
• (1) Braking cylinder
• (2)' Throttle cylinder' -
• (3) Throttle cylinder air inlet
'. (4) , Cylinder vent jumper hose
• (5) Vent to the engine air Intake or breather
• ' (6) Throttle cylinder extension rod
• (7) Boot
• (8) Roller tappet and bushing
• (9) Throttle lever
• (10) Braking cylinder extension rod
• (11) B raking cylinder air inlet

Using your hand, push the throttle lever (9) toward the ~
cylinders (lOW idle position). The braking cylinder exten' ~
sion rod (10) must move smoothly to the retracted posi-
tion. The cylinder spring must push the throttle lever from
the air cylinders approximately 1/2 of the distance be-
tween the Idle and full fuel positions.
If the cylinder does not move smoothly or does not push
the throttle lever, the cylinder must be replaced.
Throttle Travel/Throttle Air Cylinder Section 7 • Maintenance Procedures Everv 6,000 Hours or 2 Years
Page 7·8 - K38 and K50

Use your hand, pull the throttle lever (9) away from the
air cylinder (full fuel position). Pull the throttle cylinder
extension rod (6) toward the throttle lever. The extension
rod cap must touch the roller tappet on the throttle lever.
Release the throttle cylinder extension rod. The rod must
move toward the cylinder.
If the rod does not move smoothly or does not return to
the retracted pOSition, the cylinder must be replaced.

Connect a source of compressed air to a pressure gauge

and a regulator (12). Connect a hose from the regulator
12
to the braking cylinder air inlet (11).
Adjust the regulator until 560 kPa [80 psi] air pressure is
applied to the air cyHnaer. The-braking cylinder extension
rod (10) must be in the retracted pOSition completely
when the pressure is applied.

'~® FS6ACSC

Increase the regulator pressure to 689 kPa [100 psi].

There must be no air leaking from the vent (5) or around
the ext~!l~\on rod.
Reduce the air pressure to "0". The extension rod must
move approximately 1/2 onts distanCe of travel.

Connect the compressed air supply to the throttle cylin-

der air inlet (3).
Adjustthe regulator until 560 kPa [80 psi] is appliedtothe
air cylinder. The cylinder extension rod (6) must move the
throttle lever to the full fuel position. Pull the throttle lever
to be sure the lever is in the full fuel position.
 Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years Injectc
K38 and K50 Page 7

Increase the regulator pressure to 689 kPa [100 psi]. (55'1

There must be no air leaking from the vent (5) or around \[)
the throttle air cylinder.
Reduce the regulator pressure to O. The extension rod
must move to the retracted position.
If a cylinder is not within the air test specifications, the
cylinder must be replaced. Refer to the following Proce-
dure, Throttle Air Cylinder - Remove and Install in the K38
and K50 Shop Manual, Bulletin No. 3810304.
Disconnect the air supply from the air cylinder.

Pull the boots (7) off the cylinder jam nuts.

Apply grease to both of the cylinder extension rods (6)
and (10). Apply grease to the side of the roller tappets (8)
to lubricate the tappets and the bushings.
Install the boots on the jam nuts.
Connect the air supply line.

Injectors
Every 6,000 hours or 2 years clean and calibrate the ~
.",,: . injectors. This procedure must be done at a Cummins IIIIi
Authorized Repair Localion. . - - -.. - .

Removal
Steam clean the engine. Steam is the best method of ~
cleaning a dirty engine or a piece of equipment. If steamlllli
is not available, use a solvent to wash the engine.
Protect all electrical components, openings, and wiring
from the full force of the cleaner spray nozzle.
Injectors Section 7 • Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7·10 K38 and K50

Egq) Remove the rocker lever cover.

Egq) Remove the rocker lever assembly.

. . .~

;-)r I----....JI_=_ 0 ' - " ~ --=n==(h~oOma

NOTE: This step applies only to engines equipped with STC

or HVT injectors.
Remove"the banjo connector mounting screw: Hemova"""""" "
the oil transfer tube. Remove and discard the sealing
washers (48) arid me o-rrnrH49}. .

NOTE: The rocker housing has been removed from the

illustration for clarity.
Remove the injector hold down capscrews. Remove the
clamp.
 Section 7 • Maintenance Procedures Every 6,000 Hours or 2 Years Inject!
K38 and K50 Page 7·

NOTE: Do not let the tappet fall out of the HVT injector.
Damage can result.
For STC or HVT injectors, use an injector puller, Part No.
3376497. Be sure the puller arms are firmly under the top
stop screw. Tighten the clamping ring (1). Use the slide &/.1
hammer to remove the injector. \l:>"!J

For standard injectors, use injector puller, Part No. ffi

3376000 or 3376497. Put the split collar over the injector. \l:>~
Slide the locking collar over the split collar. Use the slide
hammer to remove the injector.

Checking
NOTE: Injector plungers and barrels have a very precise fit
and are damaged easily. Do not remove the plungers unless
.. you have been trained using the proper techniques. Do not
all~ the plungerto fall out of the injector.

Remove the a-rings (1, 2, and 3). Discard the a-rings.

NOTE: Sealing rings-am available in different thicknesses
to adjust the injector protrusion.
Remove the sealing ring (4), and note the .cylinder loca-
tion. .
fi40rga
Use a lint free cloth and clean the exterior of the injector. ~.
Carefully check the area where the sealing ring makes _'\
contact with the injector.
Check the orifice screen (5). It must be clean. If there is ~
debris on the screen, remove the retaining clip and the .~
screen for cleaning. Clean the screen in solvent and dry
with compressed air. Install the screen and retaining clip.
Injectors Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-12 K38and K50

Calibration
Calibrate the injectors. This procedure requires special
equipment and must be done at a Cummins Authorized
Repair Location. For PTD injectors, refer to the Injector
PT Rebuild Manual, Bulletin No. 3379071. For HVT/STC
~ injectors, refer to the PT (Type D) STC Injector Shop
Manual, Bulletin No. 3810313.

Installation
Identify the o-rings so they can be installed in the correct
injector groove.
O-ring (1), Part No. 3010510, has a red dot or stripe. The
o-ring is a dull gray in appearance.
O-ring (2), Part No. 205216, has no markings.
O-ring (3), Part No. 193736,-has'agreen dot or stripe. The.
ring is shiny black in appearance. Lubricate the o-rings
with vegetable oil and install them on the injector.
(~ Instaii the proper size seal ring (4).
~
NOTE: Premium K injectors use the same o-ring, Part No.
193736, in all three locations, (1,2,3). Premium K injectors
can be identified by the presence of two balance orifices (5)
in the injector body. Standard STC injectors have only one
orifice.
Posiiion the stancllii'diiijectiir'-in the liore~ Turn theIn- - .
jector so that the iojector..screen points toward.the hold
down capscrew hole on the intake side of the head.
 Section 7 • Maintenance Procedures Every 6,000 Hours or 2 Years Inleolol
K38 and K50 Page 7.1

NOTE: Do not let the tappet fall out of the HVT injector.
Damage can result.
The tappet musl be installed correctly. The large holes
in the side must be near the rocker lever assembly.
The tappet can nol fall out of the STC Top Stop injector.

.at...

NOTE: Do nol push the injector on the seat until it is cor-

rectly aligned.
Position the STC or HVT injector in the bore. Turn the
injector so thatthe hole in the top stop screw points to the
oil supply hole in the rocker lever housing.
Use the oil jumper tube and the connector screw as tools.
Turn the injector until the holes are aligned. Remove the
connector screw and the tube.

caullon: Do NOT use a wooden 100110 push the Injector A.

on the seat. Failure can result due to splinters failing Into ..Ll.
the tappel. Use a socket size of 1·1/41noh or 27 mm to
_SeaJtheJnJelltor . . --_...-.... . . » . " . _ " • •_ • •

Use a blunt object that touches the top stop screw. Use
. -lfCcjuick, hard push wiih your hands to seat the injector..
A single snapping sound will be heard when the injector
- -.' -- - isseatedproperly.·

NOTE: The injector hold down clamp that is used on engines

with STC or HVT requires capscrews that are 3 mm [1/8
inchjlonger than those on other K38 and K50 engines.
Install the hold down clamp and the self-locking cap-
~
screws. Tighten the capscrews alternately and evenly so
the clamp will be centered on the injector body. Tighten
~
the capscrews to 16 Nem [145 in-Ibj.
:®
Injectors Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-14 K38and K50

Install the o-ring (49) on the jumper tube. Lubricate the

o-ring with engine oil. Install the jumper tube and the
copper sealing washers (48).lnstall the connector screw.
Tighten the screw to 25 Nem [20 ft-lbJ.
NOTE: The oil jumper tube for full top stop STC injectors is
8 mm [5/16 in) shorter than tnatube used\vith the early HVr
injectors. The tubes can not be mixed.

Install the rocker lever assembly and STC injector link, if

applicable.
Torque Value: 90 Nem [65 ft-Ib)

~ Adjust the rocker levers. Refer to Section 6 for this

procedure.

Install the rocker lever cover.

~
~ Torque Value: 40 Nem (30 ft-Ib)
 Section 7 • Maintenance Procedures Every 6,000 Hours or 2 Years Cooling Sysll
K38 and K50 Page 7·

Cooling System
Cleaning System and Changing Antifreeze
Caution: Do not use caustic cleaners In the cooling A
system. Aluminum components will be damaged. .L.l.
NOTE: Read Section V, Coolant Recommendations/ ~
Specifications, before attempting cooling system mainte- I~':;;;=;;:;::-I--f~
nance.
Every 2 years or 6,000 hours of operation (whichever
comes first), change the coolant.
The cooling system must be clean to work correctly.

Warning: Walt until the temperature Is below 50°C A

[120°F] before removing the coolant system pressure ~ @~~'
cap. Failure to do so can cause personal Inlury from
heated coolant spray.

NOTE: The performance of RESTORE is dependent on

time, temperature, and concentration levels. An extremely
scaled or flow restricted system, for example, may require
higher concentrations of cleaners"higher temperatures"or
longer cleaning times or the use of RESTORE PLUS. RE-
STORE can be safely used up to twice the recommended--'-"-'-
concentration levels. RESTORE PLUS must be used oniy
at its recommended concentration level. Extremely scaled
"or fouTed'sysiems may require more than one cleaning.
RESTORE CC2610 (1 gallon)
RESTORE CC2611 (5 gallons)
RESTORE CC2612 (55 gallons)
RESTORE PLUS CC2638 (1 gallon)

Drain the cooling system. Do not allow the coaling sys-

tem to dry out. RESTORE will not be as effective if the
cooling system is allowed to dry.
Do not remove the coolant filter.
CoClllng System Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-16 K38 and K50

Caution: Fleetguard® RESTORE contains no antifreeze.

Do not allow the cooling system to freeze during the
cleaning operation.
Immediately add 3.8 liters [1 U.S. gallon] of Fleetguarci@
RESTORE, RESTORE PLUS, (or equivalent) for each 38
to 57 liters [10 tor5 gallons] of cooling system capacity,
and fill the system with plain water.
Turn the heater temperature switch to high to allow max-
imum coolant flow through the heater core. The blower
does not have to be on.

Operate the engine at normal operating temperatures (at

~
., least 85'C [185'F]) for 1 to 1 1/2 hours.
Shut the engine off, and drain the cooling system.

Fill the cooling system with clean water to flush the cool-
ing system.

Operate the engine at high idle for 5 minutes with the

coolant temperature above 85'C [185'F].
Shut the engine off, and drain the cooling system.
NOTE: If the water being drained is still dirty, the system
must be flushed again until the water is clean.
Refill system with new heavy duty coolant and SCA as
earlier described.

..
C), '
,
Sectlon 7 • Maintenance Procedures Every 6,000 Hours or 2 Years Fan
K38 and K50 Page'

Fan Hub
Inspection
Every 6,000 hours or 2 years inspect the fan hub for
proper end clearance and grease leakage.
Remove the fan belt. Referto Section A forthis procedure.

Rotate the fan hub pulley to check for rough or damaged

bearings. I nspect the pulley grooves for excessive wear.
Check for grease leakage. Use a dial indicator to check
the bearing end clearance.

Bearing End Clearance

mm In
0.03 MIN 0.001
0.15 MAX 0.006

Replace a fan hub with a new or rebuilt unit as necessary.

Refer to the Troubleshooting and Repair Manual, K38
and KsO Series Engines, Bulletin No. 3810432, for reo
m9)1al..iln9.replacem emt J.nli!tnJc.tlomL_ ....

Install the fan belt. Refer to Section A for the installation

procedures. ~
~
~

la6blha
Fan Idler Pulley Assembly Section 7 • Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-18 K38and K50

Fan Idler Pulley Assembly

Rebuild/Replacement
~ Every 6,000 hours or 2 years inspect the idler pulley
~ assembly. Rebuild or replace the idler pulley as neces-
~ sary. Refer to the Troubleshooting and Repair Manual,
.~ K38 and K50 Series Engines, Bulletin No. 3810432, for
rebuild and replacement procedures.

Rebuild
Remove the fan belt. Refer to Section A for the removal
procedures.

Remove the three capscrews. Remove the idler assem-

bly.
NOTE: Engines with a 457 mm [18 in] fan center have-an
~<!1.~~~er plate ~tween,th~ idler and the front.JJ_e~r.covero ..
'\l:} Remove the adapter plate.
~ Refer to the Shop Manual;K38 and K50 Series Engines,
Bulletin No. 3810304, for rebuild procedures of the fan
idler pulley and pivot arm.

Installation
NOTE: If the engine has two vibration dampers, a longer
idler arm than shown'is required.
lithe engine hasafan hub with 457 mm [18 in] center Oow
mount fan), an adapter plate is required between the idler
arm and the front gear cover.
Check to make sure the spring on the idler arm is not
@ under tension. This will aid the future installation of the
fan hub.

rffu Install the fan belt idler assembly, the three lock washers
~ and capscrews.

.~
Torque Value: 60 Nem [45 ft-Ib]
 Section 7 • Maintenance Procedures Every 6,000 Hours or 2 Years Water Pu~
K38 and K50 Page 7·'

Install the fan belt. R.efer to Section A.

Water Pump
Rebuild/Replacement
Every 6,000 hours or 2 years rebuild or replace the water
pump.
NOTE-: A minor chemical build up or streaking at the water
pump weep hole is normal. Do not repair or replace the
water pump unless an actuilileak is confirmed. Refer to the
Troubleshooting and Repair Manual, K38and K50 Series
Engines, Bulletin No. 3810432.

Thermostats and Seals

Replacement
Remove the:
(1) -Capscrews and lock washer (two each)
(2) Plate, cover (or water filter head)
,(3)-' Se!;lll?, _o-ring (two each)
(4) Capscrews and lock washers (four each)
(5) Shield, heat (right bank only)
(6) Capscrews and lock washers (two each)
(7) Housing, thermostat
(8) Gasket
Check the support. For further information, refer to Pro-
cedure No. 08-15, Thermostat Support-Clean and Check ~
for Reuse, in the K38 and K50 Shop Manual, Bulletin No.
3810304.
Thermostats and Seals Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-20 K38and K50

Remove the thermostats. Remove the seals (10) from the

housing. Discard the seals.
Check the thermostats for wear. If the barrel of the ther-
mostat is worn or fretted, it must be discarded.
Clean all gasket surfaces and bores.
Use solvent or steam. Clean the parts.

---...
_ec4bdma

The seal must be installed with the part number posi-

tioned up.

~ Use a mallet and thermostat seal driver, Part No. 3375411,

~ or equivalent, to install the thermostat seal. Install the
seal.
NOTE: Install the seal no more than 0.51 mm [0.020 inl
below the top of the cast edge.

~ Install the thermostat by pushing on the outer rim.

~ NOTE: If the engine being serviced Is a K50, make sure the
- cofr"ebf tfiei'itlOSfafis Tnstalleo~Tfierlfi()$tats'for thEiK38 anti
.. 1(50 Emginesa,rE! diffEt!!ln!.
The K50 thermostats contain a nitrile rubber seat vulea-
3)izElct t{Lthe .bmS.lt.Q.Q.llar_aLttJe.b.a((eL$~at. Tl:li~. sEta!.
prevents coolant leakage and wear. The thermostat with
the rubber seat must be on K50 engines. The thermostat
with the rubber seat is not required for the K38 engine,
but can be installed.

NOTE: Do not tighten the capscrews until assembly is com-

plete.

® Install the:
(8) Gasket
~ (7) Housing, thermostat
(6) .Capscrews and lock washers (two each)
~ (5) Shield, heat (right bank only)
(4) Capscrews and lock washers (four each)
(3) Seals, o-ring (two)
(2) Plate, cover (or filter head)
(1) Capscrews and lock washers
Tighten the capscrews.
Torque Value: 45 Nem [35 It-Ibl
 Section 7 • Maintenance Procedures Every 6,000 Hours or 2 Years Turbocharg
K38 and K50 Page 7·:

Turbocharger
Inspection
Inspect the turbocharger every 6,000 hours or 2 years.
Remove the. air intake and the exhaust piping. Check the
turbocharger as follows:
Look for damaged or cracked compressor or turbine
blades. Check to see that the turbocharger shaft spins
freely.
NOTE: If visual inspections or dimensional checks indicate
a problem, contact a Cummins Authorized Repair Location
for assistance. Refer to the model number on the turbo-
charger dataplate.

Holset Model HC5 and AIResearch Model T·18A

Measure the axial clearance (end to end). Rebuild or
replace the turbocharger if axial motion (end play) is
greater than specified below. Refer to the Troubleshoot·
ing and Repair Manual, K38 and K50 Series Engines,
Bulletin No._aatQ432,_forremovalprocedu~es lap-a to the
Turbocharger Rebuild Manual, Bulletin Nos. 3379091
(T-18A), 3810243 (HC5), or 3810386 HT100 Shop Man·
J.li3I,lqr rebujld pro"E!dl,lre~.

End Play Dimension

Model Min Max
RC5A 0.05 mm 0.13 mm
[0.002 in] [0.005 in]
T18A 0.10 mm 0.23mm
[0.004 in] [0.009 in]
HTiOO 0.06 mm 0.16 mm
[0.002 in] [0.006 in]

Measure'lhe radial clearance (Side to ·side). ...~

. NOTE: Hold·the shaft teward the feeler gauge to check this \.[)
dimension.

Model HC5A
Compressor Impeller
Min Max
0.15 mm [0.006 in] 0.45 mm [0.018 in]

Turbine Wheel
Min Max
0.20 mm [0.008 in] 0.55 mm [0.021 inJ
Model T18A
Compressor Impeller
Min Max
0.08 mm [0.003 in] 0.18 mm [0.007 in]
Turbocharger Section 7· Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-22 K38 and K50

Model HT100
Compressor Impeller
Min Max
0.25mm 0.46 mm
[0.010 inj , [0.018 in]

Turbine Wheel
Min Max
0.38mm 0.53 mm
[0.015 in] [0.021 in]

Brown Boverl®, Model RR·153 and RR·151

q) To measure axial clearance, use Part No. ST-53? Dial

Depth Gauge, or a dial indicator. Measure the axial
motion.
@ BBC (RR·151) and (RR.153) End Clearance
~ _____m~m~______~~~______~~I~n~____
0.09 MIN 0.004 '
0.13 MAX 0.005
If the end clearance exceeds the soecificetions. the part
must be replaced or reouilt. Refer to Bulletin NO. 3810235,
Exhaust Gas Turbocharger, R R-153, Instructions for Op-
eration and Maintenance or Bulletin No. 3810325,
Exhaust-Gas Turbocharger, RR151-12, Instructions for
Operation and Maintenance.

J35\ .. N9IE: T,he.£ompressohr,~'ld t~!lbinle casings TdOh-"!'t reqlJire

\.[) removaI to measure t e radla c earance. e parts are
, _.. ,..l>ttQWn remQy~d for (;/iHJ1y. ,.,.,.__" '.
@ Use a dial indicator. Measure the clearance.

~ BBC (RR·151) and (RR·153) Bearing Radial Clearance

mm In
RR-153 0.55 MAX 0.021
RR-151 0.75 MAX 0.030
r
If the clearance exceeds the specifications, the part must
tb6beja be replaced or rebuilt. Refer to Bulletin No. 3810235,
Exhaust -Gas Turbocharger, RR-153, Instructions for 0 p-
eration and Maintenance or Bulletin No. 3810315,
Exhaust-Gas Turbocharger, RR151-12, Instructions for
Operation and Maintenance
 Section 7 • Maintenance Procedures Every 6,000 Hours or 2 Years Air Compressc
K38 and K50· Page 7-2

Air Compressor
Checking
Complete air compressor inspection is required every
6,000 hours or 2 years.
NOTE: All air compressors have a small amount of oil
carryover which lubricates the piston rings and moving parts.
When this oil is exposed to normal air compressor operating
temperatures over a period of time, it will form varnish or
carbon deposits. If the following inspections are not done,
the air compressor piston rings will be affected by high
operating temperatures and pressures, and will not seal
correctly.

Air Compressor Discharge-Checking

Drain the air system wet tank to release the system air ffi
pressure. Remove the air discharge line from the air iQ)~
compressor.

cp81bma

Measure the total carbon deposit thickness inside the air

discharge line as shown. If the total carbon deposit (X) i~ 10 of Discharge Line
exceeds 2 mm [1/6 inch], clean and inspect the cylinder
- -head, the valve assembly, and the discharge line, He- . ~.
place if necessary. Refer to the appropriate Air Equip- .~
.. ment M anuallisted below for procedures, or contact your
Cummins Authorized Repair Location:
.-Single Cylinder, Bulletin No. 3810242
• Twin Cylinder, Bulletin No. 3379056

10 of Carbon Build Up

If the total carbon deposit exceeds specifications, con-

tinue checking the air discharge line connections, up to
11\:1
•
the first tank, until total carbon deposit is less than 2 mm
[1/16 inch]. Clean or replace any lines or connections that
exceed this specification.
Air Compressor Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-24 K38 and K50

~Inspect any air driers, spiller valves, pressure reliet.valves,

~and alcohol injectors for carbon deposits or malfunction-

o ing parts. Inspect for air leaks. Maintain and repair the
~ parts according to the manufacturer's specifications.

Air Compressor Intake-Checking

Remove the air governor or air governor signal line from
the air compressor unloader body.

.<: l 1-.J7 C'>

Remove the center un loader valve .

.-. ..,

Caullon: The unloadervalve body Is Installed with spring

tension. To avoid personal Injury, hold unloader body
down while removing the capscrews.
Hold the un loader body down and remove the two cap-
screws and washers.
• Remove the two unloader assemblies. One is above
each cylinder. Discard the a-rings and seals.
Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years Air Compress(
K38 and K50 Page 7-2

Clean the unloader valves with solvent and a non-metallic

brush to remove carbon. Do not use a sharp object. The
11\:1
IIMI
sealing surfaces can be damaged.

Inspect the upper part of the center un loader valve cap

where the rectangular ring seal seats for scoring. Re-
@
.:;;;;;;
~
place if scored.

Visually inspect the un loader valves for deep scratches

or cracks. Replace if scratched or cracked.

Visually inspect the unloader valves for carbon buildup.

If carbon or heavy varnish is present, remove, clean, and
inspect the compressor head and the valve assembly.
Replace the parts as necessary. Refer to the appropriate
Air Equipment Manual listed below for procedures, or
contact your nearest Cummins Authorized Repair Loca-
tion:
• Single Cylinder, Bulletin No. 3810242.
• Twin Cylinder ST676, Bulletin No. 3810257
• Twin Cylinder, ST773, Bulletin No. 3810347
Air Compressor Secllon 7 - Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-26 K38 and KsO

".
Install the unloader valve cap spring in the air compres-
~ sor.
NOTE: Some unloader bodies require 2 yellOW o-rings. Lu-
El bricate the unloader body o-ring with engine oil.
NOTE: Thl9 rectangular ring seal must be installed with the
grooved side up.

".
~ Install the rectangular ring seal as shown.
Use anti-seize compound to lubricate the outside diam-
El eter of the cap.
Install the unloader valve cap in the unloader body.
~
gv60rha

W
Install the center unloader. Tighten the capscrew to 40
~ Nem [30 ft-Ib].
~

...
"",

~ Install the cap into the cover and make sure the three
~ tangs are in the three slots of the intake valve seat.
--I o...l-·-lubricateth_~_ unlo~:rvalve with anti-seize compound..

Caution: The rectangular ring seal MUST BE Installed

with the grooved side up; failure to do so will result In air
system damage and brake failure.
Install a new rectangular seal inside the unloader body
cavity.

-,
 Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years Air Compress~
K38 and K50 Page 7-2'

~
Install new top and bottom o-ring seals.

Use clean engine 011 to lubricate the seals.

Install the unloading body Into the cover. ~
~
~

Install the unloading valve body.

~
NOTE: Press the unloading valve body down to be sure the ~
tangs of the unloader valve cap are In the three slots of the
Intake valve seat. 'If the parts are not aligned, the'compres-
_~orw/ll not/unction properly.

Hold the unloading body down and install the two plain
... washerfj and captive washer capscrews.
~ ..

Tighten the capscrews to 15 Nem [120 In-Ib] torque.

Install the air governor or air governor signal line to the ~.' ~
unloader body. ~ ~ .

gv6vasa
Vibration Damper Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years
Page 7-28 K38 and K50

@ Operate the engine and check for air leaks.

Vibration Damper
Checking
NOTE: Vibration dampers have a limited service life. The
dampers must be inspected every 6,000 hours of service,
and must be replaced after 24,000 hours in service. 1<2000
engine dampers are replaced every 12,000 hours.
NOTE: Do not repair or balance a viscous damper in the
field.
• Use solvent. Clean the exterior of the damper.
'j~ •• ~;-,-..;.';:'~ '~:-,-~ " , .......... ,.i.:j.-.g :.--<f~i::i~ ~.....-, ,-,, __ .c,';,
• Inspect the housing for dents, bulges, or leaks.
• Replace the damper if it is damaged.

Thickness Measurement
-EJ::~:= [0.125
3.18 mm ---l X I--
- In] 1\:1 Use a paint solvent and a fine emery cloth. Remove paint
--iIIIlII· ·from·thelront andback··of·the housing at the four areas
1
as shown in the drawing.
~ Measure the damper thickness no less than 3 mm [1/8
inch] from the outside circumference to be sure readings
are taken on a flat sLifface.
Measure the thickness (x) at four locations around the
damper, 90 degrees apart. The readings must not vary
o more than 0.25 mm [0.010 inch]. Refer to the Maximum
Vibration Damper Thickness table for the thickness. If the
daaOOns
thickness exceeds these specifications, the damper must
be replaced
Maximum Vibration Damoer Thickness
Vendor mm In
Houdaille® 65.38 2.574
Made in England 65.66 2.585
F-82 and After
Made in England 65.91 2.595
Before F-82
NOTE: If the damper has been in service for 24,000 hours
or more, it must be replaced, regardless of the thickness
measurement. Dampers on K2000 engines must be re-
placed after 12,000 hours of service.
Section 7 - Maintenance Procedures Every 6,000 Hours or 2 Years Engine Protection SyatE
K38 and K50 Page 7 ..

Damper Leakage Detection

If visual inspection found signs of leaks, thorough leak- ~
age detection is required. ~
Use crack detection developer, Part No. 3375434 or equiv-
alent. Spray the rolled lip of the damper.
NOTE: The crack detection kit, Part No. 3375432, contains
the necessary cleaner, the penetrant and the developer to
check for cracks using the dye penetrant method.

daSOOse

Caullon: Wear protective clothing to prevent personal

Injury from burns.'
Place the damper in an oven with the rolled lip toward the
bottom.
Adjust the temperature of the oven to 93'C (200'F] and
allow the damper to remain in the oven for 2 hours.

daBOOsf

Caution: Wear protecllve clothing to prevent personal A.

Injury from burns. .L:l.
Remove the damper and look for fluid leakage around the ffi
'roIlM11p~TM 'da:mperrfiUa1'blHepIMen inh8i'eilr-ahy 'D'<$)"
fJuid leak~9.e.

..BOOsg

Engine Protection System

Calibration
The engine protection system must be calibrated every
6,000 hours or 2 years. Follow the manufacturer's rec-
ommended maintenance procedures.
If the CompuSave unit is in use, refer to the Operations
and Maintenance Manual for the Flight Systems 9560
Test Set, Bulletin No. 57-9560-01.
If the Flight Systems Engine Saver is in use, refer to the ~
Engine Saver Level 7 Manual, Bulletin No. 57-A550-26.
....... "'~ ..... .__ .~, ~._.r" _.,_ ",=
Section 8 - Other Maintenance Procedures
K38 and K50 Page

Section 8 - Other Maintenance Procedures

Section Contents
P
Miscellaneous ...................................................................................................................................................

, , - , " _ - _ ' , •••••••• _._.~~._. , .••••• ~_.~ • • ,._ ••. ~.t:o<.-

Miscellaneous Section 8 - Other Maintenance Procedures
Page 8-2 K38 and KSO

Miscellaneous
On the following components follow the manufacturer's
~ recommended maintenance procedures.
• Alternator
• Generator
• Starter
• Air Compressor (non-Cummins)
• Electric Connections
• Batteries
• Freon Compressor
• Hydraulic Governor
• Fan Shaft Bearings
• Clutch or Marine Gear
Section D • Systems Diagrams
K38 and K50 Page I

Section D . Systems Diagrams

Section Contents
Pa
Air System Flow Diagrams ....................................................................................................." .........._... ... ... ... D-
Exhaust System - Center Mount Aftercooler ................................ ., ........................ ' .............. " ......... .......... ... D-
Exhaust System - KTT A Engines ...... ' ....................................................... ,. ......... ... ............. ................ ...... ... D-
Intake System - Center Mount Aftercooler ......... ............. ...... ............. ......... ......... ... .......... ... ...... .......... ...... ... 0-
Intake System - KTI A Engines ............................................................................................... '" ... ....... ..... .... 0-
Compressor Air System Flow Diagram .......................................................................................................... D-
Coolant System Flow Diagrams .... '" .. ' ........................ '" ..................... ,...................................................... ' .. . O-
Cooling System - Top Mounted Aftercooler ..........................................................................." ..................... . 0-
Cooling System Flow (LTA) - K2000, KTIASO-G2, KTASO-G3/G4 .................................................................. 0-'
Cooling System Flow (l TA)-K2000, KTI A50-G2, KT ASO-G3/G4 ................ " ................................................. . 0-'
Cooling System Flow (Outboard Aftercoolers) ........................................... " ................................................. . 0-'
Thermostat Housing Flow ......................................................................... " .................................................. 0-'
Fuel System ................................................................ '" ... ... ....... ..... ............. .... ..... .......................... ... ........ ..... D
Fuel Systems Flow Diagram ........................................ '" ...................................................................... " ..... ..... D·
General Information ................................... " ... .... .... ..... ... ... ... ....... ..... ....... .......... ... ............................ ..... ..... ...... D·
Lubrlcatlng-0i1-F'lowDia1jrams ......................................................................................................................... D·
lubricating 011 System .......... ... .... ......... ... .... ...... ... ...... ... ... .......... ..... ....... ... ....... ... ................................. .... .... ... 0-
Front Gear Train ............................................................................................................................................. D·
Full Flow Lubrtcating Oil Filter Head........ ,.................................. " ..... ....... ....... .... ............................ ....... ........ D-
Piston Cooling, Connecting Rod, Overhead .................................................................................................... D-
R ear Gear Train, Turbocharger ....................................................................... '" ... .............................. .... ....... D-
STC Lubricating Oil Flow (Advanced Timing) Hydromechanically Controlled.... ...... .......... .................... ... .... .... 0-
STC Lubricating Oil Flow (Normal Timing) Hydromechanically Controlled ..................................................... D-t,
General Information Section D - Systems Diagrams
Page D-2 K38 and K50

General Information
Trw following drawings display the Ilow through the engine systems. Although parts can change between different
applications and installations, the flow remains the same. The systems shown are:
• Fuel System
• Lubricating Oil System
• Coolant System
• Intake Air System
• Exhaust Air System
• Compressed Air System
Knowledge of the engine systems can help you in troubleshooting, service and general maintenance of your
engine.
Section 0 • Systems Diagrams Fuel Systems Flow Dlagra~
K38 and K50 Page D·.

Fuel Systems Flow Diagram

9
5
8
~-

'..
"
'"l <:?'

',i!r ,(.r
ri --::
7

Fuel System 3
2
1. Fuel Inlet
2. Fuel Filters The PT fuel system is used exclusively on Cummins
3. Fuel Pump Diesels. The identifying letters, PT, are an abbre-
4. Check Valve viation of pressure-time.
5. Fuel Block The PT Fuel System consists of the fuel pump,
6. Fuel Supply to Right Bank Fuel Manifold supply lines, drain lines, fuel passages and injec-
7. Fuel Supply to Left Bank Fuel Manifold tors.
8. Fuel Return from Right Bank
9. Fuel Manifold
10. Injector NOTE: Some engines built after 1986 will have the
11. Fuel Return to Tank fuel supply and return check valves (4) contained
12. Gear Pump Coolant Drain within the fuel block (5).
Lubricating 011 Flow Diagrams Section 0 - Systems Diagrams
Page 0-4 K38 and K50

Lubricating Oil Flow Diagrams

10

4
Lubricating Oil System
1. Oil Inlet Tube
2. Lubricating Oil Pump
3. High Pressure Relief Valve - K38
4. High Pressure Relief Valve - K50
5. Jumper Cover
6. Oil Cooler
7. Oil Filter
8. Piston Cooling Rifle (Outboard) NOTE: Older K50 engines possessed a high pres-
9. Main Oil Rifle sure relief valve attached to the lubricating oil pump
10. Cam Oil Rifle front cover.
Section D • Systems Diagrams Lubricating 011 Syste~
K38 and K50 Page D·,

) 10

1 ('
I I
1
i'

Piston Cooling, Connecting Rod, Overhead

1. Main Oil Rifle
2. P islon Cooling Rille (Outboard)
3. Cam Oil Rifle
4. Piston Cooling Nozzle (Outboard)
5. Orifice
6. Cam Follower Note: Engines with inboard piston cooling nozzles
7. Rocker Lever (Exhaust) will not possess items 2 and 4.
8. Oil Supply to Main Bearings
9. Oil Supply to Connecting Rod Older engines with outboard piston cooling nozzles
10. Piston Cooling Nozzle Onboard) will not possess item 10.
Lubricating 011 System Section D - Systems Diagrams
Page 0-6 K38 and KSO

Front Gear Train

1. Main Oil Rifle
2. Idler Gear
3. Oil Flow through Gear Housing into Front Cover
4. Oil to Water Pump
5. Oil to Air Compressor
6. Oil to Hydraulic Pump Drive NOTE: Oil flow to the idler gears (2) is through the
7. Air Compressor Oil Drain (Cummins 2 Cylinder) cylinder block.
 Section 0 . Systems Diagrams
K38 and K50 Lubricating 011 Syste
Page 0

2
Rear Gear Train, Turbocharger
1. From Main Oil Rifle
2. Oil Supply to Thrust Bearing
3. Cam Oil Rifle
4. Idler Gear
5. Oil Supply to Upper Output Housing
6. Turbocharger Oil Supply
7. Turbocharger Oil Drain
Lubricating 011 System Section D • Systems Diagrams
Page 0·8 K38 and KSO

Full Flow Lubricating Oil Filter Head

1. Oil Supply to Filterhead
2. Oil Return to Pan
3. Oil Supply to Filters
4. Oil Pressure Regulator
5. Oil Filter
6. Control Rifle
7. Filter Bypass Valve
8. Piston Cooling Control Valve (Outboard)
9. Piston Cooling Rifle (Outboard)
10. Piston Cooling Nozzle (Outboard)
11. Main Oil Rifle
12. Piston Cooling Control Valve (Center Mount) NOTE: Engines with center mount piston cooling
13. Piston Cooling Nozzle (Center Mount) nozzles will not possess Item Nos. 8, 9, or 10.
 Section D • Systems Diagrams lubricating Oil Syste
K38 and K50 Page D

Fuel
~0 ~
6E;:f'fQ.
~.c~6 *11,1(0\ Fuel Pressure Less than 53 psi (365 kPa)
'.;'0:.':, Oil Drain
_ Oil Pressure More than 10 psi (69 kPa)
{'.:::'':~:; Fuel Drain

".

STC Lubricating Oil Flow (Advanced Timing) Hydromechanically Controlled

1. Oil Supply to Oil Control Valve
2. Oil Filler Head
3. Oil Control Valve Cutaway
4. Fuel Pressure Signal to Oil Control Valve
5. Fuel Supply to Injectors
6. Oil Control Valve Plunger
7. Oil Manifold
8. STC Tappet
9. Oil Transfer Connection
10. Oil Supply to Tappets
Lubricating all System Section 0 • Systems Diagrams
Page 0-10 K38 and KSO

Fuel

\lb._ Fuel Pressure More than 53 psi (365 kPa)

I.'<&."%'l Oil Pressure 2·6 psi (14-41 kPa)
_~o~>\°r.~ Oil Drain ___ .-
~ Oil Pressure More than 10 psi (69 kPa)
~:::;z';J; Fuel Drain

~;::;." .. '.".'.' ..~

STC Lubricating Oil Flow (Normal Timing) Hydromechanically Controlled

1. Oil Supply to Oil Control Valve
2. Oil Filter Head
3. Oil Control Valve (Hydromechanical) Cutaway
4. Fuel Pressure to Oil Control Valve
5. Fuel Supply to Injectors
6. Oil Control Valve Plunger
Section D • Systems Diagrams Coolant System Flow Dlagrllr
K38 and K50 Page D·

Coolant System Flow Diagrams

11
10

Cooling System - Top Mounted Aftercooler

1. Aftercooler Housing
2. Aftercooler Core
3. Aftercooler Coolant Supply
4. Aftercooler Coolant Return
5. Coolant Return to Radiator
6. Coolant Transfer Tube (Head to Head)
7. Thermostat
8. Coolant Filters
9. Oil Cooler
10. Water Pump
11. Coolant Supply from Radiator
12. Bypass Tube
13. Coolant to Block V
14. Cylinder Liner
15. Cylinder Head
Coolant System Flow Diagrams Section 0 • Systems Diagrams
Page 0·12 K38 and KSO

Cooling System Flow (Outboard Aftercoolers)

3
1

Outboard (Side Mounted) Aftercooler

1. Aftercooler Housing
2. Aftercooler Supply
3. Aftercooler R elurn
Section 0 - Systems Diagrams Coolant System Flow Dlagran
K38 and K50 Page 0·1

Cooling System Flow (LTA) - K2000, KTTASO·G2, KTASO-G3/G4

Low Tem perature Aftercooler

1. Aftercooler Housing
2. Aftercooler Supply
3. Aftercooler Core Return
4. Aftercooler Core Vent
5. Coolant Filter Inlet
6. Coolant Filter Outlet
7. Bypass Tube
8. Coolant Supply from Radiator
9. Aftercooler Core Drain
Coolant System Flow Diagrams Section 0 • Systems Diagrams
Page 0-14 K38 and KSO

Cooling System Flow (L TA)-K2000, KTTASO-G2, KTASO-G3/G4

3 S

Thermostat Housing Flow

1. To LTA Radiator
2. From LTA Radiator
3. To LTA Thermostat
4. Aftercooler Supply NOTE: The KTA50-G3/G4 and KTT A50-G2 contain
5. Aftercooler Return LTA hardware, but are nol low temperature after-
6. Aftercooler Core Vent cooled. These engines do nol flow coolant to or from
7. Coolant Return to Radiator an LTA radiator (lor 2).
 Section D - Systems Diagrams Coolant System Flow Dlagra~
K36 and K50 Page D-'

Thermostat Housing Flow

ka
2
Non-L TA
1. From Coolant Manifold
2. Thermostat
3. Coolant to Radiator
4. Bypass Coolant
5. Coolant Filter 5

L
. ~,)

{?"
:A
~.:,
8

.c 12
; ..rJ"
'.}

I 3

LTA
1
2
1. From Coolant Manifold
2. Main Engine Thermostats
3. Bypass Coolant
4. Coolant to Main Radiator
5. Coolant Bypass Coolant
\~ LTA Thermostat
7. Block Coolant NOTE: The KTASO-G3, KTASO-G4, and KTTASO-G2
.~·8. To LTA Radiator have LTA cooling system hardware, but are NOT
'9. To Aftercoolers low temperature aftercooled. In this situation, the
>10. From LTAR adiator LTA thermostat is NOT installed and an l TA radiator
'11. From Aftercoolers ~NOT used. Coolant flows directly from the block
12. Vent to Radiator Top Tank (7) to fllea:fiercoolers (9).
 Air System Flow Diagrams Section D • Systems Diagrams
Page D·16 K38 and K50

Air System Flow Diagrams

Intake System· Center Mount Aftercooler 3

1. Intake Air Inlet to Turbocharger 2

2. Turbocharger
3. Turbocharged Air to Aftercooler
4. Intake Air to Cylinders

Exhaust System· Center Mount Aftercooler

1. Exhaust Manifold
2. Turbocharger
3. Turbocharger Exhaust Outlet
Section D • Systems Diagrams
K38 and K50 Air System Flow 0la9ra;
Page D·

Intake System· KTTA Engines

1. Intake Air Inlet to Turbocharger
2. Low Stage Turbocharger 1
3. High Stage Turbocharger
4. Turbocharged Air to Aftercooler 2

1 - _......

Exhaust System· KTT A Engines

1. Exhaust Manifold 3
2. High Stage Turbocharger
3. Low Stage Turbocharger
4. Turbocharger Exhaust Outlet

1
Compressor Air System Flow Diagram Section 0 • Systems Diagrams
Page 0·18 K38 and K50

Compressor Air System Flow Diagram

Air Governor Signal Air Governor 8Ignol--,,/

Air

Lubricant :4,
....10--""1' Lubricant
Section T - Troubleshooting
K38 and K50 Page T

Section T - Troubleshooting
Section Contents
Pal
Procedures and Techniques ............................................................................................................................. T
Troubleshooting Symptoms.............................................................................................................................. T
Coolant Temperature Above Normal .................................................................................................... T-10, T·1
Coolant.Temperature Below Normal. ............................................................................................................. T-1
Engine Cranks But Will Not Start (No Smoke From Exhaust) .......................................................................... T
Engine Hard to Start or Will Not Start (Exhaust Smoke Present) .... ...... ......... ... ....... ... ............. ........... ...... ....... T·
Engine Power Output Low........................... .......................... .... ...... ... .......... ... .......... ......... ................. T-14, T·1
Engine Starts But Will Not Keep Running ....................................................................................................... To
Engine Will Not Crank or Cranks Slowly (Air Starter) ...................................................................................... To
Engine Will Not Crank or Cranks Slowly (Electric Starter) ............................................................................... T
Engine Will Not Reach Rated Speed When Loaded ...................................................................................... T-1
Engine Will Not Shut Off ..................... ......... ...... ................... ... ...... ..... ... ............................................ .... .... ..... T·
Exhaust Smoke Excessive Under Load ......................................................................................................... T-1
Lubricating Oil Pressure Low.... ...................... ...... ........................... ...... ...... ...... ... ...... ........ ........ .... ....... .... ..... T
White Smoke or Rough Running At Idle (After Warmup Period) .................................................................... T-1
Procedures and Techniques Section T - Troubleshoo.ting
Page T-2 K38 and KSO

Procedures and Techniques

This guide describes some typical engine operating problems, their causes, and some acceptable corrections to
those problems. For more procedure information, refer to the K38 and KSO Engine Series Troubleshooting and
Repair Manual, Bulletin No. 3810432. Unless noted otherwise, the problems listed are those which an operator
can diagnose and repair. See a Cummins Authorized Repair Location for diagnosis and repair of problems not
listed.
Follow the suggestions below for troubleshooting:
• Study the problem thoroughly before acting.
• Refer to the engine system diagrams.
• Do the easiest and most logical things first.
• Find and correct the cause of the problem.
Troubleshooting Symptoms
Section T - Troubleshooting Troubleshooting Sympton
K38 and K50 Page T

Engine Will Not Crank or Cranks Slowly (Air Starter)

Cause Corrections

Incorrect Oil For Operating Conditions Change oil and filters. Use recom-
mended type (15W-40).

OK
•
Oil Temperature Too Low Install oil pan heater.

OK
•
Insufficient Air Pressure Increase pressure using external air
supply.

OK
•
Starter Malfunction or Incorrect Starter ~ - - - - - - -- Refer to manufacturer's instructions.

OK
•
External or Internal Conditons Affect- Check engine for ease of crankshaft
ing Engine Crankshaft Rotation rotation.

OK
•
Contact an Authorized Repair Facility
 Troubleshooting Symptoms Section T • Troubleshooting
Page T·4 K3B and K50

Engine Will Not Crank or Cranks Slowly (Electric Starter)

Cause Corrections

External or Internal Conditions Affect· Check engine for ease of crankshaft.

ing Engine Crankshaft Rotation

OK
•
Battery Connections Broken. Loose or Check battery connections. Refer to
Corroded Section A.

OK
•
l_____________
_ ,n_c_o_rr_ec_t_O_i_,__________

OK
•
~I--------L
I ___ mended type (15W-40).
C_h_a_n_g_e_O_il_a_n_d_f_ilt_e_rs_._u_s_e_r_e_co_m_.
____ ~

I. ______ f----
O_i_I_T_e_m_p_9_ra_t_ur_e_L_o_w_____..... nn '--______ ~ln_s_ta_lI_o_i_1
p_a_n__
he_a_t_er_.________..J
n~ _ -'

•
I. ______ __R_a_t_in_g_T_O_O_L_O_W______..If --- ----
B_a_t_te_ry '--_____R_e_PI_a_ce__w_it_h_c_o_rr_e_ct_r_a_ti_ng_.______-'
OK
•
Battery Temperature Too Low Check battery heater operation:

OK
•
l___________ ha-r-g-e-L-O-w-------~Lnn
B_a_tt_e_ry_C

OK
•
__ I L ___gravity. Refer to __ Section
C_h_e_c_k_e_le_c_tr_o_lyt_e 6.
le_v_el_a_n_d_s_p_e_c_if_iC____-'

Starting Circuit Component Check starting circuit components.

Malfunction

OK
•
Contact an Authorized Repair Facility
 Section T - Troubleshooting Troubleshooting Symptc
K38 and K50 Page

Engine Hard to Start or Will Not Start (Exhaust Smoke Present)

Cause Corrections

Engine Cranking Speed Low (Below -------- Check engine cranking RPM.
150 RPM)

OK
•
Engine Driven Units Engaged -------- Disengage engine driven units.

OK
•
Cold Start Aid Needed or Not Working -.------ Install cold start aid. Check, repair, or
Correctly replace if necessary.

OK
•
I Fuel Filter Plugged
fu nU-1 Replace fuel filter.

OK
-- --- ---- . •
funn
I
Check for air in fuel, tighten fuel
Air in the Fuel System connections and filter, check fuel tank
stand pipe.

OK
•
Fuel Suction Line Restricted --~-----
Check fuel line for restrictions.

OK
•
Intake Air System Restricted ------.- Check intake air system for restrictions.

OK
•
fnnn
I Fuel Contaminated

OK
•
Verify by operating engine from a
temporary supply tank.

Contact an Authorized Repair Facility

Troubleshooting Symptoms Section T • Troubleshooting
Page T·6 K38 and K50

Engine Cranks But Will Not Start (No Smoke From Exhaust)
Cause Corrections

I No Fuel In Tank

OK
f----j Add fuel.

•
I Shut-off Valve Closed

OK
•
f---- Use manual override. Repair electrics.

, .

I
Loosen fuel supply line between fuel pump
No Fuel To Injectors

OK
f---- and cylinder head while cranking engine -
check for fuel.

•
Tighten all fuel filter fittings and
Fuel Conne.ctions Loose On Suction ~~-------
connections from fuel tank to fuel .. , ...... -
Side Of Fuel Pump
pump.
0l r

•
Fuel Filter Plugged or Suction Line -------- Replace fuel filter. Inspect fuel hose for
Restricted restriction.

OK
•
I No Fuel in Pump
f--n--j Prime fuel punip.

I
OK
•
Intake or Exhaust System Restricted -------- Check intake and exhaust system for
restrictions.

OK
•
Contact an Authorized Repair Facility
Section T - Troubleshooting Troubleshooting Sympton
K38 and K50 Page T

Engine Starts But Will Not Keep Running

Cause Corrections

Check for air in fuel, tighten fuel

Air In The Fuel System connections, tighten filter, check fuel
tank stand pipe.

OK
•
Engine Driven Units Engaged Disengage engine driven units.

OK
•
Fuel Filter Plugged or Fuel Waxing Replace fuel filter. Weather conditions
Due to Cold Weather can require fuel heater.

OK
•
Fuel Suction Line Restricted Inspect fuel line for restriction.

OK
•
_____
_
1 F_u_e_1_c_o_nt_a_m_in_a_te_d_ _ _ _ I --
--1L m - temporary supply tank.
v_e_r_ify_by_O_pe_r_a_ti_ng_e_ng_i_n_e_fr_o_m_a
' -_ _ _ _---I
..

OK
•
Intake or Exhaust System Restricted Check intake and exhaust system for
restrictions.

OK
•
Contact an Authorized Repair Facility
Troubleshooting Symptoms Section T - Troubleshooting
Page T-8 K38 and K50

Engine Will Not Shut Off

Cause Corrections

Fuel Pump Manual Override Open. Check to make sure manual override
screw is out to maximum travel.

OK
•
Fuel Pump Shut-off Valve Disc Stuck Check opening and closing of electrics.

OK
•
Fuel Tank Vents Plugged Remove, clean, or replace vents.

OK
•
Fuel Drain Line Restricted Check fuel drain line for loops, crimps,
or· clamped points." .

OK
'"
Engine Running on Fumes Drawn into Locate and isolate the source of fumes.
Air Intake

OK
•
Contact an Authorized Repair Facility
Section T - Troubleshooting Troubleshooting Sympto
K38 and K50 Page

Lubricating Oil Pressure Low

Cause

. Corrections

I ~
Check for oil leaks. Add or drain engine

__ _ _ _ _I_nc_o_r_re_c_t_O_il_L_e_ve_I_ _ _ _--'_ - n - - - n L._Oi_I._R_e_fe_r_l_o_S_e_c_ti_o_n

calibration. Refer to _5_. _C_h_ec_k_d_i_P_SI_iC_k
Section A. _ _...l
...
OK
•
Oil Pressure Gauge Malfunctioning Check oil pressure gauge.

OK
•
~
Change oil. If oil becomes diluted
_____O_i_I_D_il_ut_e_d_w_i_th_F_ue_I_ _ _ _...1_ - - - n -. - L._ag_a_i_n,_c_o_n_ta_c_t_A_u_th_o_r_iz_ed_R_e_p_ai_r
Facility. _ _ _--'
...
OK
•
Incorrect Oil Specifications Change oil and check oil specifications.

OK
•
Oil Temperature Above Normal (120°C Refer to Coolant Temperature Above
[250°F]) Normal Chart.

OK
•
Contact an Authorized Repair Facility
 Troubleshooting Symptoms Section T - Troubleshooting
Page T-10 K38 and K50

Coolant Temperature Above Normal

Cause Corrections

LI_ _ _ _ _ L_O_W_C_o_ol_a_n_t_Le_v_e_I_ _ _ _.....f------ --jL_ _ _ _ _ _A_d_d_C_O_O_la_n_t._ _ _ _ _......l

OK
•
Radiator Fins Damaged or Obstructed Inspect radiator fins. Clean or repair if
with Debris necessary.

OK
•
Collapsed or Restricted Radiator Hose Inspect hoses. Replace il necessary.

OK
•
_
LI__________L_o_o_s_e_F_a_n_D
__ I
fi_v6__B_e_It________.....l ........ necessary. Reteno Section 5. _ _ _-1
L _ _C_h_ec_k_b_e_lt_te_n_s_io_n_a_n_d_t_i9_h_te_n_il

rv(

I ~
Add or drain engine oil. Reier to Section 5.

____________ln_c_o_r_re_c_t_O
__il_L_e_ve_I__________J.-
• ...... L_C_h_e_c_k_d_iP_s_ti_c_k_c_a_li_b_ra_t_io_n_._R_e_fe_r_t_o
Section A. _____ ~
L
OK
•
Cooling Fan Shroud Damaged or Inspect shroud. Repair, replace, or
Missing install.

OK
•
Incorrect or Malfunctioning Radiator Check the radiator cap. Replace if
Cap necessary.

OK
•
Temperature Gauge Malfunctioning Test the gauge. Repair or replace il
necessary.

OK
• (Continued)
Section T - Troubleshooting TroubleshootingSymptCl
K38 and K50 Page T

Coolant Temperature Above Normal (Continued)

Cause Corrections

Radiator Shutters are not Opening Inspect the shutters. Repair or replace
Completely or Cold Weather Radiator if necessary. Open radiator cover.
Cover Closed

OK
•
Contact an Authorized Repair Facility
Troubleshooting Symptoms Section T - Troubleshooting
Page T-12 K38 and K50

Coolant Temperature Below Normal

Cause Corrections

Radiator Shutters Stuck in Open Inspect the shutters. Repair or replace

Position or Opening Early if necessary.

OK
•
Temperature Gauge Malfunctioning Test the gauge. Repair or replace if
necessary.

OK
•
Contact an Authorized Repair Facility
Section T - Troubleshooting Troubleshooting Sympto~
K38 and K50 Page T-'

Exhaust Smoke Excessive Under Load

Cause Corrections

Intake Air System Restricted Check intake air system for restrictions.

OK
•
charger
ln_ta_k_e_A_I_'and
__ Cylinder Head_T_u_rb_o_-_ _....J
r_L_e_a_ks_B_et_w_e_e_n ------ --lL.I_____C_he_c_k_f_o_r_al_·r_le_a_k_s_,_ _ _ _.1
L
OK
•
Fuel Specifications Wrong ~.------- Check fuel specifications.

OK
•
Valves or Injectors Adjusted Wrong Check/adjust valves or injectors. Refer
to Section 6,

OK
•
Fuel Drain Line Restricted Inspect fuel return system for loops,
crimps, or clamped points.

OK
•
Contact an Authorized Repair Facility
Troubleshooting Symptoms Section T - Troubleshooting
Page T-14 K38 and KSO

Engine Power Output Low

Cause Corrections

E_x_c_e_S_S_iv_e_L_o_a_d_f_o_r_E_ng_i_n_e_H_o_rs_e_p_o_w_e_r....l - - - - - -
__Rating ..JLI_____R_e_d_u_ce_v_eh_i_c_le_l_oa_d_._ _ _ _ ...l
L
OK
•
Derate engine for altitude. Refer to engine
Low Power Due to Altitude data sheet for specifications, Bulletin No.
3381194.

OK
•
Fuel Suction Line or Fuel Filter Check fuel line for restriction. Replace
Restricted fuel filter.

OK
•
Lubricating Oil Level Too High Check dipstick calibration and oil pan
capacity. Refer to Section A.

•
Throttle Linkage Adjustment Wrong Check throttle linkage adjustment for
full opening of throttle lever.

OK
•
Intake or Exhaust System Restricted Checkihtake·and exhaust systems for
restrictions.

OK
•
Check for air in fuel, tighten fuel
Air in Fuel - Spongy Throttle is connections and filter, check fuel tank
Symptom
stand pipe.

OK
• (Continued)
Section T - Troubleshooting Troubleshooting Sympton
K38 and K50 Page T-·

Engine Power Output Low (Continued)

Cause Corrections

Fuel Drain Line Restricted or Fuel Check fuel drain line for loops, crimps or
Tank Vents Plugged clamped points. Remove, clean, or replace
vents.

OK
•
Valves or Injectors Adjusted Wrong Check/adjust valves or injectors. Refer
to Section 6.

OK
•
I ~
Verify by operating engine from a
_ _ _ _ _ _F_U_e_I_Q_U_a_li_ty_p_o_o_r_ _ _ _....J• - - -- -- -- ,-_t_e_m_p_o_ra_ry_ta_n_k_t_h_a_t_co_n_t_ai_n_S_g_O_Od_fu_e_I_-1
and refer to fuel oil specifications.
L
OK
•
High Intake Air Temperature - (Above Use outside air to turbocharger in warm
38°C (100oFJ) weather.

OK
•
Low Intake Air Temperature· (Below Use intake air from under hood in cold
DOC [32°FJ) weather.

OK
•
High Fuel Temperatures - (Above 70°C Fill fuel tanks; turn off fuel heater.
[158°FJ) Maximum fuel temperature 7Doe
[158°F).

OK
•
Contact an Authorized Repair Facility
Troubleshooting Symptoms Section T - Troubleshooting
Page T-16 K38 and K50

Engine Will Not Reach Rated Speed When Loaded

Cause Corrections

J
Excessive Load for Engine Horsepower
Rating
__ - - - - - -
I Reduce load.

~----------------------~
OK
•
Tachometer Has a Malfunction Check with hand or digital tachometer.

OK
•
Throttle Linkage Adjustment Wrong Check for full throttle travel. Refer to
Section 6.

OK
•
Fuel Suction Line.Restricted... Check fuel inlet for restriction.

nv
•
Contact an Authorized Repair Facility
Section T - Troubleshooting Troubleshooting Symptol
K38 and K50 Page T-

White Smoke or Rough Running At Idle (After Warmup Period)

Cause Corrections

Low Coolant Temperature Refer to Coolant Temperature Below

Normal chart.

OK
•
_____
l
_ F_U_e_I_Q_u_a_li_ty_p_o_o_r_ _ _ _

OK
I _
--ILu --
temporary tank that contains good _fuel.
'-_v_e_ri_fy_b_y_Op_e_r_at_in_g_en_g_i_ne_fr_o_m_a _ _-'

•
Contact an Authorized Repair Facility
Section A - Adjustment, Repair, and Replacement
K38 and K50 Page A·'

Section A - Adjustment, Repair, and Replacement

Section Contents
Pag.
Air Starting Motors ........ ... ... .... ... ............ ............. ......... ...... .... ......... ..... ....... ....... ... ... ............................... ........ A·:
Maintenance ...... .......... ... ... .......... ............... ....... ............... ....... ......... ......... ....... ... ...... .................................... A-:
Alternator Belt ....... ............ ... .......... ...... ...................... ......... ....... ...... ...... ......... ....... ......... ....... .............. ............ A~
Adjustment .......................... ,. ....... ......... .......... .... ..... ......... ....... ...... ............ .... ...... ... .... ..... .............................. A~

Battery Connections .... ..... ....... ... ..... ....... ................... ...... .......... ... ... ... ...... .......... ...... ...................... ........... ...... A-:
Dipstick.... ....... ... ... ... ................. ..... ...... ... ................ ... ... .... ...... ....................... .............. ............................. ... .... A-1 (
Calibration .. , ... ...... ...... .... ......... ......... ... ................... ... .... ......... ...... .......... ............... ... .......... ...... ... ... .... ... ... .... A-1 (
Fan Belt.................. ......... ...... .... ...... ......... ...................... ................... ......................................... ....................... A-'
Adjustment... ....... ... ... ...... ........ ........ ......... ....... ...... ....... ..... ....... ...... ....... ..... ...... .... ...... ...... .... ......... ........ ......... A-!
~';~r!~~n:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ~~
Removal ......................................................................................................................................................... A ..
Storage for Engines Out of Service........... ...................... ................................... .......... .............. ...... .............. A-1'
Long Term Storage ....................................................................................................................................... A-1:
Short Term Storage...................................................................................... ................................................ A-1'
Air Starting Motors Section A - Adjustment, Repair, and Replacement
Page A-2 K38.and K50

Air Starting Motors

The air starting motor system (tanks, line sizes, and
valves) is designed and installed by the original equip-
ment manufacturers and the starting motor suppliers.
Refer any questions about the air starting systems to the
manufacturer.
Maintenance
• Do not operate the air starting motor with air pres-
sure lower than 480 kPa [70 pSi].
• Maintain the air compressor according to the rec-
ommendations outlined in the manual.
• For maximum efficiency, the hoses, tubes, and lines
must not leak.
e Refer to the original equipment manufacturers' and
starting motor manufacturers' manuals for specific
information regarding the starting motors, valves,
and systems.

Battery Connections
Caution: When using jumper cables to start the engine,
make sure to connect the cables In parallel: positive (+ )
to positive (+) and negative (-) to neQative (-). When
using an externafelecti'lcar source to ·start the engine,
turn the disconnect switch to the OFF position and re-
move the key before attaching the jumper cables.
The accompanying illustration shows a typical parallel
battery connection. This arrangement doubles the crank-
ing amperage.

This iIIustrati0.ll show~a typical series ba!lery conn(jc-

tion. This arrangement, pOSitive to negative, doubles the
voltage.
 Section A - Adjustment, Repair, and Replacement Alternator Be
K38 and KSO Page A-

Alternator Belt
Adjustment
NOTE: The lower jam nut has left-hand threads.
Loosen the alternator and adjusting link mounting cap-
screws.
Loosen the jam nuts on the adjusting screw.

ah4lkull.

Turn the adjusting screw clockwise to tighten the belt

tension.
Belt tension: 356 N [80 Ibf]
Burroughs Tension Gauge: (ST-1293)
NOTE: Over-tensioning of alternator belts can result in pre-
mature accessory drive bushing wear and seal leakage.

NOTE: The lower jam nut has left-hand threads.

Tighten the jam nuts on the adjusting screw to 55 Nem rf&,1~~
[40 ft-Ib]. ~
""'"
Tighten the adjusting link and alternator mounting cap-
screws to 55 Nem [40 ft-Ib].

Check the belt tension again to make sure the tension Is ~

correct. ~

aMlogll.
Fan BeH Section A - Adjustment, Repair, and Replacemen'
PageA-4 K38and K50

Fan Belt
Removal
Back Side Idler System
Remove the back side idler end of the shock absorber,
solid contrOJ rod (turnbuckle), or control rod tensioner
assembly.
NOTE: The back side idler system uses one of two types o.
control rods (turnbuckles) or a shock absorber. Refer to the
instructions that apply to the engine being serviced.
Loosen the upper capscrew (31). Remove the lower cap
screw (31).

NOTE: One of the jam nuts on the solid control rod (turn-
buckle) has left hand threads.
Loosen the solid control rod (turnbuckle) jam nuts (11)
Turn the adjusting screw (10) until the spacer (1) is not
touching the end of the slot in the control rod (9).

Remove the capscrew (7), washers (2, 3) and spacers (1)

Remove the control rod assembly from the idler assembly

To remove the control rod with spring, remove the !We

jam nuts (26), washers (25, 24), and spring (23).
 Section A - Adjustment, Repair, and Replacement Fan Be
K38 and K50 PageA·

Remove the parts.

• (20) Capscrew
• (19) Washer, Lock
• (18) Washer
• (17) Spacer
• (14) Capscrew
• (13) Washer, Lock
• (12) Washer
• (15) Control Rod

Caution: 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.
Use an 8-point socket and breaker bar or large wrench to
hold the idler in position against the spring tension. Re·
move the capsemws from the spring· cap.
Slowly turn the wrench until the spring tension is relieved.
_.. . _ .Rem()ye.JiJe fan pelt.

Two Pulley Fan Drive (Without Idler Pulley)

NOTE: The fan center distance is the distance between the
crankshaft and fan center lines.
On systems that use a 20, 22, or 24 (without idler pulley)
inch fan center, loosen the bOits that pass through the
slotted holes in the fan hub bracket.
.... -Loosen the fan hub adjusting screw.

On engines that use a two pulley drive with a 28 inch fan

center distance, loosen the bolts that pass through the
slotted holes and fan hub bracket ofthe 28 inch fan center
system. The adjusting screw (16) is below the fan hub.
The lock nut (17) must be loosened before loosening the
fan hub adjusting screw.
Loosen the fan hub adjusting screw.
Fan Belt Section A - Adjustment, Repair, and Replacement
PageA-6 K38 and K50

Remove the fan belt.

Checking
Visually inspect the belt for:
e Cracks
e Glazing
e Tear$~ or cuts.

Installation
I nstall the belt on the crankshaft and fan hub p~lIey. Jl.ligr:J
rfiTh
~
the grooves on the belt on the ribs of the pulley.

Back Side Idler System

rfiTh
~
After installing the fan belt, install the fan idler system.
Caution: The fan belt Idler Is under tension. Do NOT
A allow your hands to get between the Idler and the belt or
the fan hub. Personal Injury can result.
Rotate the idler against the spring tension until the cap-
screw holes are aligned. Install the lock washer and cap-
screw.
Torque Value: 45 Nem [35 ft-lbJ
Slowly turn the wrench until the idler is against the belt.
 Section A - Adjustment, Repair, and Replacement Fan Be
K38 and K50 PageA·

NOTE: The fan hub pulley and the fan belt are shown re-
moved for clarity.
When installing the solid control rod (tLirnbuckle) on older
engines. the capscrews (4 and 7) are 64 mm [2 1/2 inJ in
length. On the newer engines. the capscrew (4 and 7) are
57 m [2 1/4 inJ in length. It is recommended that SAE
Grade 8 capscrews that are 57 mm [2 1/4 inJ be installed
or the caps crews can ,break.
Install a spacer (1). a heavy flat washer (2). and a lock
washer (3). Install a SAE Grade 8 capscrew (4). 57 m
[7/16-14 X 21/4 inJ in the upper control rod end (5). Hand
tighten the capscrew. Install the upper control rod end in
the fan hub support (6).
Install a spacer (1), a lock washer (3). and a heavy flat
washer (2). Install a SAE Grade 8 capscrew (7). 57 mm ~
[7/16-14 X 21/4 inJ in the lower control rod end (8). Install ~
the lower control rod end on the idler arm (9). Tighten the
capscrews (4 and 7).
Torque Value: 90 Nem [65 ft-lb]

NOTE: The fan belt mustbe installed and under the tension
of the fan idler arm spring to adjust the control rod. The fan
belt and a portion of the flat washer are not shown for clarity.
-T-urn the· adjusting screw (10) until the end of-the slot on
the lower control rod end (9) is touching the spacer (1).
One of the nuts has left hand threads.
Hold the adjusting screw and tighten the two jam nuts
(11).

To install the control roawith sprlng, Install the flat washer

(12), lock washer (13). and capscrews (14) in the upper
end ofthe control rod (15). Install the control rod inthe fan
support (16). Tighten the capscrew.
Torque Value: 60 Nem [45 ft-lb] ~
Install the spacer bushing (17). flat washer (18). lock
washer (19), and capscrew (20) in the lower end of the ~
control rod (21). I nstall the lower end of the control rod ~
on the fan idler arm (22). Tighten the capscrew.
Torque Value: 60 Nem [45 ft-Ib]
Fan Belt Section A • Adjustment, Repair, and Replacement
Page A·8 K38and K50

Install the parts.

~ e (23) Spring
~ e (24) Spring retainer washer
e (25) Flat washer
e (26) Jam nuts (two)
NOTE: Do not tighten the inner fan nut excessively. If the
jam nut is too tight, the spring retainer will bend and the
control rod will fail.
Turn the Inner jam nut until the spring retainer washer
(24) touches the cylinder on the lower control rod end
(27). Hold the Inner jam nut and tighten the outer jam nut.

NOTE: The shock absorber must be installed with the larger

outer tube of the absorber attached to the fan hub support.
lithe absorber is installed wrong, dirt can enter the tube and
cause the part to fail.
~ To install the shock absorber, install these parts:
~ e (28) Spacer
e (29) Flat washer_
• (30) Lock washer - -
e (31) Capscrew
e (32) Shock absorber

I \~\ ) '\
'\ '\ f.6.jhd

Install the shock absorber (32) in the fan support (6).

~
~ Install the flat washer (29), lock washer (30), and cap-
screw (31) in-the lower end -of the shock absorber.-
Install the shock absorber on the fan idler arm. Tighten
the two capscrews (31).
-~ Torque Value: 60 Nem [45 ft-Ib]

Two Pulley Fan Drive Belt· [28 In center]

Install the poly vee 20 rib L-section fan belt (23) on the
crankshaft pulley (22) and the fan hub pulley (7). Align the
grooves in the belt on the ribs in the pulleys.
Make sure the heavy nut (17) is positioned to allow the
adjusting capscrew (16) to turn freely.
Turn the adjusting capscrew (16) counter clockwise to
remove the slack from the belt.
 Section A • Adjustment, Repair, and Replacement Fan Belt
K38 and K50 PageA-9

Two Pulley Fan Drive Belt - (20, 22, or 24 Inch

center)
Install the poly vee 20 rib L-section fan belt (18) on the
crankshaft pulley (17) and the fan hub pulley (7). Align the
grooves in the belt on the ribs in the pulleys.
Turn the adjusting capscrew (10) clockwise to remove
slack from the belt.

Adjustment
Two Pulley Fan Drive Belt
Only one method is acceptable for setting the two pulley
fan drive belt tension. The recommended method is to
use a beIUensiorl-gauge.

Caution: Incorrect belt tensioning procedures can cause

component failure and personal Injury.
Install the belt tension gauge, Part No. 3823875 or equiv-
alent; on theoelfinlhii iniddle between the tWo'pulleys.
C9ntirlu!!J)ghtenlng the adjusting cap:;;crew to a belt ten-
sion of 2668.9 to 2891.3 N [600 to 650 IbfJ. The belt
tension will increase when the capscrews tighten the fan
, hub assem bly to'thefan-support. Tighten the capscrews.
Torque Value: 285 Nem [210 ft-Ib]
Remove the tension gauge and position the gauge on the
other side of the belt. Verify the belt tension Is correct,
2891.3 to 3336.2 N [650 to 750 Ibfl. If the belt tension is
not correct, loosen the capscrews and adjust to the cor-
rect tension again.
Torque Value: 285 Nem [210 It-Ib]
Dipstick Section A • Adjustment, Repair, and Replacement
Page A·10 K38 and K50

\
U6'h~ I ,~: F= Dipstick
-
Calibration
L -.J Ii l ~

+;r
'-'---'
,= Drain the oil from the pan. Refer to Section 5.
~ ~-.
""""0 0 0 oJ_
~~~
"-=;; ~'-

~~~
-,/
- op600wa

Install the dipstick in the dipstick tube.

Use clean 15W-40 oil to fill the oil pan to the low level
(specified low level). Refer to the lubricating oil system
specifications in Section V.

Ig6luha I

NOTE: The dipstick will break if the scribe mark is too deep.
Remove the dif,:lstick and sc.ri.be. a mark across the dipstick
at the oil level. Mark the low level with an L.

Install the dipstick.

Add additional oil to the oil pan to specified full level.
Refer to the lubricating 011 system specifications in Sec-
tion V.

---------~--------

Ig6dssb
Sect/on A - Adjustment, Repair, and Replacement Storage for Engines Out of Servl(
K38 and K50 Page A-1

NOTE: The dipstick will break if the scribe mark is too deep.
Remove the dipstick and scribe a mark across the dipstick
at the oil level. Mark the high oil level with anH.
With a fill to the high oil level, oil can start to flow from the
pipe plug at the center of the pan adapter.
There is a 1/8 inch pipe plug located inthe rightbank side
of the oil pan adapter. This plug is near the center of the
adapter and is located at the high oil level.

Storage for Engines Out of Service

Short Term Storage
One Month to 6 Months
This procedure describes the proper method for the short term storage of an engine.
Shari Term Storage Preparation
Operate the engine-i!t-HIGH 16LE until the coolant temperature 1S-70°C-1160°Fj.
Turn the engine OFF.
Disconnect the fuel lines to the engine fuel filter and the injector return line.
Use a preservative oil. Use Daubert Chemical NoxRust No. 518, or eqUivalent. The oil must be Military SpeCi-
fication MIL-L-644, Type p-g.
Fill one container with diesel fuel, and the second container with preservative oil. Put both fuel lines in the container
of diesel fuel.
START the engine.
After the engine is operating smoothly, transfer the fuel supply line to the container of preservative oil. Operate
the engine untn~he preservative all flows out althe injector-return line. ------~-. - - --,,-
Turn the engine OFF. Connect the fuel lines to the fuel filter and the injector return line.
Dr'ain the -oil-pan surr;p-;Ojiffiters~ and fuel filters.
Install the drain plugs in the oil sump. The sump can remain empty until the engine is ready to put in a service
application.
Disconnect the electrical wiring from the fuel pump solenoid.
Turn the fuel pump manual shutoff valve counterclockwise until it stops.
Crank the engine slowly. Spray lubricating oil into the intake manifold and the inlet of the air compressor.
Drain the coolant.
NOTE: It is not necessary to drain the coolant if it is a permanent type antifreeze with a rust inhibitor.
Put a warning tag on the engine. The tag must read:
• The engine does NOT contain all •
• Do NOT operate the engine.
Store the engine in an area that is dry and has a uniform temperature.
Bar the crankshaft two or three revolutions every 3 to 4 weeks.
Storage for Engines Oul of Service Section A - Adjustment, Repair, and Replacement
Page A-12 ,1(38 and K50

Short Term Storage Removal

Prime the lubricating system:
• Fill the oil pan sump, oil filters, and fuel filters.
• Fill the coolant system if necessary.
• Disconnect the electrical wire from the fuel pump solenoid valve.
• Rotate the crankshaft by the starting motor until oil pressure appears on the gauge or the warning light goes
out.
• Connect the electrical wire to the fuel pump solenoid valve.
• Start the engine. (Refer to Normal Starting Procedures).
Long Term Storage
Six Months to 24 Months
A Caution: After 24 months In storage, the engine cooling system MUST be flushed with a suitable solvent
~ or a hot, lightweight minerai 011. This procedure MUST then be repeated.
This procedure describes the proper method for the long term storage of an engine.
Long Term Storage Preparation
Operate the engine at HIGH IDLE until the coolant temperature is 70°C [160°Fj.
Turn the engine OFF.
Drain the oil. Install the drain plugs. Use Sheil 66202 or equivalent, preservative oil. The oil must meet Military
Specification MIL-L-21260, Type P-1 0, G'rade' 2, SAE 30. Fill the engine to the HIGH mark.
Disconnect the fuel lines to the engine fuel filter and the injector return line.
U~a LJoU06h' tI.,..,l J&i"i/i0o.l r'H.i,,~rHl.:H i ... v ...... I v, Vi al i ~'-jUI'~ ~:h'<;;II'l PiC0'v1-I,;QUIfI.J VI> •. i •• a VII HIU~, li-i.e.'-.-....,-. ,1 .. 0.1 'i vt-'c\"'<oi~d.iiC-i I
MIL-L-644 Type P9.
Fill one container with diesel fuel, and the second container with preservative oil. Put both fuel lines in the
container of diesel fuel.
START the engine.
After the engine is operating smoothly, transfer the fuel supply line to the container of preservative oil. Operate
the engine until the preservative oil flows out of the injector return lirie.
Turn the engine OFF. Connect the fuel lines to the fuel filter and the injector return line.
Drain the preservative oil from the engine oil pan sump, the air compressor and the oil filters.
Remove the Intake and exhaust manifolds. Spray preservative oil into the Intake and exhaust ports in the cylinder
heads and in the manifolds.
Spray preservative oil in the intake port on the air compressor.
Use a rust preventative compound that meets Military Specification MIL-C-16173C, Type P-2, Grade 1 or 2. Brush
or spray the compound on all of the exposed surfaces that are not painted.
Remove the rocker lever covers. Spray the rocker levers, the valve stems, the springs, the valve guides, the
crossheads, and the push rods with preservative oil. Install the covers.
Cover all of the openings with heavy paper and tape to prevent dirt and moisture from entering the engine.
Put a warning tag on the engine. The tag must Indicate:
• The engine has been treated with preservatives.
• Do not bar the crankshaft.
• The coolant has been removed.
• The date of treatm ent.
• Do not operate the engine.
Store the engine in an area that is dry and has a uniform temperature.
Section A • Adjustment, Repair, and Replacement Storage for Engines Out of Servlc
K38 and K50 Page A·1

Long Term Storage Removal

Remove the plug from the main oil rifle. Use a hot, lightweight mineral oil. Flush all of the preservative oil frol
the engine. Bar the engine crankshaft three to four revolutions during the flushing procedure.
Fill the oil pan sump, oil filters, and fuel filters.
Drain the rust preventative compound from the cooling system. Fill the cooling system with coolant.
Prime the lubricating system:
• Disconnect the electrical wire from the fuel pump solenoid valve.
• Rotate the crankshaft by the starting motor until oil pressure appears on the gauge or the warning light goe
out.
• Connect the electrical wire to the fuel pump solenoid valve.
• Start the engine. (Refer to Normal Starting Procedures).
Use clean diesel fuel. Flush the fuel system by operating the engine at low idle until the preservative oil is removed
Section V - Specifications and Torque Values
K38 and 50 Page

Section V • Specifications and Torque Values

Section Contents
PI
Air Intake System ........... ....... .... ....... ... ........ ... ................... .......... ...................... ......... ............. ...... ..... .... ........ ... '
capscrew Markings and Torque Values ......................................................................................................... V
Capscrew Markings and Torque Values - U.S. Customary ............................................................................ V·
Compressed Air System ............................................................. ......................... ............................................. ,
Coolant Recommendations/Specifications..................................................................................................... V·
Coolant Capacity Chart................................................................................................................................. V-
Cooling System Maintenance......................................................................................................................... V-
Cooling System Soluble Oils ......................................................................................................................... V-
Fleetguard® DCA4 Service Filters and Liquid Pre-Charge ............................................................................. V.;
Heavy Duty Coolant ...................................................................................................................................... V-·
Supplemental Coolant Additives (SCA·s) ....................................................................................................... V-·
Drive Belt Tension .......................................................................................................................................... V-:
Electrical System ......... ...... ............. .............. ........ ..... ................. ...................... ...... ..................... ............. ........ V
Engine Component Torque Value .................................................................................................................. V-~
Engine-Specifications ...........................................................................,. ...... ............. ................ .................. ..... V·
Cooling System .............. ......................... ............................. ............ ......... ................... .......... ....................... V·
Engine Specifications - K38 and K50.. ......... ....... ......... ............................ ................... .......... .......................... V·
Fuel System .....................~.. ,.~... " ..... , .._.....' ••.•.... ~ ........................................................................ ".,...... ,..... :.-.;;. V·
- General SpecfficatTons -~ K38 ........................................................................................................................... V-
General Specifications - K50 .......................................... , ............ , ... .... ........................... ....... ...... .•.... .............. V-
Lubricating Oil System........................ ................ ................... ............... ............ ............. ............. .................... V-
Exhaust System .. ...................... ... ...... ...... .......... ...... ...... ............. ...... ....... .... ....................... ......... ....... ... .......... . V"
Fuel RecommendationS/Specifications ............................................................................................................ V-!
Lubricating 011 Recommendations/Specifications ........................................................................................... Vol
~h~~ S1:h:1.~~:::::::: ::::::::::::::::::::::::::::::::::'.::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ::::::::::::: :::::::::: ::: ::: :::::::.. V~-~
Fixed Mileage or Hours Oil Change Interval (All Applications) ...................................................................... V-1'
New EnginE1.~reak-in Oils ............................... _....................................................................; .......... ;.......... .-.-.. - V-!
Oil Drain InterVal Charts ............................................................................................................................... V-1'
. ViscS!§ity Rliu;pmmendalions .......... _ ....................' ... M "';0..........-.- .. .-;;;:;;.;; .. .-.;;;;:;:; .... ;..V-~
• .-.' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications Section V - Specifications and Torque Values
Page V·2 K38 and 50

Engine Specifications
General Specifications. K38

Aspiration KT One Stage Turbocharged

KTA One Stage Turbocharged and Aftercooled
KTTA Two Stage Turbocharged and Aftercooled

Bore and Stroke 159 mm x 159 mm [6.25 in x 6.25 in]

Compression Ratio KT 15.5:1

KTA 14.5:1 or 15.5:1 or 13.8:1
KTA-G3 13.9:1
KTA-P(1350) 13.5:1
KTTA 13.5:1
KTTA-GS/GC 14.5:1

Displacement 38 Liters [2300 cu in]

Firing Order 1R-6L-SR-2L-3R4L-6R-1 L-2R-5L4R-3L

Type 4 Cycle, 60-ge§Hle-V~ei 12 Cylinder

Weight Refer to Engine Lifting Weight in Section E.

Crankshaft Rotation
(viewed from front of engine) Clockwise

General Specifications· K50

Aspiration KTA One Stage Turbocharged and Aftercooled

KTTA Two Stage Turbocharged and Aftercooled

Bore and Stroke 159 mm x 159 mm [6.25 in x 6.25 in]

KTA 13.8:1 or 13.9:1 or 14.5:1 or 15.5:1

KTTA 13.5:1 or 13.8:1 or 13.9:1

Displacement 50 Liters [3067 cu in]

Firing Order 1R-1 L-3R-3L-7R-7L-SR-5L-6R-8L-6R-6L-2R-2L4R4L

(Original Standard)

Note: Some KTTA50 engines manufactured after September 1986, the KTA50G3/4 and
KTTA50G2, will have a different firing order. These engines have the REVISED FIRING
ORDER on the engine data plate.

Revised Firing Order 1R-1 L-3R-3L-2R-2L-SR4L-6R-8L-6R-6L-7R-7L4R-5L

Type 4 Cycle, 60 Degree Vee, 16 Cylinder

Weight Refer to Engine Weight in Section E.

Crankshaft Rotation
(viewed from front of engine) Clockwise
 Section V - Specifications and Torque Values Engine Speclflcatio
K38 and 50 Page \I

Engine Specifications - K38 and K50

Metric [U.S. Custom a,
Valve and injector settings:
Intake valve adjustment .................................................................................................. 0.36 mm [0.014 i
Intake valve recheck limits .................................................................... 0.28 to 0.43 mm [0.011 to 0.017 i
Exhaust valve adjustment .................................................................................................. 0.69 mm [0.027 il
Exhaust valve recheck limits ..................................................................... 0.60 to 0.76 mm [0.024 to 0.030 il
PTD Non·Top Stop injector travel adjustment ..................................................................... 7.82 mm [0.308 i,
PTD Non·Top Stop injector travel limits .................................................... 7.77 to 7.87 mm [0.308 to 0.310 if
STC or HVT Injector Adjustment .......................................................................................... 10 Nem [90 in-II

Fuel System
NOTE: For performance and fuel rate values, refer to the engine data sheet, or the fuel pump code for the particulc
model involved.
Maximum Allowable Restriction to Pump:
e With Clean Filter .................................................................................................. 100 mm Hg [4 in H~
e With Dirty Filter .................................................................................................... 200 mm Hg [8 in H£
Maximum Allowable Return Line Restriction .................................................................. 63 mm Hg [2.5 in Hg
Maximum Allowable Return Line Restriction
.._...... _.Vlith.<::l"!e.c.k. VCilves aDd/or O\fElrh.Elad yallk§ ...... ~~..._'".""" ... m •.•Aw"'" •••••••••••• ~••••••••••••• 165 mm j,!g [6.5 in Hg
Minimum Allowable Fuel Tank Vent Capability
with 63 mm Hg [2.5 in Hg] or less back pressure ........................................................ ..425 Uhr [15 cu ft/hr

Lubricating Oil System

011 Pressure
Oil Pressure, Main Oil Rifle (15W-40 oil at 107°C [225°F]):
Maximum at Rated RPM ..................................................................................................... 483 kPa [70 psi:
Minimum at Rated RPM ..................................................................................................... 310 kPa [4.5 psi:
Minimum at Idle RPM·: ....... :.:::.::::::::::·.::.. :.::::::::.:: .. :.. :.:........ :.:: ........................................... 138 kPa [20 psi:
Oil Temperature- Maximum .... ;·.-;;~C·.-;;7;;;; ••••• ,,~;; •••••••••••••••• : ••••••••••••••••••.••••••.••••• : •• : ••.••••• : ••• :: •••• :.: 120··C--[250·"1=:
011 Filter Capacity (Each Filter)
Bypass filter (spin-on) (2 required on K38 and K50) ................................................. 2.27 liter [0.60 U.S. gal]
Full flow filter (spin-on) (4 required on K38, 5 required on K50) ............................... 2.65 liter [0.70 U.S. gal]
 Engine Specifications Section V • Specifications and Torque Values
PageV-4 K38 and 50

011 Pan Capacity

The following tabulation gives the low and high STATIC (engine not operating) oil level for the pan installed. Use
this information when calibrating the oil gauge (dipstick).
NOTE: Only the casting number and finished part number of the oil pan (sump) is given. The part number of the oil
pan adapter does not change the engine oil capacity.

Oil Pan 011 Pan 011 Low 011 High

Engine Casting Finished Level Level
Model Number Number Liter (U.S. Gag Liter (U.S. Gal) Remarks
K38 206100 3036455 87 [23] 114 [30] Standard
K38 3034652 3034653 114 [30] 140 [37] Double-Deep
K38 None 3013864 129 [34] 185 [49] Subbase
K50 206100 3036455 121 [32] 151 [40] Standard
K50 3032001 3033565 174 [46] 204 [54] Double-Deep
K50 None 3013865 170 [45] 227 [60] Subbase
Total System Capacity
Total system capacity is the summation of the oil pan capacity at the high mark on the dipstick, the full flow
oil filter capacity, and the capacity of any bypass filters that are used.
Cooling System
Cooling System Specifications. Construction, Power Units, and Locomotive

K1800E
1ROO HP
KLuvvt::.
KTTA50 KTTA50
KT38 KTA38 KTTA38 KTA50 1800 HP 2000 HP
Coolant ca~city 104 118 118 153 153 161
(Engine On y) [110] [125] [125] [162] [162] [170]
Liters [Qts]
Standard Modulating 80 - 90'C 80 - 90 a C 80 - 90 a e 80 - 90'C 80 - 90'C 80 - 90'C
-'''-TffermOStatRange ' . [175'C"195"F]1175"'195"Fl [175 ~·195'Fn175"195·Fn175 - 195'F] [17S-;"'t9S'Fr
. LTA-Modulating 74 - 82'C
Thermostat Range [165 - 180'F]
Maximum Coolant . ·.. ···...241- .--·· .. _.241-·... " ,·,241 ··2-83 345 ·345· ..
Pressure kP a [PSi] [35] [35] (35] [41] [50] [50]
~clusive of Pressure
ap)
Minimum Pressure Cap 50 50 50 50 50 50
kPa [PSi] (7] (7] (7] (7] (7] (7]
Maximum Allowable Top 93'C 95'C 93'e 95'C 95'C 95'C
Tank Temperature [200'F] [203'F] [200'F] [203'F] [203'F] [203'F]
Minimum Recom- 70'C 70'C 70'C 70'e 70'e 70'C
mended Top Tank [160'F] [160'F] [160'F] [160'F] [160'F] [160'F]
Temperature
Maximum Allowable 25 25 25 25 25 25
Deaeration Time
(Minutes)
Minimum Allowable 21 21 23 26 29 29
Drawdown [22] [22] [24] [28] [31] [31]
Liters IQts]
Section V • Specifications and Torque Values Engine Specificati
K38 and 50 Page

Cooling System Specifications· Generator Drive Engines

All KTA50·G1 KTA50·G3

KTA38 KTA50·G2 KTA50·G4 KTTA50·G2
Coolant Capacity (Engine Only) 118 153 163 161
Liters [U.S. Ots) [125] (162) [172) (170)
Standard Modulating Thermostat Range 82·93'C 82·93'C 82 - 93'C 82 - 93'C
[180 - 200'F) [180 - 200'F] [180 - 200'F] [180 - 200'F]
Maximum Coolant Pressure 240 283 283 283
kPa [psi) (Exclusive of Pressure Cap) [35) [41) (41) [41)
Minimum Pressure Cap kPa [PSi] 50 50 50 50
(7) [7] [7] (7)
Maximum Allowable Top Tank Temperature
• Standby Power 104'C 104'C 104'C 104'C
[220° F) [220 'F) [220°F] [220°F]
• Prime Power or Base Load 100°C 100°C 100°C 100'C
[212'F) [212°F] [212°F] [212°F]
Minimum Recommended Top 70'C 70'C 70'C 70'C
Tank Temperature [160'FJ [160'FJ [160°F] !160'F)
Maximum Allowable Deaeration 25 25 25 25
Time (Minutes)
Minimum Allowable Drawdown 21 36 36 36
Liters [Ots) [22) [38J [38J [38)

Cooling System Specifications· Marine Engines

KT38 KTA38 KTA50

Coolant Capacity (Engine Only) 104 118 174
Liters [Ots] [110] [125] [184]
Standard Modulating Thermostast 80 - 90'C 80 - 90°C 80 - 90'C
Range [175 - 195'F] [175 -195'F] [175 - 195°F]
-.' ,,-
Maximum Static Coolant Pressure 103 103 103
kPalpsiJ (Exclusive of Pressure Cap) [15] (15) [15)
Maximum Allowable Top Tank 93'C 93°C 93°C
Temperature [200°F] [200'FJ [200°F)
Maximum Sea Water Pump Inlet 34 34 34
Restriction kPa pn HgJ [10] [1 OJ [10]
Maximum Allowable Sea Water 103 103 103
Pressure kpa [psi J [15J (15) [15]
Minimum Allowable Drawdown 24 24 24
Liters [Ots] [25J [25] [25]
 Air Intake System Section V - Speclflcallons and Torque Val ues
Page V-6 K38 and 50

Air Intake System

NOTE: Engine intake air must be filtered to prevent dirt and debris from entering the engine. If intake air piping is
damaged or loose, unfiltered air will enter the engine and cause premature wear.
Metric [U.S. CustomaryJ
Maximum intake restriction:
Clean air filter element ....................................................................................... 380 mm H2 0 [15.0 in H 2 0J
Dirty air filter element ......................................................................................... 635 mm H2 0 [25.0 in H 2 0J

Exhaust System
Maximum back pressure (at rated speed and load) ........................................................ 75 mm Hg [3.0 in H9J
Exhaust Pipe Size (Normally Acceptable Inside Diameter):
• KT38 ............................................................................................................................... 127 mm [5.0 inJ
• KTA38 ............................................................................................................................. 127 mm [5.0 in]
• KTTA38 ........................................................................................................................... 152 mm [6.0 in]
• KTA50 ............................................................................................................................. 152 mm [6.0 inJ
• KTTA50 ........................................................................................................................... 203 rilm [8.0 in]

Compressed Air System

Upright Two Cylinder Air Compressor
Cylinders ................................................................. :.................................. , .................................................. 2
Compressor Capacity @ 1250 RPM ..................................................................... 14.2 L per sec. [30.00 CFM]
, ...... " ..... " . . _".,. _,_ . . f?f C.f", f~1.""-.l' GJ ~
Bore ................................................................................................................................. 92.08 mm [3.625 inJ
Stroke .................................................................................................................................. 50.8 mm [2.00 in]
Speed ....................................................................................................................................... Engine Speed
Cooling .................................................................................................................................... Engine Cooling
Lubrication ..................................................................................................................... Engine Lubricating Oil
.PIIJmlJin.g.~ine Sizes: .. __ .• _........ ,._ ._ ....... __ ._ .... __ ................. _ ... _.•... _. .
Coolant Inlet and Outlet (Pipe Fitting) ...................................................... 9.53 mm NPTF [0.375 inch NPTFJ
·-Air-·lnlet·~nside·Diameter) .........................................., .................................................. ,·22.2~·mm·[O.875 inJ .
Air Outlet (Minimum Inside Diameter) ........................................................................... 15.88 mm [O.6251nJ
Height, Overall (approximaier::. ~:.... :.::. :.:::::~:'............ : ...~:-: ......... :~ ..... :~~.~ .................... : ......... 34.S·em· [f:l:S-O InJ
Width, Overall (approximate) ................................................................................................. 17.8 cm (7.00 inJ
Length, Overall (approximate) ............................................................................................. 28.7 cm [11.30 in]
Weight (approximate) ......................................................................................................... 33.5 Kg (74.50 Ibs]
 Section V • Specifications and Torque Values Electrical SySl
K38and 50 Page
Tilted Two Cylinder Air Compressor
Cylinders .....................................................................................................................................................
Compressor Swept Volume Capacity @ 1250 RPM ............................................. 16.1 L per sec. [34.00 CF
Piston Displacement .......................................................................................................... 773 C.C. (47.2 C
Bore ......................................................................................... , ....................................... 98.43 mm [3.875
Stroke ......................................................................-............................................................ 50.8 mm [2.00
Speed ....................................................................................................................................... Engine Spe
Cooling .................................................................................................................................... Engine Cooli
Lubrication .................................................................................................................... Engine Lubricating
Plumbing Line Sizes:
Coolant Inlet and Outlet (Pipe Fitting) ...................................................... 9.53 mm NPTF [0.375 inch NPl
Air Inlet Qnside Diameter) ............................................................................................. 22.22 mm [0.875
Air Outlet (Minimum Inside Diameter) ............................................................................... 12.7 mm [0.05
Height, Overall (approximate) .............................................................................................. 40.1 cm [15.80 .
Width, Overall (approximate) ............................................................................................... 27.3 cm [10.75 i
Length, Overall (approximate) ............................................................................................. 28.7 cm [11.30 i
Weight (approximate) ........................................................................................................... 36.3 Kg [80.0 It

Electrical System
Minimum Recommended Battery Capacity
Engine Temperature System Cold Cranking Ampere Reserve
Model Range Voltage Am[!eres Hours Ca[!acft}':
K38 -18toO'C [0. to 32'F] 24 1800 400 640
32 1560 340 550
K38 above O'C [32'F] 24 1280 260 480
32 1560 240 390
K50 All 24 1800 400 640
32 1560 340 550

- _ • • co . . . . • . . . . • . .
--NO-TE} The· number of plates within a given battery size determines reserve capacity. Reserve capacity is the lengtl
of time sustained cranking can occur.
NOTE: CCA ratings are based on two, 12 volt batteries in series.
Battery cable sizes -Americanwire.gauge--{Maximum length in cranking motor circuit)
24 to 32 volt
No. 00 ............................................................................................................................ 6.1 meters [20 ft
No. 000 .......................................................................................................................... 8.2 meters [27 ft
No. 0000 or two No. O' ................................................................................................ 10.7 meters [35 ft
Two No. 00 .................................................................................................................. 13.7 meters [45 ft
Minimum ambient temperature without starting aid Refer to the following chart.
Minimum cranking speed without starting aid ................................................................................... 150 RPN
• Two strands of No. 0 cable can be used in place of one No. 0000 cable providing all connections are carefulll
made to ensure equal current flow in each parallel cable.
Electrical System Section V - Specifications and Torque Values
PageV-8 K38 and 50

Refer to the following chart to determine the temperature for which a cold weather starting aid is required.

KTA38 KTTA38 KTTA50

KT38
-1"C

Starting Aid Required

NOTE: Starting aids such as block heaters, lubricating oil pan heaters, etc. are available to aid in cold weather starting.
Batteries (SpecifiC Gravity)

- Battery State Specific Gravity

. -.,--.' ofCharge-- @27°C [80°F]
-·1009Al- -- 1.260-1-.280-- . -
75% 1 .230-1.250
50% 1.200-1.220
25% 1.170-1.190
Discharged 1.110-1.130
,.'001"
 Section V • Specifications and Torque Values Fuel Recommendatlons/Speclficallc
K38 and 50 Page'

Fuel Recommendations/Specifications
Warning: Do NOT mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
Cummins Engine Company, Inc. recommends the use of ASTM No.2 diesel fuel. The use of NO.2 diesel fuel v
result in optimum engine performance. At operating temperatures below DoC [32 OF], acceptable performance c,
be obtained by using blends of No.2 D and No.1 D. The use of lighter fuels can reduce fuel economy.
The viscosity of the fuel m US! be kept above 1.3 cSt to provide adequate fuel system lubrication.
For a more detailed description of fuel properties, refer to Fuel For Cummins Engine, Bulletin No. 3379001. S.
ordering information in the back of this manual.
Lubricating Oil Recommendations/Specifications
The use of quality engine lubricating oils combined with appropriate oil drain and filter change intervals is a critic
factor in maintaining engine performance and durability,
Cummins Engine Company, Inc. recommends the use of a high quality SAE 15W-40 heavy dUty engine oil (sue
as Cummins Premium Blue) which meets the American Petroleum Institute (API) performance classification C
or CF4.
NOTE: CD or CD/SF engine oils can be used in areas where CE or CF4 oils are not yet available.
A sulfated ash content of 1,0 mass percent will yield optimal control of piston and valve deposits and will minimi2
oil consumption, The sulfated ash limit must not exceed 1,85 mass percent.

~ For further details and discussion of engine lubricating oils for Cummins engines, refer to Bulletin N.
'~ 3810340, Cummins Engine Oil Recommendations.
Arctic Operation
If an engine is operated in ambient temperatures consistently below ·23°C [-10°F] and there are no provision
tokeepthe engine warm when itis not in operation, use a synthetic CE/SF engine oil with adequate low temperatur
properties such as 5W -30.
The oil supplier must be responsible for meeting the performance service specifications.
it.. Caution: The use of a synthetic base 011 does not Justify extended oil change Intervals. Extended 0
~ change Intervals can decrease engine life due to factors such as corrosion, deposits, and wear.
New Engine Break-in Oils ... -_.";'1! _

Special break-in engine lubricating oils am not recommended for new or rebuilt Cummins engines. Use the sam.
'-Iypeoil during theilreak-in as that which is used in normal operation. ----"'-~,-- " ""'--'

" ,~,f.ddi.ljmal infQrmOltiQn (egardiog lubricating oil availability throughout the world is available in the E.M.A
-~ Lubricating Oils Data Book for Heavy DUty Automotive and Industrial Engines, The data book can b.
ordered from the Engine Manufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago
IL U.S.A. 60601. The telephone number is: (312) 644-6610.
Viscosity Recommendations
The viscosity of an oil is a measure of its resistance to
flow. The Society of Automotive Engineers has classified
engine oils in viscosity grades. Oils that meet the low
temperature (-18°C rO°F]) requirement carry a grade des-
ignation with a W suffix. Oils that meet both the low and
high temperature requirements are referred to as
multigrade or multiviscosity grade oils.
Cummins Engine Co" Inc. has found that the use of
multigrade lubricating oli improves oil consumption con-
trol and engine cranking in cold conditions while main-
taining lubrication at high operating temperatures and
can contribute to improved fuel consumption, ol809gl1
Lubricating 011 Recommendations/Specifications Section V - Specifications and Torque Values
Page V-10 K38 and 50

Cummins Engine Company, lnc.® recommends the use

·c -40 -30 -20 -10 0 10 20 30 40 !l0 of multigrade lubricating oils with the viscosity grades for
·F -40 -22 -·4 14 32 50 81 115 1041%2
the ambient temperatures indicated. This picture shows
only the preferred oil grades.
All Seasons ... , ..lH'.:e:I·l' . :'. ,., ..
Single grade oils can be substituted for short durations
Winter CondlUons until the recommended multigrade is procured. Arctic
Condition oils are available commercially with better low
·Af,(:lIc Condllions temperature properties. Consult your supplier.
_SW..§D
caution: When single grade oil Is used, make sure the
·c -40 -30 -20 -HI 0 10 20 30 40 60 011 will be operating within the temperature ranges In-
-F -40 -.22 -4 14 32 50 6B 86 104122 dicated In the table below. .
Di900dll
The primary criterion for selecting an oil viscosity grade
is the lowest temperature the oil will experience while in
the engine oil sump. Bearing problems can-be caused by
the lack of lubrication during the cranking and start up of
a cold engine when the oil being used is too viscous to
flow properly. Change to a lower viscosity grade of oil as
the temperature of the oil in the engine oil sump reaches
the lower end of the ranges shown in the picture and
table.

As the engine all becomes contaminated, essential oil

Oil Additives in Used Oil additives are depleted. Lubricating oils protect the engine
as long as these additives are functioning properly.Proc ·
gressive contamination of the oil between all and filter
change intervals is normal. The amount of contamination
.~~ ;;; .. .:... 1 \.l .-'t'''''I''':;''~ ...... i l ~'IE. '-'t-'\#l Co~,,-, •• ;..r • .. , Iv Ci I~" h'I ~ ;vui S
or miles on the oil. fuel consumed. and new oil added.
~~-!Iliii! 175 Km/L
[400 MPQ)

~~~520Kmll
(1,200 MPO]

Kilometers [MUeage]/Hours-+
Section V • Specifications and Torque Values Lubricating 011 Recommendations/Speclflcatic
K38 and 50 PageV·

NOTE: Do not extend oil and filter change intervals beyond

250 hours or 6 months, whichever occurs first, unless the
Chart Method Is used. Refer to the charts below. Extended
oil and filter change intervals will decrease engine life due
to factors such as corrosion, deposits, and wear.
There are two recommended methods used to determine
the proper oil and filter change interval:
• Chart Method (based on known fuel and oil con-
sumption rates).
• Fixed Hours Method (based on fixed hours, or
months; whichever occurs first).

Chart Method
The Chart Method is recommended to provide the lowest
total cost of operation while still protecting the engine.
Use the Chart Method with the required information listed
below to determine the correct oil and tilter change in-
terval for your engine:
• Fuel'consumption rate
• Oil consumption rate
• Total System Capacity

LUBE SYSTEM CAPACITY - 34 U.S. CALLONS

80r-----~-----,------r---~,

- 0 l CONS MPTION
;~ii: 70t--~-t-------'-,r-(rrTRS /QT)

.Oa--
n. __
I-J:
:iE(I)
=>Z
(1)0
Z...J
8<iCJ
...J
~ u.! 30
u..2

10~----~----~----~----~
200 300 400
OIL CHANGE INTERVAL
(HOURS)
500 600
_.
Lubricating Oil Recommendallons/Speclflcatlons Section V • Specifications and Torque Values
Page V·12 K38 and 50

Determine fuel and oil consumption rates:

• To use the Chart Method effectively, accurate fuel and oil consumption records must be kept and maintained.
• As oil and fuel consumption rates change as a result of a change in operation or duty cycle of a particular
engine, the oil change interval established by the Chart Method must be re-evaluated based on the change
in oil and/or fuel consumption.
Determine total lubricating oil system capacity:
• Total lubricatinq oil system capacity in U.S. gallons can be determined by adding the high level of the oil in
the oil pan pius the capacity of the full flow and by-pass oil filters. Refer to the chart below.

011 Pan 011 High Lubrlcallng

Engine Finished Level 011
Model Part No. Liter [U.S. Gal] Filler Capacity
K38 3036455 114 [30) Full Flow Filter (each) 2.65 liter
(LF670) [0.7 U.S. Gal)
K38 3034653 140 [37]
K38 3013864 185 [49] Spin-on by-pass (each) 2.27 liter
(LF777) [0.6 U.S. Gal]
K50 3036455 151 [40]
K50 3033565 204 [54] Remote by-pass filter 11.02 liter
(750 in 3, LF750A, or LF750B) [2.91 U.S. Gal]
K50 3013865- . -227 .. [50]-

For the above charts. determine the total lubricating oil system capacity.
Example: A KTA38 engine has oil pan, Part No. 3036455, and utilizes the standard full-flaw filter head (4 LF670
filters) and two spin-on by-pass filter (LF777).
Total capacity equals:
30 U.S. gal (all pan)
2.8 U.S. gal (4 x LF670 filters)
1.2 U.S. gal (2 LF777 filter)
34 U.S. gal Total Capacity,
If_nEj<:.essary, round th~total capacity to the nearest whole U.S. gallon and select the appropriate chart.
For our example, assume the average fuel consumption equals 30 U.S. gallons per hour and the average oil
consumption equals 4 hoursp!lr U.S. quart.
Section V • Specifications and Torque Values Lubricating Oil Recommendalions/Specificatiol
K38 and 50 Page V·,
To read the chart:
Select the chart entitled Lube System Capacity 34 U.S. gallons.
The left vertical axis of the chart represents fuel consumption in U.S. gallons per hour.
Determine the location of 30 gal/ons on the left vertical axis and draw a line from left to right across the chart, paral/I
with the bottom of the chart, until it intersects with the curve marked 4 (4 hours per quart).
From the intersection pOint on the curve 4, draw a line perpendicular to the bottom of the chart. The number acros
the bottom of the chart represents the oil change interval in hours. In this case, the total oil capacity, c
consumption, and fuel consumption of this engine indicates that an oil change interval of 375 hours is recOIT
mended.
The charts that follow will allow oil change intervals to be calculated for the total lubricating oil system capacit
of any K38 and K50 series engines.

LUBE SYSTEM CAPACITY - 34 U.S. CALLONS

80r-----~----~-----.-----,

- 0 L CONS MPTION
za:
O~
-- 701-------t------'+- (HRS/an

j::0
o..:r:
~. Ci)..
~z
(1)0
Z-'
0-'
u<C
-'(!)
w'
~Cf.!
u..2

10 L...- --O-·,.....30+-·0--"···"'-·L-4-'-OO--·--5.....J,O-O--6~OO
2 OO
OIL CHANGE INTERVAL
(HOURS) .......
Lubricating 011 Recommendations/Specifications Section V • Specifications and Torque Values
Page V·14 K38 and 50

Oil Drain Interval Charts

LUBr-E_S..:...Y..:...S..:...T:..:.Er-M..:...C::..:.AP..::.....:....A:..:.C.;.;.ITY...:.....• .:.3..:..4.:.U.;.:.S:.:,.'.:.C:.;AU=-=,ONS
80
1---_---1'--------_---.:O=+=,L~CONS MPTION
- 70
za: (HRS/QT)
O=>
-0
I-:r:
0._
:ECI)
=>z
~g
0.....1
ooe(
.....Ie!)
w'
=>CI.!
....
u..=>

10~----~----~------~----~
200 ... 300·. 400 - 500 - 600
OIL CHANGE INTERVAL
(HOURS) of,,",,'

80 LUBJ: SYSTEM CAPACITY· 41 U.S. GALLONS

~r_~~~oa~~~~P~TKIO~N~
70P (HRS/QT)

10200 300 400 500 600

OIL CHANGE INTERVAL
(HOURS) .......
Section V • Speclflcatlons and Torque Values Lubricating 011 Recommendallons/Speciflcati
K38 and 50 Page 1

100 LUBE SYSTEM CAPACITY - 45 U.S. GAlLONS

Il CONSUMPTION
(HRS/QT)
oc80~~--+-----+-----+-----~
Z:::>
00
§~
::>Z 60 t>.\..~..,..--I---=::"""'d----+------I
eng
Z-I
0«
U(!)
-I •
w~ 40 1----~..,;4"OC'+-..:::::::""-d:------I
:::>:::>
u.~

20~---=~--~~--~~--~
.. 200 ... 300. 400 500 600
Oil CHANGE INTERVAL
(HOURS)

_ ..... sbUSE SYSTEM CAPACITY-53 U.S. GALLONS

~~~_-_--~O~L~CONS MPTION
__
(HRS/QT)

10200 300 400 500 600

OIL CHANGE INTERVAL
(HOURS)
Lubricating 011 Recommendations/Specifications Section V - Specifications and Torque Values
PageV-16 K38 and 50

LUBE SYSTEM CAPACITY -59 U.S. GALLONS

100
--OIL CONSU PTION
(HRS/OT)
80~~~~----~----+-----~

ZCC
05
1i::;E 60 I-_~~""::""_---l----=..:..:.O::::"'d-_ _ _ ~
:2rn
:JZ
rnO
Z...J
o<t
() ~ 40 I---+----I-::;".".~"='f--__=:::j
...J '
wrn
:J'
u.2-
-- 20'----~--_4.,,-_'"'=b__~
200 300 400 500 600
OIL CHANGE INTERVAL
n 'r-.l P,,....,··
,- -

- -- -,- --LUBE SYSTEM CAPACITY -65 U,S. GALLONS

100~~~~~~~~~-.----,

- - 0 L CONSU PTION
- --(HAS/aT)

zlI:
o:J 1.0
i= 0 6011----.....;>4-'......---">~----f....:""""=---I
o.I
:2w
:JZ
rno
Z...J
o <t 40 I------l-----+-~...,....;P>-~-I
()~
...J •
wrn
:J'
u.2
20L-__~~--~~--~~--~
200 300 400 500 600
OIL CHANGE INTERVAL
(HOURS)
Section V - Specifications and Torque Values Coolant Recommendations/Specificatio
K38 and 50 Page V-

Fixed Mileage or Hours Oil Change Interval (All Applications)

If the Chart Method is not used, Cummins Engine Company Inc.® recommends an oil change interval for all K:
and K50 series engine applications of 250 hours or 6 months whichever occurs first.

Coolant Recommendations!
Specifications 50%
Antifreeze
50%
Water
Heavy duty diesel engines require a heavy duty coolant.
Heavy duty coolant is defined as a correct mixture of good
quality water, low silicate antifreeze and supplemental
coolant additives (SCA's). DCA4
The following information provides an explanation of wa-
ter, antifreeze, and SCA's, the correct way to mix them
and how to test antifreeze and SCA levels.
"'-.
This section also contains information on cooling system
maintenance and a coolant treatment chart that is used " n (1 i1 f
to determine the correct DCA4 service filters and liquid
pre-charge.

Heavy Duty Coolant

- ...
Water Water Quality
Water quality is important for COOling system performance.
Excessive levels of calcium and magnesium contribute to Calcium
scaling problems, and excessive levels of chlorides and Magnesium 170 PPM
sulfates cause cooling system corrosion. (Hardness) as (CaCo, + MgCo.J

Chloride 40 PPM as (C1)

Sulfur 100 PPM as (SO.)

IlSOOwa

Antifreeze Antifreeze
Cummins and Fleetguard® recommend USing a low-
silicate antifreeze concentrate that meets ASTM D4985
specifications (less than .10% silicate, expressed as
Na,,810,,).
Coolant Recommendations/Specifications Section Y - Specifications and Torque Y al ues
Page Y-18 K38 and 50

Low-silicate antifreeze must be mixed with quality water

..
.. 320
at a SO/SO ratio (40 to 60% working range). A SO/50
~
u
••
•
...
~
:m
ao
2M
mixture of antifreeze and water gives a -34 of freeze point
and a boiling point of 228 ° F, which is adequate for lo-
cations in North America. The actual lowest freeze point
...
..
..13
Z70
...,
2M
of ethylene glycoi antifreeze is at 68%. Using higher
...... ......"'"
41 248 concentrations of antifreeze will raise the freeze point of
the solution and increase the possibility of a silicate gel

...
~
-7.
~
..
212
203
1M
R103 0 1Q 20 30 4D 50 ISO 70 80 1M11Cx1
7f1
problem.

"of Antifreeze
ol801wh

A refractometer must be used to accurately measure the

freeze point of the coolant.

Using floating ball hydrometers can give incorrect

readings.
Hydrometer
(Do Not Use)

Cooling System Soluble Oils

Do not use soluble oils in the cooling systems. The use
of soluble oils will:
• allow cylinder liner pitting,
• corrode brass and copper,
• damage heat transfer surfaces, and
• damage seals and hoses.
 Section V • Speclflcallons and Torque Values Coolant Recommendatlons/Speclficatl~
K38 and 50 PageV.

Supplemental Coolant Additives (SCA's)

SCA
Correct use of SCA's in conjunction with water and an- Precharge
tifreeze are needed to protect engines from cooling sys-
tem problems. The system musl be pre-charged with the
correct concentration of SCA.
Cummins and Fleetguard® use the SCA unit to define the
required concentration level to protect against liner pitting.

When coolant is replaced in the field, it m usl be replaced

with Heavy Duty Coolanl pre-charged with SCA's. In
addition, a service coolant filter must be installed. To-
gether, this will result in a total pre-charge of approxi-
mately 1.5 SCA units per gallon of coolant.

SO/50" (SCA) Precharge

Mixture (1.5 unHs per
U.S. Gallon)
ol80Svh

Coolant Blending/Mixing
DCA4 Mix
Proper blending of Heavy Duty Coolanl requires:
t_J'.our water ioU>. the,cofltainer
2. Add low-silicate antifreeze
----3•. Add OCA4liquid
4. Thoroughly blend the components
-- Followin€}-the correet- or{jerfor mixing the Heavy Duly' - - . -
Coolanl will prevent additive dropout during the mixing
process.

I ~ ........ " ,.. ,~

This chart, shown later in this section, must be followed

to determine how much liquid SCA musl be added to
pre-charge different quantities of make-up coolant (water
and low-silicate antifreeze). Remember, a service filter
must also be Installed.
In addition to using the chart as shown, the system re-
qUirements can be also calculated as shown in the fol-
lowing examples. _
M _ n..u_
10-" 1_
~.

NOTE: It is important to know the cooling system capacity.

If not sure of system capacity, contact the equipment OEM.
The following example illustrates how to calculate the
required SCA quantity to add to the coolant to reach the
PARTtUIIIER:
t.Nrs OF OCM;
WFI07t
R
.,..," ""'"
•
deSired concentration level.
Coolant Recommendations/Specifications Section V - Specifications and Torque Values
PageV-20 K38 and 50

For an 80-gallon system, three (3) gallons of DCA4 liquid

must be added to pre-charge the coolant to the correct
SCA concentration level.
U.S. Customary Example:
80 gallons X 1.5 units = 120 units
gallon
120 units + 20 units = 6 half gallon containers of DCA4
1/2 gallons DCA4
3 U.S. Gallon or 3 gallons of DCA4
OCA4
Units per U.S. 1f2 Gallon Cor'tal~,erll Metric Example:
300 Liter x -4 units = 120 Units
Liter
120 Units + 20 Units = (6) 1.89 Liter Containers of DCA
1.89 Liters DCA4

Fleetguard® DCA4 Service Filters and Liquid Pre-Charge

Fleetguard® Part No. DCA4

Spin-On Coolant Filters _ Cummins Part No. DCA4 Units

WF-2070 3318157 2
WF-2071 3-3151 If' <1
WF-2072 3318201 6
WF-2073 3315115 8
WF-2074 3316053 12
WF-2075 3318318 15
WF-2076 3318319 23

_____DCA4 Liquid
DCA60L(1 pint) 3315459 5
DCA65L .(1/2 gallon) 3305373 20
DCA75L (5 gallons) 3317428 200
__ QCA80L (55 gallons) 2200

DCA4 Powder
DCA95 3318320 20
Section V • Specifications and Torque Values Coolant RecommendatlonstSpeclflcatiol
K38 and 50 Page V·~

Coolant Capacity Chart

PRECHARGE SERVICE
UNITS OF DCA4 PER GALLON OF COOLANT
GALLONS DCM DCA4 INSTALL SERVICE GALLONS ADD DCA4 LIQUID
OF LIQUID DCA4 UNITS FILTERS WITH DCA4 OF PINTS AS SHOWN
COOLANT GALLONS UNITS PER GAL. HOURS UNITS TOTALING COOLANT 250 HRS. 500 HRS.
51 ·75 2.25 90 12-1.8 51 -75 4 8
76 - 100 3.00 120 1.2-1.6 625 60 68 100 "125 76 - 100 5 10
101-150 4.50 180 1.2-1.8 500 40 50 80 100 101-150 8 15
151 -200 6:00 240 1.2 - 1.6 375 30 38 60 75 151 - 200 10 20
201 - 250 7.50 300 1.2 -1.5 250 20 25 40 50 201 - 250 13 25
251 - 300 9.00 360 1.2-1.4 251 - 300 15 30
301 - 360 10.50 420 1.2 -1.4' 51-75 76-100 101-150 151-200 301 - 350 18 35
351 - 400 12.00 480 1.2 - 1.4 SYSTEM SIZE IN GALLONS 351 - 400 20 40
* Requires liquid in addition to 8 PINTS EQUALS 1 U.S. GALLON
Cummins largest filters.

Notes:
A. Consult the vehicle equipment manufacturer's maintenance information for total coolin9_s.y.stem capacity.
B. After draining and replacing the coolant, always pre-charge the cooling system to a SCA level of 1.5 units pel
gallon. This concentration level must never. be allowed to go below 1.2 units and must be controlled wher
level is greater than 3 units. Action needed when I,eve/ goes be/ow 1.2 III ,a filter and liquid; above 1.2 to;3.(
filter only; 'above 3.0, teSfand addlilters-wlien'3.0 and below.
it.. Caution: Under NO Circumstances MUST a customer exceed one 011 change Interval before addlnt
~ chemicals (by filter or liquid) to the coolant. If the recommended service Intervals are neglected, there
Is a high probability that cylinder liner corrosion will occur.
NOTE: When performing service which requires draining the cooling system, take special precautions to collect it in
a clean container, seal It to prevent contamination, and save for reuse.
C. Change coolant filters at each oil change to protect the COOling system. The service filters are satisfactory for
use with maintenance intervals from 125 hours to 6,000 hours.
Coolant Recommendations/Specifications Sect/on V • Specifications and Torque Values
Page V·22 K38 and 50

Cooling System Maintenance

Supplemental Coolant Additives (DCA4), or equivalent,
are required to protect the cooling system from fouling,_
solder blooming, and general corrosion. The cooling filter
Is required to protect the coolant system from abr<lslve
materials, debris, and preclplt!lted coolant additives.

NOTE: Cummins Engine Company requires that a service

filter be used and SCA liquid added when the coolant Is,
changed or a significant (more than 50 percent) coolant loss
occurs. A service filter must be used during the normal oil'
change Interval due to normal depletion (refer to the Oper-
ation-and-MalntenanceMantlal).
Diesel Coolant Additives (or equivalent) are used to pre-
vent liner pitting, corrosion, and scate deposits. In the
COOling system.

1.2 Unit oeM ~1()O," ~

After changing the coolant, the initial charge of DCA4 (or

1.5 Units Per equivalent) concentration must be 1.5 unit per 3.8 liters
U.S.Gallon.~-- ... ,. _ ... [l.U.S. gallonJof coolant In the system.
NOTE: Tile ()Ooling system mlJjlt be .cle.!lrLQefQIEU!dJ!i09
DCA4 (or equivalent).

01801'11'

The DCA4 concentration must not fali below 1 .2 units or

® @ ® exceed 3 units per gallon of cooling system capacity.

If make-up coolant Is added between Intervals, additional
DCA4 (or equivalent) Is required. Any coolant added must
be pre-mixed with DCA4 to a concentration of 1.2 units

!l"m ~~~
'.~

-.-.~
per 3.8 liters [1 U.S. gallonJ of coolant. With the service
E~ ~.NV'IDu\y
GaHon
~;;: :..r:u'"
filter Installed, the total system concentration must be 1,5
units DCA4 per gallon of coolant.
I:-CooIMt.,

Less Than
[1~
More Than
1.2 Unit DCM 1.6 Unit DCM 3 Units DCM
. ~
 Section V - Specifications and Torque Values COolant Recommendatlons/Speclflcatlol
K38 and 50 Page V-:

Caution: Under-concentration of the coolant additive

can result In liner pitting and system corrosion. Over-
concentration can result In water pump seal leakage.
® @ ®
Ie~
'.~

-_._.".
,~--
~~~........
JIj~ ~,GaHon
ro' .
~--=-~

tfl;~:E
~,Gauon
'.~~?~
""~:'!
[1~
Less Than More Thar
1.2 Unit DCA4 1.5 Unit DCA4 3 Units DCA
~,~

Use the correct Fleetguard® coolant filter to maintain the

recommended DCA4 concentration in the system.
Maintain the correct concentration by changing the ser-
vice coolant filter at each oil drain interval.
NOTE: The correct filter is determined by the total COOling
system capacity aAd ether operational factors.

o!aoovt

Testing is recommended if the operator is not sure of his

cooling system condition due to leaks, uncontrolled top· When to Test
ping off of the system, or major coolant loss.
Testing is also recommended twice a year to monitor the
SeA level. If the SCA level is above 3 units, test at sub-
.. sequent oil drain'intervals until the concentration is back • When Not Sure of SGA Level-·-
under 3 units. When the concentration is back under 3 • Twice a Year
_. JJDits.slar:tinstalting service filters at each drain Interval. • When Over 3 Units Per Gallon.ot-SeA ..-

"'OOwb

If the concentration Is below 1.2 units per gallon, replace

the filter and pre-charge with liquid,
Below 1.2 Units

• Replace Service Filter

• Pre-charge with Liquid

UBOOwc
Coolant Recommendations/Specifications Section V • Specifications and Torque Valut
Page V-24 K38 and 5~

If the concentration is 1.2 to 3 units per gal/on, replace It

filters.
1.2 to 3 Units

• Replace Service Filters

11600wd

If the concentration is above 3 units per gallon, do not

replace the service filter. Test the coolant at subsequent
oil drain intervals until the concentration is back under,
Above 3 Units units. When the concentration is back under 3 units, stal_
installing service filters at each oil change interval.
• Do Not-Replace-Sel"Vice-FlIters
• Test at Every Oil Change

11000wa

Testing SeA Concentration Level CC-2626 Test Kit

Testing SolutIon #1
BoHle If unsure about coolant loss and coolant condition, use
the CC-2626 test -kit to determine the SCA level of the
. Smalf"PI •• tlc~- ...: _~ cooling system.

cont~.,n.r ~-~~~ 5(----

_
"-'-~
-.. . . .
B
--\dBI~
Large Plastic
.....,;.... -'"'-" Cup
SyrJnge
Test StrIp BoHles
Ol304vz

Precautions:

DO Don't
Do carry out testing in a well-lighted area. Don't handle pad ends of strip.
Do make sure that hands are dry before removing Don't allow pad ends of wet strips to touch during
strips from bottles. testing.
Do allow coolant sample to reach room temperature Don't get solution in eyes or on skin and clothing.
for best results. Don't allow contamination of the strips and solution
Do make sure that pad ends of strips are dipped. bottles.
Do replace and tighten caps on strip bottles to avoid Don't allow contamination of the plastiC containers
getting moisture on strips. during testing.
Do make sure that all plastic containers are rinsed Don't use kits beyond expiration date.
wi!h water after each use to avoid conlamination.
Section V - Specifications and Torque Values Coolant Recommendations/Specification,
K38 and 50 Page V-2i

Any variation to the technique listed below will give false readings resulting in incorrect service action.
Instructions For Proper Kit Use
1. Fill large plastic cup at least half full with coolant.
2. With syringe, draw coolant sam pie to the stop point and dispense into small plastic container.
3. Hold small plastic container at eye level and fill to the black line with Solution #1, then swirl to mix. (Note: Manl
coolants will become cloudy at this point which is normal.)
4. Dip strip A into solution for 1 to 2 seconds, remove and shake vigorously to remove excess coolant. This actior
is much like shaking down a thermometer. Lay strip A down on a clean surface and read after reading strip B.
5. Dip strip B into solution for 1 to 2 seconds, shake vigorously, wait 30 seconds and match to nearest color or
the test kit chart within the next 30 seconds. If not sure of exact color, read to the left or lower concentration,
6. Read strip A the same as strip B.
7. Determine the intersecting block of strips A and B on the chart, and follow requirements listed above under
Testing DCA4.
S. Clean all plastic containers by rinsing cups and filling or flushing syringe with tap water after each use.

NOTE: Do not utilize the test kit to maintain minimum SCA

concentration levels (i.e., 1.5 units).
NOTE: In some instances, the A or B readi(19 pan be high.
However, it is ttie'combiried reading that is important. Al-
ways follow the chart.

The following coolant testing devices are available to assist in determining the condition of the coolant:
GC262& Goolant Test·Klt Works with any SCA formulation (CaIl1-S00-521-4005 if you have thisfes\' kit
and the color chart does not show the number of units of DCA per gallon of
coolant. A new chart will be mailed to you free of charge. The new chart will allow
you to use your existing test kit with the new service requirements detailed on
the reverse side of this paper.)
Proballzer:
33181695 Plug - Installs on the engine for easy coolant sampling
33181688 Cap Use with Monitor C bottle to sample coolant
CC2706 Monitor C - Lab analysis of coolant samples
Coolant Recommendations/Specifications Section V - Specifications and Torque Values
Page V-26 . K38 and 50

Coolant Replacement Requlrem~nt

Drain and flush the cooling system after 2 years or 6, 000

hours of service. Refill with new Heavy Duty Coolant and
Install the correct service coolant filter.
NOTE: If the coolant is not going to be reused, dispose of
used coolant/antifreeze in accordance with federal, state,
and local laws and regulations.

50/50 precharge
Mixture (SCA) (1.5 units per
U.S. Gallon)

olB05vh

Call the following numbers to get answers to any questions you may have about cooling
system maintenance.

Cummins: 1-800-DIESELS Fleetguard: 1-800-521-4005

Section V - Specifications and Torque Valuea Drive Belt Tenslol
K38 and 50 Page V-2i

Drive Belt Tension

SAE Belt Size Belt Tension Gauge Belt Tension Beft Tension
Part No. NEW USED
Click-type Burroughs N Ibf N Ibf
1/2 3822524 ST-1138 356 80 267-356 60-80
11/16 3822524 ST-1138 356 80 267-356 60-80
3/4 3822524 ST-1138 356 80 267-356 60-80
7/8 3822524 ST-1138 356 80 267-356 60-80

5 RIB 3822524 ST-1138 356 80 267-356 60-80

9 RIB 3822525 ST-1293 356 80 267-356 60-80
23 RIB N/A N/A BACKSIDE IDLER SELF TENSIONING
31 RIB N/A N/A BACKSIDE IDLER SELF TENSIONING
16 RIB N/A 3376344 2000-2224 450-500 1557-2224 350-500
or 3823875
20 RIB N/A 3823875 2670-2890 600-650 2447-2890 55(MlSO.
Engine Component Torque Value Section V - Specifications and Torque Values
Page V-28 K38 and 50

Engine Component Torque Value

Component Wrench Size Torque Value

[In] Nem [ft-Ib]
Oil Drain Plug ............ 1-1/4 ........... . .. ........... 100 ............ . . ............. 75 ............. .
Crosshead Adjusting
Screw Lock Nut
With Adapter ............ 9/16 .......... .. .............. 35 ............ .. .............. 25 ............. .
Without Adapter ............ 9/16 ........... . .............. 40 ............ .. ..............30 ............. .
Valve Adjusting Screw
Lock Nut .
With Adapter .. ...........3/4 ........... .. ............. .45 ............ .. .............. 35 ............. .
Without Adapter ............. 3/4 ........... .. .............. 60 ............ .. . ............. 45 ............. .
Rocker Lever Cover ............ 9/16 ........... . ............. .40 ............. . .............. 30 ............. .
Rocker Lever Shaft ............. 1/2 ............ . .............. 90 ............ .. .............. 65 ............. .
(12 pi capscrew)
Injector Hold Down Clamp ............. 1/2 ............ . .............. 16 ............. . .. ....... 145 in-Ib .........
Capscrew
Injector Adjusting Screw.
LockNut
With Adapter ............. 3/4 ........... .. ............. .45 ............ .. .. ............ 35 ............. .
vV HOOut. hOapter .............'dj4 ............ . .............. 6U ............ .. . .............45 ............. .
Adjusting Link and .............3/4 ............ . .............. 55 ............. . . ............ .40 ............. .
Alternator Mounting
Capscrews
Fan Idler Control Rod ............ 5/16 ........... . .............. 60 ............ .. .. ........... .45 ............ ..
Adjusting Screw Lock Nut
fan Idler Control Rod ............. 5/8 ............ . .............. 90 ....... :...... .............. 65 ............ ..
Capscrews
Fan Idler Arm Shock ............. 5/8 ............ . .............. 60 ............. . ..............45 ............. .
Absorber
Fan Hub Assembly to Fan ............. 5/8 ........... .. ............. 290 ........... .. ............. 215 ............ .
Support (12 pt capscrew)
Fan Belt Idler Assembly ............. 5/8 ........... .. .............. 60 ............ .. ............. .45 ............ ..
Thermostat Housing ............ 9/16 .......... .. ............. .45 ............. . .............. 35 ............. .
Mounting Capscrews
Air Compressor Unloader ............ 9/16 .......... .. .............. 40 ............ .. .............. 30 ............ ..
Valve Cap
Air Compressor Unloader ............ 9/16 .......... .. .............. 15 ............. . .. ....... 120 in-Ib .........
Valve Body Capscrew
Fuel Pump Drive Coupling ............. 1/2 ............ . ............. .45 ............. . .............. 35 ............ ..
Capscrews
Section V - Specifications and Torque Values Capscrew Markings and Torque Va,
K38and 50 Pagel

Capscrew Markings and Torque Values

it. Caution: When replacing capscrews, always use a capscrew of the same measurement and strengll
.L.l. the capscrew being replaced. Using the wrong capscrews can result In engine damage.
U.S. Customary caps crews are identified by radial lines stamped on the head of the capscrew.
The following examples indicate how capscrews are identified:
U.S. Customary [5116 X 18 X 1-1/21
5/16 18 1-1/2
Major Number Length
Thread Threads in
Diameter per Inch Inches
in Inches

NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other sections of this manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft..jb value is less than 10, give consideration to converting the ft-Ibvalue-to in~b to g!:Jtain a bett,
torque withan-in~Ib-.torque wrench. Example: 6 ft-Ib equalS 72 in-lb.

Capscrew Markings and Torque Values - U.S. Customary

SAE Grade Number 5 8
Capscrew Head Markin gs

@~
These are all SAE Grade 5 (3) line

@@g
Capscrew Torgue - Grade 5 Capscrew Capscrew Torgue - Grade 8 Capscrew
Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum
Nem fI·lb Nem fI·lb Nem ft·lb Nem fI·lb
1/4 - 20 9 7 8 6 15 11 12 9
"- 28 12 9 9 7 18 13 14 10
5/16 - 18 20 15 16 12 30 22 24 18
- 24 . 23 17 19 14 33 24 25 19
3/8 - 16 40 30 25 20 55 40 40 30
- 24 40 30 35 25 60 45 45 35
7/16-: 14 60 45 45 35 90 65 65 50
- 20 65 50 55 40 95 70 75 55
1/2 - 13 95 70 75 55 130 95 100 75
- 20 100 n 00 00 150 110 120 90
9/16 - 12 135 100 110 80 190 140 150 110
- 18 150 110 115 85 210 155 170 125
5/8 - 11 180 135 150 110 255 190 205 150
- 18 210 155 ·160 120 290 215 230 170
3/4 - 10 325 240 255 190 460 340 365 270
- 16 365 270 285 210 515 380 410 300
7/8 - 9 490 360 380 200 745 550 600 440
- 14 530 390 420 310 825 610 660 490
1 - 8 720 530 570 420 1100 820 890 660
- 14 800 590 650 480 1200 890 960 710
Section S - Service Assistance
Page!

Section S - Service Assistance

Section Contents
Pal
Distributors - International ........ ....................................................................................................................,. So'
Distributors and Branches - Australia ......................................................................................................... ... So'
Distributors and Branches - Canada............................................................................................................... So'
Distributors and Branches - New Zealand...................................................................................................... S-1
Distributors and Branches - United States....... ....... ........... ...... ................... ... ....... ................ ............. ........ ...... S·
Division and Regional Offices. ...................................... ............. ..... ................. .... ....... ... ....................... ... ........ S·
Emergency....... .......................... .......... ....... ........... ........ ... .... ...... ...... .... ........ ....... .... ........... ........ ....... ... ........ .... S·
Problem Solving ...........................................................................................................................' ... ................ S-
Regional Offices - International ..... ................................................ ,. .......... ..... ..... ....... ... .................... ...... ....... S-1
Routine ......... ..............................................................................................................................................'" .... So:

~--.-- -.~-~--~--.--- ---..--------

Routine Section S - Service Assistance
Page S-2

Section S - Service Assistance

Routine
Personnel at a Cummins Authorized Repair Location·
can assist you with the correct operation or service of
your engine. We have a worldwide service network of
more than 5,000 Cummins Distributors and Dealers who
have been trained to provide sound advice, expert ser-
vice, and complete parts support. Check the telephone
directory yellow pages or refer to the directory in this
section for the nearest Cummins Authorized Repair Lo-
cation.
Emergency
The Cummins Customer Relations Department provides
a 24-hour, toll free telephone number to aid in locating
emergency service when a local Cummins Authorized
Repair Location can not be reached. The emergency
service telephone numbers are:
• United States and Canada (excluding Alaska and
Hawaii)
- (800) D-I-E-S-E-L-S ..
- (800) 343-7357
Qi800w • Outside of North America contact your Regional
.,,-,,
._ _
~-
."
-.'
<..-<.i.-...
. : ,__ .J.v
'. __ ••
-.
,- .... '--- ....

listed in this section.

Section S - Service Assistance Problem Solvin
Page S·

Problem Solving
Normally, any problem that arises with the sale, service, or repair of your engine can be handled by a Cum min
Authorized Repair Location in your area. Refer to the telephone directory yellow pages for the one nearest yOl
If the problem has not been handled satisfactorily, follow the steps outlined below:
1. If the disagreement is with a Dealer, talk to the Cummins Distributor with whom he has his service agreemen'
2. If the disagreement is with a Distributor, call the nearest Cummins Division or Regional Office; however, mOf
problems are solved below the Division or Regional office level. Telephone numbers and addresses are liste
in this section. Before calling, write down the following information:
a. Engine model and serial number
b. Type and make of equipment
c. Total kilometers [miles] or hours of operation
d. Warranty start date
e. Nature of problem
f. Summary of the current problem arranged in the order of occurrence
g. Name and location of the Cummins Distributor or Dealer
3. If a problem can not be resolved satisfactorily through your Cummins Authorized Repair Location or Divisior
Offi ce, write to:
Customer Relations - 41403, Cummins Engine Company, Inc., Box 3005, Columbus, IN 47202-3005
 Division and Regional Offices Section S - Service Assistance
Page S-4

Division and Regional Offices

NOTE: The following list contains offices in U.S., Canada, Australia, New Zealand, and Puerto Rico.

United States Australia Regional Office

Northern Division Office· . Cummins Diesel Australia
Cummins Engine Company, Inc. 513-515 Maroondah Highway
2629 Waterfront Ringwood 3134
Parkway East Drive Victoria, Australia
Suite 200 Telephone: (3) 871-2222
Indianapolis, IN 46204
Telephone: (317) 328-3740 NOTE: This office also serves New
Zealand.
Southern Division Office
Cummins Engine Company, Inc. Cummins Americas Regional
425 Franklin Road Office
Suite 500
Marietta, GA 30067 Cummins Caribbean
Telephone: (404) 423-1108 16085 N. W. 52nd Avenue
Western Division Office Hialeah, FL 33014
Telephone: (305) 621-1300
Cummins Engine Company, Inc.
5660 Greenwood Plaza Blvd. NOTE: This office serves Puerto Rico
Englewood, CO 80111 and South America exeluding BrilziL
Telephone: (303) 773-2866
Western Regional Office
Cummins Engine CompanY,·jnc.
584 First Street East
Sonoma, CA 95476
._, __
~~ (7,. . ---.''"';,..-
~~_, 0~ ,u-

Plains Regional Office

Cummins Engine Company, Inc.
1303 Walnut Hill Lane
Suite 100
Irving, TX 75038
Telephone: (214)580-7745
Canada
Canadian Division. Office.
Cummins Diesel of Canada, Ltd.
700 Dorval Drive
Suite 600
Oakville, Ontario L6K 3V3
Telephone: (416) 842-8070
Western Canada Regional Office
Cummins Diesel of Canada, Ltd.
Suite 303
22359 Longheed Highway
Maple Ridge, B.C. V2X 7G2
Telephone: (604)463-2359
Eastern Canada Regional Office
Cummins Diesel of Canada Ltd.
800 Montee DeLiesse
Saint Laurent, Quebec H4T 1P3
Telephone: (514)342-4042
Central Canada Regional Office
Cummins Diesel of Canada Ltd.
CIO Cummins Albeta
14755 - 121 A Avenue
Edmonton, Alberta T5L 2T2
Telephone: (403)455-2151
 Section S - Service Assistance
Distributors and Branches· United States
Alabama
Birmingham Distributor
Cummins Alabama, Inc.
2200 Pinson Highway
P.O. Box 1147
Birmingham, AL 35201
Telephone: (205) 841-0421
Mobile Branch
Cummins Alabama, Inc.
1924 Beltline Highway,
1-65 North
P.O. Box 2566
Mobile, AL 36601
Telephone: (205) 456-2236
Mobile Marine Branch
Cummins Alabama, Inc.
Marine Center
921 Corporate Drive South
P.O. Box 2566
Mobile, AL 36601
Telephone: (205) 456-2236
Mobile Onan Branch
Cummins Alabama, Inc.
Cummins/Onan/Power Systems Center
-- 3422-Georgia Pacific Avenue
Mobile, AL 36617
Telephone: (205) 452-6426
Montgomery Branch
Cummins Alabama, Inc.
2325 West Fairview Avenue
P.O. Box 9271
Montgomery, AL 36108
Telephone: (205) 263-2594
Alaska
Anchorage - (Branch of Seattle)
Cummins Northwest, Inc.
2618 Commercial Drive
Anchorage, AK 99501-3095
Telephone: (907) 279-7594
Arizona
Phoenix Distributor and Branch
Cummins Southwest, Inc.
2239 North Black Canyon Hwy.
P.O. Box 6688
Phoenix, AZ 85005-6688
Telephone: (602) 252-8021
Phoenix Generator Branch
Cummins Southwest, Inc.
Power Systems Division
2222 N. 23rd Drive
Phoenix, AZ 85009
Telephone: (602) 252-8021
Tucson Branch
Cummins Southwest, Inc.
1912 West Prince Road
Tucson, AZ 85705
Telephone: (602) 887-7440
Distributors and Branches - United State!
Page S-!
Arkansas Rialto Branch
Little Rock - (Branch of Memphis) Cummins West, Inc.
161 East Valley Road
Cummins Mid-South, Inc. Rialto, CA 92376
6600 Interstate 30 Telephone: (714) 877-0433
Little Rock, AR 72209
Telephone: (Sales): (501) 569-5600 San Diego Branch
(Service): (501) 569-5656 Cummins West, Inc.
(Parts): (501) 569-5613 9191 Kearny Villa Court
Van Buren - (BranCh of Memphis) San Diego, CA 92123
Telephone: (619) 278-4160
Cummins Mid-South, Inc.
1906 N. 6th Street Memphis San Leandro Branch
Van Buren, AR 72956 Cummins West, Inc.
Telephone: Sales: (501) 474-7953 1601 Aurora Drive
Parts: (501) 474-7951 San Leandro, CA 94577
Service: (501) 474-7955 & 474-7956 Telephone: (415) 351-6101
California Stockton Office
San Leandro Distributor Cummins West, Inc.
41 W. Yokuts Avenue, Suite 131
Cummins West, Inc. Stockton, CA 95207
1515 Aurora Drive Telephone: (209) 473-0386
San Leandro, CA 94577
Telephone: (415) 351-6101 West Sacramento Branch
Bakersfield Branch Cummins West, Inc.
2661 Evergreen Avenue
Cummins West, Inc. West Sacramento, CA 95691
301 East Fourth Street Telephone: (916) 371-0630
Bakersfield, CA 93304
Telephone: (805) 325-9407 Colorado
Eureka/Arcata Branch Denver Distributor
Cummins West, Inc. Cummins Power, Inc.
4801 West End Road 5100 East 58th Avenue
Arcata, CA 95521 Commerce City, CO 80022
Telephone: (707) 822-7385 Telephone: (303) 287-0201
Fresno Branch Denver Generator Branch
Cummins West, Inc. Gen Power, Inc.
2740 Church Avenue 3801 E. 50th Avenue
Fresno, CA 93706 Denver, CO 80216
Telephone: (209) 486-6050 Telephone: (303) 399-7697
Los Angeles Industrial Branch Grand Junction Branch
Cummins West, Inc. Cummins Power, Inc.
1939 Deere Avenue 2380 U.S. Highway 6 & 50
Irvine, CA 92714 P.O_ Box 339
Telephone: (714) 756-8700 Grand Junction, CO 81501
Los Angeles Branch Telephone: (303) 242-5776
Cummins West, Inc. Greeley Branch
1661 McGarry Street
Cummins Power, Inc.
Los Angeles, CA 90021 250 Sixth Avenue
Telephone: (213) 746-3850 Greeley, CO 80631
Branch: (213) 746-6410 Telephone: (303) 351-0448
Montebello Branch Connecticut
Cummins West, Inc.
1105 South Greenwood Avenue Hartford Distributor
Montebello, CA 90640
Cummins - Connecticut, Inc.
Telephone: (213) 728-8111 260 Murphy Road
Redding Branch Hartford, CT 06114
Telephone: (203) 527-9156
Cummins West, Inc. Parts: (203) 525-5606
2725 FavreUo Avenue
Redding, CA 96001
Telephone: (916) 241-2154
 Distributors and Branches - United States
Page S-6
Florida
Tampa Distributor
Cummins Southeastern
Power, Inc.
Corporate Office and Energy System
5421 N. 59th Street -
Tampa, FL 33610
Telephone: (813) 621-7202
Ft_ Myers Branch
Cummins Southeastern Power, Inc.
2671 Edison Avenue
Ft. Myers, FL 33902
Telephone: (813) 337-1211
Jacksonville Branch
Cummins Southeastern
Power, Inc.
2060 West 21 st Street
P.O. Box 12036
Jacksonville, FL 32209
Telephone: (904) 355-3437
Miami Branch
Cummins Southeastern
Power, Inc.
9900 N.W. 77th Court
Hialeah Gardens, FL 33016
Telephone: (305) 821-4200
Orlando Branch
Cummins Souti)eastern
Power, Inc.
4020 North
Orange Blossom Trail
Orlando, FL 32810
Telephone: (407) 298-2080
Tampa Branch
Cummins- Southeastern Power, Inc.
5910 E. Hillsborough Avenue
P. O. Box 11737
Tampa, FL 33680
Telephone: (813) 626-1101
Georgia
Atlanta Distributor
Cummins South, Inc_
5125 Georgia Highway 85
College Park, GA 30349
Telephone: (404) 763-0151
Albany Branch
Cummins South, Inc.
1915 W. Oakbridge Drive
Albany, GA 31707-4938
Telephone: (912) 888-6210
Atlanta Branch
Cummins South, Inc.
100 University Avenue, S.W.
Allanta, GA 30315-2202
Telephone: (404) 527-7800
Augusta Branch
Cummins South, Inc.
1255 New Savannah Road
Augusta, GA 30901-3891
Telephone: (404) 722-8825
Dalton Branch
Cummins South, Inc.
204 Carbondale Road
Dalton, GA 30720-5303
Telephone: (404) 277-1144
Savannah Branch -
Cummins South, Inc.
8 Interchange Court
Savannah, GA 31401-1627
Telephone: (912) 232-5565
Hawaii
Honolulu Distributor
Cummins Hawaii, Inc.
215 Puuhale Road
Honolulu, HI 96819-2235
Telephone: (808) 845-6606
Idaho
Boise - (Branch of Salt Lake City)
Cummins
Intermountain, Inc.
2851 Federal Way City
P.O. Box 5212
Boise, 10 83705
Telephone:-(208} 336'5000 --
Pocatello - (Branch of Salt Lake
City)
Cummins Intermountain, Inc.
1429 Highway 30 West
Pocatello, 10 83201
Telephone: (208) 234-1661
Illinois
Chicago Distributor
Cummins'Northam-iliinois; lnc: ..
7145 Santa Fe Drive
Hodgkins, IL 60525
Telephone: (708)579-9222
Bloomington-Normal - (Branch of
Indianapolis)
Cummins Mid-States Power, Inc.
P.O. Box 348
(at U.S. 51 N and I-55)
Bloomington-Normal, IL 61761
Telephone: (309) 452-4454
Harrisburg (Branch of St_ Louis)
Cummins Gateway, Inc.
Rt. 4, Box 629
Harrisburg, IL 62946
Telephone: (618)244-1232
Rock Island - (Branch of Omaha)
Cummins Great Plains
Diesel, Inc.
7820-42nd Street West
Rock Island, IL 61204
Telephone: (309) 787-4300
Rockford Branch
Cummins Northern Illinois, Inc.
4617 Sandy Hollow Road
Rockford, IL 61109
Telephone: (815) 874-1700
Section S - Service ASSistance
Indiana
Indianapolis Distributor
Cummins Mid-States Power, Inc.
2421 Production Drive
Indianapolis, IN 46241
Telephone: (317) 243-7979
Evansville - (Branch of Louisville)
Cummins Cumberland, Inc.
7901 Highway 41 N.
Evansville, IN 47711
Telephone: (812) 867-4400
Ft_ Wayne Branch
Cummins Mid-States Power, Inc.
3415 Coliseum Blvd. West
(At Jct. 1-69 & 30/33)
Ft. Wayne, IN 46808
Telephone: (219) 482-3691
Gary - (Branch of Chicago)
Cummins Northern Illinois, Inc.
1440 Texas Street
Gary, IN 46402
Telephone: (219) 885-5591
Indianapolis Branch
Cummins Mid-States Power, Inc.
P. O. Box 41317
3621 West Morris Street
I~ __ ';,, __ ~~-,I;.,.. !!,-! /:C"C'-'
Telephone: (317) 244-7251
Linton Branch
Cummins Mid-States Power, Inc.
1244 N_E. A Street
(Indiana Highway 54 East)
Linton, IN 47441-0678
Telephone: (812) 847-2201 and
(812) 847-2202-
Iowa
Cedar Rapids - (Branch of Omaha)
Cummins Great Plains
Diesel, Inc.
625 - 33rd Avenue SW
P.O. Box 1107
Cedar Rapids, IA 52406
Telephone: (319) 366-7537
(24 hours)
Des Moines - (Branch of Omaha)
Cummins Great Plains
Diesel, Inc.
1680 N.E. 51st Avenue
P.O. Box B
Des MOines, IA 50313
Telephone: (515) 262-9591
Parts: (515) 262-9744
(515) 262-9591 after midnight
Des Moines - (Branch of Omaha)
Midwestern Power Products
Division of Cummins Great Plains
Diesel, Inc.
10100 Dennis Drive
Des Maines, IA 50322
Telephone: (515) 278-5521
 Section S - Service Assistance
Kansas
Colby - (Branch of Kansas City,
Missouri)
Cummins Mid·America, Inc.
1880 South Ranae
P.O. Drawer "p,i'
Colby, KS 67701
Telephone: (9t 3) 462·3945
(913) 462-3143
Garden City - (Branch of Kansas
City, Missouri)
Cummins Mid·America, Inc.
2203 W. Jones Frontage Road
Box 2598
Garden City, KS 67846
Telephone: (316) 275·2277
Olathe - (Branch of Kansas City,
Missouri)
Cummins Mid·America, Inc.
11615 South Rogers Road
P. O. Box 3108
Olathe, KS 66062
T-elel'hone: (913) 469·5660
Wichita - (Branch of Kansas City,
Missouri)
Cummins Mid·America, Inc.
5101 North Broadway (67219)
P.O. Box 2681
Wichita, KS 67201
Telephone: (316) 838·0875
Kentucky
Louisville Distributor
Cummins Cumberland, Inc.
(Corporate Office)
_•. " _..••, .... ~~~I,~~~~s~o';~tway
Telephone: (502) 491·6060
. Hazard Branch
Cummins Cumberland, Inc.
Highway 15 South
P.O. Box 510
Hazard, KY 41701
Telephone: (606) 436·5718
Louisville Branch
Cummins Cumberland, Inc.
9820 Bluegrass Parkway
Louisville, KY 40299
Telephone: (502) 491·4263
Louisiana
Morgan City - (Branch of Memphis)
Cummins Mid·South, Inc.
Hwy. 90 East
P.O. Box 1229
Amelia, LA 70340
Telephone: (504) 631·0576
Distributors and Branches - United Stat,
New Orleans - (Branch of Mem-
phis)
Cummins Mid·South, Inc.
110 E. Airline Highway
Kenner, LA 70062
TelephOne: (504) 468·3535
Maine
Bangor (Branch of Boston)
Cummins North Atlantic, Inc.
142 Target Industrial Circle
Bangor, ME 04401
Telephone: (207) 941·1061
Scarborough - (Branch of Boston)
Cummins North Atlantic, Inc.
10 Gibson Road
Scarborough, ME 04074
Telephone: (207) 883·8155
Maryland
Baltimore Distributor
Cummins Chesapeake, Inc.
6120 Holabird Avenue
Baltimore, MD 21224
Telephone: (301) 633·5161
. Baltimore Branch
Cummins Chesapeake
3140 Washington Boulevard
Baltimore, MD 21230·1090
Telephone: (301) 644·6500
Massachusetts
Boston Distributor
Cummins North Atlantic, Inc.
100 Allied Drive
Dedham, MA 02026
Telephone: (617)329·1750
West Springfield Branch
Cummins North Atlantic, Inc.
124 Ashley Avenue
West Springfield, MA 01089
Telephone: (413) 737·2659
Michigan
Detroit Distributor
Cummins Michigan, Inc.
41216 Vincenti Court
Novi, MI 48375
Telephone: (313) 478·9700
Blissfield, Michigan
Diesel Fuel Systems, Inc.
Subsidiary of Cummins Michigan, Inc.
109 East Adrian Street
Blissfield, MI 49228
Telephone: (517) 486-4324
Dearborn Branch
Cummins Michigan, Inc.
3760 Wyoming Avenue
Dearborn, MI 48120
Telephone: (313) 843·6200
Page S
Grand Rapids Branch
Cummins Michigan, Inc.
3715 Clay Avenue, S.W.
Grand Rapids, MI 49508
Telephone: (616) 538·2250
Grand Rapids Branch
Standby Power, Inc.
7580 Expressway Drive S.W.
Grand Rapids, MI 49548
Telephone: (616) 281·2211
Iron Mountain - (Branch of De Pen
Cummins Great Lakes, Inc.
P.O. Box 703
1901 North Stephenson Avenue
Iron Mountain, MI 49801
Telephone: (906) 774·2424
Saginaw Branch
Cummins Michigan, Inc.
722 N. Outer Drive
Saginaw, MI 48605
Telephone: (517) 752-5200
Standby-Power-- (BranCh of
Detroit)
Standby Power, Inc.
12130 Dixie
Redford, MI 48239
Telephone: (313)538-0200
Minnesota
St. Paul Distributor
Cummins Diesel Sales, Inc.
2690 Cleveland Avenue North
St. Paul, MN 55113
(Mailing Address)
P.O. Box 64578
S1. Paul, MN 55164
Telephone: (612)'636'1000
Duluth Branch -- -
Cummins Diesel Sales, Inc.
3115 Truck Center Drive
Duluth, MN 558M ..
Telephone: (218) 628-3641
Hibbing Branch
Cummins Diesel Sales, Inc.
604 West 41st Street
P.O. Box 159
Hibbing, MN 55746
Telephone: (218) 263·7558
Mississippi
Jackson - (Branch of Memphis)
Cummins Mid-South, Inc.
325 New Highway 49 South
P.O. Box 54224
Jackson, MS 39288-4224
Telephone: Admin.: (601) 932-7016
Parts: (601) 932-2720
Service: (601) 939·1800
 Section 5 - Service Assistance
North Dakota
Dickinson - (Branch of St. Paul)
Cummins Diesel Sales, Inc.
Highway 10 West
P.O. Box 1246
Dickinson, ND 58602
Telephone: (701) 225·9194
(701) 677-5354
after 12:30 a.m.
Fargo - (Branch of St. Paul)
Cummins Diesel Sales, Inc.
4050 West Main Avenue (58103)
P.O. Box 2111
Fargo, ND 58107
Telephone: (701) 282-2466
Grand Forks - (Branch of St_ Paul)
Cummins Diesel Sales, Inc.
4728 Gateway Drive
P.O. Box 636
Grand Forks, ND 58201
Telephone: (701) 775-8197
(701) 772-7689
after 12:30 a.m.
Minot - (Branch of St. Paul)
Cummins Diesel Sales, Inc.
....... _ ._. __ i.5QL.2QlhAvenUe, S.E.
P.O. Box 1179
Minot, ND 58702
Telephone: (701) 852-3585
(701) 839-3417
after 12:30 a.m.
Ohio
Columbus Distributor and Branch
Cummins Ohio, Inc.
4000 Lyman Drive
Hilliard (Columbus), OH 43026
~- ---·--Telephone: (614) 77HOOO
_Akron Branch
Cummins Ohio, Inc.
1033 Kelly Avenue
.. ...Ak]""oh~- OH 44306 '-'--~'TUrsii ~
Telephone: (216) 773-7821
Cincinnati Branch
Cummins Ohio, Inc.
10470 Evendale Drive
CinCinnati, OH 45241
Telephone: (513) 563-6670
Cincinnati Branch
Power Systems Division
Cummins Ohio, Inc.
10660 Evendale Drive
CinCinnati, OH 45241
Telephone: (513) 563-9303
Cleveland Branch
Cummins Ohio, Inc.
7585 Northfield Road
Cleveland, OH 44146
Telephone: (216) 439-6800
Lima Branch
Cummins Ohio, Inc.
960 Broadway
Lima, OH 45804
Telephone: (419) 227-2641
Strasburg Branch
Cummins Oh[o, Inc.
777 South Wooster Avenue
Box 136
Strasburg, OH 44680
Telephone: (216) 878-5511
After hours: (216) 364-1433
Toledo Branch
Cummins Ohio, Inc.
801 Illinois Avenue
Maumee
(Toledo), OH 43537
Telephone: (419) 893·8711
Youngstown Branch
Cummins Ohio, Inc.
7145 Masury Road
Hubbard
(Youngstown), OH-44425
Telephone: (216) 534-1935
Oklahoma
Cummins Southern Plains, Inc.
1400 East Bois D'Arc
P.O. Box 310
Duncan, OK 73534-0310
Telephone: (405) 255-1414
(24 Hours)
Oklahoma City - (Branch of Arling-
ton)
Cummins Southern Plains, Inc.
... -..... 5800.West··RellO· -" .
P.O. Box 1636
Ok/ahoma. City,.OK 73101-1636
Telephone: (405) 946-4481
(24 hours)
(Branch oOrrlfngfon) .
Cummins Southern Plains, Inc,
16525 E. Skelly Drive
P.O. Box 471616
Tulsa, OK 74147-1616
Telephone: (918) 234-3240
(24 hours)
Oregon
Bend - (Branch of Seattle)
Cummins Northwest, Inc,
3500 N. Highway 97 (97701-5729)
P.O, Box 309
Bend, OR 97709-0309
Telephone: (503) 389-1900
Distributors and Branches - United St.
Page
Eugene - (Branch of Seattle)
Cummins Northwest, Inc.
91201 Industrial Parkway
Coburg, OR 97401
(Mailing Address)
P.O. Box 10877
Eugene, OR 97440-2887
Telephone: (503) 687·0000
Medford - (Branch of Seattle)
Cummins Northwest, Inc.
4045 Crater Lake Highway
Medford, OR 97504-9796
Telephone: (503) 779-0151
North Bend - (Branch of SeattlE
Cummins Northwest, Inc.
612 California Avenue (97459-3402)
P.O. Box 447
North Bend, OR 97459-0105
Telephone: (503) 756-3111
Pendleton - (Branch of Seattle)
Cummins Northwest, Inc.
223 S.W. 23rd Street
Pendleton, OR 97801-1810
Telephone: (503) 276-2561
Portland - (Corporate" Branch.,(
SeaUle)
Cummins Northwest, Inc.
4711 N. Basin Avenue
P. O. Box 2710 (97208-2710)
Portland, OR 97217-3557
Telephone: (503) 289-0900
Portland - (Branch of Seattle)
Cummins Northwest, Inc,
4711 N. Basin Avenue
P. O. Box 2710 (97208-2710)
." .• , ,-portllih"tl, OR 97217'3551"·......
Telephone: (503) 289-0900
Pennsylvania
Philadelphia Distributor.
Cummins Diesel Engines, Inc.
3941 Commerce Avenue
Willow Grove, PA 19090-1108
Telephone: (215) 657-2200
Philadelphia (Bristol) Branch
Cummins Diesel Engines, Inc.
2727 Ford Road
Bristol, PA 19007
Telephone: (215) 785-6005
Clearfield Branch
Cummins Diesel Engines, Inc.
Clearfield Parts Center
501 Williams Street
Clearfield, PA 16830
Telephone: (814) 765-2421
Harrisburg Branch
Cummins Diesel Engines, Inc.
4499 Lewis Road
Harrisburg, PA 17111-2541
Telephone: (717) 564-1344
 Distributors and Branches - United Stales
Page S-10
Monroeville Branch
Cummins Diesel Engines, Inc.
2740 Mosside Boulevard
Monroeville, PA 15146
Telephone: (412) 856·6700
Puerto Rico
Puerto Nuevo - (Branch of Tampa)
Cummins Diesel Power, Inc.
Calle C #31 EI Matadero
Puerto Nuevo, Puerto Rico 00920
Telephone: (809) 793·0300
South Carolina
Charleston - (Branch of Charlotte)
Cummins Atlantic, Inc.
3010 West Montague Avenue
P.O. Box 10341
Charleston, SC 29411-0341
Telephone: (803) 554-5112
Columbia - (Branch of Charlotte)
Cummins Atlantic, Inc.
1233 Bluff Road
P.O. Box 13543
Columbia, SC 29201-3543
Telephone: (803) 799-2410
South Dakota
Cummins Great Plains
Diesel, Inc.
2310 Haines Avenue
P.O. Box 244
Rapid City, SD 57701
Telephone: (605) 343·6130
Sioux Falls - (Branch of Omaha)
•••.•••
_~. " .. L'L.'~ ___ .~_'
Cummins Great Plains
Diesel,lnc.
701 East 54th Street I'forth
Sioux Falls, SD 57104
Telephone.: (60;;) 336-1715.
(605) 334-6492
Tennessee
Memphis Distributor & Distribution
Center
Cummins Mid-South, Inc.
666 Riverside Drive
P.O. Box 3080
Memphis, TN 38103
Telephone: (901) 577-0666
Chattanooga - (Branch of Atlanta)
Cummins South, Inc.
1509 East 26th Street
Chattanooga, TN 37407-1095
Telephone: (615) 629-1447
Knoxville - (Branch of Louisville)
Cummins Cumberland, Inc.
1211 Ault Road
Knoxville, TN 37914
Telephone: (615) 523-0446
Memphis Branch
Cummins Mid-South, Inc.
1784 E. Brooks Road
Memphis, TN 36116
Telephone:
Sales/Admin.-(901) 345-7424
Parts - - - - -(901) 345-1784
Service - - - -(901) 345-6185
Nashville - (Branch of Louisville)
Cummins Cumberland, Inc.
706 Spence Lane
Nashville, TN 37217
Telephone: (615) 366-4341
Texas
Arlington Distributor and Branch
Cummins Southern Plains, Inc.
600 N. Watson Road
P.O. Box 90027
Arlington, TX 76004-3027
Telephone: (617) 640-6801
(24 hours)
AmarillO Branch
Cummins Southern Plains, Inc.
5224 Interstate 40 -
Expressway East
P.O. Box 31570
Amarillo, TX 79120-1570
::elephon~: (606) 373-3793
,-
.
Corpus Christi Branch
Cummins Southern Plains, Inc.
1302 Corn Products Road
P.O. Box 48
Corpus Christi, TX 78403-0046
Telephone: (512) 289-0700
(24 hours)
• ,.. • .•• ,__ 0_' •
Dallas Branch
Cummins Southern Plains, Inc.
3707 Irving Boulevard
Dallas, JX]5247
- Telephone: (214) 631-6400
(24 hours)
EI Paso - (Branch of Phoenix)
Cummins Southwest, Inc.
14333 Gateway West
EI Paso, TX 79927
Telephone: (915) 852-4200
Fort Worth Branch
Cummins Southern Plains, Inc.
3250 North Freeway
Fort Worth, TX 76111
Telephone: (817) 624-2107
(24 hours)
Houston Branch
Cummins Southern Plains, Inc.
4750 Homestead Road
P.O. Box 1367
Houston, TX 77251-1367
Telephone: (713) 675-7421
(24 hours)
Section S - Service Assistance
Mesquite Branch
Cummins Southern Plains, Inc.
2615 Big Town Blvd.
Mesquite, TX 75150
Telephone: (214) 321-5555
(24 hours)
Odessa Branch
Cummins Southern Plains, Inc.
1210 South Grandview
P.O. Box 633
Odessa, TX 79760-0633
Telephone: (915) 332-9121
(24 hours)
San Antonio Branch
Cummins Southern Plains, Inc.
6226 Pan Am Expressway North
P.O. Box 18365, Serna Station
San Antonio, TX 76218-0365
Telephone: (512) 655-5420
(24 hours)
Utah
Salt Lake City Distributor
Cummins Intermountain, Inc.
1030 South 300 West
P.O. Box 2!i426
Salt Lake City, UT 84125
Telephone: (801) 355-6500
Cummins Intermountain, Inc.
1435 East 335 South
P.O. Box 903
Vernal, UT 84078
Telephone: (801) 789-5732
Virginia
Bristol - (Branch of Louisville)
Cummins Cumberland, Inc.
400 Stage Coach Road' .
1·81 at Old Airport Road
Bristol, VA 24201
Telephone: (703) 669·42"00 -... -.~~.~-~
Norfolk - (Branch of Charlotte)
Cummins Atlantic, Inc.
CumminsiOnan Power Systems
1114 Ballentine Blvd.
Norfolk, VA 23504
Telephone: (804)627-9470
Richmond - (Branch of Charlotte)
Cummins Atlantic, Inc.
3900 Deepwater Terminal Road
Richmond, VA 23234
Telephone: (804) 232-7691
Roanoke - (Branch of Charlotte)
Cummins Atlantic, Inc.
5307 Peters Creek Road
P.O. Box 7237
Roanoke, VA 24019-7237
Telephone: (703) 362-1673
 Section S • Service Assistance Distributors and Branches· United St
Page ~

Washington Chippewa Falls Branch

Seattle Distributor Cummins Great Lakes, Inc.
Route #7
Cummins Northwest, Inc. Box Number 88
811 S. W. Grady Way (98055-2944) Chippewa Falls (Eau Claire), WI 54729
p.o. Box 9811 Telephone: (715) 832-4329
Renton, WA 98057·9811
Telephone: (206) 235-3400 DePere Branch
Chehalis Branch Cummins Great Lakes, Inc.
939 lawrence Drive
Cummins Northwest, Inc. (Mailing Address)
1200 N. W. Maryland P. O. Box 530
Chehalis, WA 98532-1813 DePere, WI 54115·0530
Telephone: (206) 748·8841 Telephone: (414)336·9631
longview Branch Milwaukee Branch
Cummins Northwest, Inc. Cummins Great Lakes, Inc.
1153 Third Avenue (98632-3204) 9401 South 13th Street
P.O. Box 1459 Oak Creek, WI 53154
Longview, WA 98632-0141 Telephone: (414) 768·7400
Telephone: (206) 425·0100
Wyoming
Spokane Branch
Gillette . (Branch of Denver)
Cummins Northwest, Inc.
E. 3904 Trent Avenue (99202-4471) Cummins Power, Inc.
P.O. Sox 2746 • 2700 Hwy. 14 & 16 North
Terminal Annex P.O. Box 1207 (82717)
Spokane, WA 99220·2746 Gillette, WY 82716
Telephone: (509) 534·0411 Telephone: (307) 682·9611
Tacoma Branch Rock Springs . (Branch of Salt
Cummins Northwest, Inc. lake City)
3701 Pacific Highway East Cummins Intermountain. Inc.
Tacoma, WA 98424-1135 2000 Foothill Blvd.
Telephone: (206) 922-2191 P.O. Box 1634
Rock Springs, WY 82901
Yakima Branch Telephone: (307) 362-5168
Cummins Northwest, Inc.
1905 East Central Avenue (98901·3609)
P.O. Box 9129
Yakima, WA 98909·0129
T!1I"phone: (509) 248·.9033
West Virgi l1 ia ___ .
Charleston· (Branch of Louisville)
. Cummins Cumberland, Inc,.. ··
Charleston Ordnance Center
P.O. Box B456
South Charleston, WV 25303
Telephone: (304) 744-6373
Fairmont· (Branch of louisville)
Cummins Cumberland, Inc.
South Fairmont Exit, 1-79
Rt. 73, South
P.O. Box 988
Fairmont, WV 26554
Telephone: (304) 367·0196
Wisconsin
DePere Distributor
Cummins Great Lakes, Inc.
875 Lawrence Drive
(Mailing Address)
P.O. Box 530
DePere (Green Bay), WI 54115·0530
Telephone: (414) 337-1991
 Distributors and Branches • Canada Section S - Service Assistance
Page S-12

Distributors and Branches - Canada

Alberta New Brunswick Whitby Branch
Edmonton Distributor Fredericton - (Branch of Montreal) Cummins Ontario Inc.
1311 Hopkins Street
Cummins Alberta Diesel Cummins Whitby, Ontario L1 N 2C2, Canada
14755 - 121A Avenue~ Telephone: (416) 668-1375
Edmonton, Alberta T5L 2T2, Canada Branch of Cummins Americas, Inc.
Telephone: (403) 455-2151 Vanier Highway Quebec
P.O. Box 1178, Station "A"
Calgary Branch Fredericton, Montreal Distributor
New Brunswick E3B 5C8, Canada
Cummins Alberta Telephone: (506) 452-1940 Diesel Cummins Branch of Cummins
703-64 Avenue S.E. Americas, Inc.
Calgary, Alberta T2H 2C3, Canada Newfoundland 7200 Trans Canada Highway
Telephone: (403) 255-6691 Pointe Claire, Quebec H9R 1C2, Can-
St. John's - (Branch of Montreal) ada
Fort McMurray Branch Telephone: (514) 695-8410
Diesel Cummins
Cummins Alberta Montreal Branch
158 Becker Crescent Branch of Cummins Americas, Inc.
Fort McMurray, Alberta T9K 1M7, Can- 122 Clyde Avenue Diesel Cummins Branch of Cummins
ada Donovans Industrial Park Americas, Inc.
Telephone: (403) 791-6836 (Mailing Address) 7200 Trans Canada Highway
P. O. Box 159 Pointe Claire, Quebec H9R 1C2, Can-
Hinton Branch Donovans Industrial Park ada
Mount Pearl, Newfoundland AI N 2C2 Telephone: (514) 695-8410
Cummins- Alberta Canada
135 Yeats Avenue Sales: (514) 694-5143
Telephone: (709) 364-6972 Parts: (514) 694-5880
Hinton, Alberta T7V 1S8, Canada
Telephone: (403) 865-5111 Nova Scotia Quebec City Branch
Lethbridge Branch Halifax - (Branch of Montreal) Diesel Cummins Branch of Cummins
Cummins Alberta Americas, Inc.
Diesel Cummins 2400 Watt Street
230· 24th Str0o.t N,....,r-t~ .- '" ,-."·-'--·r-··"r;....,......,,r ..-.., . . . ::;
LetflDl"loge, AlDena 1- h.J ;,,:~d:., vafii:Hja
Telephone: (403) 329-6144 3204'Ba~~i"'gi~~'Si;~~i-' '---, ... -. Telephone: (418) 651-2911
Halifax, Nova Scotia B3K 2X6, Canada
British Columbia Telephone: (902) 429-6613 Saskatchewan
Vancouver Distributor Ontario Lioydminster (Branch of
Winnipeg)
Cummins British Columbia Toronto Distributor
4270 Dawson Street Cummins Mid-Canada Ltd.
Burnaby, B.C. V5C.AB1, Canada ..... _, .. _ Cummins Ontario Inc. 3709 - 44th Street
Telephone: (604) 299-9111 150 N. Queen Streer~ P.O: Bcix 959 -'- -_. -.-.~

Etobicoke, Ontario M9C 1A8 L1oydminster, SK S9V OY9, Canada

Kamloops Branch' P.O. Box 40;'Station'''U'' Telephone: (403)~825-2062~-.. ·-~·- ~
Toronto, Ontario M8Z 5Nl
Cummins British Columbia Telephone: (416) 621-9921 Regina - (Branch of Winnipeg)
976 Laval Crescent
Kamloops, B.C. Canada V2C 5P5 Milton Branch Cummins Mid-Canada Ltd.
Telephone: (604) 828-2388 110 Kress Street
Dieselguard P.O. Box 98
Sparwood Branch Division of Cummins Ontario Inc. Regina, SK S4P 2Z5, Canada
40 Chisholm Dr. Telephone: (306) 721-9710
Cummins British Columbia Milton, Ontario L9T 4N9
731 Douglas Fir Road Telephone: (416) 876·4623 Saskatoon - (Branch of Winnipeg)
Sparwood, B.C. VOB 2GO, Canada
Telephone: (604) 425-0522 Oakville Industrial Branch Cummins Mid-Canada, Ltd.
3001 Faithful Avenue
Tumbler Ridge Branch Cummins Ontario Inc. P.O. Box 7679
301 Wyecroft Road Saskatoon, SK S7K 4R4, Canada
Cummins British Columbia Oakville, Ontario L6K 2H2, Canada Telephone: (306) 933-4022
Box 226 Telephone: (416) 844-5851
Tumbler Ridge, B.C.
Canada VOC 2WO Ottawa Branch
Telephone: (604) 242-4217
Cummins Ontario Inc.
Manitoba 3189 Swansea Crescent
Ottawa, Ontario Kl G 3W5, Canada
Winnipeg Distributor Telephone: (613) 736-1146
Cummins Mid-Canada Ltd. Thunder Bay Branch
489 Oak Point Road
P.O. Box 1860 Cummins Ontario Inc.
Winnipeg, MB R3C 3Rl, Canada 1400 W. Walsh Street
Telephone: (204) 632-5470 Thunder Bay
Ontario P7C 4V9, Canada
Telephone: (807) 577-7561
 Section S - Service Assistance Distributors and Branches - Austr,
PageS

Distributors and Branches - Australia

Sydney (Lansvale) Grafton (South Grafton) Swan Hill
Cummins Diesel Sales & Cummins Diesel Sales & Cummins Diesel Sales & Service
Service Service P.O. Box 1264
P.O. Box 150 P.O. Box 18 5 McAllister Road
164·170 Hume Highway 18-20 Induna Street Swan Hill, 3585
Lansvale, 2166 South Grafton, 2461 Victoria, Australia
Cabramatta 2166 New South Wales, Australia Telephone: (61-50) 32-9722
New Soulh Wales, Telephone: (61-66) 42-3655
Australia Tamworth
Telephone: (61-2) 728-6211 Kalgoorlie
Cummins Diesel Sales &
Cummins Diesel Sales & Service Service
Branches: P.O. Box 706 P.O. Box 677
Adelaide (Gepps Cross) Kalgoorlie, 6430 Lot 65 Gunnedah Road
Western Australia, Australia Tamworth, 2320
Cummins Diesel Sales & Location: New South Wales, Australia
Service Cnr. Keogh Way & Atabara Street Telephone: (61-67) 65-5455
P.O. Box 108 Telephone: (61-90) 71-2994
45-49 Cavan Road Wodonga
Gepps Cross, 5094 Mackay
Cummins Diesel Sales &
Blair Athol, 5084 Cummins Diesel Sales & Service
South Australia, Australia Service P.O. Box 174
Telephone: (61-8) 262-5211 P.O. Box 842 9-11 McKoy Street
Brisbane (Darra) 4 Presto Avenue Wodonga, 3690
Mackay, 4740 Victoria, Australia
Cummins Diesel Sales & Queensland, Australia Telephone: (61-60) 24-3655
Service Telephone: (61-79) 55-1222
P.O. Box 124
2506 Ipswich Road Melbourne (Campbellfield)
Dana; 4076
Queensland, Australia
"'--''Cuinmlns Diesel Sales &
Service
Telephone: (61-7) 375-3277 Private Bag 9, G.P.O.
Cairns 1788-1800 Hume Highway
Campbellfield 3061
Cummins Diesel Sales & Service Victoria, Australia
Cnr. Toohey & Knight Streets Telephone: (61-3) 357-5622
Portsmith, Cairns, 4870
Queensland, Australia Moorabbin
Telephone: (61-70) 52-1488 Cummins Diesel Sales & Service
Canberra P.O. Box 368
Moorabbin, 3189
,Cummins Diesel Sales & Service' Victoriaj Australia ,. 0'.:-"_'-<'

15-27 Bayldon Road Location:

Queanbeyan, ,2620 5 Linton Street
A.C.T., Australia Telephone: (61-3) 555-2255
Telephone: (61-62) 97-3433
Mount Gambier
Darwin (Winnellie)
Cummins Diesel Sales & Service
Cummins Diesel Sales & P.O. Box 2219
Service 2 Avey Road
P.O. Box 37587 Mount Gambier, 5290
Lot 1758 Graffin Crescent South Australia, Australia
Win nellie, 5789 Telephone: (61-87) 25-6422
Winnellie, Darwin, 578
Northern Territory, Australia Newcastle
Telephone: (61-89) 47-0766 Cummins Diesel Sales &
Devonport Service
21 Galleghan Street
Cummins Diesel Sales & Hexham, 2322
Service New South Wales, Australia
P.O. Box 72E Telephone: (61-49) 64-8466
2 Matthews Way
East Devonport, 7310 Perth (Welshpool)
Tasmania, Australia Cummins Diesel Sales &
Telephone: (61-04) 24-8800 Service
P.O. Box 275
50 Kewdale Road
Kewdale, 6106
Cloverdale, 6105
Western Australia, Australia
Telephone: (61-9) 458-5911
 Distributors and Branches - New Zealand Section S - Service Assistance
Page S-14

Distributors and Branches - New Zealand

Auckland
Lees Power
8 The Furlong
Takanini, Auckland,
New Zealand
Telephone: (64-9) 299-7448
Branches:
Auckland
Lees Power
P.O. Box 12-120
440 Church Street
Penrose, Auckland,
New Zealand
Telephone: (64-9) 591-009
Christchurch
Lees Power
P.O. Box 16-149, Hornby
266 Main South Road
Sockburn, Christchurch,
New Zealand
Telephone: (64-3) 497-178
Napier
Lees Power
P.O. Box 3021, Onekawa
Austin Street
Onekawa. Napier,
i ,,;;.. .. ':"_~:.,;..,-.¥.
Telephone: (64-70) 436-129
Palmerston North
Lees Power
P.O. Box 9024
852-860 Tremaine Avenue
Palmerston North,
New Zealand
Telephori,,:'(64-63) 02'209 _. ~".- -.
Rotorua
Lees Power
P.O. Box 934
Te Ngae Road
Rotorua, New Zealand
Telephone: (64-73) 56-699
Wellington
Lees Power
P.O. Box 30-447,
Port Road South
Seaview, Lower Hut!,
New Zealand
Telephone: (64-4) 686-029
Section S - Service Assistance Regional Offices - Internatiol
Page S·

Regional Offices· International

Latin America Area Office - Hialeah Brazil Cumbrasa Office· Sao Paulo
Cummins Americas, Inc. Cummins Brasil S.A.
16085 N.W. 52nd Avenue Rua Jali, 266
Hialeah, FL 33014 07270 Guarulhos
U.S.A. Sao Paule, Brazil
Teleph?ne: (305) 6~1-4451 MailingAddress:
Countries Arg.entma Honduras P.O. Box 13
Covered: Bohvla Nicaragua 07270 Guarulhos
Chile . Panama Sao Paulo, Brazil
Cosl~ .Rlca . Paraguay Telephone: (55-11) 945-9811
Dominican Repubhc Peru Co I
EI Salvador Uruguay un ry
Guatemala Covered: Brazil

Colombia Regional Office - Bogota. South And East Asia Area Office -
Cummins Engine Co. de Colombia SA Singapore
Carrera llA No. 90-1501.601/602 Cummins Diesel Sales Corporation
Bogota, DE, Colombia 8 Tanjong Penjuru
Telephone: (57-1) 218-6248 Jurong Industrial Estate
Singapore 2260
Mailing Address: Telephone: (65) 265-0155
Apartado Aereo 90988 Coullt~ies Bangladesh Laos
Bogota DE, Colombia Covered: Brunei Malaysia
Countries Burma Philippines
Covered: Colombia Gaml:l.Qdia .Singapore
Ecuador Guam Sri Lanka
Hong Kong Taiwan
Venezuela Regional Office - Caracas Indonesia Thailand
Cummins Engine Company Vietnam
Olicina del Delegado
Torre La Primera, Oficlna 5-0 South Pacific Area Office - Scoresby
Av. Francisco de Miranda Cummins Australia Pty. Ltd.
Chacao, Caracas 1060, Venezuela 2 Caribbean Drive
Mailing Address: Scoresby, 3179
Victoria, Australia
Cummins Engine Company M-227
Telephone:. (f11c3) 765-3222 ., ........... , .... , .. .
. ... c/o.JetCargo..lntematior:1al .
P.O. Box 020010 Countries Australia New Caledonia
---Miami; ·,F/:-·331 ON~Ol 0 Covered: French Polynesia New Zealand'
Telephone: (58-2) 32-0563, 32-7187 (including Tahiti)
South PacifiC Islands (including
COllntry: _ .
Eastern New Guinea,
Covered: Venezuela Fiji Islands, and the Solomo.n Is-
India Kirloskar Office - Pune lands)
Kirloskar Cummins Limited
Kothrud
North Asia Area Office - Tokyo
Cummins Diesel Sales Corporation
Pune - 411 029, India
1-12-10 Shintomi
Telephone: (91-212) 33-0240,33-1074,33-1105
Chuo.·ku, To.kyo. 104
Countries Japan
Covered: Bhutan Telephone: (81-3) 555-3131/2/3/4/5
India
Countries
Nepal
Covered: Japan
South Korea
 Regional Offices - International Section S - Service Assistance
Page S-16

China Regional Office - Beijing Shotts

Cummins Corporation Cummins Engine Company Limited
China World Tower, Suite 917 Calderhead Road
China World Trade Centre Shotts, Lanarkshire ML7 4JT
No. 1 Jianguo Men Wai Scotland
Beijing 100004 Telephone: (44-786) 824879
People's Republic of China
Telephone: (86-1) 505-4209/10 East and Southern Africa Regional Office -
Country Harare
Covered: China Cummins Diesel International Ltd.
72 Birmingham Road
U.K. Area Office - New Malden (Heavy Industrial Sites)
Cummins Engine Company Limited Southerton
46-50 Coombe Road Harare, Zimbabwe
New Malden
Surrey KT3 4QL Mailing Address:
England P.O. Box 8440, Causeway
Telephone: (44-1) 949-6171 Harare, Zimbabwe
Telephone: (263-4) 67645
U.K. Regional Office - Wellingborough Countries Botswana Namibia
Cummins Diesel Covered: Congo Reunion
Denington Estate Djibouti Seychelles
Welllngborough Ethiopia Samalia
Northants, NN8 2QH Kenya South Africa
England Lesotho Swaziland
. ---. "Telephone: (44-933) 76211 Madagascar Tanzania.·-
Countries Malawi Uganda
Covered: Ireland Mauritius Zambia
,,---, ... ' . ' -
..
. -- ;:,-'....-, ..
~.--

Middle East Regional Office - Mechelen West/Northern Africa Regional Office -

Cummins Diesel N.V. Mechelen
Blarenberglaan 4 Cummins Diesel N.V.
Industriepark Noord 2 Blarenberglaan 4
2800 Mechelen Industriepark Noord 2
Belgium 2800 Mechelen
Telephone: (32-15) 200031 .,. Belgium
.J:ountries Afghanistan Lebanon Sudan Telephone: (32-15) 200031
Covered: Bahrain North Yemen Syria Countries Benin Giliriea Bissau
Cyprus Oman Turkey Covered: Burkina Faso Liberia
Egypt - _. Pakistan United Burundi Mali
Iran Quatar Arab Cameroon Malta
Iraq Saudi Arabia Emirates Cape Verde Mauritania
Jordan South Yemen Central African Morocco
Kuwait Republic Niger
Chad Nigeria
Daventry Cote d'ivoire Rwanda
Cummins Engine Company Ltd. Equatorial Sao Tome &
Royal Oak Way South Guinea Principe
Daventry, Northants NNll 5NU Gabon Senegal
England Gambia Sierre Leone
Telephone: (44-327) 76000 Ghana Togo
Guinea Tunisia
Darlington Zaire
Cummins Engine Company Limited
Yarm Road
Darlington, Co. Durham DL1 4PW
England
Telephone: (44-325) 460606
 Section S - Service Assistance Regional Offices - Internatiol
Page S·

North Africa Regional Office - Algiers Germany Regional Office - Gross-Gerau

Cummins Corporation Cummins Diesel Deutschland GmbH
Bureau de Liaison Odenwaldstr. 23
38, Lotissement Benachour Abdelkader D-6080 Gross-Gerau
Cheraga Federal Republic of Germany
42300 Wilaya de Tipasa Telephone: (49-6152) 174-0
Algeria
Mailing Address:
Telephone: (213) 281-06-90
P.O. Box 1134
Countries 0-6080 Gross Gerau
Covered: Algeria
Federal Republic of Germany
Angola
Countries Albania
European Regional Office - Mechelen Covered: Bulgaria
Cummins Diesel N.V. Federal Republic of Germany
Blarenberglaan 4 German Democratic Republic
Industriepark Noord 2 Poland
2800 Mechelen Romania
Belgium U.S.S.A.
Telephone: (32-15) 200031 Yugoslavia
Countries Austria Iceland
Covered: Belgium Israel Spain Representation Office - Madrid
Cummins Diesel N.V.
Czechoslovakia Luxembourg
C Andarrios 11-C
Denmark Netherlands
28043 Madrid
Finland Norway
Spain
Greece Portugal
Telephone: (34-1) 759-2880
Hungary Sweden
Switzerland Country
Covered: Spain
France Regional Office - Lyon
Cummins Diesel Sales Corporation Moscow
39, rue Ampere - Zone Industrielle Cummins Engine Co., Inc.
69680 Chassieu c/o Control Data Corporation
France Krasnopresnenskaya Nab. 12, Office 2006
Telephone: (33) 78-90·43-05 123100 Moscow
U.S.S.R.
Country
Telephone: (7-95) 253-8379
Covered: France
' 0 " 'Italy Regional OffiCe;" Milan
Cummins Diesel Italia S.pA
.. Piazza:" IocateHis . .
Zona Industriale
··20098 San Giuliano Milanese
Milan, Italy
Telephone: (39-2) 982-81235/6/7
Country
Covered: Italy
Mexico Cummsa Office -Mexico City
Cummins, SA de C.V.
Arquimedes No. 209
Col. Polanco
11560 Mexico, D.F.
Mexico
Mailing/Shipping Address:
Gonzalez de Castilla Inc.
P.O. Box 1391
4605 Modern Lane
Modern Industrial Park
Laredo, TX 78040
Telephone: (52-5) 254-3822
Country
Covered: Mexico
 Distributors - International Section S - Service Assistance
Page S-18

Distributors - International
ABU DHABI BAHRAIN BOLIVIA
-See United Arab Emirates Bahrain La Paz
AFGHANISTAN Yusuf Bin Ahmed Kanoo W.L.L. Machinery & Auto Service
-See Middle East Regional Office Kanoo Commercial Casilla 4042
P.O. Box 45, Manama La Paz, Bolivia
ALBANIA Bahrain Location:
-See Germany Regional Office - Telephone: (973) 252454 Av. 20 de Octubre Esq.
Gross Gerau BALEARIC ISLANDS Rosendo Gutierrez
Telephone: (591-2) 379650, 366394
ALGERIA Madrid (Office in Spain)
Cummins Ventas y Servicio, S.A.
BONAIRE, ISLAND OF
Algiers
Torrelaguna, 56 -See Netherlands Antilles
Cummins Corporation
Bureau de Liaison 28027 Madrid, Spain BOTSWANA
38, Lotissement Benachour Abdelkader BANGLADESH -See East and Southern
Cheraga Africa Regional Office
43200 Wilaya de Tipasa Dhaka Harare
Algeria Equipment & Engineering Co., LId.
Telephone: (213) 281-0690 P.O. Box 2339 BRAZIL
AMERICAN SAMOA Dhaka 1000, Bangladesh Ananindeua
Location: Marcos Marcelino & Companhia
Pago Pago 56, Dilkusha Commercial Area Llda.
Burns Philp (South Seas) Co. Ltd. 2nd FloorlEastern Block Rodovia BR-316, Km 9
P.O. Box 129 Telephone: (880·2) 34357, 34060 67000 Ananindeua, Para,
Pago Pago, American Samoa Brazil
Telephone: (684) 633-4281 BARBADOS Telephone: (55-91) 235-4100141321
Miami (Office in U.S.A.) 414314QR __
ANDORRA
-See European Regional Office Cummins Southeastern Power, Inc. Belo Horizonte
- Mechelen 9900 N.W. 77 Court Distribuidora Cummins
Hialeah Gardens. FL 33016 Mi"13S Uda.
Anl'U~h.. bri Ilua h, 25, (,alGaia
-See Anlig ua BELGIUM 30770 Belo Horizonte,
Minas Gerais, Brazil
ANTIGUA Brussels Telephone: (55-31) 462-5144
Miami (Office In U.S.A.) Cummins Distributor Campo Grande
Cummins Southeastern Power, Inc. Belgium S.A. Distribuidora Cummins
9900 N.W. 77 Court 6231629 Chaussee de Haecht Mato Grosso Ltda.
Hialeah Gardens, FL 33016 B·1030 Brussels, Belgium Rodovia SR 163 Km 01
.. " .... 'I"elephone:-(305) 821-4200 Telephone; (24.b[.)... . __ _ 79060 Campo Grande
(32-2) 216·81-10 Mato Grosso do Sui, Brazil
.ARGENTINA Telephone:.(55_67) 387,11.66..
BELIZE
Buenos Aires Curitiba
Motores Stork
Miami (Office in U.S.A.) Festugato S.A.,
Werkspoor S.A.I.C. Cummins' Southeastern Power, Inc. Distribuiilbra Cummins
Av. Ader 3707-11 9900 N.W. 77 Court Rua Brasilio ltibere, 2195
1605 Carapachay Hialeah Gardens, FL 33016 80230 Curitiba, Parana
Buenos Aires, Argentina Telephone: (305) 821-4200 Brazil
Telephone: (54-1) 766·0B651073810580 BENIN Telephone: (55-41) 222-4036
ARUBA, ISLAND OF -See Togo Fortaleza
·See Netherlands Antilles Distribuidora Cummins Diesel
BERMUDA Do Nordeste Llda.
AUSTRIA Bronx (Office in U.S.A.) Av. da Abolicao, 3882,
Mucuripe
Vienna Cummins Metropower, Inc. 60165 Fortaleza, Ceara
Cummins-Industriemotoren 890 Zerega Avenue Brazil
Ges.m.b.H. Bronx, NY 10473 Telephone: (55-85) 244-9292
Bickfordstr. 25 Telephone: (212) 892-2400
GOianian
A-7201 Neudoerfl Austria BHUTAN
Tel~phone: (43-26) 22-77-418 Distribuidora de Motores Cummins
Pune (Office in India) Centro Oeste Llda.
AZORES ISLANDS Av. Caiapo 777 - Sta. Genoveva
Cummins Diesel Sales & 74410 Goiania, Goias
-See Portugal Service (India) Ltd. Brazil
BAHAMAS 35N112, Erandawana Telephone: (55-62) 264-1144
Pune - 411 038, India
Miami (Office in U.S.A.) Telephone: (91-212) 560961718
Cummins Southeastern Power, Inc.
9900 N.w. 77 Court
Hialeah Gardens, FL 33016
Telephone: (305) 821-4200
 Section S - Service Assistance Distributors - Internation
Page S-1

Manaus CAMBODIA Bucaramanga

Distribuidora Cummins -See South & East Asia Cummins API, Llda.
Amazonas Llda. Regional Office - Singapore Apartado Aereo 352
Estrada da Ponta Negra, 6080 - Sao Bucaramanga, Colombia
Jorge CAMEROON Location:
69037 Manaus, Amazonas, Limbe Autopista a Giron, Km 7
Brazil Telephone: (57-73) 68060
Telephone: (55-92) 238-7174/71771 LEYCAM Motors Lid.
8856/7631 P.O. Box 307 Cali
Limbe Distribuidora Cummins del Valle, Llda.
Porto Alegre Cameroon Apartado Aereo No. 6398
Distribuidora Cummins Telephone: (237) 33-22-66 Cali, Colombia
Meridional SA
Rua Dona Alzira, 98, Sarandi CANARY ISLANDS Location: Av. 3a. # 39-35 - Vipasa
91050 Porto Alegre, Telephone: (57-3) 65-4343
Rio Grande do Sui, Brazil Madrid (Office in Spain) Medellin
Telephone: (55-512) 40-8222 Cummins Ventas y Equipos Tecnicos Llda.
Rio de Janeiro Servicio, SA Apartado Aereo No. 2046
Torrelaquna, 56 Medellin, Colombia
Distribuidora Cummins 28027 Madrid, Spain
Leste Llda. Location: Carrera 52 No. 10-184
Rua Sariema, 138-01aria CAPE VERDE Telephone: (57-4) 255-4200
21030 Rio de Janeiro, -See West/Northern Africa Pereira
Rio de Janeiro, Brazil Regional Office - Mechelen
Telephone: (55-21) 290-7899 Equipos Tecnicos Llda. C.O.A.
CENTRAL AFRICAN REPUBLIC Apartado Aereo No. 1240
Sao Paulo Pereira, Colombia
Companhia Distribuidora -See West/Northern Africa
Regional Office - Mechelen LOG-ation:-Carrera 8a. No. 45-39
de Motores Cummins Telephone: (57-63) 366341/43
Rua Martin Burchard, 291 - Bras CEYLON
03043 Sao Paulo,
-See Sri Lanka
COMOROS
Sao Paulo, Brazil .... -See East and Southem·--··- .
. .... ····Tefephtme: (55'11) 270:231"1 Africa Regional Office
CHAD
Sao Paulo -See West/Northern Africa Harare
Motores Cummins Diesel Regional Office - Mechalen CONGO, PEOPLE'S REPUBLIC
do Brasil Llda.
Av. Thomaz Edson, 448 - Barra Funda CHILE Brussels (Office in Belgium)
01140 Sao Paulo, Santiago Bureau Technique Bia, SA
Sao Paulo, Brazil Rameistraat, 123
Telephone: (55-11) 826-9376, 867-3702 Distribuidora Cummins Diesel
SAC.I. B-1900
BRITISH VIRGIN ISLANDS Casilia Postal 1230 Overijse, Belgium
Santiago, Chile Telephone: (32-2) 6892811
-See Puerto Rico
Location: CORSICA
. BRUNEI Avda. Providencia 2653;Office 1901 -See France
-See Malaysia Providencia
Telephone: (56-2) 321940,517464/5/6 COSTA RICA
BURKINA - FASO
-See West/Northern Africa Regional CHINA, PEOPLE'S REPUBLIC San Jose
.. Office - Mechelen. '. - •. , _.. -See China Regional Servicios Unidos, SA
Office - Beijing P.O. Box 559
BULGARIA San Jose, Costa Rica
-See Germany Regional Office - Gross COLOMBIA Location: .
Gerau Barranquilla Curridabat
BURMA Cummins de Colombia SA Telephone Office: (506) 53-93-93
Apartado Aereo 5347 Telephone Service Shop:
Kuala Lumpur (Office In Malaysia) Barranquilla, Colombia (506) 26-00-76
Contact: Scott & Location: Calle 30, No. 19 - 21 COTE D'IVOIRE
English (M) Sdn Bhd Telephone: (57-58) 40-11-99, 40-13-46
P.O. Box 10324 Abidjan
50710 Kuala Lumpur Bogota AFI·TECHNIK
West Malaysia Cummins Colombiana Llda. 2 Rue Clement Ader, Zone 4
Location: Apartado Aereo No. 7431 04 B.P. 350
16 Jalan Chan Sow Lin Bogota, DE Colombia Abidjan 04
55200 Kuala Lumpur Location: Cote d'ivoire
West Malaysia Av. Americas X Carrera Telephone: (225) 35-70-96, 35-65-06
Telephone: (60-3) 2211033 42C No. 19·45
Bogota, DE, Colombia CUBA
BURUNDI Telephone: (57-1) 244-5688/5882 Miami (Office in U.S.A.)
Brussels (Office In Belgium) Cummins Southeastern Power, Inc.
Bureau Technique Bia, SA 9900 N.W. 77 Court
Rameistraat, 123 Hialeah Gardens, FL 33016
B-19oo - Overijse, Belgium Telephone: (305) 821-4200
Telephone: (32-2) 6892811
 Distributors - International Section S - Service Assistance
Page S-20

CURACAO, ISLAND OF EGYPT FINLAND

-See Netherlands Antilles Cairo Helsinki
CYPRUS ADAT' Machinery OY
P.O. Box 1572 P.O. Box 56
Nicosia 25, Pyramids Road Location:
Alexander Dimitriou & Sons Ltd. Giza T eollisuuskatu 29
P.O. Box 1932 Cairo, Egypt SF 00511 Helsinki, Finland
Nicosia, Cyprus Telephone: (20-2) 850077, 851829 Telephone: Nat: (9-0) 77221
Telephone: (357-2) 461350 Cairo (Egyptian Marine Markel) Int: (358-0) 77221
CZECHOSLOVAKIA Egypt Diesel (Sales Office) FRANCE
-See European Regional 6 Abdel Rahman Abu Taleb Street
Office - Mechelen P.O. Box 72 Lyon
Saveda Nafisa Cummins Diesel
DENMARK Cairo 11411, Egypt Sales Corporation
Telephone: (20) 3631413 38, rue Ampere Z.1.
Glostrup
EL SALVADOR 69680 Chassieu, France
P. L. Industrimaskiner NS Telephone: (33-7) 8-90·43-05
Post Box 166 San Salvador
2605 Broendby, Denmark
Salvador Machinery
GABON
Location: Company, S.A. de C.V.
Midtager 22 Libreville
P.O. Box 125 SODIM T.P.
Telephone: (45-2) 96-21-61 San Salvador, EI Salvador B.P.506
DJIBOUTI Location: Libreville, Gabon
-See East and Southern Blvd. Ejercito Nacional Location:
Africa Regional Office - Telephone: (503) 711022, 228388 Zone Industrielle d'Oloumi
Harare Telephone: (241) 72-06-85
ENGLAND
DOMINIC.tL .. -!le~J'!nitr,-d_!sjD9!!OITl. ,_ . GAMBIA.,.
Miami (Office In U.S.A.) -See West/Northern Africa
Regional Office - Mechelan
Cummins Southeastern Power, Inc.
99!"(" 1\! V,f 77 rr;, 'IT
Hialeah Gardens, FL 33ut6 -See W. Germany Regional Office -
Telephone: (305) 8214200 • All applications except marine market. Gross-Gerau
DOMINICAN REPUBLIC EQUATORIAL GUINEA GERMANY, WEST
Santo Domingo -See West/Northern Africa Regional Gross-Gerau
Argico C. Por A. Office - Mechelen
Cummins Diesel Deutschland GmbH
P.O. Box 292-2 Feria ETHIOPIA P.O. Box 1134
Santo Domingo D-6080"(3rQs~-Gerau,
. 'Dominican Republic, ZP-6 Addis Ababa W. Germany
Location: AFCOR (Ethiopia) P.L.C. Location: Odenwaldstr. 23 .
-- - -Calle Jose A. Soler P.0:Box'263 - ...
Telephone: (49-6152) 174-0
No.3, ESO. Addis Ababa, Ethiopia
Avenida Lope de Vega TE!~_h-"nEl: 12511_:19_., GHAN~
Telephone-: (809) 562-628 f
FAROE ISLANDS Accra
DUBAI Leyland DAF (Ghana) Ltd.
-See United Arab Emirates
Wellingborough (Office In United P.O. Box 2969
Kingdom) Accra, Ghana
ECUADOR Cummins Diesel Location:
Guayaquil Denington Industrial Estate 39/40 Ring Road South
Wellingborough Industrial Estate
Motores Cummins (MOTCUM) S.A. Northants NN8 20H,
P.O. Box 1062 Telephone: 22-88-06
England
Guayaquil, Ecuador GREECE
Location: FERNANDO PO
Avenida Carlos Julio -See Spain Athens (Ag. loannis Rentis)
Arosemena Km. 4 Cummins Distributor Hellas Ltd.
Telephone: (593-4) 204264, 202600 FIJI 4b Thessalonikis Str.
Quito 182 33 Ag. loannis Rentis
Suva Greece
Rectificadora Botar S.A. Burns Philp (South Seas) Co. Ltd. Telephone: (I) 493-1086
P.O. Box 3344 P.O. Box 355
Ouito, Plchincha, Ecuador Suva, Fiji Workshop:
Telephone: (679) 31-1777 Cummins Distributor Hellas Ltd.
Location: 4 Thessalonikis Str.
Av. 10 de Agosto No. 5980 Telephone: (30-1) 491-5264
Telephone: (593-2) 241-544
GREENLAND
-See Denmark
 Section S - Service Assistance Distributors - Internalion
Page S-~

GRENADA HONDURAS IRAQ

Miami (Office in U.S.A.) Tegucigalpa Genk (Office in Belgium)
Cummins Southeastern Power, Inc. Comercial Laeisz Industrial Construction Consultancy,
9900 N. W. 77 Court Honduras, SA N,V.
Hialeah Gardens, FL 33016 P.O. Box 1022 Essenlaan 5, Bus 4
Telephone: (305) 821·4200 Tegucigalpa, D,C" Honduras 3600 Genk
location: Belgium
GUADELOUPE Zona La Burrera, Telephone: (32-11) 38-48-32
Miami (Office in U.S.A.) Blvd, Toncontin IRELAND
Cummins Southeastern Power, Inc. Frente a Gasolinera Esso.
9900 N.w. 77 Court Telephone: (504) 333570,331148, Welling borough (Office in En-
Hialeah Gardens, FL 33016 335615 gland)
Telephone: (305) 8214200 HONG KONG Cummins Diesel
GUAM Denington Estate
Kowloon Welling borough
Tamuning Cummins Diesel Sales & Service Ltd, Northants NN8 2QH, England
Mid-Pac Far East, Inc. G,P.O, Box 10004
150 E. Harmon Hong Kong, B,C,C. ISRAEL
Industrial Park Road Location: Tel Aviv
Tamuning, Guam 96911 Unison Industrial Centre Israel Engines &
Telephone: (671) 646-5447/1770 15th Floor, Units C & 0 Trailers Co, Ltd,
27-31 Au Pui Wan Street Levinson Brothers Engineers
GUATEMALA Fo Tan, Shatin p, 0, Box 390
Guatemala City Telephone: (852-0) 6065678 Tel Aviv, Israel 61003
Maquinaria y Equipos, SA MUNGARY Location:
P.O. Box 2304 33 Hahashmal Street
Guatemala City, Guatemala Vienna (Office in Austria) Telephone: (972-3) 6226711213/4/5
Location: Cummins-Industriemotoren
... Carretera Amatitlan ,..· ...... GesdnoboH. .. '-'" .,' iTALY ....-- ...,-~ ..
Km 12 zona 12 Bickfordstr. 25 Milan
Telephone: (502-2) 773334/7/9 A-7201 Neudoerfl, Austria
Cummins Diesel italia S.p,A.
GUINEA ICELAND Piazza Locatelli. 8 (gia' Via Basento)
Zona Industriale
-See West/Northern Africa Regional Reykjavik 20098 S, Giuliano
Office - Mechelen Bjorn & Halldor Ltd, Milanese (Milan), 'italy
GUINEA BISSAU P.O, Box 8560 Telephone: (39-2) 988·1235/6/7
Sidumula 19 Rome
-See West/Northern Africa Regional 128 Reykjavik, Iceland
Office - Mechelen Telephone: (354-1) 36030, 36930 O. ME. CO. S,pA
Via Trionfale 12526
GUYANA INI:)I,~, ,,',
'Miami (Office inU,S:A.) Pune
~~:tli~ri.r(3&~r:l76:5r521515 f/5702'··
,Cummrns Southe.astern Power, Inc. "-Gummlns Diesel Sales & IVORY COAST-
9900 N,W, 77 Court Service (India) Ltd, -See Cote d' Ivoire
Hialeah Gardens, FL 33016 35A1112, Erandawana
Telephone: (305) 821-4200_ , --""Pune··-4tt'OS8; India- JAMAICA·
GUYANA, FRENCH Telephone: (91-212) 31234, 31534, Miami (Office in U.S.A.)
31635, 30066,
Miami (Office in U.S.A.) 30166, 30356, Cummins Southeastern Power, Inc,
31706 9900 N,W. 77 Court
Cummins Southeastern Power, Inc, Hialeah Gardens, FL 33016
9900 N.w, 77 Court INDONESIA Telephone: (305) 8214200
Hialeah Gardens, FL 33016
Telephone: (305) 8214200 Jakarta JAPAN
HAITI P,T, Alltrak 1978 Tokyo
P.O, Box 64/KBJL
Miami (Office in U.S.A.) Jakarta Selatan 12330, Indonesia Cummins Diesel (Japan) Ltd.
1·12·10·Shintomi
Cummins Southeastern Power, Inc, Location: Chuo·ku, Tokyo 104
9900 N.W. 77 Court J1. R.S,C, Veteran No.4 Japan
Hialeah Gardens, FL 33016 Bintaro, Rempoa Telephone: (81-3) 555·8511
Telephone: (305) 8214200 Telephone: (62-21) 773377, 773155,
772401 JORDAN
HOLLAND
-See Netherlands IRAN Amman
-See Middle East Regional S,E.T,I, Jordan Limited
Office - Mechelen P,O, Box 8053
Amman, Jordan
Telephone: (962-6) 621867
 Distributors - International Section S - Service Assistance
Page S-22

KENYA LIBERIA MARTINIQUE

Nairobi Monrovia Miami (Office in U_S_A.)
Werro! & Company Limited Electromotor, Inc. Cummins Southeastern Power, Inc.
P.O. Box 41216 P.O. Box 573 9900 N,W. 77 Court
Nairobi, Kenya Monrovia, Liberia Hialeah Gardens, FL 33016
Location: Location 1: Telephone: (305) 821-4200
Lusaka Road U.N. Drive, Bushrod Island, Waitown MAURITANIA
Telephone: (254) 150-20316 Telephone: (231) 22-19-50, 22-29-38
-See West/Northern Africa Regional
KOREA,SOUTH Location 2: Office - Mechelen
Tubman Blvd. & 3rd SI.
Seoul Telephone: (231) 26-12-40, 26-12-41 MAURITIUS
Hwa Chang Trading Co., Ltd. -See East/South Africa Regional
Central P.O. Box No. 216
LIBYA Office - Harare
Seoul, South Korea Valletta (Office in Malta)
Location: Plant and Equipment Ltd.
MEXICO
143-11 Doksan-Dong, Kuro-Ku Regency House Guadalajara
Telephone: (82-2) 854-007112/3/4/5, 254, Republic Street Cummins de Occidente, S.A.
869-14111213 Valletta, Malta Apartado Postal 1-1065
Repair Shop: LIECHTENSTEIN 44890 Guadalajara,
336-6, Won-Doug, Osan-City Jalisco, Mexico
Kyeongi-Province, South Korea -See Switzerland
Location:
Telephone: (82-339) 73-0235/6/7/8,
73-2146
LUXEMBOURG Calz. Gonzalez Gallo No. 2213
Col. EI Rosario
Brussels (Office in Belgium) Telephone: (52-36) 39-3101,39-3153
KUWAIT Cummins Distributor Belgium S.A. Merida
Kuwait 623/629 Chausse de Haecht
Cummins del Sureste, S.A. de C.V.
Gen"ral Transportation & B-1030 Brussels, Belgium
, Teleprrone,'(32'2)'2to'81-10' Av. Aviacion 647,
Equipment Co. Esquina Calle 100, Col. Sambula
(Sales Department)
P.O. Box 1096 MACAU 97000 Merida, Yucatan
Mexico
k\-;eXi(..O "'rtY
Location: MADAGASCAR Cummins de Mexico, S.A.
Shuwaikh Behind -See East and Southern
Canada Dry Factory Norte 35 No. 1015
Africa Regional Office - Col. Industrial Vallejo
Telephone: (965) 4833380/81 Harare 07700 Mexico 14, D.F., Mexico
Kuwait Telephone: (52-5) 567-37-00
General Transportation &
MADEIRA ISLANDS
Equipment Co. -See Portugal Monterrey
(Service Department) , Tecnica Automotriz, S.A.
MALAWI·· ,-_.. _- Ave:tJniwrsidad
East Ahmadi Area
13011 Safat, Kuwait -See East and Southern No. 3637 Nte.
",,,Ispoona-: (965) 3981577 Alries-Regional-Office - Monterrey"Nuevo Leon, Mexico
Harare Telephone: (52-83) 51-41-51, 51-46-56
LAOS
-See'Sooth anel" East
MALAYSIA MOROCCO---- ",- ..-..
Asia Regional Office Kuala Lumpur Casablanca
- Singapore Cummins Diesel Sales & Service Societe Auto-Hall, S.A.
LEBANON Div. of Scott & English 44, Boulevard Lalla Yacout
(M) Sdn. Bhd. Casablanca, Morocco
Beirut P.O. Box 10324 Telephone: (212) 31-84-60, 31-70-52,
S.E.T.I. Charles Keller 50710 Kuala Lumpur, West Malaysia 31-90-56, 31-70-44
S.A.L. Location: MOZAMBIQUE
IMM.B.P. 16-6726 16 Jalan Chan Sow Lin
Beirut, Lebanon 55200 Kuala Lumpur, West Malaysia -See East and Southern
Telephone: (60-3) 2211033 Africa Regional Office -
Location: Harare
Corniche du Fleuve MALI
Telephone: (961-1) 425040/41, 426042
-See West/Northern Africa Regional
NAMIBIA (Southwest Africa)
LESOTHO Office - Mechelen Windhoek
-See EastlSouth Africa Regional Office - Propower, Namibia
Harare
MALTA P.O. Box 3637, Windhoek
Valletta Namibia (Southwest Africa)
Plant & Equipment Ltd. Location: 7 Nasmyth Street
254, Republic Street Telephone: (264-61) 37693
Valletta, Malta
Telephone: (356) 23-26·20, 23-33-43
 Section S • Service Assistance Distributors· Internat
Page

NEPAL NORWAY PHILIPPINES

Pune (Office in India) Oslo Makati (Head Office)
Cummins Diesel Sales & Cummins Diesel Salg & Service NS CDSS, Inc.
Service (India) Ltd. Verkseier Furulunds vei 11 P.O. Box 248
35N1I2, Erandawana Boks 6288 Makati
Pune, • 411 038, India Etterstad 0603, Oslo 6 Philippines
Telephone: 560961718 Norway Location:
Telephone: (47-2) 326110 6264 Estacion Street
NETHERLANDS Makati, Metro Manila
OMAN Telephone: (63-2) 85·81·56,87-45·16
Dordrecht
Cummins Diesel Sales & Ruwi 87·61-84, 87·61·23
Service, b.v. Universal Engineering 87·59-01
Galvanistraat 35 Services L L C. Mikati
3316 GH DORDRECHT P.O. Box 5688 W & L Corporation
Netherlands Ruwi Rm. 704, 7th Floor
Telephone: (31.78) 18·12·00 Sultanate of Oman FNM Lopez Bldg.
Telephone: (968) 797589 Legaspi cor Herrera Sts.
NETHERLANDS ANTILLES Legaspi Village, Makati
PAKISTAN Metro Manila, Philippines
Miami (Office in U.S.A.)
Cummins Southeastern Power, Inc. Karachi Telephone: (63-2) 8163031/2
9900 NW. 77 Court Prime power Diesels Tondo
Hialeah Gardens, FL33016 Sultan Centre· Ground Floor Power Systems, Inc. (Navotas)
Telephone: (305) 821·4200 11 West Wharf Road 1099 P.O. Box 3241
Karachi 2, Pakistan Manila CPO
NEW CALEDONIA Telephone: (92·21) 202733/4 Pmllppines
·Se&south-Pacific Regional
Office· Melbourne PANAMA Location: '
160 H Lopez Blvd., Balut
NEW GUINEA Panama City Tondo. Manila
.... -See-Papua New Guinea TRACT.QMOVIL,SA --Tlllephone: (63-2) 264561121314/5,
Apartado Postal #9532 208709
NICARAGUA Panama City 4, Panama
Telephone: (507) 341111, 341868, POLAND
Managua 341948 -See W. Germany Regional Office -
F. Alf. Pellas & Cia. Gross-Gerau
6a. Calle N.O., PAPUA NEW GUINEA
30 Y 31 Avs. N.O., Zona 5 PORTUGAL
Apartado Postal No. 46
Sydney (Office in Australia)
Cummins Diesel Sales & Service lisbon
Managua, Nicaragua
Telephone: (505-2) 660616 P.O. Box 150 Electro Central
Cabramatta, 2166 Vulcanizadora, Lda.
NIGER New South Wales, Australia P.O. Box 3077
1302 lisbon, Pertufjal,--- ' ,--",.".
··,,·_·-·-Nlamey . . "PARAGUAY
Location:
MECA Diesel . ', -Asuncion·- ' Rua Gonselheiro-'" ...
. B.P. 11279' Martins de Carvalho
Niamey, Niger Automotores y Maquinaria,
S.R.l. Lote 1480
Telephone: (227) 73-41-90 1400 lisboa (Restelo)
-'Yegros y Fulgenclo He Moreno
NIGERIA P.O. Box 1160 Telephone: (351-1) 615361
Asuncion, Paraguay QATAR
Lagos Telephone: (595-21) 93-111115
SCOATRAC Doha
P.M.B.21108 PERU Jaidah Motors & Trading Co,
Ikeja, Lagos lima P.O. Box 150
Nigeria Doha, Qatar (Arabian Gulf)
Comercial Diesel
Location: del Peru SA Telephone: (974) 426161 Sales
Apapa-Oshodi Expressway P.O. Box 14·0234 (974) 810000 Spares &
Isola Industrial Estate, lima, Peru Service
Isola
Telephone: (234·1) 52·16·83, 52-17-74, Location: REUNION
52·46-70,52-18·03, Ave. V.R. Haya -See EasUSouth Africa Regional
52-36-08 de la Torre 2648 Office - Harare
lima 3, Peru
Paris (Office in France) Telephone: (51-14) 32·9990, 31·5761, RIO DE ORO
SCOATRAC 32-7639,32-7518 -See Spain
cia SCOA
9/11 rue Robert de Flers ROMANIA
75740 Paris, Cedex 15 -See W. Germany Regional Office -
France Gross·Gerau
Telephone: (33·1) 40·58-48-48
RUSSIA
NORTHERN IRELAND -See U,S.S.R.
-See United Kingdom
 Distributors - International Section S - Service Assistance
Page S-24

RWANDA SOMALIA SWITZERLAND

Brussels (Office in Belgium) -See East and Southern Zurich
Africa Regional Office -
Bureau Technique Bia, S.A. Harare Robert Aebi AG
Rameistraat, 123 Baumaschinen und
B-1900 - Overijse, Belgium SOUTH AFRICA Spezialfahrzeuge
Telephone: (32-2) 6892811 Uraniastrasse 31133
Isando 8023 Zurich, Switzerland
ST. LUCIA Propower Ply. Ltd. Telephone: (41-1) 211-0970
Miami (Office in U.S.A.) Cnr. Diesel and Industry Roads
P.O. Box 12 SYRIA
Cummins Southeastern Power, Inc. Isando 1600, Transvaal
9900 N.w. 77 Court South Africa
Damascus
Hialeah Gardens, FL 33016 Telephone: (27-11) 974-2751 Puzant Yacoubian & Sons
Telephone: (305) 821-4200 P.O. Box 3617
SOUTHWEST AFRICA Damascus, Syria
ST. MARTIN, ISLAND OF -See Namibia Location:
·See Netherlands Antilles Abou Baker EI Saddik Street
SPAIN Kafar Sou sse Square
ST. VINCENT Telephone: (963-11) 231547/8/9
Madrid
Miami (Office in U.S.A.)
Cummins Southeastern Power, Inc.
Cummins Ventas y TAHITI, ISLAND OF
Servicio S.A. -See French Polynesia
9900 N.w. 77 Court Torrelaguna, 56
Hialeah Gardens, FL 33016 28027 Madrid, Spain TAIWAN
Telephone: (305) 821-4200 Telephone: (34-91) 267-2000/2404
Taipei
SAN MARINO SPANISH GUINEA Cummins Corporation· Taiwan
-See Italy -See Spain 4th Floor
SAO TOME AND PRINCIPE 238, Chungshan N Road
SRI LANKA S.61:.lloO.6
-See West/Notthern Afric'a Regional - <-. - - - - --'.'.'.

Taipei, Taiwan
Office - Mechelen Colombo Telephone: (886-2) 834-9168,
Blackwood Hodge (Ceylon) Ltd. 836·6414/8143
SI.I,UDI ARABIA P_O. R0 Y 27
Dammam T\liDrcl.lUWa, ~n LanKa
General Contracting Company Location: (Service Department) Dar es Salaam
P.O. Box 5111 653, Galle Road
Laxapathiya Falcon Engineering Africa Ltd.
Dammam 31422, Saudi Arabia P.O. Box 5272
Telephone: (966-3) 842-1216 Moratuwa, Sri Lanka
Telephone: (94-1) 505354, 507330 Dar as Salaam
SCOTLAND Tanzania
-See United Kingdom
SUDAN Telephone: 23268
. Khartoum THAlbAND
SENEGAL Bittar Engineering Ltd.
- P,O. Box 1011
Bangkok _
Dakar
Gamhuria Street Diethelm & Company Ltd.
NOSOCO Dept. Matforce 280 New Road
B.P.341 Khartoum, Sudan
-Telephone: (249-11) 70952,71245, G.P.O. Box 14
Dakar, Senegal Bangkok 10100, Thailand
70306
Location: Location:
10 Avenue Faidherbe SURINAM 1696 New Pelchburi Road
Telephone: (221) 22-18-35, 22-30-40 Bangkok 10310
Miami (Office in U.S.A.) Telephone: (66-2) 254-4900
SEYCHELLES Cummins Southeastern Power, Inc.
-See East/Southern Africa Regional Of- 9900 N.W. 77 Court TOGO
fice - Harare Hialeah Gardens, FL 33016
Telephone: (305) 821-4200 Lome
SIERRA LEONE Togomat
-See WestlNorthern Africa Regional SWAZILAND Zone Industrielle CNPPME
Office - Mechelen -See South Africa B.P. 1641
Lome, Togo
SINGAPORE SWEDEN Telephone: (228) 21-23-95
Singapore Stockholm TONGA, ISLAND OF
Applied Diesel Sales & Service SMA Maskin AB
8 Tanjong Penjuru Aggelundavagen 25 Nuku-Alofa
Jurong Industrial Estate S-17562 Jarfalla Burns Philp
Singapore 2260 Sweden (Tonga) Co. Ltd.
Telephone: (65) 261-3555 Telephone: (46·8) 760·0080 P.O. Box 55
Nuku-Alofa, Tonga
SOLOMON ISLANDS Telephone: 21-500
-See South Pacific Regional
Office - Melbourne
 Section S - Service Assistance Distributors - Internatiol
Page S-

TRINIDAD and TOBAGO U.S.S.R. YEMEN,NORTH

Miami (Office in U.S.A.) -See European Regional Sana'a
Office· Mechelen
Cummins Southeastern Power Inc. Zubieri Trading Co.
9900 N.W. 77 Court Contact address in Moscow: P.O. Box 535
Hialeah Gardens, FL 33016 Cummins Engine Co. Sana'a, Yemen Arab Republic
Telephone: (305) 8214200 clo Control Data Corporation
Krasnopresnenskaya Nab. 12, Location:
Zubieri Street
TUNISIA Office 2006
Telephone: (967-2) 79336, 79149
123100 Moscow
Tunis U.S.S.R.
Dalmas et Cie Telephone: (7-095) 253-83-79
YEMEN, SOUTH
2 Rue de Thebes -See Middle East Regional Office -
2014 Megrine Riadh VATICAN CITY Mechelen
Tunisia -See Italy YUGOSLAVIA
Telephone: (216·1) 49·55-99, 49·51·50,
49·57-65, 49-52-29 VENEZUELA Belgrade
Caracas Universzal Commercial
TURKEY Representations
Sudimat
Istanbul Apartado Postal 1322 Auto Put Beograd - Zagrab 22
Hamamcioglu Muesseseleri Caracas 1010 11000 Beograd
Ticaret TAS. Venezuela Yugoslavia
P.K.136 Location: Location:
80222 Sisli Final Avenida San Martin Majke Jevrosime 51
Istanbul, Turkey a 100 Metros de la Loteria de Caracas Telephone: (38-11) 600-333
Location: Urb. la Quebradita ZAIRE
Buyukdere Caddesi, 13/A Telephone: (58-2) 442-6161/2647
P.O. Box 136
Caracas Brussels (Office in Belgium)
80222 Sisli Bureau Technique Bia, S.A.
Istanbul, Turkey Equipos Diesel C.A.
(EQUIDICA) Rameistraat, 123
Telephone: (90-1) 131-3406 .. IH900, Overijse, Belgium ........_ ,
EdiL-insenlca. Calle 11-1
.. -UGANDA La Urbina - Caracas Telephone: (32-2) 689-28-11
-See East and Southern Venezuela Kinshasa
Africa Regional Office - Telephone: (58-2) 241-7043/74 Bureau Technique Bia, S.P.R.L.
Harare Maracaibo B,P, 8843
Equipos y Servicios, CA Kinshasa 1
UNITED ARAB EMIRATES (ESERCA) Zaire
Abu Dhabi Apartado Postal No. 1484 Location:
Darco Machinery Maracaibo, Edo. Zulia, Venezuela Avenue Bobozo
P.O. Box 2263 Telephone: (58-61) 34-4858, 344376 (ex-Route des Poids Lourds)
kinshasa·Limete, Zaire
Abu Dhabi, Valencia Telephones: (243) 77797/8, 78427
United Arab Emirates Dieselval, C.A .
•TeJePhone: (971-2) 562712 - 'AvenidlfLisandro Alvarado, ZAMBIA' ., ... '."--".......
(Umm al Nar office La Florida
. .!!'ld workshop) .... ·Apartado Postal 3147 . Ndola
Valencia - Edo. Carabobo, Venezuela N.E.I. (Zambia) Ltd.
UNITED KINGDOM Telephone: (5841) 50-557/8 P,O. Box 71501
Wellingborough --VieTNAM . Ndola; Zambia
Cummins Diesel Telephone: (260-2) 610729
Denington Estate -See South and East Asia
Regional Office - Singapore ZIMBABWE
Wellingborough
Northants NN8 2QH, England WESTERN SAMOA Harare
Telephone: (44-933) 76231 Cummins Zimbabwe (Pvt) Ltd.
Apia P.O. Box ST363
UPPER VOLTA Burns Philp Southerton
-See Burkina - Taso (South Seas) Co. Ltd. Harare. Zimbabwe
P.O. Box 188 Telephones: (263-4) 67645, 69220
URUGUAY Apia, Western Samoa
Montevideo Telephone: 20-800
Santaro SA
P.O. Box 379
Montevideo
Uruguay
Telephone:(598-2) 93908
Section C - Component Manufacturers
PageC

Section C - Component Manufacturers

Section Contents
Pag
Component Manufacturers' Addresses ............................................................................................................ C·
Air Compressors ....................................................................................................................................... ...... C·
Air Cylinders ..............................................................................................;.................................................. C·
Air Heaters ................. ......................... .................... ............... ...... ........................... ................................ ...... C-
Air Starting Motors ........................................................................................................................................ C-
Alternators .... ... ........ ..... ....... ............ ...... ... .... ... ....... ............ ............. ... ................. ........... ........ ... .... ............ .... C-
Auxiliary Brakes ............................................................................................................................................. C-
Belts ............................................................................................................................................................. C-
Clutches ..............................................................................................................:......................................... Co.
C.oolant Heaters ..... ..... ........... ....... .... ............ ....... ................................................. ............... ..... .... ............ .... Co:
Drive Plates .................................................................................................................................................., C-;
Electric Starting Motors ................. 0............................................................................................................... C-;
Engine Protection Controls ........................ ................. ........................ ............... ....... .......... ....................... .... Co.
Fan Clutches ....... "........................................................................................................................................ Co.
Fans .............................................................................................................................................................. Co.
Filters . .... ............. ...................................... .......................... ...... ........ ................ ... .......... ... .... ......... ............... Co!
Flexplates .. ..... .......... .............. ...... ..... ..... ....... ... ........ ..... ..... ...... ........ .... ............ ...... ......... ........................ ..... Co!
Fuel Warmers ................................................................................................................................................ Co!
Gauges .......................................................................................................................................................... C·!
Governors ..................................................................................................................................................... Co!
Hydraulic and Power Steering Pumps ........................................................................................................... C-E
Oil Heaters .. ... ........... ..... ................................................... ...... ... .................. .................. ............................ ... C-E
Torq ue .Converters .................... :., :.~c.o,,·c. ,','0,.,;:;,-:..,;, :,-'-. c;~. ~;; ............... , ....... .-;',-, .. ;; :.";.~;" ,.-............ : ....... : .......... ;........ C-E
 Component Manufacturers' Addresses Section C - Component Manufacturers
Page C-2

Component Manufacturers' Addresses

NOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins
engines. Suppliers may be contacted directly for any specifications not covered in this manual.

Air Compressors Butec Eleclrics Clutches

Cleveland Road
Bendix Heavy Vehicles Systems Leyland Twin Disc International S.A.
Div. of Allied Automotive PR51XB Chaussee de Namur
901 Cleveland Street England Nivelles
Elyria, OH 44036 Telephone: 0744-21663 Belguim
Telephone: (216) 329·9000 Telephone: 067·224941
C.A.V. Electrical Equipment
Midland-Grau P.O. Box 36 Twin Disc Clutch Co.
Heavy Duty Systems Warple Way RaCine, WI 53403
Heavy Duty Group Headquarters London Telephone: (414) 634·1981
10930 N. Pomona Avenue W37SS
Kansas City, MO 64153 England
Coolant Heaters
Telephone: (816) 891·2470' Telephone: 01·743·3111 Fleetguard, Inc.
Route 8
Air Cylinders AC. Delco Components Group
Cookeville, TN 38501
Civic Offices
Bendix Ltd. Telephone: (615) 526·9551
Central Milton Keynes
Douglas Road MK93EL
Kingswood England
Drive Plates
Bristol Telephone: 0908·66001 Detroit Diesel Allison
England Divisioii-of-General-Mot-ers
Telephone: 0272·671881 Delco·Remy Corporation
P.O. Box 2439 P.O. Box 894
Catching Engineering Anderson, IN 46018
2101 Roberts Drive Indianapolis, IN 46206
Telephone: (317) 646-7838 Telephone: (317) 244·1511
"Bmadview, IL 60153
Telephone: (312) 344·2334 Leece·Nevilie Corp.
1374 E. 51st SI. Electric Starting Motors
Air HeBters CI'?'veiand, OH 44013 p. !t~_" FT~'--f-...-:-... ",

jl,;;.!c:pJ Ivllt:. {2 I 0, 4..:.> 1-O, <tV Cleveland hoad

Fleetguard, Inc.
Route 8 Leyland
Cookeville, TN 38501
Auxiliary Brakes PR51XB
Telephone: (615) 526·9551 The Jacobs Manufacturing Company England
Vehicle Equipment Division Telephone: 0744·21663
Kim Hotstar! Co. 22 East Dudley Town Road
West 917 Broadway C.A.V. Electrical Equipment
Bloomfield, CT 06002 P.O. Box 36
Spokane, WA 9921 0 Telephone: (203) 243·1441
Telephone: (509) 534·6171 WarpleWay
Belts London·
Air Starting Motors' W37SS
DaycoJly,bber UJ~. , England
Ingersoll Rand Sheffield Street
Chorley New Road Telephone: 01-743·3111
Stockport
Horwich A.C. Delco Components Group
Cheshire ,
Bolton SK41RV Civic Offices
Lancashire Central Milton Keynes
England
England Telephone: 061-432·5163 MK93EL
BL66JN England
Telephone: 0204·65544 T.B.A. Ind. Products Telephone: 0908·66001
P.O. Box 77
Ingersoll· Rand Engine Delco·Remy
Wigan
Starting Systems P.O. Box 2439
Lancashire
888 Industrial Drive Anderson, IN 46018
WN24XQ
Elmhurst, IL 60126 Telephone: (3U) 646·7838
England
Telephone: (312) 530·3800 Telephone: 0942·59221 Leece·Nevilie Corp.
StartMaster 1374 E. 51st Street
Dayco Corp.
Air Starting Systems Cleveland, OH 44013
Belt Technical Center
A Division of Sycon Corporation Telephone: (216) 431·0740
P.O. Box 3258
P. O. Box 491 Springfield, MO 65804 Nippondenso Sales, Inc.
Marion, OH 43302 24777 Denso Drive
Telephone: (417) 881·7440
Telephone: (614) 382·5771 P.O. Box 5133
Gates Rubber Company
Alternators Southfield, MI 48086·5133
5610 Crawfordsville Road
Telephone: (313) 350·7500
Rober! Bosch Ltd. Suite 2002
P.O. Box 98 Speedway, IN 46224
Broadwater Park Telephone: (317) 248·0386
North Orbital Road Goodyear Tire and
Denham Rubber Company
Uxbridge 49 South Franklin Road
Middlesex UD9 5HG Indianapolis, IN 46219
England Telephone: (317) 898·4170
Telephone: 0895·833633
 Section C - Component Manufacturers Component Manufacturers' Addresse!
Page C-3

Engine Protection Controls Schwitzer England

1125 Brookside Avenue Telephone: 021-359-4876
Teddington Industrial P.O. Box 80-B
Equipment Indianapolis, IN 46206 Kabi Electrical and Plastics
Windmill Road Telephone: (317) 269-3100 Cranborne Road
Sunburn on Thames Potters Bar
Middlesex Filters Herts
TW167HF EN63JP
England Fleetguard International Corp. England
Telephone: 09327-85500 Cavalry Hill Industrial Park Telephone: 0707-53444
Weedon
The Nason Company Northampton NN7 4TD Datcon Instrument Co.
10388 Enterprise Drive England P.O_ Box 128
Davisburg, MI 48019 Telephone: 0327-41313 East Petersburg, PA 17520
Telephone: (313) 625-5381 Telephone: (717) 569-5713
Fleetguard, Inc.
Robertshaw Controls Co. Route 8 Rochester Gauge of Texas
P.O. Box 400 Cookeville, TN 38501 11637 Denton Drive
Knoxville, TN 37901 Telephone: (615) 526-9551 Dallas, IX 75229
Telephone: (615)546·0550 Telephone: (214) 241-2161
Flight Systems Flexplates
Hempt Road Box 25
Governors
Corrugated Packing and
Mechanicsburg, PA 17055 Sheet Metal Woodward Governors Ltd.
Telephone: (717)697-0333 Hamsterley P.O. Box 15
Newcastle Upon Tyne 663/664 Ajax Avenue
Fan Clutches Telephone: 0207-560-505 Slough
Holset Engineering Co. Ltd. Bucks
Detroit Diesel Allison SL1 4DD
P.O. Box 9 Division of General Motors
Tumbridge England
Corporation Telephone: 0753-26835
Huddersfield P.O. Box 894
England Indianapolis, IN 46206 Woodward Governor Co.
Telephone: 0484-22244 Telephone: (317) 244-1~11. 1000 E. Drake Road
- - --··-Horton Industries, Inc. Fort .Collins, CO 80522
. - DetroiCOiesel Allison Telephone: (303) 482-5811
P.O. Box 9455 Division of General Motors
Minneapolis, MN 55440 36501 Van Born Road Barber Colman Co.
Telephone: (612) 378-6410 Romulus, MI 48174 1300 Rock Street
Rockford Division Telephone: (313) 595-5711 Rockford, IL 61101
Borg-Warner Corporation Telephone: (815) 877-0241
Midwest Mfg. Co.
1200 Windsor Road 30161 Southfield Road United Technologies
P.O. Box 7007 Southfield, MI 48076 Diesel Systems
Rockford, IL 61125-7007 Telephone: (313) 642-5355 1000 Jarie Blvd.
Telephone: (815) 633-7460 Oak Brook, IL 60521
Transportation Components Group Fuel Warmers Telephone: (312) 325-2020
Facet Enterprises, Inc. Fleetguard, Inc. __ J:ly.~r.~ulic and Power
Elmira, NY 14903· ..... -----., Route 8
Telephone: (607) 737-8212 Cookeville, TN 38501 Steering Pumps
...... Telephone: (615j"526-9551 . _. ··-HobournEaton Ltd .
Fans Priory Road
Truflo Ltd. Gauges Strood
Westwood Road AI.S. ... -.- Rochester-
Birmingham Dyflon Industrial Estate Kent
B67JF Ystrad Mynach ME22BD
England Hengoed Telephone: 0634-71773
Telephone: 021-557-4101 Mid Glamorgan Honeywell Control Systems Ltd.
Hayes-Albion CF87XD Honeywell House
1999 Wildwood Avenue England Charles Square
Jackson, MI 49202 Telephone: 0443-812791 Bracknell
Telephone: (517) 782-9421 Grasslin U.K. Ltd. Berks RG12 lEB
Vale Rise Telephone: 0344-424555
Engineering Cooling Systems
201 W. Carmel Drive Tonbridge Sundstrand Hydratec Ltd.
Carmel, IN 46032 Kent Cheney Manor Trading Estate
Telephone: (317) 846-3438 TN91TB Swindon
England Wiltshire
Brookside Telephone: 0732-359888 SN22PZ
McCordsville, IN 46055 England
Telephone: (317) 873-5093 Icknield Instruments Ltd.
Jubilee Road Telephone: 0793-30101
Aerovent Letchworth Sperry Vickers
8777 Purdue Rd. Herts 1401 Crooks Road
Indianapolis, IN 46268 England Troy, MI 48084
Telephone: (317) 872-0030 Telephone: 04626-5551 Telephone: (313) 280-3000
Kysor Superb Tool and Gauge Co.
1100 Wright Street 21 Princip Street
Cadillac, MI 49601 Birmingham
Telephone: (616) 775·4681 B461E
Component Manufacturers' Addresses
Page C-4
Z.F.
P.O. Box 1340
Gralvonsoden Strasse
5-907070
Schwaebisch Gmuend
West Germany
Telephone: 7070-7171-31510
Oil Heaters
Fleetguard, Inc.
Route 8
Cookeville, TN 38501
Teleplione: (615) 526-9551
Kim Hotstart Co.
West 917 Broadway
Spokane, WA 99210
Telephone: (509) 534-6171
Section C - Component Manufacturers
Torque Converters
Twin Disc International S.A.
Chaussee de Namur
Nivelles
Belgium
Telephone: 067-224941
Twin Disc Clutch Co:
Racine, WI 53403
Telephone: (414) 634-1981
Rockford Division
Borg-Warner Corporation
1200 Windsor Road
P.O. Box 7007
Rockford, IL 61125-7007
Telephone: (815) 633-7460
Modine
1500 DeKoven Avenue
Racine, WI 53401
Telephone: (414) 636-1640
Section W Warranty
0

K38 and K50 Page \'Ii

Section W - Warranty
Section Contents
Pas
Generator Drive ................................................................................................................................................ W
International Industrial .................................................................................................................................... W
Marine Propulsion Products International ................................................................................................... Wo'
0

Marine Propulsion Products 0 U. S. and Canada ........................................................................................... Wo'

United States and Canada Industrial .............................................................................................................. W
Generator Drive Section W - Warrant}
Page W-2 K38 and K50

Generator Drive
Engines Warranted
This warranty applies to Engines sold by Cummins Engine Company and delivered to the first user on or afte
June 1, 1993 that are used in generator drive application anywhere in the world where Cummins-approvec.
service is available. These Engines will have the following rating designations:
Standby Power Rating
Engines ofthis rating are applicable for supplying emergency power forthe duration of the utility power outage.
No overload capability is available forthis rating. Under no condition is an Engine allowed to operate in parallel
with the public utility at the Standby Power rating. This rating should be applied where reliable utility powe
is available. A standby rated engine is to be sized for a maximum of an 80 percent average load factor ant
200 hours of operation per year. This includes less than 25 hours per year althe Standby Power rating. Standby
rating should never be applied except in true emergency power outages. Negotiated power outages contracte"
with a utility company are not considered an emergency.
Unlimited Time Running Prime Power Rating
Engines with this rating are available for an unlimited number of hours per year in a variable load application
Variable load is not to exceed a 70 percent average of the Prime Power Rating during any operating perio(
of 250 hours. Total operating time at 100 percent Prime Power shall not exceed 500 hours per year.
A 10 percent overload capability is available for a period of one-hourwithin'a-twelve hoar»eriod-utoperation
Total operating time at the 10 percent overload power shall not exceed 25 hours per year.
limited Time Running Prime Power Rating
Engines of this rating are available for a limited number of hours in a non-variable load application. It is
intended for use in situatkms where power outaqes are contracted, such as in utility power curtailment.
engines Inay Ue OpE.:fatt:o ill pdrcii,ollO i;.~ P;..io,JiiG lIi.il!~y up ·..0 i::>U nvt..H~ P~f yeCi.( at j:.hJVv{.1\ iQVCi;j II~JEk lvexceed
the Prime Power rating.
Limited Time Running Prime Power ratings differ from Unlimited Time Running in that even though the
maximum power outputofthe engines are the same, the Limited Time Running allows the Engine to be parallel
to Public Utility and run at the full Prime Power rating and must never exceed the Prime Power rating.
Continuous/Base Power Rating
.. ~ -.-
Engines with this rating are available for supplying utility power at a constant 100 percent load for an unlimited
number of hours per year. NQ overload capability.·is available for this rating.
Continuous/Base Power ratings differ from Unlimited Time Running Prime Power ratings in that the Continuoust
.... Base.Loadratings are significantly reduced from the Prime Power ratings. Continuous/Base Load ratings have
no load factor or application restrictions.
Coverage
Base Engine Warranty
This warranty covers any failures of the Engine, under normal use and service, which result from a defect
in material or workmanship (Warrantable Failure).
Coverage begins with the sale of the Engine by Cummins and continues for the Duration stated below. The
Duration commences either on the date of delivery of the Engine to the first user, or on the date the Engine-
is first leased, rented or loaned, or when the product has been ran for 50 hours, whichever of the three occurs
first.
Section W • Warranty Generator Dri
K38and K50 Page \/I

Base Engine Warranty

Duration
Months or Hours of Operation
Rating Whichever Occurs First
Standby Power 24 400
Unlimited Prime Power 12 Unlimited
Limited Prime Power 12 750
Continuous/Base Power 12 Unlimited
Extended Major Components Warranty
The Extended Major Components Warranty applies to Engines other than Band C series and cove
Warrantable Failures of the Engine cylinder block, camshaft, crankshaft and connecting rods (Covered Partl
Bushing and bearing failures are not covered. This coverage begins with the expiration of the Base Engir
Warranty and continues for the Duration stated below. The Duration commences either on the date of delive
of the Engine to the first user, or on the date the Engine is first leased, rented or loaned, or when the produ
has been run for 50 hours, whichever of the three occurs first.

Extended Major Components Warranty

Duration
Months or Hours of Operation
Rating Whichever Occurs First
Standby Power 36 600
Unlimited Prime Power 36 10,000
Limited Prime Power 36 2,250
Continuous/Base Power 36 10,000
Consumer Products
This warranty on Consumer Products in the United States is a LIMITED warranty. CUMMINS IS NO
RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. Any implied warranties applicable t
Consumer Products terminate concurrently with the expiration of the express warranties applicable to suc
products. In the United States, some states do not allow the exclusion of incidental or consequential damage,
or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply t
you.
These warranties are made to all Owners in the chain of distribution, and coverage continues to a
subsequent Owners until the end of the periods of coverage.
Cummins Responsibilities
During Base Engine Warranty
Cummins wiil pay for all parts and labor needed to repair the damage to the Engine resulting from
Warrantable Failure.
Cummins will pay for the lubricating oil, antifreeze, filter elements, belts, hoses and other maintenance item
that are not reusable due to a Warrantable Failure.
Cummins will pay reasonable travel expenses for mechanics to and from the Engine site, including mealf
mileage, and lodging when the repair is performed at the site of the failure.
Cummins will pay reasonable labor costs for Engine removal and reinstallation when necessary to make th'
warranty repair.
During the Extended Major Components Warranty
Cummins will pay for the repair or, at its option, replacement of the defective Covered Part and any Covere,
Part damaged by a Warrantable Failure of the defective Covered Part.
Owners Responsibilities
During the Base Engine Warranty
Owner is responsible for the cbst of lubricating oil, antifreeze, filter elements and other maintenance item:
provided during repairs unless such items are not reusable due to the Warrantable Failure. .
Generator Drive Section W - Warranty
Page W·4 K38 and K50

During the Extended Major Components Warranty

Owner is responsible for the cost of all labor needed to repair the Engine, including the labor cost for Engine
removal and reinstallation. When Cummins elects to repair a part instead of replacing it, the Owner is not
responsible for the labor needed to repair the part.
Owner is responsible for the cost of all parts required for the repair except for the defective Covered Part and
any Covered Part damaged by a Warrantable Failure of the defective Covered Part.
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items
replaced during repair of a Warrantable Failure.
During the Base Engine and Extended Major Components Warranties
Owner is responsible for the operation and maintenance of the Engine as specified in the Cummins Operation
and Maintenance Manuals. Owner is also responsible for providing proof that all recommended maintenance
has been performed.
Before the expiration of the applicable warranty, Owner must notify a Cummins distributor, authorized dealer
or other repair location approved by Cummins of any Warrantable Failure and make the Engine available for
repair by such facility. Locations in the United States and Canada are listed in the Cummins United States
and Canada Sales and Service Directory; other locations are listed in the Cummins International Sales and
Service Directory.
Owner is responsible for communication expenses, meals, lodging and similar costs incurreLl as a result of
a Warrantable Failure.
Owner is responsible for non-Engine repairs and for "downtime" expenses, fines, all applicable taxes, all
business costs and other losses resuliing·from a Warrantable Failure.
Owner is responsible for providing sufficient access to and reasonable ability to remove the Engine from the
installation in the event of a Warrantable F~ilure.
Owner is responsible for maintaining an operating Engine hourmeter. If the hourmeter is not operational,
engine usage will be estimated at 400 hours per month.
Limitations
Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or
neglect, including but not limited to: operation without adequate coolant or lubricant; overfueling; overspeed-
..... ing;.Iackof.maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in
or shutdown practices. Cummins is also not responsible for Engine performance problems or failures caused
by incorrect fuel, or by water, dirt or other-contaminants in the fuel.
This warranty does not apply to accessories supplied by Cummins which bear the name of another company.
This category includes, but is not limited to:"alternators,starters; fans, air conditioning compressors, clutches,
filters, transmissions, air cleaners and safety shutdown switches.
Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentation
to show that consumption exceeds Cummins published standards.
Failure of belts and hoses supplied by Cummins are not covered beyond the first 500 hours or one year of
operation, whichever occurs first.
Parts used to repair a Warrantable Failure may be new Cummins parts, Cummins approved rebuilt parts, or
repaired parts. Cummins is not responsible for failures resulting from the use of parts not approved by
Cummins.
A new Cummins or Cummins-approved rebuilt part used to repair a Warrantable Failure assumes the identity
of the part it replaced and is entitled to the remaining coverage hereunder.
Cummins is not responsible for Engine performance problems or failures resulting from:
1. Use or application of the Engine inconsistent with its rating designation as set forth above.
2. Inadequate or incorrect installations deviating from Cummins Generator Drive Installation Guidelines.
CUMMINS IS NOT RESPONSIBLE FOR WEAR OR WEAROUT OF COVERED PARTS.
CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
THE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CUMMINS IN REGARD
TO THESE ENGINES. CUMMINS MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF
Section W • Warranty Generator Dri
K38 and K50 Page W

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to stal
In case of consumer sales, in some countries, the Owner has statutory rights which cannot be affected
limited by the terms of this warranty.
Nothing in this warranty excludes or restricts any contractual rights the owner may have against third partie
United States and Canada Industrial Section W - Warranty
Page W-6 K38 and K50

United States and Canada Industrial

Coverage
PRODUCTS WARRANTED
This warranty applies to new Engines sold by Cummins Engine Company and delivered to the first user on
or after February 1, 1993, that are used in off-highway applications in the United States' and Canada, except
for Engines used in marine, generator drive and certain defense applications, for which different warranty
coverage is provided.
BASE ENGINE WARRANTY
This warranty covers any failures of the Engine, under normal use and service, which results from a defect
in material or workmanship (Warrantable Failure).
Coverage begins with the sale of the Engine by Cummins. Coverage continues for two years or 2,000 hours
of operation, whichever occurs first, from the date of delivery of the Engine to the first user, or from the date
the unit is first leased, rented or loaned, or from the date the Engine reaches 50 hours of operation in
demonstration use, whichever of the three occurs first. If the 2,000 hour limit is exceeded during the first year,
coverage continues until the end of the first year.
EXTENDED MAJOR COMPONENTS WARRANTY
The Extended Major Components Warranty covers Warrantable Failures of the Engine cylinder block, cam-
shaft, crankshaft and connecting rods (Covered Parts).
Bushing and bearin>/ fa.i.I.u~e~_ll.r~_no!~()v~~ed: . . ..... _ .. ___ ....
This coverage begins with the expiration of the Base Engine Warranty and ends after three years or 10,000
hours of operation, from the date of delivery of the Engine to the first user, or from the date the unit is first
'-""~,:,c__--l r-c--"';--' ,..'" 1.--- .-...) -, .. f·---I'---"; '.'~ r:'~-'r:> Fe- .-;:-:.~ ,..,...:),~h,:"_", !::~n f""l.-.,,>· ~. r,,....,·~.•·~_~-; .... ,..., i:-' -'!--'---'-"~"--!--:'-::-"!,!r- tr~ ........
","'--"CO .I'

whichever of the three occurs first.

CONSUMER PRODUCTS
The warranty on Consumer Products in the United States is a LIMITED warranty. CUMMINS IS NOT
RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. Any implied warranties applicable to
Consumer Products in the United States terminate concurrently with the expiration of the express warranties
applicable to such products. In the United States, some states do not allow the exclusion of incidental or
consequential damages,'orlliT,if<iti6ns-6i1 h-owlor,~ran-irTlplleii-warrani}i"fasis;'so the above limitations or
exclusions may not apply to you.
These warranties are made to all Owners in the chain of distribution, and coverage continues to all
subsequent Owners until the end of the periods of coverage •.
Cummins Responsibilities
DURING THE BASE ENGINE WARRANTY
Cummins will pay for ali parts and labor needed to repair the damage to the Engine resulting from a
Warrantable Failure.
Cummins will pay for the lubricating oil, antifreeze, filter elements, belts, hoses and other maintenance items
that are not reusable due to a Warrantable Failure.
Cummins will pay reasonable costs for mechanics to travel to and from the equipment site, including meals,
mileage and lodging, when the repair is performed at the site of the failure.
Cummins will pay reasonable labor costs for Engine removal and reinstallation when necessary to repair a
Warrantable Failure.
DURING THE EXTENDED MAJOR COMPONENTS WARRANTY
Cummins will pay for the repair or, at its option, replacement of the defective Covered Part and any Covered
Part damaged by a Warrantable Failure of the defective Covered part.
 Section W • Warranty United States and Canada Industr
K38 and K50 Page \IIi

Owners Responsibilities
DURING THE BASE ENGINE WARRANTY
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance iten
provided during warranty repairs unless such items are not reusable due to the Warrantable Failure.
DURING THE EXTENDED MAJOR COMPONENTS WARRANTY
Owner is responsible for the cost of all labor needed to repair the Engine, including the labor to remove ar
reinstall the Engine. When Cummins elects to repair a part instead of replacing it, Owner is not responsib
fer the labor needed to repair the part.
Owner is responsible for the cost of all parts required for the repair except for the defective Covered Part ar
any Covered Part damaged by a Warrantable Failure of the defective Covered Part.
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance iterr
replaced during repair of a Warrantable Failure.
DURING THE BASE ENGINE AND EXTENDED MAJOR COMPONENTS WARRANTIES
Owner is responsible for the operation and maintenance of the Engine as specified in Cummins Operation
and Maintenance Manuals. Owner is also responsible for providing proof that all recommended maintenanc
has been performed.
Before the expiration of the applicable warranty, Owner must notify a Cummins distributor, authorized deale
or other repair location approved by Cummins of any Warrantable Failure and make the product available fe
repair by such facility. Locations in the United States and Canada are listed in the Cummins Off Highwa
Authorized Dealer Directory.
---_.' -.---- --_.---, ... - ... - .... - -- ...... ..
.~ ."."

Owner is responsible for communication expenses, meals, lodging and similar costs incurred as a result c
a Warrantable Failure.
'Owner is responsible for non-Engine repairs, "downtime" expenses, cargo damage, fines, all applicable taxes
all business costs and other losses resulting from a Warrantable Failure.
Limitations
Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse 0
neglect, including, but not limited to: operation without adequate coolant or lubricants; overfueling; over
speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up
'.- ... - -' ... " . --rwn-in.or-shutdown·praGtioesj·unautl1orized mooifioatiens oHhe·Engille."Gummins is also nel·respOflSible· fej
failures caused by incorrect fuel or by water, dirt or other contaminants in the fuel.
~ .. " .. -,' . -'"-.-,, - _._-- -
-----~

For power units and fire pumps (package units), this warranty applies to accessories, except for clutches ane
filters, supplied by Cummins which bear the name of another company.
- . --- '_.- -. -- ._._-. --_ .. --_. -~- '--'-~- ....
Except for power units and fire pumps, this warranty does not apply to accessories which bear the name o'
another company. This category includes, but is not limited to: alternators, starters, fans, air conditionin~
compressors, clutches, filters, transmissions, torque converters, steering pumps, and non-Cummins far
drives, engine compression brakes and air compressors.
Cummins Compusave units are covered by a separate warranty.
Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentatior
to show that consumption exceeds Cummins published standards.
Failures of belts supplied by Cummins are not covered beyond the first 500 hours or one year of operation
whichever occurs first.
Parts used to repair a Warrantable Failure may be new Cummins parts, Cummins approved rebuilt parts, 01
repaired parts. Cummins is not responsible for failures resulting from the use of parts not approved b~
Cummins.
A new Cummins or Cummins-approved rebuilt part used to repair a Warrantable Failure assumes the identit~
of the part it replaced and is entitled to the remaining coverage hereunder.
CUMMINS DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS.
CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
United States and Canada Industrial Seclion W - Warranty
Page W-8 K38 and K50

THESE WARRANTIES SET FORTH HEREINAFTER ARE THE SOLE WARRANTIES MADE BY CUMMINS
IN REGARD TO THESE ENGINES. CUMMINS MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED,
OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
This warranty gives you specific legal rights. and you may also have other rights which vary from state to state .
• United States includes American Samoa, the Commonwealth of Northern Mariana Islands, Guam. PUerto
Rico and the U.S. Virgin Islands.
Section W - Warranty International Indus'
K38 andK50 Page

International Industrial
Coverage
PRODUCTS WARRANTED
This warranty applies to new Engines sold by Cummins Engine Company and delivered to the first user
or after February 1, 1993, that are used irroff-highwayapplications anywhere in the world where Cummi
approved service is available, except the United States' and Canada. Different warranty coverage is provic
for Engines used in marine, generator drive and 'certain defense applications.
BASE ENGINE WARRANTY
This warranty covers any failures of the Engine, under normal use and service, which results from a def
in material or workmanship (Warrantable Failure).
Coverage begins with the sale of the Engine by Cummins. Coverage continues for two years or 2,000 hal
of operation, whichever occurs first, from the date of delivery of the Engine to the firsfuser, or from the dl
the unit is first leased, rented or loaned, or from the date the Engine reaches 50 hours of operation
demonstration use, whichever of the three occurs first. If the 2,000 hour limit is exceeded during the first ye
coverage continues until the end of the first year.
EXTENDED MAJOR COMPONENTS WARRANTY
The Extended Major Components Warranty covers Warrantable Failures of the Engine cylinder block, ca
sRaft, crankshaft and connecting rods (Covered Parts).
Bushing and bearing failures are not covered .
.. ~ ..T.hjs co.v.erage.begins.with.the.expiration of the Base Engine.Warranty.and ends after three years or 10,01
hours of operation, from the date of delivery of the Engine to the first user, or from the date the unit is fil
leased, rented or loaned, or from the date the Engine reaches 50 hours of operation in demonstration us
whichever of the three occurs first.
These warranties are made to all Owners in the chain of distribution, and coverage continues to I
subsequent Owners until the end of the periods of coverage.
Cummins Responsibilities
DURING THE BASE ENGINE WARRANTY
.~ .. C.ummjns. ,1O(UI..pay. .IoLalLparts.. and .. Iabor.. neededN!!) ..repair_the.. damage..to the Engine ·resulting . from·
Warrantable Failure.
Cummins will pay for the lubricating oil, aniiireeze, filter elements, belts, hoses and other maintenance iterr
that are not reusable due to a Warrantable Failure.
_. -' - <-~

Cummins will pay reasonable costs for mechanics to travel to and from the equipment site, including meal;
mileage and lodging, when the repair is performed at the site of the failure.
Cummins will pay reasonable labor costs for Engine removal and reinstallation when necessary to repair
Warrantable Failure.
DURING THE EXTENDED MAJOR COMPONENTS WARRANTY
Cummins will pay for the repair or, at its option, replacement of the defective Covered Part and any Covere
Part damaged by a Warrantable Failure of the defective Covered part.
Owners Responsibilities
DURING THE BASE ENGINE WARRANTY
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance item
provided during warranty repairs unless such items are not reusable due to the Warrantable Failure.
DURING THE EXTENDED MAJOR COMPONENTS WARRANTY
Owner is responsible for the cost of all labor needed to repair the Engine, including the labor to remove an
reinstall the Engine. When Cummins elects to repair a part instead of replacing it, Owner is not responsibl
for the labor needed to repair the part.
International Industrial Section W • Warranty
Page W·10 K38 and K50

Owner is responsible for the cost of all parts required for the repair except for the defective Covered Part and
any Covered Part damaged by a Warrantable Failure of the defective Covered Part.
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items
replaced during repair of a Warrantable Failure.
DURING THE BASE ENGINE AND EXTENDED MAJOR COMPONENTS WARRANTIES
Owner is responsible for the operation and maintenance of the Engine as specified in Cummins Operations
and Maintenance Manuals. Owner is also responsible for providing proof that all recommended maintenance
has been performed.
Before the expiration of the applicable warranty, Owner must notify a Cummins distributor, authorized dealer
or other repair location approved by Cummins of any Warrantable Failure and make the product available for
repair by such facility. Locations are listed in the Cummins International Sales and Service Directory.
Owner is responsible for communication expenses, meals, lodging and similar costs incurred as a result of
a Warrantable Failure.
Owner is responsible for non·Engine repairs, "downtime" expenses, cargo damage, fines, all applicable taxes,
all business costs and other losses resulting from a Warrantable Failure.
Limitations
Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or
neglect, including, but not limited to: operation without adequate coolant or lubricants; overfueling; over-
speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up,
run-in or shutdown practices; unauthorized modifications of the Engine. Cummins is also not responsible for
failures caused by incorrect fuel or by water, dirt or other contaminants in the fuel.
With certain exceptions, this warranty does not apply to accessories supplied by Cummins which bear the
r""--:-'P 0~ ~ "',",~~-';:''''- :",r--.,,-,","",:, TJ...,.,.,. 9·-'.o::·":-,L;_~.,..,,,... f..-. • ~·h.in!~ {-t-~C' .,,~..- ... _: ...,.L~, -::l,:,''"''~ ;::.:-;. !:~. 0'_"":"':

1. Accessories, except for clutches and filters, supplied by Cummins as part of a fire pump or power unit
(package units) are covered for the duration of Base Engine Warranty.
2. Starters, alternators, power steering pumps and non-Cummins air compressors supplied by Cummins
on B or C Series Engines in applications other than fire pumps or power units are covered for six months.
Examples of accessories to which this warranty does not apply are: air conditioning compressors, clutches,
air cleaners, fans, filters, transmissions and torque convertors.
Cummins Compusave units are covered by a separate warranty.
Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentation
to show that consumption exceeds Cummins published standards.
Failures of belts supplied by Cummins are not covered beyond the first 500 hours or one year of operation,
whichever occurs first.
Parts used to repair a Warrantable Failure may be new Cummins parts, Cummins approved rebuilt parts, or
repaired parts. Cummins is not responsible for failures resulting from the use of parts not approved by
Cummins.
A new Cummins or Cummins-approved rebuilt part used to repair a Warrantable Failure assumes the identity
of the part it replaced and is entitled to the remaining coverage hereunder.
CUMMINS DOES NOT COVER WEAR OR WEAR OUT OF COVERED PARTS.
CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
THESE WARRANTIES SET FORTH HEREINAFTER ARE THE SOLE WARRANTIES MADE BY CUMMINS
IN REGARD TO THESE ENGINES. CUMMINS MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED,
OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
In case of consumer sales, in some countries, the Owner has statutory rights which cannot be affected or
limited by the terms of this warranty.
Nothing in this warranty excludes or restricts any contractual rights the Owner may have against third parties.
• United States includes American Samoa, the Commonwealth of Northern Mariana Islands, Guam, Puerto
Rico and the U.S. Virgin Islands.
Section W • Warranty Marine Propulsion Products· U. S. and Can;
K38 and K50 Page 11\

Marine Propulsion Products· U. S. and Canada

Products Warranted
These warranties apply to Cummins Engine Company, Inc, hereinafter 'Cummins', Products used in mar
propulsion applications in the United States' and Canada and delivered to the first user on or after Octo
1, 1991. The 'Product' consists()(anew Cummins engine and other acc()mpanying new components. Thl
Products have the following rating designations:
RECREATION/LIGHT DUTY COMMERCIAL RATING
Engines with this rating are intended for powering marine pleasure craft used for personal use only and
powering some marine commercial boats such as gillnetters, bowpickers, skiffs, oil skimmers, and sn
fishing craft.
This power rating is intended for use in variable load applications where full power is limited to one hour (
of every eight hours of operation. Also, reduced power operations must be at or below. 200 RPM of the t
maximum rated RPM. This rating is an ISO 3046 Fuel Stop Power Rating and is for applications that open
less than 750 hours per year.
MEDIUM CONTINUOUS RATING
Engines with this rating are intended for powering commercial boats such as lobster boats, crew boats, pa
fishing boats, charter fishing boats, long range cruisers, harbor and coastal patrol boats, search and resc
boats, fire boats, bay shrimpers, clam boats, crab boats and seine skiffs.
This power rating is intended for continuous use in variable load applications where full power is limited
six hours out of every twelve hours of operation. Also, reduced power operations must be at or below 200 RF
.. of thIEI:t~iI11LJmra\ed. .I3PM . lbIs ift an ISQ 3049. Fuel. Stop Power Rating and is for applications that opera
less than 3000 hours per year.
CONTINUOUS RATING
Engines with this rating are intended for powering commercial boats such as buoy tenders, research vessel
offshore supply boats, fishing trawlers, purse seiners, tugs, tow boats, and car/passenger ferries.
This power rating is intended for continuous use in applications requiring uninterrupted service at full pawl
This rating is the ISO 3046 Standard Power Rating and the SAE J1228 Continuous Crankshaft Power Ratin
Coverage
Base EngineWarranty··
The Base Engine Warranty covers any failures of the Product which result, under normal use and servic,
from defects in material or workmanship (Warrantable Failure). This coverage begins with the sale of th
Product by Cummins and continues for the Duration stated below. The Duration commences either on th
date of deliverialthe F'roifuctloifienrsfuser,·oronThs"da:te tne unit is first leased, rented or loaned, or·whe
the Product has been operated for 50 hours, whichever occurs first.

Duration
Whichever Occurs First
RATING Years Hours
Recreational/Light Duty 1 Unlimited
Commercial·
Personal Use
Recreational/Light Duty 750
Commercial·
Commercial Use
Medium Continuous 1 3000
Continuous 1 Unlimited
Extended Major Components Warranty
The Extended Major Components Warranty applies to Engines other than A, Band C series and cover
Warrantable Failures of the Engine cylinder block, camshafts, crankshaft and connecting rods (Covere
Parts). Bushing and bearing failures are NOT covered. This coverage begins with the expiration of the Bas
Engine Waranty and ends three years or 10,800 hours of operation, whichever occurs first, after the Bas
Engine Warranty start date.
Marine Propulsion Products - U. S. and Canada Section W - Warranty
Page W-12 K38 and K50

Consumer Products
The warranty on Consumer Products in the United States is a LIMITED warranty. CUMMINS IS NOT
RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. Any implied warranties applicable to
Consumer Products terminates concurrently with the expiration of the express warranties applicable to such
products. Some states do not allow the exclusion of incidental or consequential damages, or Iimitationl3 or
how long an implied warranty lasts, so the above limitations· or exclusions may differ in certain areas of the
United States.
These warranties are provided to all Owners until the end of the Duration stated above.
Cummins Responsibilities
During the Base Engine Warranty
Cummins will pay for all parts and labor needed to repair the damage to the Product resulting from a
Warrantable Failure.
Cummins will pay for the lubricating oil, antifreeze, filter elements, belts, hoses, and other maintenance items
that are not reusable due to the Warrantable Failure.
Cummins will pay reasonable labor costs for engine removal and reinstallation when necessary to make the
warranty repair.
When it is necessary for mechanics to make on-site warranty repairs, Cummins will pay up to six hours total
travel expenses for mechanics to and from the repair dock.
During the Extended Major Components Warranty
. Cummins will pay for the repair or, ai its option,replacement of the defective Covered Part and of a'~y Covered
Part damaged by a Warrantable Failure of the defective Covered Part .
.po.. .~. 'V~r~

'v ii'~ i H:;:k ~- "'~~t-i--I';"";;U'''h';'i..;#;;';''

During the Base Engine Warranty

Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items
replaced during warranty repairs unless such items are not reusable due to the Warrantable Failure.
During the Extended Major Components Warranty
Owneris responsible for the'cosrotall-Iabor needed tompainhe Product, including the labor to rel1'fQveatid .... ···
reinstall the Product. When Cummins elects to repair a part instead of replacing it, Owner is not responsible
for the labor needed to repair the iiiuO[ ... " . ""~,, ... .
Owner is responsible for the cost9f "all RCl!1.!lJegulr~dJQr t"~ teJ?!ijLexcept for the defective Covere"clPart..Bnd" ..
any Covered Part darnaged by a Warrantable Failure of the defective Covered Part.
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements, and other maintenance items
replaced during the repair.
Additional Responsibilities During Both Warranties
Owner is responsible for the operation and maintenance olthe Product as specified in the Cummins Operation
and Maintenance Manuals. Owner is also responsible for providing proof that all recommended maintenance
has been performed.
Before the expiration of the applicable warranty, Owner must notify a Cummins Distributor, authorized dealer
or other location approved by Cummins of any Warrantable and make the product available for repair by such
facility. Locations in the United States are listed in the Cummins U.S. and Canada Sales and Service Directory.
In the event of any Product failure, Owner is responsible for the cost of towing the boat to the repair dock and
for all associated docking and harbor charges.
Owner is responsible for communication expenses, meals, lodging and similar costs incurred as a result of
Warrantable Failure.
Owner is responsible for maintaining the engine hourmeter in good working order at all times and to ensure
that the hourmeter accurately reflects the total hours of operation of the product.
Owner is responsible for costs to investigate complaints, unless the problem is caused by a defect in Cummins
material or workmanship.
Section W - Warranty Marine Propulsion Products - U. S. and Canac
K38 and K50 Page W-1

Owner is responsible for non-Engine repairs, "downtime" expenses, cargo damage, fines, all applicab
taxes, all business costs and other losses resulting from a Warrantable Failure.
Limitations
Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse (
neglect, including but not limited to: operation without adequate coolant or lubricants; overfueling; ove
speeding; lack of maintenance of lubricating; cooling or 1ntake systems; improper storage, starting, warm-lIl
run-in, or shutdown practices; unauthorized modifications of the Engine. Cummins is also not responsible f(
failures caused by incorrect fuel, or by water, dirt, or other contaminants in the fuel.
Cummins is also not responsible for failures resulting from:
1. Use or application of the product inconsistent with its rating designation set forth above.
2. Incorrect installation
Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentatio
to show that consumption exceeds Cummins published standards.
Failures of belts and hoses are covered only during the first 90 days of the warranty period.
Parts used to repair a Warrantable Failure may be new Cummins parts, Cummins approved rebuilt parts (
repaired parts. Cummins is not responsible for failures resulting from the use of parts not approved b
Cummins.
A new Cummins-oreummins-approved rebuilt part used to repair a Warrantable Failure assumes the identit
of the part it replaced and is entitled to the remaining coverage hereunder.
CUMMINS DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS.
CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
THE WARRANTIES SET FORTH HEREINAFTER ARE THE SOLE WARRANTIES MADE BY CUMMINS"
REGARD TO THESE PRODUCTS. CUMMINS MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED
OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state
*United States includes American Samoa, Commonwealth of Northern Mariana Islands, Guam, Puerto Rico, and U. S. Virgin Islands.
Marine Propulsion Products - International Section W - Warranty
Page W-14 K38 and K50

Marine Propulsion Products - International

Products Warranted
These warranties apply to Cummins Engine Company, hereinafter 'Cummins', Products used in marine
propulsion applications anywhere in the worlde~c_ept in the United States' and Canada and deliveredto the
first user on or after October 1, 1991. The 'Product' consists of a new Cummins engine and other accom-
panying new Cummins components. These Products have the following rating designations:
RECREATION/LIGHT DUTY COMMERCIAL RATING
Engines with this rating are intended for powering marine pleasure craft used for personal use only and for
powering some marine commercial boats.
This power rating is intended for use in variable load applications where full power is limited to one hour out
of every eight hours of operation. Also, reduced power operations must be at or below 200 RPM of the the
maximum rated RPM. This rating is an ISO 3046 Fuel Stop Power Rating and is for applications that operate
less than 750 hours per year.
MEDIUM CONTINUOUS RATING
This power rating is intended for continuous use in variable load applications where full power is limited to
six hours out of every twelve hours of operation. Also, reduced power operations must be at or below 200 RPM
of the maximum rated RPM. This is an ISO 3046 Fuel Stop Power Rating and is for applications that operate
less than 3000 hours per year.
CONTINUOUS RATING
This'power rating is intended for continuous-use in applications're-qairtng-unlritElrrapted service at full powee"
This rating is the ISO 3046 Standard Power Rating and the SAE J1228 Continuous Crankshaft Power Rating.
r:- t"\'1_~~:~ !""f'.;:'!o
--~-

Base Engine Warranty

The Base Engine Warranty covers any failures of the Product which result, under normal use and service,
from a defect in material or workmanship (Warrantable Failure). This coverage begins with the sale of the
Product by Cummins and continues for the Duration stated below. The Duration commences either on the
date of delivery of the Productto the first user, oron the date the unit is first leased, rented or loaned, or when
the Product has beel]oP.efl;\Jed fp! .~9.D.9urs.whichever qCc!-jrj3 first. .

Duration
Whichever Occurs First
RATING " .._. Years· -'''-'''''' - .--•. ~ .•. -- .. Hours
Recreation/Light Duty 1 Unlimited
Commercial -
Personal Use
Recreation/Light Duty 1 750
Commercial -
Commercial Use
Medium Continuous 1 3000
Continuous 1 Unlimited
Extended Major Components Warranty
The Extended Major Components Warranty applies to Engines other than A, Band C series and covers
Warrantable Failures of the Engine cylinder block, camshafts, crankshaft and connecting rods (Covered
Parts). Bushing and bearing failures are NOT covered. This coverage begins with the expiration of the Base
Engine Warranty and ends three years or 10,800 hours of operation, whichever occurs first, after the Base
Engine Warranty start date.
These warranties are provided to all Owners until the end of the Duration stated above.
 Section W • Warranty Marine Propulsion Products - Internation
K38 and K50 Page W-'

Cummins Responsibilities
During the Base Engine Warranty
Cummins will pay for all parts and labor needed to repair the damage to the Product resulting from
Warrantable Failure.
Cummins will pay for the lubricating oil, antifreeze, filter elements, belts, hoses and other rnainter:1ance iten
that are not reusable due to the Warrantable Failure.·
Cummins will pay reasonable labor costs for engine removal and reinstallation when necessary to make tt
warranty repair.
When it is necessary for mechanics to make on-site warranty repairs, Cummins will pay up to six hours tot:
travel expenses for mechanics to and from the repair dock.
During the Extended Major Components Warranty
Cummins will pay for the repair or, at its option, replacement of the defective Covered Part and of any Covere
Part damaged by a Warrantable Failure of the defective Covered Part.
Owner Responsibilities
During the Base Engine Warranty
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance item
replaced during-warranty-repairs-rmless such items are noi reusable due to the Warrantable Failure.
During the Extended Major Components Warranty
.............. Qwner·is--responsiblefor the' cost of all labor needed to. repair the Product, including the labor cost to remov
and reinstall the Product. When Cummins elects to repair a part instead of replacing it, Owner is IT(
responsible for the labor needed to repair the part.
Owner is responsible for the cost of all parts required for the repair except for the defective Covered Part an
any Covered Part damaged by a Warrantable Failure of the defective Covered Part.
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements, and other maintenance item
replaced during the repair.
Additional Responsibilities During Both Warranties
...... Q\'ille..r..LHe.(ipoJ1lli.QJ\3.f.p.r.!h~..oJm.r.ali9.!1.anc!.ll1.aiQtenance.of tOe Product as specified in the Cummins Operatiol
and Maintenance Manuals. Owner is also responsible for providing proof that all recommended maintenane,
has been performed ..
Before the expiration of the applicable warranty, Owner must notify a Cummins Distributor, authorized deale
" .._..... .. 9f-other repair .location approved byGummi~s of any Warrantable Failure and make the Product available fa
repair by such facility. Locations are listed in the Cummins International Sales and Service Directory.
In the event of any Product failure, Owner is responsible for the cost of towing the boat to the repair dock ani
for all associated docking and harbor charges.
Owner is responsible for communication expenses, meals, lodging and similar costs incurred as a result c
Warrantable Failure.
Owner is responsible for maintaining the engine hourmeter in good working order at all times and to ensun
that the hourmeter accurately reflects the total hours of operation of the product.
Owner is responsible for costs to investigate complaints, unless the problem is caused by a defect in Cummin:
material or workmanship.
Owner is responsible for non-Engine repairs, "downtime" expenses, cargo damage, fines, all applicabl<
taxes, all business costs and other losses resulting from a Warrantable Failure.
Limitations
Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse a
neglect, including, but not limited to: operation without adequate coolant or lubricants; overfueling; over
speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up
run-in, or shutdown practices; unauthorized modifications of the Engine. Cummins is also not responsible fa
,failures caused by incorrect fuel, or by water, dirt, or other contaminants in the fuel.
Marine Propulsion Products· International Section W • Warranty
Page W·16 K38 and K50

Cummins is also not responsible "for failures resulting from:

1. Use or application of the product inconsistent with its rating designation set forth above.
2. Incorrect installation
Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentation
-- to show that consumption exceeds Cummins published standards.
Failures of belts and hoses are covered during the first 90 days of the warranty period.
Parts used to repair a Warrantable Failure may be new Cummins parts, Cummins approved rebuilt parts or
repaired parts. Cummins is not responsible for failures resulting from the use of parts not approved by
Cummins.
A new Cummins or Cummins·approved rebuilt part used to repair a Warrantable Failure assumes the identity
of the part it replaced and is entitled to the remaining coverage hereunder.
CUMMINS DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS.
CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
THE WARRANTIES SET FORTH HEREINAFTER ARE THE SOLE WARRANTIES MADE BY CUMMINS IN
REGARD TO THESE PRODUCTS. CUMMINS MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED,
OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
In case of conSlJmer sales, in SOmB countries, the Owner has statutory rights which Gannot be-affected or
limited by the terms of this warranty.
Nothing in this warrantyel<c:;ludes qr restricts any contractual rights the Ow!wr may have against third parties.
·United States includes American Samoa. Commonwealth of Northern Mariana Islands, Guam, Puerto Rico, and U, S. Virgin Islands.
Section L • Service Literature Section Conter
K3B and K50 Series Page l

Section L - Service Literature

Section Contents
Pa!
Publications Titles ............. ........... ................................. ....... ..................... ..................................... ............ ....... L
Section Contents ................. ........... "......... ...... ............ ....... .................... ........................................ ................... L
Service Literature Ordering Location .............................................................................................................. L
Service Publications Order Form ........ ......................................... """" ...... ................ .................... ................... L
Publications Titles Section L • Service Literature
Page L·2 K38 and K50 Series

Publications Titles
The following publications can be purchased by filling in and mailing the Service Literature Order Form:

Bulletin No, Title of Publication

3810304 KT/KTA38/KTA50 Shop Manual
3810432 K38/K50 Troubleshooting and Repair Manual

3379035 K19/K38/K50 Alternative Repair Manual

3810497 K38 and K50 Engine Series 0 & M Manual

3810458 KTA50,G3, KT A50-G4 and KTT A50-G2 Engine Service Bulletin

3810334 K38 Standard Repair Times

3810335 K50 Standard Repair Times
3810346 Low Power Electric Drive System Troubleshooting Manual

3810386 HT100 Turbocharger Shop Manual

3379231 Electronic Fuel Control Governor
3810349 Industrial Electronic Fuel Control
3379084 Fuel Pump Rebuild Manual
. -- - -- .-- -_ .. _------_.--_ ..

3379071 Injector Rebuild Manual

3810242 Single Cylinder Air Compressor Shoo Menual
3810257 Two Cylinder Air Compressor Shop Manual
3379091 Turbochargers Rebuild Manual
3810243 HC·5A Turbocharger Shop Manual
3387082 K Temperature Sensing Fan Drive Operation and Installation (Recall Book)
Fuel PumpP'r'\typs"GTCililjjration Values
3379068 1970-1975
3379182 1976~1982 ....

3379352 1983-Present
Engine Data Sheets/Performance Curves
3381194 Construction, Mining, Locomotive, and Agriculture
3381174 Generator Drive and Genset
3381237 Automotive
Section L • Service Literature Publications Til
K38 and K50 Series Page

Bulletin No. Title of Publication

Installation Recommendations Bulletin
Construction, Mining, Logging, and Agriculture
3382108 Air Intake System
3382118 Cold Weather Operation
3382643 Compressed Air System
3382171 Cooling System
3382362 Engine Mounting
3382138 Engine Performance
3382109 Exh aust System
3382409 Fuel System
3382113 Lubrication System
3382110 Noise Control
3382014 Power Trains
3382150 Service Accessibility
3382452 Starting & Electrical System
3382135 Torsional Vibration
K38 Parts Catalog
3379518 KT/KTA38 Series
KT-2300, L, P900
KTA-2300, P1200
KTA-2300, L, Pl050
3379570 KT, KTA38-GS/GC
3379578 KT. KTA38 Generator_ Drive
3822102 KTTA38 Construction
3822115 KTTA38 Generator Drive
-3884249 KT, KTA38 Construction
3884295 KTA38-G3 Generator Drive
3884296 KT, KTA38 Marine
K50 Parts Catalog
3379592 KTA50 Generator Drive
3379595 KTASO Marine
3822112 KTT ASO Construction
3884205 KTTA2000 Construction
3884255 KT ASO Construction
3884280 KTASO-G3/G4 Generator Drive
3884281 KTTASO Generator Drive
3884306 KTASO Low Mount Aftercooler, Construction
3884347 KTTASO Side Mount Aftercooler, Construction
3884348 KTASO Power Unit
3884355 KTTA50-G2 Generator Drive
Service Literature Ordering Location Section L • Service Literature
Page L·4 K38 and K50 Series

Service Literature Ordering Location

Region Ordering Location

United States and Canada Cummins Distributors
or
Cummins Engine Co., Inc.
Publishing Services CMC 40924
Box 3005
Columbus, IN 47202·3005
U.K., Europe, Mid-East, Africa, Cummins Engine Co., Ltd.
and Eastern European Countries Royal Oak Way South
Daventry .
Northants, NN11 5NU, England
South and Central America Cummins Americas, Inc.
(excluding Brazil and Mexico) 16085 NW. 52nd Avenue
Hialeah, FL 33104
Brazil and Mexico Cummins Engine Co., Inc.
International Parts Order Dept., MC 40931
Box 3005
Columbus, IN 47202·3005
Far East (excluding Cummins Diesel Sales Corp.
Australia and New Zealand) Literature Center
8 Tanjong Penjuru
.. .. ... . . ............................ Jurong-Indostrial Estate· ..· .... _·
Singapore
Australia and New Zealand Cummins Diesel Austm1ia
iha!vuiiua.n 1"'fI~IL~-.a.1. 1~.v.D-. iv~
Ringwood 3134
Victoria, Australia

Obtain current price information from your local Cummins Distributor or (for U.S.A.) by calling Cummins Toll Free
Number 1-800-DIESELS (1-800-343-7357).
Section L - Service Literature Service Publications Order Fori
K38 and K50 Series Page L·

Service Publications Order Form

Use this form for prompt handling of your literature order from the factory.

Bulfetin litle of U.~.Price

Item Number Publication Quantity Each Amount
$ $
1

2
3

Publications Total

0 Payment Enclosed. Make certified check or Indiana Residents:

money order payable to Cummins Engine Co. Add 5% Sales Tax

0 Please ship C.O.D. (U.S.A. only) Handling & Shipping Chg:

No. Items X $1.50 = I
Prices subject to change without.notJce. 1$
Order Total I
Please Cut on Dotted Une

Service Publications Order Form

Use this form for prompt handling of your literature order from the factory.

Bulletin ." '" ... . "Title Of U.S. Price

Item Number Publication Quantity Each Amount
,- ..
$ $
1

Publications Total

0 Payment Enclosed. Make certified check or Indiana Residents:

money order payable to Cummins Engine Co. Add 5% Sales Tax

0 Please ship C.OD. (U.S.A. only) Handling & Shipping Chg:

No. Items X $1.50 =
Prices subject to change without notice. f$
Order Total
Service Publications Order Form Section L - Service Literature
Page L-S K38 and K50 Series

For factory orders, mail the Service Publications Order Form along with your ship-to address to:
Cummins Engine Co., Inc., Publishing Services (MC 41407)
Box 3005, Columbus, IN 47202-3005.

FROM:

Name:
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City: _ _ _ _ _ _ _ _ _ __ State: Zip Code:
Country: _ _ _ _ _ _ _ _ _ __

SHIP TO: (Name and address where literature is to be shipped)

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Street Address:
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Country:

Please cut on the dotted line

For factory orders, mail the Service Publications Order Form along with your ship-to address to:
Cummins Engine Co., Inc., Publishing Services (MC 41407)
Box 3005, Columbus, IN 47202-3005.

FROM:

Name:
Street Address: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
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Country: _ _ _ _ _ _ _ _ _ __

SHIP TO: (Name and address where literature is to be shipped)

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About the Manual ....................................................................... i-2
Air Cleaner Element - Replacement ........... ,............. "." .... ,...... 4-3
Cartridge l)'pe Element Cleaning ..................... " ................... 4-5
p Coolant Recommendations/Specifications ..................... ;...... V-'
Dual - Heavy Duty Dry-Typ. EI.m.nt - Replac.ment ............... 4·4
Single - Heavy Duty Dry-Type Element - Replacement " ........... 4-3
Air Cleaner Pre-Cleaner and Dust Pan ..... " .. " ......................... 3·4
Checking/Cleaning ................... " ............... ,....... ,... ,............... ,. 3-4
Air Compressor ....................................................................... 7·23
Air Compressor Discharge-Checking ...................................... 7-23
Air Compressor Intake·Checking" ........ " .. ,............ ,................. 7-24
Checking ................................................................................ 7-23
Air Compressor Air CI •• ner Elemen!... ................................... S-tO
Bendix-Westlnghous. Pap.r EI.m.nt - Raplacement.. ............ S-tO
B.ndix-W.stinghouse Spong. Element - Replac.ment ........... S-tO
Cummins lWo-Cylinder Only - Replacement ............................ 5-10
Air Intake Hoses, Pipes, and Clamps ...................................... 4-6
Checking ,......................... ,.......... ,.................. ,......... ,.............. 4-6
Air Intake System ..... ,............................. ,........... ,.................. ,... V-6
Air St.rtlng Motors .................................................................. A-2
Maintenance ' ........................................... " ........ ,.................... A-2
Air System Flow Diagrams ..................................................... 0-16
Exhaust System - Center Mount Aftereooler .. ,.................. " ... , 0-16
Exhaust System· KTTA Engines ....... ", ....... ,.. ,.................. " ... 0-17
Intake System - Center Mount Aftercooler ... ,.......................... 0-16
Intake 8ystem - KlTA Engines ............ ,..................... " ........ ," 0-17
Air Tanks ............................. ,......... ,.......... ,............................... ,' 4-6
Alternator Belt ..... "." .......... ,................ ,........... " ........ ,......... " .. A-3
Adjustment. .. ,.. ,..... ,.......... ,... " .... " ............................................ A-3
Batteries ., ................. " ............................................................. 6-22
Checking, ..... ,." ..... ,." ... ,................................... " .... ,.... ,.......... 6-22
Battery Connections " ......... " ........ " ........................... " ............ A·2
_._ BeRTans.lon "' ... 5-11
« ..... « . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking ............ ,............................. " ........ ,........................... 5-11
Belts ...................................................................................." ... 5-11
Checking ................................................................................ S-lt
Capscrew Markings and Torque Values ............... " ................. V-29
Capscrew Markings and Torque Values - U.S. Customary ...... V-29
Cold st.rt Aids ........................................................................ 6·23
Checking .. " .. ,..... "., ............................... ,.................... ,........... 6-23
Cold Weather Engine Operation ..... " ........... " .... " ..................... 1-5
Cold Weather Starting ..................................................... ,......... 1-4
Using Starting Fluid With Mechanical or Electrical
Metering Equipment .............. ~ ..•............ ,..................... ,............ 1-4
Using Starting Fluid Without Metering Equipment .................... 1-5
Cold We.ther Starting Aids ....................................••.._.. _......... t -6
Electrically Operated Ether Valve ...................... ,........................ 1-7
~th.r Starting Aids ..........................................................., .... , ... 1.. 6 ___
Installation Recommendations ....................... "......................... 1-7
Manually Operated Ether Valve ................................................ 1-7
Component ManufactUrers' Address.es ............... " ... ,,, ...... ,, .... ,. C-2.
Air Compressors ..................................................................... C-2
Air Cylinders ..................................................................... ,..... C-2
Air Heaters ..................... ,..... ;......................... ,.... ,.................. C-2
Air Starting Motors ....... ,...................... "" ................................ C-2
Alt.mators .............................................................................. C-2
Auxiliary Brak.s ....................................................................... C-2
Belts .................................. ,................ ,.", ...... ,., ....... ,....... " ..... C-2
Clutches .. ............................................................................... C-2
Coolant Heaters ., ...... ,............................... ,...... ,............. ,.. ,..... C·2
Drive Plates ............ ................................................................ C-2
Electric Starting Motors ..... ,.......... ,.................... ,........ " ....... ". C-2
Engine Protection Controls ..................................................... C-3
Fan Clutch.s .......................................................................... C·3
Fans ....................................................................................... C-3
Filters ..................................................................................... C-3
Flexplates ..................................... ,......................................... C-3
Fuel Warmers ......... ,...................... ,........ ,.................... ,...... ,... C-3
Gaug.. ....... ............................................................................ C-3
Governors ................ ,...... " .................................. " .............. ,... C-3
Hydraulic and Power Steering Pumps ..................................... C-3
Oil Heaters ..................... " ................ " ....... ,.. ,......................... C-4
Torque Converters ...... ,... ,................... ,................................... C-4
Compressed Air System ......................................... ,................. V-6
Compressor Air System Flow Diagram .............................. ,... 0-16
Cool.nt Filter ............................................................................. 5-8
Replacement ... ,.. ,.. ,......... " ............................. ,......................... 5-6
Inde
Page X.
Coolant Lev.I............................................................................. ~
Checking ... " ..................................... " ........................... ,.......... ~
Coolant Capacity Chart .......................................................... V-:
Cooling System Maintenance ................................................. v-:
Cooling System Soluble Oils .................................................. V·'
Fleetguard® OCA4 Service Filters and Liquid Pre-Charge ....... V-:
Heavy Duty Coolant ............................................................... V·'
Suppl.mental Coolant Additives (SCA's) ........................ ......... V-'
Coolant System Flow Diagrams .............................................. 0-
Cooling System - Top Mounted Aftercooler ................. ... ......... 0-·
Cooling System Flow (LTA) - K2000, KTTASO-G2,
KTASO-G3/G4 ..................................................................•...... D-t
Cooling System Flow (LTA)-K2000, KTTASO-G2, KTASO-G3/G4. 0-1
Cooling System Flow (Outboard Aftercoolers) ......................... 0-1
Thermostat Housing Flow ................................................... ". 0-1
Cooling Fan ........................................................... ,.................. 5-~
Checking .................................................................... ,........... 5-1
Cooling System ........ :.............................................................. 7·1
Cleaning System and Changing Antifreeze ....... ,..................... 7-1
Cooling System Additives .............................................. " ........ 5·
Checking ... ,................................... ,.......................................... 5-
Crankcase Breather Thbe/Hose ................................................. 5-
Checking/Cleaning ................................................................... 5-
Crankshaft End Clearance ....................................................... 6-2
Inspection ............................................................................... 6-2
Definition of Terms, ........................................... ,..... " ................. i-
Blpstick ...................................... " ............................................ A-1'
Calibration .............................................................................. A-ll
Distributors ·Internatlonal ...... ,................ ~ ............................... S-11
Distributors and Branches ~ Australia .................................... 8-1:
Distributors and Branches - Canada ............ " .............. ,......... 8-1:
Distributors and Branches - New Zealand .............................. 8-1'
Distributors and Branches ~ United States. 8-5 S-6 18-7 S-8 , Sot I I
, S-10, S-lt
Division and Regional Offices ...................... ,........................... So,
Drive Belt Tension ................................................................... V-2',
Electrical Syst.m .......... ....... ................................................ ..... V-;
Emergency ................................................................................ S-~
Engine Component Torque Value ........................................... V-2£
Engine Diagram ~ KT38............................................................. E-£
Left Bank View ....... "................................................................ E-~
Rear and Front View ............................ ,.... ,.,........................... E-l'
Right Bank View ...................................................................... E-~
Top Vi.w ................................................................................ E,1(
Engine Diagram - KTA38 Center Mount Aftercooler
. _.(KSO Simllar) .............................. _.............................•..•..........._ E-tl
Rear and Front View.,............................................................ E-1t
Top View ...... ,......................................................................... E-11.
Englrl~ Diagram ~ KTA38 Center Mount Aftercooler
(KTA50 Similar) ....................................................................... E-1~
Left Bank View ..... ,................................................................. E-1~
Right Bank View .................................................................... E-1~
Engine Diagram ~ KTA38 Outboard Aftercoolers
(KTASO Similar) ....................................................................... E-21
L.ft Bank View ......................•................................................ E-2t
Rear and Front View .............................................................. E-2~
Right Bank View .................................................................... E-2C
Top View .... ,........................................................................... E-2~
Engine DI.gr.m - KTTA38 (KTTA50 Similar) .......................... E-17
Left Bank View ................................ ,...................................... E-17
Rear and Front View .................... " ........................................ E-19
Right Bank View .................................................................... E-16
TopVi.w ................................................................................ E-1B
Engine Id.ntlflc.tlon................................................................. E-2
Cummins Engine Nomenclature ............................................... E-2
Engine Oataplate ...... ,.............................................................. E-2
Fuel Pump Dataplate ............................. .................... .............. E·2
Engine Maintenance Schedule ................................................. 2-3
Page References for Maintenance Instructions .......... " ............. 2-4
Engine Monitor System .......................................................,..... 3-5
Checking ............. ,.................................................................... 3~5
Engine Mounting Bolts and Nuts .................................. "........ 6-24
Checking ............................................................. ,.................. 6-24
Engln. Dp.r.tlng R.nge ....................................................... " 1-10
Engine Operation Report .......................................................... 3-2
 Index
Page X-2
Engine Protection System .... "." ............................................. , 7-29
Callbrallon .............................................................................. 7-29
General Information ................................... "" ............... "., ...... 6·23
Engine Shul-down ................................................................... 1-11
Engine Speclflc.llons ............................................................... V-2
Cooling System ............................................. ,." ..................... V-4
Engine Specifications - K38 and K50 ........................... " ...... ,,,. V-3
Fu.1 Syslem ............................................................................. V-3
General Specifications . K38 ...... " ... ,.... "',, ............................... V-2
General Specifications . K50 ................. " ................................. V-2
Lubricating Oil System ............................................. , ......... ,..... V-3
Engln. Welghl ........................................................................... E-7
Exh.ust System ........................................................................ V-6
F.n B.II........ ................... .......................................................... A-4
Adj ustment., ...... '............ ......... ......... ........ ........ ....... ... .............. A~9
Checking ............. .................................................................... A-6
Installation ............................................................................... A·6
Removal .................................................................................. A·4
F.n Hub .................................................................................. 7-17
Inspection ............................................................................. 7-17
Fan Idl.r Plvol Arm.. ............................................................... 6-20
F.n Idl.r Pulley A.sembly ...................................................... 7-18
Installation ........................... ,...... " ... ,....... ,.......... ,... , ... ,...... ,... , 7-18
Rebuild ................................................................................... 7-18
Rebuild/Replacement ............ ,.... ,... ,... ,... ,... ,..................... ,.. ,. 7-18
Fan Idler Pulley Tensloner Adjustment .................................. , 6-20
Engines With Control ADd Spring .. ,......................... ,...... " ...... 6-21
Engines With Shock Absorber ......................................... ,...... 6-21
Engines With Solid Control Rod .. ,........ ,.............. ,................. , 6-20
Front Engine Support ............ ,...................... ,....... ,..... ,............ 6-24
Fuel Control Valve·· Single Bank ............................................ 1-13
Fuel Fllt.r(s) .............................................................................. 5-2
Replacement ...... ,...... ,..... ,." .. ,........... ,.......... ,.......... ,...... "........ 5-2
Fuel Pump ... .. . ........................... 7·2
\,....;c,;::. . .;'..,;-..Jn ............ ,.,."., •••.•• , .......................................... , .........
Checking .............. .................................................................... 7-4
Installation ....................... ,.. ,..................................................... 7-5
Removal ....................... ,........................................................... 7-2
Fuel Recommendatlo ns/Speclflcatlons .............................. ,.;... V-9
Fuel System .............................................................................. D-3
Fuel Systems Flow Diagram ........... ,......................................... D-3
Fuel-Water Separator ........... ,............... ,... ,....... ,........................ 3-2
General Information , ................ ,....... ,................................. ,...... 1-2
Generallnformatlon .......... ;.·.... ;·:-.;--;.·.:.":"... :.':.·... ~.. ::.':.:::.. :.-... :::: .......... 4~2
General Safety Instructions .................... ,......................... , ........ 1-8
Important Safety Notice ......................... " ... ,.............................. i-8
General Speclflcatlol1s .... ,..... " .. ,......................................... , ..... E-3
Air Induction System ............. ,,, .............................................. ,. E-5
Cooling Sy.tem .... c ................................................................... E-5
Electrical System ..................................................................... E-6
Exhausl System....................................................................... E-6
Fuel System ......... ............. ....................................................... E-6'
Lubricating Oil System ......................... " ................ ,................. E·5
He.1 Exchang.r Zinc Plug. (Marin. Only) .............................. 6-21
Checking ................................................................................ 6-21
Hos ....... _.................. _.............................................................. 6-20
Ch.cklng/Replacement........... ................................................ 6-20
How to Use the Manual .............................................................. i·2
lJJustr.llons ................................................................................. 1-7
In/eclo"' ..................................................................................... 7-9
Calibration .............................................................................. 7-12
Checking ................................................................................ 7-11
Inslallation ............ .................................................................. 7-12
Removal ................................ ,.............. ,... ,............................ ,.. 7·9
Inl.t Air R.slrlctlon Indlcalors ................................................. 4-2
Mechanical Indicator . .............................................................. 4-2
Vacuum Indicator ........................ ,.... ,................ ,..................... 4-2
International Industrial ..................... ,..................................... W-5
Literature Survey Form ................... " .......................... ,............. ,.. 2
Lubrlc.tlng 011 and 011 FIII.r..................................................... 5-3
Changlng/Replacemenl............................ ................................ 5-3
lubricating 011 Flow Dlagr.ms ................................................. D-4
lubricating 011 Recommendations/Specifications ................... V·9
Arctic Operation ................. ,,, ....................... ,........................... V-9
Chart Method ......................................................................... V-ll
Fixed Mileage or Hours Oil Change Interval
(All Applications) ................................................................... V-17
New Engine Break·in Oils ....................................................... V-9
Oil Drain Interval Charts ......................................................... V-14
Viscosity Recommendations .................................................... V-9
lubricating 011 Syslem ............................................................. D-4
Front Gear Train ....................................................................... D-6
Full Flow Lubricating Oil Filter Head ........................................ 0-8
Piston COOling, Connecting Rod, Overhead ............................. 0·5
Rear Gear Train, Turbocharger .......................... ,.... ,... ,........ ,.... 0-7
STC Lubricating Oil Flow (Advanced Timing)
Hydromechanically Controlled .................................................. o·g
STe lubricating Oil Flow (Normal Timing) Hydromechanically Con-
lrolled.............................. ................ ....... ................................ D-10
Marine Propulsion Products· InternationaL .......................... W-10
Marine Propulsion Products - U. S. and Canada ... " ............... W-7
Miscellaneous ,......................................................................... B-2
Normal Starting Procedure (Above O°C [32 C1 F]) ....................... 1-2
Oil Level..................................................................................... 3-3
Checking .................................................................................. 3-3
Operating the Engine ................................................................ 1-9
Power Takeoff Application with Variable Speed Controls ...... 1·11
Problem Solving ...................................................................... S-3
Procedures and Techniques ............................ ,........................ T·2
Publlc.tlon. TIUes..................................................................... L-2
Raw Water Strainer .... " ............. " ..................................... " ....... 3·4
Cleaning .................... " ........ ,...... , ............................................. 3-4
Regional Office. - Inlern.llon.I ......................... S-15 , S-16 , S-17
Routine .......... ,........................................................................... 8-2
Section Contents ....................................................................... L-1
Service Literature-Ordering location ........... " ............. " .......... l-4
Service Publications Order Form .............................................. L-5
Starting Procedure - After Extended Shutdown or 011
Chang.e ............. ....................... .............. ... ............... 1-8
,-..;. :;:',<:,.;1'1' \..o1t;:all inc i:..,~'il<:: ........................................................... 1J-L
Slep Timing Control (STC) ...................................................... 1-11
Storage for Engines Out of Service ........................................ A-11
Long Term Storage ................................................................. A-12
Short Term Storage ................................................................ A-11
Symbols ..................................................................................... i-3
Thermostats and Seals ........................................................... 7-19
Replacement .......................................................................... 7-19
Throttle. Travel/Throttle Air Cylinder .............................. :.;._.'_.:: ..:" 7·6
Ch.ckmg .................................................................................. 7-6
Variabl. Speed (VS) Throttle Linkage Adjustment..................... 7-6
-- To the Owner and Operator ....................................................... i-2
Tool Requirements ... ,................................................................ 2-2
Troubleshooting Symptoms ...................................................... T-2
Coolant Temperature Above Normal .............................. T·10. T-1l
Coolant Temperature Below Normal ........................................ T-12
Engine Cranks Bul Will Not Start (No Smoke From Exhausl) .... T-6
Engine Hard to Start or Will Not Start (Exhaust Smoke
Presenl) ................................................................................... T-5
Engine Power Outpul Low .......: .................................... T-14. T-15
Engine Starts But Will Nol Keep Running ................................. T-7
Engine Will Not Crank or Cranks Slowly (Air Starter) ................ T-3
Engine Will Not Cr.nk or Cranks Slowly (Electric Starter) ......... T-4
Engine Will Not Reach Rated Speed When Loaded ............... T-16
Engine Will Not Shut Off .......................................................... T-8
Exhaust Smoke Excessive Under Load .................................. T·13
Lubricating Oil Pressure Low .................................................... T·9
White Smoke or Rough Running At Idle (After Warmup
Period) ................................................................................... T-17
Thrboch.rger........ .................................................................... 7-21
Inspection ..... ., ...... ,.................................. "".""" .................... 7~21
Unll.d St.t.s and C.nada Induslrl.1 ..................................... W-2
Unu.u.1 Engln. Nols................................................................ 3-2
Checking.................................................................................. 3-2
Valves and Injectors .................................................................. 6·2
Generallnform&tion ~ Checking and Adjustment ....................... 6·2
PT (typ. D) Injec10r and Valve Set Procedures ......................... 6-4
STC or HVT OBC Valve and Injector Set Procedure ............... 6-12
Vibration D.mp.r .................................................................... 7-28
Checking ................................................................................ 7-28
Damper Leakage Detection .................................................... 7-29
Thickness Measurement. ........................................................ 7-2B
 Ind
Page)
Water Pump ...............................................................:............. 7·19
Rebuild/Replacement ............................................................. 7·19
NOTES
 MAGNAMAX
GENERATOR

INSTALLATION
OPERATION, AND
MAINTENANCE
MANUAL

1
TABLE OF CONTENTS
TABLE OF CONTENTS ............................................................................................................... 2
SAFETY.......................................................................................................................................... 6
GENERAL INFORMATION ........................................................................................................ 7
MECHANICAL DESIGN ......................................................................................................................7
General ............................................................................................................................................................... 7
Conduit Box ....................................................................................................................................................... 7
MagnaMAX UnirotorTM Construction ............................................................................................................ 7
Adapters and Drive Discs.................................................................................................................................. 7
ELECTRICAL DESIGN........................................................................................................................8
Temperature Rise .............................................................................................................................................. 8
Standby Generator Ratings .............................................................................................................................. 8
Premium Insulation System.............................................................................................................................. 8
Power Factor...................................................................................................................................................... 8
MagnaMAX Voltage Regulator ....................................................................................................................... 8
HOW TO READ A MODEL NUMBER...............................................................................................9
INSTALLATION.......................................................................................................................... 10
RECEIVING YOUR MAGNAMAX GENERATOR ........................................................................10
UNPACKING AND HANDLING .......................................................................................................10
STORAGE .............................................................................................................................................10
PREPARATION FOR USE .................................................................................................................10
GENERATOR MOUNTING - SINGLE BEARING .........................................................................10
GENERATOR MOUNTING-TWO BEARING ................................................................................11
BELT DRIVE ........................................................................................................................................11
ENVIRONMENTAL CONCERNS.....................................................................................................11
ELECTRICAL CONNECTIONS ................................................................................................ 12
GENERATOR LEAD CONNECTIONS ............................................................................................12
12 LEAD HIGH WYE CONNECTION..............................................................................................13
12 LEAD LOW WYE CONNECTION...............................................................................................13
12 LEAD HIGH DELTA CONNECTION .........................................................................................14
12 LEAD LOW DELTA CONNECTION ..........................................................................................14
10 LEAD HIGH WYE CONNECTION..............................................................................................15
10 LEAD LOW WYE CONNECTION...............................................................................................15
6 LEAD WYE CONNECTION ...........................................................................................................16
6 LEAD DELTA CONNECTION .......................................................................................................16
3 LEAD DELTA CONNECTION .......................................................................................................17
4 LEAD WYE CONNECTION ...........................................................................................................17

2
 DOUBLE DELTA -- SINGLE PHASE CONNECTION ..................................................................18
LOW ZIG ZAG -- SINGLE PHASE CONNECTION ......................................................................18
HIGH ZIG ZAG -- SINGLE PHASE CONNECTION .....................................................................18
PARALLELING OPERATIONS................................................................................................. 19
PRIME MOVER...................................................................................................................................19
VOLTAGE REGULATOR..................................................................................................................19
SWITCHGEAR.....................................................................................................................................19
PARALLELING BASICS....................................................................................................................19
REACTIVE LOAD CONTROL..........................................................................................................20
PARALLELING CIRCUITRY ...........................................................................................................20
THYRISTOR OR SCR LOADING .............................................................................................. 21
OPERATION................................................................................................................................ 21
PRE-START INSPECTION ................................................................................................................21
STARTING-UP THE GENERATOR.................................................................................................22
FIELD FLASHING ..............................................................................................................................22
VOLTAGE ADJUSTMENTS..............................................................................................................22
OTHER ADJUSTMENTS ...................................................................................................................23
MAINTENANCE ......................................................................................................................... 23
GENERAL INFORMATION ..............................................................................................................23
AIR INTAKE AND EXHAUST...........................................................................................................23
ELECTRICAL CONNECTIONS, WINDINGS ................................................................................24
LUBRICATION....................................................................................................................................24
DRYING ELECTRICAL INSULATION...........................................................................................26
Space Heaters................................................................................................................................................... 26
Oven.................................................................................................................................................................. 26
Forced Air ........................................................................................................................................................ 26
“Short Circuit” Method .................................................................................................................................. 26
CLEANING METHODS......................................................................................................................27
Solvents............................................................................................................................................................. 27
Cloth and Compressed Air ............................................................................................................................. 27
Brushing and Vacuum Cleaning .................................................................................................................... 27
Shell Blasting.................................................................................................................................................... 27
Steam Cleaning ................................................................................................................................................ 27
DISASSEMBLY ........................................................................................................................... 28
REMOVAL FROM PRIME MOVER................................................................................................28
CONDUIT BOX REMOVAL ..............................................................................................................29
EXCITER STATOR (FIELD) REMOVAL .......................................................................................30
EXCITER ARMATURE (ROTOR) REMOVAL..............................................................................30

3
 PMG STATOR REMOVAL................................................................................................................31
MAIN ROTOR REMOVAL................................................................................................................33
FRONT END BRACKET REMOVAL...............................................................................................35
EXCITER INSPECTION ............................................................................................................ 35
EXCITER STATOR.............................................................................................................................35
EXCITER (ROTOR) ARMATURE....................................................................................................36
PMG INSPECTION..................................................................................................................... 37
PMG STATOR......................................................................................................................................37
PMG ROTOR .......................................................................................................................................37
MAIN ROTOR INSPECTION .................................................................................................... 37
BEARING..............................................................................................................................................37
FAN ........................................................................................................................................................38
MAIN ROTOR CORE AND WINDINGS..........................................................................................40
DRIVE DISCS (SINGLE BEARING GENERATORS ONLY) .......................................................40
FRONT (EXCITER) END BRACKET INSPECTION .............................................................. 40
DRIVE END BRACKET OR SAE ADAPTER INSPECTION.................................................. 41
MAIN STATOR INSPECTION................................................................................................... 42
FRONT END BRACKET INSTALLATION .............................................................................. 42
MAIN ROTOR INSTALLATION ............................................................................................... 42
PMG INSTALLATION................................................................................................................ 45
EXCITER INSTALLATION ....................................................................................................... 46
CONDUIT BOX INSTALLATION ............................................................................................. 47
ASSEMBLY TO PRIME MOVER .............................................................................................. 48
TROUBLESHOOTING ............................................................................................................... 50
INTRODUCTION.................................................................................................................................50
SYMPTOM: ..........................................................................................................................................51
NO VOLTAGE OR RESIDUAL VOLTAGE............................................................................................... 51
LOW VOLTAGE - .......................................................................................................................................... 52
NO LOAD ........................................................................................................................................................ 52
LOW VOLTAGE WHEN LOAD IS APPLIED ........................................................................................... 53
HIGH VOLTAGE ........................................................................................................................................... 53
VOLTAGE IS FLUCTUATING .................................................................................................................... 54
OPERATES SATISFACTORILY WHEN COLD, BUT SHUTS DOWN WHEN WARM ..................... 54
BUILDS VOLTAGE FROM STARTUP,THEN GOES TO LOW (RESIDUAL) VOLTAGE................ 54
EQUIPMENT RUNS NORMALLY ON UTILITY POWER, BUT WILL NOT RUN ON GENERATOR
SET ................................................................................................................................................................... 54
GENERATOR TESTING ............................................................................................................ 55
VISUAL INSPECTION........................................................................................................................55

4
 CONSTANT EXCITATION (12V BATTERY) TEST.......................................................55
MEASURING VOLTAGES.................................................................................................................56
TYPICAL VOLTAGE MEASUREMENTS ......................................................................................57
Generator Output Voltage ................................................................................................................................. 57
Regulator Output (Exciter Stator Input) ............................................................................................................ 57
Regulator Sensing.............................................................................................................................................. 57
Regulator Input Volts (PMG Output Volts) ..................................................................................................... 57
CURRENT (AMP) MEASUREMENTS.............................................................................................57
MEASURING RESISTANCE .............................................................................................................58
Main Stator ...................................................................................................................................................... 58
Exciter Rotor.................................................................................................................................................... 58
TESTING DIODES (RECTIFIERS) ..................................................................................................58
INSULATION RESISTANCE - MAIN STATOR.............................................................................59
GENERATOR TESTING ....................................................................................................................59
INSULATION RESISTANCE - MAIN ROTOR...............................................................................59
INSULATION RESISTANCE - EXCITER STATOR......................................................................60
INSULATION RESISTANCE - EXCITER ROTOR........................................................................60
MAIN ROTOR FIELD AC IMPEDANCE TEST .............................................................................60
MAGNAMAX EXPLODED VIEW ....................................................................................................61
STANDARD TOOLS.................................................................................................................... 64
SPECIAL TOOLS ................................................................................................................................65
MISCELLANEOUS .............................................................................................................................66
PREPARATION FOR SHIPMENT OR EXTENDED STORAGE........................................... 66
SHIPPING INSTRUCTIONS..............................................................................................................66
STORAGE INSTRUCTIONS..............................................................................................................66
TABLE 12-1: MAGNA MAX - FASTENER AND TORQUE SPECIFICATIONS ................. 68
TABLE 12-2: CAPSCREW TORQUE VALUES........................................................................ 69
TABLE 12-3:EXCITATION DATA -60 HZ - 1800 RPM .......................................................... 70
TABLE 12-3:EXCITATION DATA -50 HZ - 1500 RPM .......................................................... 71
TABLE 12-5: RESISTANCE VALUES - MAIN WINDINGS................................................... 72
TABLE 12-6: RESISTANCE VALUES - EXCITER WINDINGS............................................ 73

5
SAFETY
PLEASE REMEMBER SAFETY FIRST. If you are not sure of the instructions or procedures,
seek qualified help before continuing.

This service manual emphasizes the safety precautions necessary during the installation, opera-
tion, and maintenance of your generator.

Each section has caution and warning messages. These messages are for your safety and the
safety of the equipment involved. If any of the cautions or warnings is not readily understood,
seek clarification from qualified personnel before proceeding.

Before any service work is done, disconnect all power sources and, where appropriate, lock out
all controls, to prevent an unexpected start-up of the generator set. Proper grounding in
compliance with local and national electrical codes must be provided. These safety precautions
are necessary to prevent potential serious personal injury, or even death.

The hazards associated with lifting or moving the generator are pointed out in the installation and
service sections; incorrect lifting or moving can result in personal injury or property damage.

Whenever the generator is running, always assume and proceed as if voltage is present. Residual
voltage is present at the generator leads and at the regulator panel connections, even with the
regulator fuse removed. Caution must be observed, or serious personal injury or death can result.

Whenever solvents, cleaners, or flammable liquids are present, adequate ventilation must be
available to avoid fire, explosion, and health hazards. Always avoid breathing vapors and use
suitable personal protective equipment to prevent personal injuries. (Such as eyes, face, and hand
protection.)

This manual is not intended to be a substitute for properly trained personnel. Only qualified
trained people should attempt repairs. The cautions and warnings point out known conditions
that are potentially dangerous. Each installation will create its own set of circumstances. No
manual can cover every possible situation.

When in doubt, ask. Don’t be embarrassed to ask, “dumb questions”. Remember that dumb
questions are much easier to handle than dumb mistakes.

6
GENERAL INFORMATION
MECHANICAL DESIGN
General
All single and two bearing units are
manufactured with cast iron end brackets
and adapters, and fabricated steel frames.
Flexible drive discs and SAE adapters are
machined to SAE standards. Pre-lubricated,
regreasable, shielded ball bearings are used
on MagnaMAX generators. Standard units
are fully guarded. Drip proof shields are
available as an option.
Conduit Box
The large end mounted conduit box is con-
structed of formed sheet steel that will allow
the addition of top mounted control
packages. Refer to Marathon Electric for top
mounted controls of more than 240 lbs.
There is ample room inside the conduit box
for a circuit breaker (through 800A Frame)
and other options. The conduit box cover
properly directs outside ventilating air
through the generator.
7
MagnaMAX UnirotorTM Construction
An aluminum die cast rotor core affords
high mechanical integrity and low vibration
at operating speeds. Amortisseur winding
and coil supports are die cast as an integral
part of the rotor. Laminations are 4-pole,
one piece laminations which are shrunk fit
and keyed to the shaft. No dovetails, cross
bolts or other pole to shaft connecting
devices are used. The cast unidirectional
aluminum alloy ventilation fan provides
even air distribution to maximize cooling
and generator efficiency.
Adapters and Drive Discs
All single bearing units are available with
several adapters and drive disc
arrangements. These can be shipped to order
or can be changed in the field with standard
shop tools. When changing flexible drive
discs, spacers are used between the discs and
the cast iron hub to maintain SAE standard
dimensions.
ELECTRICAL DESIGN
All standard products have 2/3 pitch main
windings to eliminate the third harmonic.
This serves to lower operating temperatures,
give lower harmonic content and better
waveform, and extend the overall life of the
generator.
Temperature Rise
All ratings and frame sizes are based on
NEMA and CSA Class F and Class H
temperature rises on both the rotor and stator
windings. Ratings for British, German,
French, IEC and all popular marine agencies
are available.
Standby Generator Ratings
Synchronous generators used on emergency
backup power can have temperature rises up
to 25°C above those for continuous
operation. (NEMA MG1 -22.40 and MG 1-
22.84).
Premium Insulation System
All MagnaMAX generators are built with
Class H or better insulation materials. All
standard generators are suitable for
continuous duty at Class F temperature rise
and will give equivalent or better winding
life expectancy to generators supplied with
Class A or B insulation systems operated
within their temperature limits. The
varnishes and epoxies used are synthetic,
non-hygroscopic. Multiple dip and bake
8
cycles of the main winding, plus a final coat
of epoxy, make the standard winding
moisture and fungus resistant. The
MagnaMAX rotor is wet wound with
thermo-setting epoxy applied between each
layer, plus a final coating of epoxy for
moisture and abrasion resistance.
MagnaMAX generators can be ordered with
an epoxy vacuum pressure impregnated
insulation system as an option. (MagnaMAX
generators with form wound coils include
VPI as standard.)
Power Factor
All standard generators are designed for
operation at rated kVA at 0.8 lagging power
factor but can be operated at rated kVA over
the 0.8 to 1 .0 power factor range.
MagnaMAX Voltage Regulator
The standard voltage regulator is a fully
encapsulated, static types with a solid state
build up circuit. Standard features include 3-
phase RMS sensing, paralleling, adjustable
under frequency protection, and over
excitation protection. The regulator meets
EMI suppression to Mil Std-461B, part 9.
An optional feature is adjustable armature
current limiting. See the regulator manual
for more information.
HOW TO READ A MODEL NUMBER
It is extremely important to properly identify the machine when requesting parts or service.
Always have the generator model number and serial number when requesting information from
the factory. We cannot help you without this information.
An Example For MagnaMAX Generators 431RSL 2000 AA - 000

Character Category Description

1st three characters Frame Number
4th character Winding type R—Random Wound
F—Form Wound
5th character Bearing arrangement S—1 Bearing
D—2 Bearings
6th character Voltage range L—Up to 480 volts
M—1000-6600 volts
S—600 volts
7th Character Product style 4-Magna
8th Character Type
9th & 10th Character Wk2 Code
11th Character Modification A-Z assigned sequentially
12th Character Mounting Arrangement A-Y see chart figurer 2-1
13th, 14th & 15th characters Modification numbers For internal use only

Arrangement Adapter SAE Size Drive Disc SAE Size

A 3 11-1/2
B 2 11-1/2
C 4 8
D 3 10
E 1 11-1/2
F 1 14
G 4 7-1/2
H 1 Delco
J 1/2 14
K 2 10
L 1/2 Delco
M 0 14
N 2 Small Delco
0 None None
P 0 18
S 0 Delco
U 00 18
V 4 6-1/2
W 00 21
Y 4 10
Figure 2-1

9
INSTALLATION
RECEIVING YOUR MAGNAMAX
GENERATOR
Upon receipt of the generator, it is
recommended that it be carefully examined
for possible damage incurred in shipment.
The generator was given to the Freight
Company in good condition, and they are
responsible for the product from our dock to
yours. Any damage should be noted on the
freight bill before accepting the shipment.
Claims for damages must be promptly filed
with the Freight Company.
UNPACKING AND HANDLING
Read all instruction cards carefully. When
lifting, attach an overhead crane to the
lifting lugs on the generator frame. Apply
lifting forces in a vertical direction.
WARNING
THE LIFTING LUGS ON THE
GENERATOR ARE DESIGNED TO
SUPPORT THE GENERATOR ONLY.
DO NOT LIFT COMPLETE
GENERATOR SET BY MEANS OF
LIFTING DEVICES ON THE
GENERATOR. PERSONAL INJURY
OR QUIPMENT DAMAGE MAY
OCCUR.
STORAGE
In the event that the generator is not to be
installed on the prime mover immediately, it
is recommended that it be stored in a clean,
dry area that is not subject to rapid changes
10
in temperature and humidity. See
"STORAGE INSTRUCTIONS" for more
information.
PREPARATION FOR USE
Although the generator is carefully
inspected and tested in operation before it
leaves the factory, it is recommended the
unit be thoroughly inspected. The insulation
on the wire should be inspected and all bolts
should be checked for tightness.
Remove all shipping tapes, bags, blocks, and
skids, which are used to prevent vibration
and rotor movement during shipment. Dry,
low-pressure compressed air of
approximately 30 PSI (206 KPA) can be
used to blow out the interior of the
generator. In the case of two bearing
machines, it is possible to turn the rotor by
hand to make sure that it rotates smoothly
without binding.
If the machine has been in storage for a year
or longer it is recommended that it be
lubricated according to the lubrication
instructions and chart supplied in the
maintenance section.
If the machine has been exposed to damp,
humid conditions the insulation resistance
should be checked. Refer to the instructions
supplied in this manual.
GENERATOR MOUNTING - SINGLE
BEARING
Single bearing generators are provided with
an SAE flywheel adapter and flexible drive
discs. Very close tolerances are maintained
in the manufacture of the generator so that
the alignment procedure is extremely
simple. A coupling hub of nodular iron is
shrunk on the shaft and special steel drive
discs are bolted to the hub. Holes are
provided in the periphery of the coupling
disc, which correspond to tapped holes in
the flywheel. The outside diameter of the
discs fits in a rabbet in the flywheel so that
concentricity is assured in all cases.
WARNING
DO NOT APPLY ANY FORCE TO THE
GENERATOR FAN FOR LIFITNG OR
FOR ROTATING THE GENERATOR
ROTOR. DISREGARDING THESE
INSTRUCTIONS MAY CAUSE
PERSONAL INJURY OR EQUIPMENT
DAMAGE
CAUTION: GRADE 8 CAPSCREWS
OR GRADE 8 PLACE-BOLTS AND
HARDENED WASHERS ARE REC-
OMMENDED TO MOUNT THE DRIVE
DISCS TO THE FLYWHEEL.DO NOT
USE HELICAL OR OTHER LOCKING
DEVICES UNLESS APPROVED.
The SAE adapter and the flywheel housing
are designed to match each other with no
further alignment necessary. Shims may be
necessary under the feet of the generator to
insure a solid mounting. See THE SERVICE
SECTION for more information.
GENERATOR MOUNTING-TWO
BEARING
Two bearing generators are provided with a
shaft extension and key way. For direct-
coupled sets the assembler furnishes a flexible
coupling which is installed between the driver
and the generator shaft.
IMPORTANT: Aligning the two machines
as accurately as possible will reduce
vibration, increase-bearing life, and insures
11
minimum coupling wear. It may be
necessary to shim the generator feet for
proper support and alignment. Consult the
coupling manufacturer’s instructions for
alignment specifications and procedures.
BELT DRIVE
Please refer to Marathon Electric for
applications involving belt driven
installations.
ENVIRONMENTAL CONCERNS
Dirt, moisture, heat, and vibration are
enemies of electrical equipment. The
ambient temperature should not exceed the
value shown on the generator nameplate.
Generators for outdoor application should be
protected from the elements by housings
with proper openings for ventilation. This
protection should be designed to prevent the
direct contact of wind driven rain, snow, or
dust with the generator. In moist or humid
areas, such as the Tropics and marine serv-
ice, additional protection is recommended.
Although the standard windings are
humidity and moisture resistant, special
insulation and accessories such as space
heaters can increase generator life. In
extremely dirty and dusty environments a
means of providing filtered cooling air to the
generator is recommended. Please refer to
Marathon Electric for filter kits that are
available.
ELECTRICAL CONNECTIONS

The generator conduit box construction

allows conduit to enter the top, bottom, or
either side of the box. A hole-saw or any
suitable tool can be used to provide for the
conduit entrance. Protect the interior of the
generator from shavings when drilling or
sawing. An approved connector must be
used in conjunction with the conduit.
To minimize the transmission of vibration, it
is essential that flexible conduit be used for
all electrical cable entrance to the generator.
Refer to the connection diagram supplied
with the generator and / or the proper
diagrams shown in this section. Install all
intercomponent and external wiring in
accordance with the regulations of the
national and local electrical codes. Clean all
contact surfaces to assure good electrical
bonding with the generator lugs or bus bars.
Use heavy-duty terminal lugs or good
quality clamps for making all connections.
Insulate all connections in accordance with
national and local regulations.
GENERATOR LEAD CONNECTIONS
The electrical connections in the conduit box
should be made in accordance with the
appropriate “connection diagram.” Use the
diagram appropriate for the number of leads
and voltage range required. Refer to the
drawings supplied with the generator and to
drawings in this section.
The final voltage setting is established
within the selected range by an adjustment
of the voltage regulator.
CAUTION: SOME GENERATORS
HAVE MULTIPLE, IDENTICALLY
MARKED, CABLES FOR EACH LEAD.
CONNECT ALL IDENTICALLY
MARKED CABLES TOGETHER
WHEN MAKING CONNECTIONS.

Be sure the generator frame is grounded to

all the other components of the system with
a ground wire in accordance with national
and local regulations.

12
12 LEAD HIGH WYE CONNECTION
L1
V O LTA G E
T1
L -L L -N

60 48 0 27 7
T4 HZ 46 0 26 6
44 0 25 4
T7 41 6 24 0
L-L 38 0 21 9

T10
T12 50 416 240
HZ 400 231
T9 T11 380 219
T6
T8
T3 T5
L3 T2 L2
L-N

12 LEAD LOW WYE CONNECTION

L1
V O LTA G E
T7 T1 L -L L -N

60 2 40 1 39
L-L HZ 2 30 1 33
T10 T4 2 20 1 27
T12 T5 2 08 1 20
1 90 1 10
T9 T2
T6 T11 50 208 120
L3 T3 T8 L2 HZ 200 115
190 110
L-N

13
12 LEAD HIGH DELTA CONNECTION
L1
T12 V O LTA G E
T1
` L -L L -N
T9 T4
T6 T7 L-L
60 240 120
HZ 277 139
T3 T10

L3 L2 50 200 100
T11 T8 T5 T2 HZ 220 110
240 220
L-N

12 LEAD LOW DELTA CONNECTION

L1
V O LTA G E
L -L L -N
T12 T1

T6 T7 L-L 60 120 N A
HZ 139
T9 T4
T3 T10
50 100 N A
T11 T8 HZ 120
L3 L2
T5 T2
L-L

14
10 LEAD HIGH WYE CONNECTION
L1
V O LTA G E
T1
L -L L -N

60 48 0 27 7
T4 HZ 46 0 26 6
44 0 25 4
T7 41 6 24 0
L-L 38 0 21 9

T0
50 416 240
HZ 400 231
T9 380 219
T6
T8
T3 T5
L3 T2 L2
L-N

10 LEAD LOW WYE CONNECTION

L1 V O LTA G E
L -L L -N
T7 T1
60 2 4 0 1 3 9
HZ 2 3 0 1 3 3
L-L 2 2 0 1 2 7
T0 T4 2 0 8 1 2 0
T5 1 9 0 1 1 0

T9 T2 50 208 120
T6 HZ 200 115
190 110
L3 T3 T8 L2
L-N

15
6 LEAD WYE CONNECTION
L1
V O LTA G E
T1 L -L L -N
13800 7967
6600 3811
4160 2400
60 H Z 3300 1905
T7 240 139
L-L 230 1363
T 220 127
T 4 203 120
6
190 110

T3 T5
50 H Z 11000 6351
6600 3811
L3 T2 L2 3300 1905
L-N 208 120
200 115
190 110

6 LEAD DELTA CONNECTION

L1
T6 V O LTA G E
T1
L -L L -N

L-L 60 7967 NA
HZ 2400

T3 T4
50 6351 NA
L3 L2 HZ 1905
T5 T2

16
3 LEAD DELTA CONNECTION
L1 V O LTA G E
L -L L -N
T1
60 H Z 7967 NA
2402 NA
L-L
50 H Z 6351 NA
1905 NA
T3 T2

L3 L2

4 LEAD WYE CONNECTION

L VO LTAG E
1
T1
L-L L-N
13800 7967
6600 3811
60 HZ 4160 2400
3300 1905
2400 1386
L-L 600 346
480 277
T 380 219
0
11000 6351
50 HZ 6600 3811
T3 3300 1905
416 240
L3 T2 400 231
L2 380 219
L-N

17
DOUBLE DELTA -- SINGLE PHASE CONNECTION

T3 T11
T5 T9 V O LTA G E
L -L L -N
T6 T8 60 24 0 12 0
T2 T12
H Z 22 0 11 0
L2 T1 T4 T7 T10 L1
20 0 10 0
50 22 0 11 0
L-N L-N
H Z 20 0 10 0
L-L

LOW ZIG ZAG -- SINGLE PHASE CONNECTION

T6 T2 V O LTA G E
T12 T8 L -L L -N
T3
T5
60 24 0 12 0
T9 T11 H Z 22 0 11 0
T4 T1 20 0 10 0
L2 T10 T7 L1 50 22 0 11 0
L-N L-N H Z 20 0 10 0
L-L

HIGH ZIG ZAG -- SINGLE PHASE CONNECTION

T12 T1

T4
V O LTA G E
T9
H Z L -L L -N
T6 T7 6 0 4 8 0 2 4 0
4 4 0 2 2 0
T3 T10 T11 T8 T5 T2
5 0 4 4 0 2 2 0
L2 L1 4 0 0 2 0 0
L-N L-N
L-L

18
PARALLELING OPERATIONS
MagnaMAX generators come standard with
amortisseur windings die cast as an integral
part of the rotor. This exclusive, UnirotorTM,
construction makes all MagnaMAX
generators suitable for paralleling operations
when the proper control equipment is added.
Paralleling with other generator sets and / or
with the utility power grid offers a number of
advantages. Multiple unit installations
increase power capacity; they can be added or
removed from the line depending on the load
requirements; they can be better maintained
and repaired (since single source breakdown
would mean total loss of power), and they
often provide more reliable, efficient, and
economical operation.
Successful parallel operation means that the
generators deliver power to the external
system without delivering power to each
other, or accepting power from the load bus or
power grid. Additional equipment is necessary
to insure safe and successful operation.
PRIME MOVER
The prime mover provides the speed and
torque which will be necessary to keep the
machines in synchronized operation. A
governor controls the prime mover's speed.
The governor will directly control the watt or
kW output and frequency of the unit. The
governor must have special paralleling
provisions to permit parallel operation with
the other machines.
VOLTAGE REGULATOR
The voltage regulator controls the generator
output voltage and the reactive power supplied
by the generator. When two or more ac
19
generators operate in parallel, the voltage regulator
must have paralleling provisions (either internally
or external to the regulator) to control the reactive
or VAR load while it is in parallel operation. A
separate paralleling current transformer is required
to sense the reactive current and signal the voltage
regulator. This additional paralleling circuitry is
absolutely necessary to control the reactive current
flowing between the generator sets.
SWITCHGEAR
There are additional relays and breaker controls
that are necessary to insure safe, trouble free
operation of paralleled units. Reverse power relays
monitor the direction of power flow to insure that
the generator is delivering power, not accepting it.
These power relays control breakers, which are a
means of connecting and disconnecting the gen-
erator from the load. The total system can include
over-voltage, over-current protection, under fre-
quency protection, power factor correction provi-
sion and a variety of associated control equipment
from manual switchgear to microprocessors. The
amount of control gear and level of sophistication
will be determined by the needs and requirements
of the particular application.
PARALLELING BASICS
The following points are basic criteria which must
be met before two units can be paralleled. THIS IS
NOT MEANT TO BE SPECIFIC
INSTRUCTIONS FOR PARALLELING
OPERATION.
1. Additional paralleling circuitry
A. Voltage regulator-paralleling provisions
B. Paralleling current transformer(s)
C. Paralleling provisions on governor controls
D. Switchgear
2. The voltage and frequency must be the same for
all sets with voltages in phase.
3. The voltage regulation characteristics of the
individual generators should be similar.
4. The generators must have the same phase
rotation.
5.The driving engines should have the same
speed regulation characteristics and the
governors should be adjusted to give the same
speed regulation.
Before operating generator sets in parallel,
each set should be checked by starting,
operating, and adjusting the sets as individual
units before attempting paralleling.
REACTIVE LOAD CONTROL
When two identical generators are operating
together in parallel and an unbalance occurs in
field excitation, circulating currents begin to
flow between the generators. This current will
appear as a lagging power factor or inductive
load to the highly excited generator, and as a
leading power factor or capacitive load to the
generator with the lower field current. This is
known as the reactive circulating current and
there are two methods of controlling it in
parallel operation:
1. Reactive droop compensation. (Formerly
known as parallel droop compensation.)
The bus voltage droops, or decreases, as the
reactive lagging power factor load is
increased.
2. Reactive differential compensation.
(Formerly known as cross current
compensation.) The reactive differential
compensation circuit allows parallel
generators to share reactive loads with no
decrease or droop in generator voltage.
20
The circuit must meet the following criteria:
A. All paralleling current transformers for all the
generators being paralleled must be included in
the secondary interconnection loop.
B. When different size generators are paralleled
all paralleling current transformers must have the
same proportional ratios that give approximately
the same secondary current.
C. Voltage regulator paralleling circuitry must be
the same.
D. Current transformer secondary and the
generator lines must be isolated electrically.
E. It is also desirable to have an auxiliary contact
on the main generator breaker to short the parallel
CT secondary when that breaker is open (not
connected to the load bus).
Because of the above criteria, reactive differential
compensation cannot be used when paralleling
with the utility power grid. There is no limit,
however, in the number of generators that can be
included in this type of circuit.
PARALLELING CIRCUITRY
Because of the number of variables involved in
paralleling generator sets, every installation will
have its own circuitry and methods or procedure
of bringing paralleled units on line. There are
numerous ways of connecting paralleled units and
an almost unlimited variety of applications and
associated equipment.
When parallel operation is desired, it is important
that the control manufacturer, the generator manu-
facturer, and the systems engineer work together
to insure the proper selection of all components.
Please refer to Marathon Electric for application
assistance.
THYRISTOR OR SCR LOADING
Solid state electronic control devices which
utilize thyristors or SCR firing circuits (such
as variable frequency induction motor
controls, precision motor speed controls, no-
break powered battery chargers, etc.) can
introduce high frequency harmonics which
adversely affect or destroy the normal
waveform of the generator. This creates
additional heat in the generator stator and
rotor, and can cause overheating. These
devices can and do present problems to non-
utility power generating equipment or any
limited power bus system. The problems that
can occur are not limited to the generator
itself, but can effect the solid state control
device, the equipment it controls, other
associated loads, monitoring devices or a
number of combinations over the entire
system.
MagnaMAX generators can supply power to
thyristor or SCR loads when properly applied.
The standard voltage regulator is PMG
powered and senses 3 phase RMS voltages for
maximum stability against severely distorted
waveforms. SCR type applications such as
cranes, shovels, etc., require special
consideration of the generator insulation
system due to greater dielectric stress and
severe environmental conditions. It is impor-
tant that the control manufacturer, the
generator manufacturer, and the systems
engineer work together to insure the proper
selection of all components. Please refer to
Marathon Electric for application assistance.
OPERATION
PRE-START INSPECTION
Before operating the generator for the first
time, the following checks are recommended.
21
1. A visual inspection should be made to check
for any loose parts, connections, or foreign
materials
2. Check for clearance in the generator and exciter
air gap. Be sure the generator set turns over freely.
Bar the generator over by hand at least 2
revolutions to be sure there is no interference.
WARNING
DO NOT APPLY ANY FORCE TO THE
GENERATOR FAN FOR LIFITNG OR
FOR ROTATING THE GENERATOR
ROTOR. DISREGARDING THESE
INSTRUCTIONS MAY CAUSE
PERSONAL INJURY OR EQUIPMENT
DAMAGE
3. Check all wiring against the proper connection
diagrams and make sure all connections are
properly insulated. Support and tie leads to keep
them from being damaged by rotating parts or by
chafing on sharp corners.
4. Be sure the equipment is properly grounded.
5. Inspect for any remaining packing materials and
remove any loose debris, building materials, rags,
etc. that could be drawn into the generator.
6. Check fasteners for tightness.
7. Check to be sure no tools or other hardware
have been left inside or near the machine.
8. Install and check to be sure all covers and
guards are in place and secure.
WARNING
RESIDUAL VOLTAGE IS PRESENT AT THE
GENERATOR LEADS AND AT THE
REULATOR PANEL CONNECTIONS EVEN
WITH THE REGULATOR FUSE REMOVED.
CAUTION MUST BE OBSERVED OR
SERIOUS PERSONAL INJURY OR DEATH
CAN RESULT.
STARTING-UP THE GENERATOR
The following procedure should be followed
for starting-up the generator for the first time:
1.The generator output must be disconnected
from the load. Be certain that the main circuit
breaker is open.
FIELD FLASHING
The standard MagnaMAX generator is supplied
with a PMG (permanent magnet generator). It will
never require field flashing. In rare cases where a
special generator may be furnished without a
PMG, refer to the factory for more detailed
information. Include the complete generator model
and serial number.

2.Disable the voltage regulator by removing VOLTAGE ADJUSTMENTS

the fuse. The voltage regulator controls the generator output
voltage. There is a cover to access the control
WARNING panel on the side of the generator conduit box
DO NOT OVERSPEED THE
GENERATOR. EXCESSIVE
CENTRIFUGAL FORCES COULD
DAMAGE THE ROTATING FIELDS. BE
PREPARED FOR AN EMERGENCY
SHUTDOWN.

3.Follow the manufacturer's instructions and

start the prime mover. Check the speed and
adjust to the RPM shown on the generator
nameplate.
Figure 4-1
4. Replace the regulator fuse and adjust the
voltage to the required. Check all line to line
and line to neutral voltages to be sure they are
correct and balanced. If the voltages are not
correct shut down immediately and recheck all
connections.

5. Close the main circuit breaker and apply the

load.

6. Monitor the generator output current to

verify it is at or below nameplate amps.

7. Adjust engine speed at full load to 1800
rpm for 60 hertz, 1500 rpm for 50 hertz.
(Refer to prime mover/governor instruction
manuals.)
8. Before stopping the engine, remove the load
by tripping the main circuit breaker.
Figure 4-2 Regulator Access
Refer to the regulator manual for detailed
information. In cases where special or remote
mounted regulators are used, refer to instructions
supplied by the generator set assembler and to the
voltage regulator manual.

22
OTHER ADJUSTMENTS
Depending upon application, adjustments to
other protective and control gear may be
required. Refer to instructions provided by the
by the supplier of the generator set.
ments or in areas where extreme temperature
changes cause condensation (dew) to form inside
the generator. Space heaters, air filters, and
premium insulation systems, such as our VPI
process, should be considered in difficult
environments.

The standard MagnaMAX voltage regulator
also has many protective and control circuits.
It is imperative that the set up instructions for
any regulator supplied be followed.
Accumulations of dust and dirt not only contribute
to insulation breakdown, but they can also increase
temperature by restricting the dissipation of heat.
Materials such as talc, lint, rock dust, or cement
dust may obstruct the ventilation.

MAINTENANCE The most harmful types of foreign materials include

carbon black, metallic dust and similar substances
GENERAL INFORMATION that not only impede ventilation, but also form a
conductive film over the insulation, increasing the
possibility of insulation failure.
Dirt, heat, moisture, and vibration are
common enemies of a generator. Keeping the
Machines operating in dirty places should be
generator clean and dry, maintaining proper
disassembled and cleaned periodically.
alignment of the generator and its prime
mover, and preventing overloads will result in AIR INTAKE AND EXHAUST
efficient operation and long life.
Check the area around the air intake and exhaust
Generators that are outdoors should be
openings to be sure they are unobstructed.
protected from the elements by suitable
houses or enclosures.

Dirt and dust will conduct electricity between

points of different electrical potential.
Moisture will aggravate the problem further.
Insulation system failure can result if
corrective action is not taken. Measuring
insulation resistance can test the condition of
the insulation system.
(See Generator Testing.).

Insulation resistance should be checked when .

putting the generator into service after it has Figure 5-1
been in storage and anytime contamination by
moisture and dirt is suspected. Normally,
moisture buildup is not a problem while the
generator is running, since heat produced
internally will tend to keep it dry but can
collect in the generator when it is shut down.
The problem will be worse in humid environ-

23
ELECTRICAL CONNECTIONS,
WINDINGS

Inspect for loose or contaminated connections
Check wires for cracked or frayed insulation.
Tighten connections and replace defective or
oil soaked insulation.
If inspection shows that varnish coatings on
the windings have deteriorated, they should be
coated with insulating varnish. Please refer to
Marathon Electric for insulation system
requirements.
LUBRICATION
All generators are lubricated before leaving
the factory and are ready for operation. As a
general rule, bearings should be re-lubricated
annually or at the indicated intervals in table
5-3, whichever occur first.
Unusually severe operating conditions, such
as high ambient or dusty environments,
require more frequent lubrication (every six
months or one half the table intervals,
whichever occurs first).
To add or renew grease, proceed as follows:
1. Stop unit.
2. Wipe the grease plugs and surrounding parts to
insure they are clean.
3. Remove both the fill and drain plugs.
See figure 5-2
4. Insert 1/8” N.P.T. grease fitting in fill pipe.
5. Free the drain holes of any hard grease, using a
piece of wire it necessary.
6. Using a low-pressure grease gun, add grease
according to the amounts in table 5-3.
7. Start unit with drain plug removed - fill pipe
may be open or closed. Allow unit to run 15
minutes to allow excess grease to drain.
8. Stop unit, wipe off any drained grease, and
replace filler and drain plugs.

Use Chevron SRI or equivalent anti-friction

type high quality, grease with a lubrication
temperature’ range of -22° to +350° F (-30°
to +175° C)

Figure 5-2

24
The amount of grease added is very important! Only enough grease should be added to replace
the grease used by the bearing.
CAUTION: TOO MUCH GREASE CAN BE AS HARMFUL AS INSUFFICIENT
GREASE. USE THE PROPER AMOUNT.
Type Frame Bearing Intervals ---
Size Size Amount of Grease Max. hours or
annually
Ounces Cubic Inches Teaspoons 60 Hz 50 Hz
Single 431,432, 433 314 1.2 2.1 7.0 6500 8400
Bearing 571,572,
Units 573, 574 316 1.5 2.6 8.3 5600 7200

741, 742, 322 2.4 4.2 14.0 3000 4500

743,744
431,432 318 1.7 3.0 9.9 4600 6200
Double 571, 572,
Bearing 573, 574 318 1.7 3.0 9.9 4600 6200
Units
741, 742, 322 2.4 4.2 14.0 3000 4500
743, 744

TABLE 5-3

During an overhaul, the grease reservoir should b thoroughly cleaned and new grease added. The
reservoir should be 1/3 to 1/2 filled with new grease

25

DRYING ELECTRICAL INSULATION
Electrical components must be dried before
placing in operation if tests indicate that the
insulation resistance is below a safe value.
(See Generator testing for test procedure.)
Machines that have been idle for sometime
in unheated and damp locations, may have
absorbed moisture. Sudden changes in
temperature can cause condensation or the
generator may have become wet by
accident. Windings should be dried out
thoroughly before being put into service.
The following are recommended drying
methods.
Space Heaters
Electric space heaters can be installed inside
of the generator. When energized (from a
power source other than the generator) they
will heat and dry the inside of the generator.
If an alternate source of electricity is not
available, enclose the generator with a
covering and insert heating units to raise the
temperature 15-18 degrees F (8-10 degrees
C) above the temperature outside of the
enclosure. Leave a hole at the top of the
enclosure to permit the escape of moisture.
Oven
Place the machine in an oven and bake it at a
temperature not to exceed 194 F (90°C). The
voltage regulator and any electronic
component accessories must be removed
from the generator when using this method.
Forced Air
A portable forced air heater can be used by
directing heat into the air intake (conduit
box) and running the generator with no load
and without excitation (this can be
accomplished by removing the regulator
fuse). Heat at point of entry should not
exceed 150° F (66° C).
26
“Short Circuit” Method
Using this method can dry out the generator
quickly and thoroughly.
WARNING:
BE SURE THAT ALL OF THE
FOLLOWING STEPS ARE
PERFORMED AND ALL PRECAU-
TIONS TAKEN AS PERSONAL
INJURY OR SERIOUS DAMAGE TO
THE GENERATOR COULD RESULT.
1. Disconnect exciter leads Fl and F2 from
the regulator.
2. Connect a battery or other dc power source
approximately 20-35 volts to the exciter lead
Fl and F2. An adjustable voltage source
desirable, however, a rheostat (rated
approximately 2 amps) in series with the dc
power source will work.
3. Short circuit the generator output lead
wires to each other (L1 to L2 to L3). If using
jumpers, be sure they are large enough to
carry full load amps.
4. Start the generator and measure the
current through the output leads with a clip-
on ammeter.
5. Adjust the voltage source to produce
approximately 80% of the rated ac
nameplate current but in no case exceed
nameplate amps. If a adjustable source is not
available and current is excessive, use a
lower dc source voltage or larger resistor in
series with the source.
Running time will be determined by the
amount of moisture present in the machine.
Insulation resistance checks should be taken
every one to four hours until a fairly
constant value obtained. (See section -
Generator testing for instructions on
measuring insulation resistance.)

6. After the generator is dry and the
insulation resistance is brought up to
specification remove the short circuit from
the line lead disconnect the dc source and
reconnect the F and F2 leads at the
regulator. Be sure all connections are tight
and correct before attempting to run the
generator.
CLEANING METHODS
When electrical components get dirty, the
insulation must be cleaned. There are a
number of acceptable methods for cleaning
the generator, each of which will necessitate
disassembly of the unit. The kind of dirt, and
when the unit must be returned to service
will determine the method of cleaning.
Drying after cleaning is necessary.
Whenever the generator is disassembled, the
windings should be given a thorough
inspection and the insulation cleaned, if
necessary. The inspection should include the
connection of the windings, insulation, and
varnish coverage. Check the winding ties
and coil supports. Look for any signs of coil
movement or looseness and repair as
required.
An electric motor repair shop in your area
can normally assist with the proper cleaning
of the generator windings. They may also be
experienced in special problems (such as
seacoast, marine, oilrig, mining, etc.) that
may be peculiar to a certain area.
Solvents
A solvent is usually required to remove
accumulated soil containing oil or grease.
Only petroleum distillates should be used for
cleaning electrical components. Petroleum
solvents of the safety type with a flash point
greater than 100° F (38° C) are
recommended.
27
CAUTION: A SOLVENT THAT DOES NOT
ATTACK EPOXY OR POLYESTER
BASED MATERIALS SHOULD BE USED.
Apply the solvent with a soft brush or rag.
Be careful not to damage the magnet wire or
insulation on the windings.
Dry components thoroughly with moisture-
free, low pressure compressed air.
Cloth and Compressed Air
Cleaning with a dry cloth may be
satisfactory when components are small, the
surfaces are accessible and only dry dirt is
removed. Blowing dirt out with compressed
air is usually effective particularly when the
dirt has collected in places that cannot be
reached with a cloth. Use clean dry air at 30
PSI (206 KPA).
Brushing and Vacuum Cleaning
Dry dust and dirt may be removed by
brushing with bristle brushes followed by
vacuum cleaning. Do not use wire brushes.
Vacuum cleaning is an effective and
desirable method of removing dry and loose
dirt.
Shell Blasting
Air blasting with ground nut shells may be
satisfactory for removal of hard dirt deposits
from insulation. Use mild abrasives such as
12-20 mesh ground walnut shells.
Steam Cleaning
If the generator is completely disassembled,
including bearings and electronic
components, steam cleaning of the major
parts and windings is very effective.
However, the machine must be thoroughly
dried in an oven to remove all moisture
before the generator can be put back into
service.
DISASSEMBLY 2. Disconnect all external wiring from the
generator leads inside the conduit box.
REMOVAL FROM PRIME MOVER
3. Remove all conduits or ducting from the
conduit box.
BE SURE ALL POWER IS OFF
BEFORE SERVICING. FAILURE TO
4. Attach a suitable hoist to the generator
FOLLOW ALL SAFETY
lifting
INSTRUCTIONS CAN RESULT IN
SERIOUS INJURY OR DEATH.
5. For single bearing generators, remove the
bolts mounting the screen assembly to the
NOTE:Before disconnecting any electrical
SAE adapter and remove the screen.
wiring, be sure it is marked and can be
(Figure 6-3.)
identified for reinstallation. Re-label as
required.

1. Remove conduit box covers

(Figure 6-1 and 6-2)

.
Figure 6-3

(NOTE: Do not remove the drip cover from

the screen assembly if so equipped )Remove
the cap screws attaching the drive discs to
the flywheel and remove the cap screws
Figure 6-1 attaching the SAE adapter to the flywheel
housing.
For two-bearing generators, disconnect the
coupling or sheave and belts between the
generator and prime mover. (Follow the
coupling manufacturer’s instructions for
direct connection.)

WARNING
DO NOT APPLY ANY FORCE TO THE
GENERATOR FAN FOR LIFTING OR
ROTATING THE GENERATOR
Figure 6-2

28
CONDUIT BOX REMOVAL

1. Note the location and markings (re-mark 3. Remove bolts holding conduit box in
as required) and remove connections from place. (Figure 6-6.)
voltage regulator (Figure 6-4), capacitor
(Figure 6-5), and any other conduit box
mounted controls.

Figure 6-6

Figure 6-4 4. Remove conduit box. (Figure 6-7).

Figure 6-5

2. On generators equipped with bus bars, Figure 6-7

mark all connections and disassemble main
stator (power) leads from the generator side
of the bus bars.

29
EXCITER STATOR (FIELD) REMOVAL EXCITER ARMATURE (ROTOR)
REMOVAL
1. Disconnect Fl and F2 leads from the
corresponding Fl and F2 terminals on the 1. Note markings and disconnect the main
regulator. rotor leads coming out of the lead hole of
the aluminum standoff plate from the
2. Remove all cable ties so the Fl and F2 rectifier aluminum angle. (Figure 6-10.)
leads can be removed with the exciter stator.
Remove the four cap screws and Belleville
washers holding the exciter stator in place.
(Figure 6-8.)

Figure 6-10

2. Remove the cap screw and Belleville

washer that holds the exciter (rotor)
armature to t generator shaft. (Figure 6-11.)

Figure 6-8

Remove the exciter stator. Using a lifting

strap or fixture. (Figure 6-9.)

Figure 6-11

3.Use a six inch, 3/4-16NF, cap screw for a

puller (See section 9.) The hole that the
mounting bolt goes through is threaded.
Screw the pull bolt into the hole and it will
push against the end of the shaft. (Figure 6-
12.)
Figure 6-9

30
 PMG STATOR REMOVAL

1. Remove exciter armature. (Follow

instructions found earlier in this section.)

2. Remove the PMG output leads from the

capacitor (Figure 6-14) and loosen all cable
ties so the leads can be removed with the
PMG stator.

Figure 6-12

Carefully feed the main rotor leads through

the hole as the exciter armature is removed.
(Figure 6-13.)

Figure 6-14

3. Note the position of the PMG stator leads

that exit at the left inboard side or mark the
stator so it can be reinstalled in the same
position.

4. Remove the four mounting cap screws.

(See Figure 6-15.)

Figure 6-13

CAUTION:
DO NOT TIGHTEN THE PULLER
BOLT BEYOND THE END OF THE
THREADS. IF A BOLT WITH
SUFFICIENT THREAD LENGTH
CANNOT BE FOUND, USE A PIECE
OF THREADED ROD WITH A NUT
WELDED ON THE END.
Figure 6-15

31
5. Carefully remove the PMG stator from its
mounting pads and slide over the PMG
rotor. The magnets used in the PMG are
very strong and will resist removal of the
PMG stator. (Figure 6-16.)

Figure 6-16

PMG ROTOR REMOVAL Figure 6-18

3. Slide the PMG rotor off of the shaft.
1. Remove the exciter armature and PMG (Figure 6-19.)
stator. (Follow instructions found earlier in
this section.)

2. Remove the snap ring that holds the PMG

rotor in place on the shaft. (Figure 6-17 and
6-18.)

Figure 6-19

4. Remove the loading spring. (if the loading

Figure 6-17 spring is not on the shaft, check to see if it is
stuck on the back of the PMG rotor.).

5. On 430 frame generators a second snap

ring is used inboard of the PMG rotor.
(Larger generators have a step on the shaft.)

32
This snap ring must be removed before the
generator main rotor can be removed.
(Figure 6-20.)

Figure 6-21

Figure 6-20

MAIN ROTOR REMOVAL

1. Remove the exciter armature and PMG.

2. For single bearing generators, remove the

four cap screws holding the bearing caps to Figure 6-22
the front-end bracket. (Figure 6-21.)
Remove the outer cap. (Figure 6-22.)

For two-bearing generators, remove the

drive coupling or sheave and key from the
shaft extension. Remove the four cap screws
holding the bearing lock to the drive end
bracket. (Figure 6-23.) Remove the four cap
screws holding the bearing caps to the front-
end bracket. (Figure 6-21.) Remove the
outer cap. (Figure 6-22.)

Figure 6-23

33
3. If the screen assembly is still mounted,
remove bolts securing the screen assembly
to the drive end bracket or the SAE adapter
and remove the screen assembly. (Figure 6-
24.) (NOTE: Do not remove the drip cover
from the screen assembly if so equipped.)

Figure 6-26

Figure 6-24
4. For single bearing generators, remove the
cap screws and hardened washers holding
the drive discs to the drive hub. (Figure 6-
25.) Remove all drive discs (and spacers if
any).
Figure 6-27
CAUTION: ON LARGE GENERATORS, A
HOIST AND LIFTING STRAP SHOULD
BE USED TO ASSIST IN DRIVE END
BRACKET OR SAE ADAPTOR REMOVAL

For two bearing generators remove the cap

screws holding the drive end bracket to the
generator and remove the bracket
(Figures 6-26 and figure 6-28)

Figure 6-25

5. For single bearing generators, remove the

cap screws holding the SAE adapter to the
generator and remove the adapter. (Figure 6-
26 and 6-27.)
Figure 6-28

34
6. Using a rotor lifting fixture and a suitable
hoist, carefully remove the rotor assembly
from the main stator and frame assembly
through the drive end. (Figure 6-29.)

CAUTION:
SPECIAL CARE SHOULD BE TAKEN
WHEN REMOVING THE MAIN ROTOR,
WINDING DAMAGE COULD RESULT IF
THE ROTOR IS ALLOWED TO HIT THE
MAIN STATOR.
Figure 6-30

Figure 6-29 Figure 6-31

WARNING
DO NOT APPLY ANY FORCE TO THE EXCITER INSPECTION
GENERATOR FAN FOR LIFTING OR
ROTATING THE GENERATOR
ROTOR. DISREGARDING THESE EXCITER STATOR
INSTRUCTIONS MAY CAUSE PER-
SONAL INJURY OR EQUIPMENT 1. Clean dust and dirt from the exciter stator
DAMAGE. winding. (Figure 6-32.) (See section 5.)

FRONT END BRACKET REMOVAL

1. Remove front bracket mounting
screws. (Figure 6-30.)

2. Remove the front-end bracket from the

main stator assembly. (Figure 6-31.)

CAUTION: ON LARGE GENERATORS,

A HOIST AND LIFTING STRAP SHOULD
BE USED TO ASSIST IN THE FRONT END
BRACKET REMOVAL Figure 6-32

35
2. Check the exciter stator for a loose,
frayed, or burnt winding. Measure winding
resistance and insulation resistance. (See
section 8.)
Repair or replace as necessary. If field repair
of the winding is necessary, contact
Marathon Electric for special winding
procedures and materials.
3. Look for score marks in the bore of the
exciter core caused by rubbing. (This could
indicate bearing or assembly problems and
should be investigated.)
EXCITER (ROTOR) ARMATURE
1. Clean dust and dirt from and rectifier
assembly. (Figure 6-33) (See Section 5)
Figure 6-33
2. Check the exciter armature for burrs on
the mating surfaces.
3. Check the rectifiers and surge protector
for proper operation. Replace defective
parts.
36
CAUTION: THREE FORWARD AND
THREE REVERSE POLARITY DIODES ARE
USED. BE SURE THE CORRECT PART IS
INSTALLED IN THE CORRECT LOCATION.
THE SURGE SUPRESSOR IS POLARIZED.
OBSERVE POLARITY MARKINGS WHEN
CHANGING THE SURGE SUPRESSOR
Figure 6-34
Torque mounting nuts to 80 in-lb. Torque
lead terminal nuts to 25 in-lb. Never torque
against the diode terminal - use a 7/16-in.
wrench to support the terminal.
Figure 6-35
4. Check the exciter armature and rectifier
assembly for loose, frayed, or burnt winding
or loose connections. Measure winding
resistance and insulation resistance. DO
NOT megger diodes or surge suppressor.
Repair or replace as necessary. If field repair
of the winding is necessary, contact
Marathon Electric for special winding
procedures and materials.
5. Look for score marks on the outside
diameter of the armature core caused by
rubbing. (This could indicate bearing or
assembly problems and should be
investigated.) Figure 6-37

1. Clean dust and dirt from the PMG rotor.

PMG INSPECTION
2.Check to be sure all magnets are tightly
PMG STATOR bonded to the PMG rotor.
1. Clean dust and dirt from the PMG stator
winding. 3.Check the bore and keyway of the PMG
rotor for burrs or corrosion.

4.Look for score marks on the outside

diameter caused by rubbing. (This could
indicate bearing or assembly problems and
should be investigated.)

5. Inspect snap rings and loading spring,

Figure 6-36
2. Check PMG stator for a loose, frayed, or
burnt winding. Measure winding resistance
and insulation resistance. (See section 8.)
Repair or replace as necessary. Contact
Marathon Electric for special winding
procedures and materials.
3. Look for score marks in the bore caused
by rubbing.
PMG ROTOR
replace as required.
MAIN ROTOR INSPECTION
BEARING
1. Check the bearing for damage or wear.
Clean old grease from the bearing cap, and
fill bearing cap grease cavity 1/3 to 1/2 full
of r Chevron SRI (or equivalent).
CAUTION: If the bearing needs to be
removed any reason, always install a new
bearing.

WARNING 2. If the bearing is to be replaced, remove

THE PMG ROTOR USES VERY STRONG with suitable puller. (Figure 6-38.)
MAGNETS. KEEP AWAY FROM IRON
AND STEEL PARTS THAT COULD BE
DRAWN TO THE MAGNETS AS WELL AS
OTHER COMPONENTS THAT CAN BE
DAMAGED BY MAGNETIC FIELDS.

37
 Figure 6-38
3.Be sure the inner bearing cap is on the
shaft before installing the new bearing.
4. Heat the new bearing in an oven to a
maximum temperature of 212°F (100°C).
Apply a thin coat of clean lubricating oil to
the press-fit area of rotor shaft. Install the
bearing over the end of the shaft until it
seats against the shaft shoulder as shown in
Figure 6-39. The bearing should slide on the
shaft and seated without excessive force. If
the bearing binds on the shaft before being
fully seated a piece of tubing, slightly larger
than the press area, can be used to drive the
bearing into place. Using light taps with a
soft mallet, apply pressure to the inner race
only.
CAUTION:
UNDER NO CIRCUMSTANCES SHOULD
PRESSURE BE APPLI ED TO THE OUTER
RACE OF THE BEARING, AS
PERMANENT BEARING DAMAGE
COULD RESULT.
Figure 6-39
Allow the bearing to cool for one
hour before attempting to assemble the
generator.
FAN
1. Check the fan for cracks or broken blades.
Replace the fan if defective.
2. Mark the hub and fan for alignment, this
is necessary to be sure the balance weights
will be in the same position when the fan is
reinstalled.
3. For single bearing generators. Remove the
fan mounting cap screws (Figure 6-40) and
slide the fan off the shaft. (Figure 6-41.)
For two-bearing generators, remove the
drive end bearing and bearing cap. (See
bearing removal instructions.) Remove the
fan mounting cap screws and slide fan off
the shaft. (Figure 6-40 and 6-41.)

38
 5. NOTE: Balance weights on the fan are for
balance of the complete rotor assembly. The
rotor assembly should be rebalance if a new
fan has been installed.

6. On two-bearing generators, install bearing

cap and new bearing according to the
bearing assembly instructions. (Item A.)

Drive Hub (Single Bearing Generators)

Figure 6-40 1. Check the drive hub for cracks or stripped

drive disc mounting holes. Replace the hub
if defective.

2. If the hub is to be replaced, remove the

fan (See Item B) and install a suitable puller
to the hub. Remove the two set screws in the
hub over the key. Using a torch, rapidly heat
the hub at the outer diameter while
tightening the puller. (This must be done
rapidly before the heat can expand the
shaft.) Remove the hub. (Figure 6-43)

Figure 6-41

4. To reinstall, slide the fan on the shaft

making sure the fan-mounting surface is
toward the drive hub. Align reference marks
(this is important for assembly balance) and
mount the fan to the drive hub with the cap
screws and Belleville washers. (Figure 6-
42.) Torque the cap screws to 60 ft-lb. (81
N-m).

Figure 6-43

3. To insure proper fan location, mark the

new hub in the same place as the old hub
relative to the keyway. Install key in shaft.
Heat the new hub in an oven to 500°-600°F
Figure 6-42 (260°-316°C). Use suitable heat resistant
gloves, slide the hub over the key in the
shaft until it seats against the shaft
shoulder. (Figure 6-44.)

39
 resistance an insulation resistance. Test for
shorted turns using an A-C impedance test A
defective rotor winding must be rewound
The rotor assembly must be rebalanced after
any rework or repair has been completed.

DRIVE DISCS (SINGLE BEARING

GENERATORS ONLY)

1. Inspect the drive discs for distorted or

bent edges. (Figure 6-46) Inspect for worn
mounting holes. Replace all defective discs
as necessary.
Figure 6-44

4. Allow the hub to cool for one hour. After

the hub has cooled, tighten the set screws in
the hub to 50 ft-lbs. (68 N.M.) torque. Match
the alignment marks on the fan and hub and
mount the fan. (See item B.)

5. Rebalancing the rotor assembly is not

necessary if only the hub is replaced and the Figure 6-46
fan is mounted in the same location relative
to the hub and shaft. 2. Inspect the drive disc mounting cap
screws for damaged threads. Replace cap
screws if damaged.
MAIN ROTOR CORE AND WINDINGS
FRONT (EXCITER) END
1. Clean all parts. Remove dust and dirt BRACKET INSPECTION
from the rotor winding air passages with
low-pressure, moisture-free air. 1. Remove the filler and drain grease pipes
and the grease plugs from outer bearing cap.
(Figure 6-47.)

Figure 6-45
Figure 6-47
2. Check the rotor for loose, frayed, or
burned windings. Measure winding

40
2. Clean the end bracket, outer bearing cap, 2. Clean the bracket or adapter, cap screws
grease pipes, and cap screws to remove all and screen assembly to remove all dust, dirt,
dust, dirt, and grease. and grease.

3. Inspect the cap screws for stripped threads 3. Inspect the cap screws for stripped threads
and replace if defective. and replace if defective.

4. Inspect the end bracket for stripped 4. Inspect the bracket or adapter for stripped
threads, cracks, and burred or rough mating threads, cracks, and burred or rough mating
surfaces. Inspect the bearing bore for burrs surfaces. (Figure 6-49 and 6-50.)
or wear. If the bracket shows excessive
bearing bore wear, it should be repaired or
replaced. (Figure 6-48.)

Figure 6-49

Figure 6-48

5. Inspect the mounting pads for the PMG

stator and exciter stator. Be sure they are
smooth, clean, and free of any burrs or rust.
That could interfere with proper alignment.
(Figure 6-47 and 6-48.)

6. Re-assemble the grease pipes and fittings

to the bearing cap. Figure 6-50

5. For two-bearing generators, inspect the

DRIVE END BRACKET OR SAE
ADAPTER INSPECTION
1. For two-bearing generators, remove the
grease plugs from the bracket.
bearing bore for burrs or wear. If the drive
end bracket shows excessive bearing bore
wear, it should be repaired or replaced.

41
MAIN STATOR INSPECTION

1. Clean dust and dirt from the stator frame

and winding. (Figure 6-51.) (See section 5.)

Figure 6-52

CAUTION: ON LARGE GENERATORS, A

HOIST AND LIFTING STRAP SHOULD
BE USED TO ASSIST IN THE FRONT END
Figure 6-51 BRACKET INSTALLATION.

2. Inspect the frame for stripped threads,

cracks, burred mating surfaces, or other
damage.

3. Inspect the stator for a loose, frayed, or

burnt winding. Measure winding resistance
and insulation resistance. (See section 8.)
Repair or replace as necessary.

FRONT END BRACKET

INSTALLATION
1.Install two guide pins (threaded rod can be
used) into the generator side of the end
bracket mounting holes. Align the guide
pins with the holes in the generator frame
and slide the bracket onto the frame. (Figure
6-52.) Install bracket mounting cap screws.
(Figure 6-53.)
Figure 6-53
2. Remove the two guide pins and insert the
remaining cap screws and torque to
specifications given in section 12.
MAIN ROTOR INSTALLATION
1. Grease bearing cavity and bearing with
Chevron SRI (or equivalent) grease.

2. Using a rotor lifting fixture and a suitable

hoist, carefully install the rotor assembly
into the main stator assembly through the
drive end. (Figure 6-54.) Carefully feed the
rotor leads through the front-end bracket
shaft hole as the rotor is installed.

42
 Figure 6-55

Figure 6-54

CAUTION:
SPECIAL CARE SHOULD BE TAKEN
WHEN INSTALLINGTHE ROTOR
ASSEMBLY. WINDING DAMAGE
COULD RESULT IF THE ROTOR
IS ALLOWED TO HIT THE MAIN
STATOR.

WARNING
DO NOT APPLY ANY FORCE TO THE
GENERATOR FAN FOR LIFTING OR Figure 6-56
ROTATING THE GENERATOR
ROTOR. DISREGARDING THESE
INSTRUCTIONS MAY CAUSE PER-
SONAL INJURY OR EQUIPMENT
DAMAGE.

3. For single bearing generators, slide the

SAE adapter over the fan and secure to the
main stator and frame assembly with cap
screws torqued per section 12. (Figure 6-55
and 6-56.) It may be necessary to raise the
rotor assembly slightly to allow the
mounting of the SAE adapter.
Figure 6-57
For two-bearing generators, insert two
guide pins in the rear bearing lock holes.
(Figure 6-57.) Fill the grease cavity of the
drive end bracket 1/3 to 1/2 full of Chevron
SRI (or equivalent) grease. Assemble all
grease plugs in the bracket. Mount the
bracket on the bearing and guide the bearing
lock pins through the bracket holes. (Figure
6-58.)

43

Figure 6-58
Align the drive end bracket and mount with
the cap screws. (Figure 6-59.) Insert two cap
screws with lock washers into the bearing
lock and tighten. Remove the guide pins and
replace with the remaining two cap screws
with lock washers. Torque bearing cap
screws to 25 lb.-ft (34 NM). Torque bracket
mounting cap screws per specifications
given in section 12.
Figure 6-59
CAUTION:
ON LARGE GENERATORS, A HOIST
AND LIFTING STRAP SHOULD BE
USED TOASSIST IN THE DRIVE END
BRACKET OR THE SAE ADAPTER
ASSEMBLY.
4. For single bearing generators, insert a
guide stud into the drive hub. Position all
44
spacers (if any), then all drive discs, one at a
time until all discs are installed. (Figure 6-
61.)
Figure 6-61
Make sure that all disc mounting holes at
the inner and outer diameter are properly
aligned. Secure the discs with the grade
eight 5/8-18 cap screws and hardened
washers. Torque to 192 ft-lb. (260 N-m).
Torque the bolts in sequence according to
Figure 6-62.
Figure 6-62
5. Install the outer bearing cap on the exciter
end. (Figure 6-63.) Align holes in inner and
outer bearing cap and install cap screws.
Torque to 25 lb.-ft (34 N-M) (Figure 6-64.)
 Figure 6-63
Figure 6-66

3. Install snap ring. (Figure 6-67.) Use a

piece of pipe slightly larger than the shaft
(2-3/4 inches) to push the rotor back against
the loading spring until the snap ring seats in
the slot. (Figure 6-68.)

Figure 6-64

PMG INSTALLATION
1. Install inboard snap ring, where supplied,
and loading spring on shaft. (Figure 6-65.)

Figure 6-67

Figure 6-65

2. Slide PMG rotor onto shaft. (Figure 6-66.) Figure 6-68

4. Install the PMG stator on its mounting

pads, with the leads in the left (9:00 o’clock)
inboard position, and secure with the four

45
mounting cap screws and Belleville washers. through the lead hole in the aluminum
(Figure 6-69 and 6-72.) standoff plate. (Figure 6-71.)
Torque to 4 ft-lb. (5 N-M).

Figure 6-69 Figure 6-71

5. Route and secure PMG moving parts. Insert the cap screw and Belleville washer
(Figure 6-72.) through the mounting hole in
the aluminum standoff plate and secure to
EXCITER INSTALLATION the shaft (Figure 6-73). Tighten the cap
screw until the armature seats on the shaft.
Torque to 84 lb.-ft (114 N-M).
1. Attach a wire to the main rotor leads and
feed the wire through the armature bore and
the lead hole in the aluminum standoff plate.
On larger exciters, it will be helpful to
install a guide pin in the end of the shaft to
support the armature while fishing the rotor
leads through. (Figure 6-70.)
Figure 6-72

Figure 6-70

Align the key in the armature bore to the

Figure 6-73
keyway in the shaft. Slide the armature on
2. Observe the polarity markings and
the shaft while feeding the main rotor leads
connect the main rotor leads to the rectifier

46
assembly. (Figure 6-74.) Torque the nuts to
4 ft-lb. (5.4 N-M).
CONDUIT BOX INSTALLATION
1. Install the conduit box over the main
stator leads (be sure the leads are in the
upper compartment and secure with bolts
and lock washers. (Fig 6-76 and 6-77.)

Figure 6-74

Figure 6-76
3. Position the exciter field leads at the left
(9:o’clock) inboard position. Using a
suitable lifting device, mount the exciter
stator on the front e bracket mounting pads
and align the mounting holes. (Figure 6-75.)
Mount the cap screws with Belleville
washers. (Figure 6-72.) Torque t cap screws
to 60 ft-lb. (81 N-M). Route and secure the
exciter stator leads away from any moving
parts.

Figure 6-77

2. On generators with bus bar assemblies,

reassemble main stator leads and insulating
blocks to bus bars. (Figure 6-78.)

Figure 6-75

Figure 6-78

47
3. Reconnect exciter leads, PMG leads and
other accessories according to the
connection prints and markings installed
before disassembly.
ASSEMBLY TO PRIME MOVER
1. Attach a suitable hoist to the generator
lifting lugs, and move the generator until the
generator foot mounting holes are aligned
with the base and slightly above.
2. For single bearing generators, if the
screen assembly is mounted on the adapter,
remove the mounting bolts and remove the
screen. (Figure 6-79.)
Figure 6-79
(NOTE: Do not remove the drip cover from
the screen assembly if so equipped.)
Insert two guide pins in the flywheel and
two in the flywheel housing. Adjust the
generator position until the drive discs are
piloted in the flywheel. Remove the guide
pins and secure the discs with Grade 8 place
bolts and hardened washers or Grade 8 cap
screws and heavy series lockwashers.
Torque per specifications given in section
12.
Position the generator so that the SAE
adapter mates with the flywheel housing.
48
WARNING
DO NOT APPLY ANY FORCE TO THE
GENERATOR FAN FOR LIFTING OR
ROTATING THE GENERATOR
ROTOR. DISREGARDING THESE
INSTRUCTIONS MAY CAUSE PER-
SONAL INJUY OR EQUIPMENT
DAMAGE.
CAUTION:
DO NOT FORCE THE ALIGNMENT
OFTHE UNITS. SHIFT THE
GENERATOR FROM SIDE TO SIDE
OR RAISE OR LOWER WITH A
LIFTING DEVICE AS NECESSARY.
It may be necessary to use shims under the
mounting feet of either the generator or the
prime mover to obtain proper alignment.
Use the same shims as removed under dis-
assembly or proceed as follows: Using the
extreme bottom four cap screws, mount the
SAE adapter to the flywheel housing.
With a .0015 to .002 inch feeler gauge at the
extreme top of the adapter to flywheel
housing fit, raise the generator or lower the
prime mover until the gauge is snug. Relieve
just enough to release the feeler gauge and
torque the remaining SAE adapter cap
screws to the flywheel housing.
Mount the screen assembly and tighten the
mounting bolts.
For two-bearing generators, align the coup-
ling halves or sheaves between the generator
and the prime mover by adding shims under
the feet.
3. Shim under the generator feet for proper
support, ensuring that the generator
mounting surfaces are level.
4. Install the mounting bolts that secure the
generator to the base.

5. For two bearing generators, assemble the

coupling halves or sheave belts between the
generator and the prime mover. (Follow the
coupling manufacturer’s instructions for
assembly and alignment.)

6. Connect all conduits and ducting to the Figure 6-80

conduit box.
NOTE: On single bearing units, the exciter
7. Connect all external wiring to the air gap cannot be checked properly until the
generator inside the conduit box. generator is mounted to the prime mover.

8. Check the exciter air gap (the gap 9. Install the conduit box covers.
between exciter armature and stator) by
inserting a .010 inch feeler gauge in the gap
and rotating around the armature diameter to
ensure the minimum air gap is available.
(See Figure 80.) If the feeler gauge cannot
be rotated full revolution, then check for a
“cocked" exciter stator or loose stator
mounting screws.

49
 WARNING
TROUBLESHOOTING HIGH VOLTAGES CAN BE PRESENT
AT THE GENERATOR AND
INTRODUCTION REGULATOR TERMINALS. HIGH
RESIDUAL VOLTAGES CAN BE
This section is intended to suggest a PRESENT EVEN WITH THE
systematic approach to locating and REGULATORDISCONNECTED OR
correcting generator or regulator ITS FUSES REMOVED. SOME
malfunctions. The sections are arranged EQUIPMENT (SUCH AS
according to the symptoms of the problem. SPACEHEATERS) MAY BE
The steps in each section have been ENERGIZED WHEN THE
arranged in an attempt to do the easy checks GENERATOR IS OFF. TOOLS,
first then to prevent further damage when EQUIPMENT, CLOTHING, AND
troubleshooting a disabled machine. YOUR BODY MUST BE KEPT CLEAR
OF ROTATING PARTS AND
The first and perhaps most important step of ELECTRICAL CONNECTIONS.
troubleshooting should be to gather as much
information as possible from personnel who SPECIAL CAUTION MUST BE TAKEN
may have been present during the failure. DURING TROUBLESHOOTING SINCE
Information on how long the generator had PROTECTIVE COVERS AND SAFETY
been running, what loads were on the line, DEVICES MAY BE DISABLED TO
weather conditions, what protective equip- GAIN ACCESS AND MAKE TESTS.
ment operated, etc., can help isolate the
problem. BE CAREFUL. SERIOUS PERSONAL
INJURY OR DEATH CAN RESULT
Always make a thorough visual inspection FROM THESE HAZARDS. CONSULT
to check for any obvious problems before QUALIFIED PERSONNEL WITH ANY
attempting to run the generator. QUESTIONS.

50
SYMPTOM:

Regulator Fuse Blown Replace bad fuse.

Check fuse with ohmmeter.
NO VOLTAGE OR
RESIDUAL VOLTAGE Voltmeter Off Check to be sure meter phase
selector switch is not in the off
position.

Defective Voltmeter Verify proper operation of panel

meter with another meter that is
known to be accurate.

Incorrect Connections Verify generator connections.

Defective Inspect all wiring for grounds, open

Connections/Wiring circuits & short circuits.

No Regulator Input Measure voltage at regulator input

(PMG output)

Defective Diodes, Surge Test generator with constant

Suppressor excitation (12 volt battery test) refer
or Generator Windings

Voltage Regulator Correct problem and adjust

Protective Shutdown regulator. Refer to regulator
Circuits are Operating manual.

Voltage Regulator Adjust or replace regulator. Refer to

Inoperative regulator manual.

51
 Under speed Operation Check speed using tachometers
and/or frequency meters.

Defective Voltmeter Verify operation of panel meter

with another meter that is known to
be accurate.
LOW VOLTAGE -
Residual Voltage Disconnect Fl and F2 leads at the
NO LOAD voltage regulator. If voltage goes
down continue on to next step, if
voltage does not change refer to
troubleshooting for symptoms of
“No Voltage - No Residual
Voltage”.

Incorrect Generator Verify generator connections refer

Connections to drawings supplied V generator
set and section 3.

Defective Connections / Inspect all wiring for grounds, open

Wiring circuits, short circuits, and loose
and dirty connections.

Regulator Adjustments Adjust regulator. Refer to regulator

manual. Check exciter field volts.

Defective Diodes, Surge Test generator with constant

Suppressor, Generator excitation (12 volt battery test)
Windings

Voltage Regulator not Adjust or replace regulator. Refer to

Operating regulator manual. Properly

52
 Overload Measure amps and verify that the
LOW VOLTAGE WHEN load does not exceed nameplate
LOAD IS APPLIED rating of the generator

Defective Ammeter Verify operation of ammeter by

using a separate meter known to be
accurate

Droop Circuit If the generator set is equipped for

paralleling, some voltage droop is
normal as load increases. Refer to
the regulator instruction manual

Continue troubleshooting Continue troubleshooting for

for symptoms “Generator symptoms “Generator Produces
Produces Low Voltage - Low Voltage - No Load”.
No Load”.

Defective Voltmeter Verify operation of panel meter

HIGH VOLTAGE with another meter that is known to
be accurate

Incorrect Operating Speed Verify speed with tachometer or

frequency meter.

Incorrect Connections Verify generator connections

Refer to drawings supplied with
generator set

Defective Connections / Inspect all wiring for grounds, open

Wiring circuits, and short circuits.

Regulator Adjustments Adjust regulator. Refer to regulator

manual

Diode Polarity Incorrect Check diodes, verify proper diodes

are installed and polarity is correct.

Voltage Regulator not Adjust or replace regulator. Refer to

Operating regulator instruction manual.

53
 Incorrect Speed Verify speed with tachometer or
VOLTAGE IS frequency meter.
FLUCTUATING
Unstable Speed Verify governor stability.

Voltage Regulator Stability Adjust regulator stability.

Refer to regulator manual.

Defective / Loose Inspect all wiring for loose or dirty

Connections connections.

Defective Diodes, Surge Test generator with constant

Suppressor or Generator excitation (12-volt battery test).
Windings

Remote Voltage Adjust Check operation. Refer to regulator

manual.

Defective Regulator Replace regulator. Refer to

regulator manual.

OPERATES Regulator Shutdown on Correct cooling problems. Refer to

SATISFACTORILY Over Temperature regulator manual.
WHEN COLD, BUT
SHUTS DOWN WHEN
WARM

BUILDS VOLTAGE Regulator Protective Check indicators on regulator.

FROM STARTUP,THEN Circuit is Operating Correct problems and adjust as
GOES TO LOW required. Refer to regulator manual.
(RESIDUAL) VOLTAGE

EQUIPMENT RUNS Voltage Waveform is Analyze load. Excessive SCR

NORMALLY ON UTILITY Distorted (Thyristor) loading will cause
POWER, BUT WILL NOT distortion. Some equipment may be
RUN ON GENERATOR sensitive to distorted waveforms.
SET Refer to Marathon Electric.

54
GENERATOR TESTING
VISUAL INSPECTION
Whenever testing and troubleshooting a
generator set, it is always a good practice to
make a thorough visual inspection. Remove
covers and look for any obvious problems.
Burnt windings, broken connectors, leads,
mounting brackets, etc., can usually be
identified. Look for any loose or frayed
insulation, loose or dirty connections,
broken wires. Be sure all wiring is clear of
rotating parts.
Verify that the generator is connected for the
voltage required this is especially important
on new installations.
Check for any foreign objects, loose nuts,
bolts, and electrical connectors. Clear paper,
leaves, building materials, etc., that could be
sucked into the generator. (Generators are
air-cooled. Air enters the lower portion of
the conduit box.) Check the air gap for
clearance or obstructions (main generator
and exciter).
If possible, rotate the generator rotor by
hand to be sure it turns freely.
If serious problems can be identified before
attempting to operate the machine,
additional damage can be avoided.
CONSTANT EXCITATION
(12V BATTERY) TEST
THEORY: The generator output voltage is
dependent on generator speed, generator
design, load, and exciter input current. If the
generator speed and exciter input are known,
the output voltage at no load can be
measured and compared to the design value.
55
Problems can be isolated to either the gen-
erator or regulator system by using this test.
TEST PROCEDURE:
1. Shut the generator set down.
2. Connect a voltmeter to the generator
output.
3. Disconnect the Fl and F2 leads at the
regulator.
4. Connect a 12-volt battery capable of
supplying 1 amp to the Fl and F2 leads. Fl is
plus (+), F2 is minus (—).
CAUTION: Beware of arcing when
connecting leads. Stay clear of battery vents.
Escaping hydrogen gas can explode. If
hazardous conditions exist - use a suitable
switch to connect or disconnect the battery.
5. With no load on the generator, (main
breakers open) run generator at rated speed.
6. Measure the generator output voltage.
7. Shut generator down.
8. Disconnect battery (see Caution - Step 3).
9. Compare voltage reading with value
shown in section 12.
Conclusion: If voltage readings are normal,
the main generator and exciter are operating
properly. Troubleshooting should continue
with the regulator. If readings are not normal
the problem is in the generator. Continue
testing diodes, surge suppressor, windings.
MEASURING VOLTAGES

When testing the generator and regulator,

the most frequent (and usually easiest)
measurement will be a voltage. The
generator will need to be running at rated
speed and may have some of the protective
guards and covers removed. BE CAREFUL.
Keep yourself and your test leads out of the
way. It is best to shut the unit down when
connecting meters. When using alligator
clips or push on terminals, be sure the leads
re supported so vibration does not shake
them loose when running the generator set.

See figure 8-1 for measurement points and

expected meter range settings. Figure 8-1
When in doubt, start with a higher range and
work down.
Consult meter instruction manual to verify
its operation and limitations.

56
TYPICAL VOLTAGE MEASUREMENTS
Voltage Measurement Test Point
Output “T” leads or bus bars,
Generator Output Voltage also main circuit breaker
“line” side.
Fl and F2 terminals at the
Regulator Output (Exciter regulator.
Stator Input)
El, E2, E3 terminals at the
Regulator Sensing Voltage the regulator.
Meter/Range Selection
Requirement
System voltage - volts AC See
generator nameplate and
connection diagram.
200 volts D.C. range. Fl is
plus (+), F2 if minus (—
Usually the same as the
system voltage (generator
output volts). However, in
some cases, sensing taken
from winding center taps or
instrument potential
transformers. Maximum 600
volts AC
Example: Center tap of 480-
volt system would give 240
volts El, E2, or E3.
Example:
A 4160-volt system must use a
transformer to step voltage
down below 600 volts.
See the connection diagram
supplied with generator set.

“PMG” leads at the regulator 200-240 VAC 300 Hz

Regulator Input Volts or capacitor. @ 1800 rpm
(PMG Output Volts) 180-220 VAC 250 Hz
@ 1500 rpm

each phase. If the physical size of the

CURRENT (AMP) MEASUREMENTS
Current measurement (AC) can be easily
taken with a clamp on type meter.
NOTE: Most clamp type ammeters will not
measure D.C.
When measuring generator output current,
be sure the clamp is around all cables for
conductors or the capacity of the meters will
not permit all cables to be measured at once,
Each one can be measured individually. Add
the individual readings together to get the
total. Compare readings to the generator
nameplate (nameplate ratings are always
given per phase).

57
Amperage should never exceed the
nameplate rating when running the intended
load. (Amperage may go above nameplate
momentarily when starting large motors.)
When measuring exciter field amps (Fl and
F2 leads) a D.C. meter is required. The
maximum field current under full regulator
forcing is 6.5 amps D.C.
MEASURING RESISTANCE
The generator windings can be measured
and compared to the values shown in the
service specifications.
Main Stator
The main stator winding resistance is very
low. A meter capable of readings in the
milliohm range would be required.
However, a standard V.O.M. can be used to
check for continuity, shorts, or grounds.
Example: With leads disconnected, a
measurement from T1 to T4 should be very
low (continuity most V.O.M’s). Measured
from T1 orT4 to any other lead should be
infinite. Measure from the ‘T’ lead the
generator frame to check for grounds
(reading should be infinite).
Normal full load reading is approximately 3
amps.
The exciter stator resistance is measured by
disconnecting the Fl and F2 leads at the
regulator. Measure the resistance between
the leads (this value is 22-24 ohms on
standard generators). Measure from the
leads to the frame to check for grounds.
58
Note markings and disconnect the main
rotor leads (Fl leads and F2 leads) from the
rectifier assembly. Measure the resistance of
the main rotor winding. Compare reading to
value shown in service specification section
12. Measure from the leads to the exciter-
mounting bolt to check for grounds.
Exciter Rotor
Disconnect the exciter rotor leads at the
diodes (leave leads disconnected if
proceeding to check diodes). Measure
resistance between phases. Compare value
to service specification section 12. Measure
from the leads to the exciter-mounting bolt
to check for grounds.
TESTING DIODES (RECTIFIERS)
Diodes perform the function of an “electrical
check valve”. They conduct in one direction
only and are used to “rectify” ac current into
dc current. To test, measure the resistance
first in one direction and then reverse the
leads and test in the other direction. The
reading should be high in the reverse
direction and low in the forward direction. A
shorted diode will read low in both
directions. An open diode will read high in
both directions.
NOTES:
1. Two different polarities of diodes are
used. The only difference is in the way the
device is mechanically placed in the case.
When changing diode, be sure the correct
polarity is used.
Refer to section 6 figure 6-34.
2. Some meters do not have enough voltage
output from their internal batteries to turn
the diode on (about 0.6 volts is required),
and the voltage can change with different
range settings. Consult the instruction
manual for your meter.
3. Polarities supplied by the meters internal
battery may or may not correspond to the
(+) (—) markings on the meter.
INSULATION RESISTANCE -
GENERAL
Insulation resistance is a measurement of the
integrity of the insulating materials that
separate the electrical windings from the
generators steel core. This resistance can
degrade over time or due to contaminants
(dust, dirt, oil, grease, and especially
moisture). Most winding failures are due to
a breakdown in the insulation system. In
many cases, low insulation resistance is
caused by moisture collected when the
generator is shut down. The problem can be
corrected simply by drying out the windings.
Section 5.
Normally the resistance of the insulation
system is on the order of millions of ohms. It
is measured with a device called a “megger”
which is a megohm meter (Meg is for
million) and a power supply. The power
supply voltage varies, but the most common
is 500 volts. A megger voltage over 500 is
not recommended except for measuring
medium voltage (2400/4160) stators only.
CAUTION: First disconnect any electronic
components, regulators, diodes, surge
protectors, protective relays, etc., will be
destroyed if subjected to the high megger
voltages.
To measure insulation resistance, connect
the red or positive megger lead to the leads
for the winding to be tested, connect the
back or negative megger lead to the
generator frame. Be sure the leads of the
part being tested are not touching any metal
parts of the generator. (If the neutral is
59
grounded, it must be disconnected.) Take
megger reading (refer to the manual for the
megger).
INSULATION RESISTANCE - MAIN
STATOR
CAUTION: Be sure the regulator, and any
other electronic components, metering,
protective relays, etc., are disconnected
before meggering. High megger voltages
will destroy these parts. All stator leads must
be isolated from ground and connected
together (on most systems with grounded
neutrals - the neutral can be isolated from
ground and used as a test point). Connect the
positive megger lead to the main stator
leads. Connect the negative megger lead to
the generator grounding stud. Take the
megohm reading (refer to instructions for
the megger).
GENERATOR TESTING
The minimum acceptable value can be
calculated using the following formula.
Minimum Insulation Resistance = Gen.
Voltage + 1 (Megohms) / 1000
Example:
For a 480 volt generator
480 + 1 = 1.48 Megohms
If the reading is below the recommended
value, the winding must be dried out or
repaired.
INSULATION RESISTANCE - MAIN
ROTOR
Disconnect the main rotor leads from the
diode bridge on the exciter rotor. Connect
the leads together with the positive megger
lead. Connect the negative megger lead to a
good ground on the rotor assembly such as
the exciter mounting bolt. Take the megohm
reading (refer to instructions for the
megger).
The minimum acceptable value is 1.5
megohms.
If the reading is low, the winding must be
dried out or repaired.
INSULATION RESISTANCE -
EXCITER STATOR
Disconnect the exciter leads Fl and F2 from
the regulator. Never subject the regulator to
a megger. Connect Fl and F2 together with
the positive megger lead. Connect the
negative megger lead to the ground stud.
Take the megohm reading (refer to
instructions for the megger).
The minimum value is 1.5 megohms.
If the reading is low, the winding must be
dried out or repaired.
INSULATION RESISTANCE -
EXCITER ROTOR
Disconnect the exciter rotor windings (6
leads from the diodes). Connect all leads
together with the positive megger lead.
Connect he negative megger lead to a good
ground on the rotor assembly such as the
mounting bolt. Take the megohm reading
(refer to the instructions for the megger).
The minimum acceptable value is 1.5
megohms.
If the reading is low, the winding must be
dried out or repaired.
60
MAIN ROTOR FIELD AC IMPEDANCE
TEST
THEORY: The main rotor resistance can be
measured with a very accurate meter that is
able to measure low (1 ohm) resistance but it
is difficult to determine if there are turn to
turn shorts in the field pole windings. One
shorted turn would only change a resistance
reading on the order of one half of one
percent.
The ac impedance test measures the
impedance (inductance and resistance) of
the field pole coils. Shorted turns in the field
pole windings change the coil inductance to
a much greater degree than the resistance.
PROCEDURE:
Step 1: The rotor must be supported on a
non-magnetic surface such as a wooden
skid. Do not use a steel table that would
create a magnetic “short circuit” between the
poles.
Step 2: Apply 120 volts ac to disconnected
main rotor leads Fl and F2.
Step 3: Measure and record voltages pole.
Between points “A” and “C”, “C” and “D”,
“D” and “E” across each “B”, “B” and
(Figure 8-1).
Step 4: The voltage readings should balance
within one volt.
RESULTS: If the ac voltages are not
balanced (30v ± lv ac with 120v ac input)
across each pole, the winding has shorted
turns and should be rewound.
Refer to Marathon Electric for further
information.
MAGNAMAX EXPLODED VIEW

61
TABLE 9-1 PARTS LIST
NOTE: The parts in this list are subject to change, model number and serial number must
accompany any parts order or inquiry.
Item Part Description 430 Frame Series 570 Frame Series 740 Frame Series
Part Number Qty. Part Number Qty. Part Number Qty.
1 Screen Assembly
Screen B-525565-1 1 B-525565-2 A- 1 B-525565-3 1
Screen Mounting Bolt Screen A-9646-200 2 9646-200 A- 2 A-9646-200 2
Mounting Nut A-7551-18 2 7551-18 2 A-7551-18 2
2 Drip Cover assembly B-525566-1 1 B-525566-2 2 B-525566-3 1
3 Adapter
#3Adapter B-525512A 1
#2Adapter B-525512B 1
#1 Adapter B-525513A 1 B-525618A 1
#1/2 Adapter B-525514B 1 B-525616A 1
#0Adapter B-525514A 1 B-525603A 1 B-525720A 1
#00 Adapter (#18 Disc) B-525617A 1 B-525721A 1
#00 Adapter (#21 Disc) B-526228A 1 B-52572 1A 1
4 Disc Mounting Fasteners
Cap screw for #11-1/2 A-9674-200 6
Cap screw for #14 A-9674-150 6 A-9674-150 9
Cap screw for #18 A-9674-150 6 A-9674-150 9 A-9674-200 18
Cap screw for #21 A-9674-150 18
Cap screw for Delco A-9674-150 6 A-9674-150 9 A-9674-200 18
Hardened Washer A-9667-1 6 A-9667-1 9 A-9667-1 18
5 Drive Discs
#11-1/2 Disc A-525506 5 — — — —
#14 Disc A-525508 5 A-525508 5 — —
#18 Disc B-525975 4 A-525579 5 A-525579 10
#21 Disc — — A-525580 10
Delco Disc (17.75” 0.0.) A-525507 5 A-525507 5 A-525507 10
6 Spacers
For #11-1/2 Disc A-525567 14 — — — —
For #14 Disc A-525567 5 A-525503 6 — —
For#18 Disc — — — — A-525503 10
For #21 Disc — — — — — —
For Delco Disc — — A-525503 1 A-525503 12
7 Fan Mounting Fasteners
Cap screw A-9626-150 4 A-9626-150 8 A-9626-1 50 8
Cap screw (2 Brg. Only) A-9626-150 4 A-9626-200 8 A-9626-200 8
Belleville Washer A-9682-1 4 A-9682-1 8 A-9682-1 8
8 Fan B-525510A 1 B-525604A 1 B-525719A 1
9 Hub
Drive Hub [Sgl Brg. Only) B-525509A 1 B-525606A 1 B-525726A 1
Fan Hub (2 Brg. Only) A-525568A 1 B-525694A 1 B-525750A 1
10 Drive Hub Set Screws — A-9675-50 2 A-9675-50 2

62
TABLE 9-1 PARTS LIST
NOTE: The parts in this list are subject to change, model number and serial number must
accompany any parts order or inquiry.
Item Part Description 430 Frame Series 570 Frame Series 740 Frame Series
Part Number Qty. Part Number Qty. Part Number Qty.
11 Drive Hub Key A-25658-30 1 A-25658-30 1 A-25658-46 1
12 Main Rotor Assembly with REFER TO FACTORY
Windings
13 Front Bearing Cap B-525519A 1 B-525613A 1 B-525743A 1
14 Front Ball Bearing A-7812R-70 1 A-7812R-80 1 A-7812R-1 10 1
15 Main Body Assembly REFER TO FACTORY
16 Adapter Mounting Fasteners -
Cap screw A-9680-125 12 A-9680-125 16 A-9626-1 50 16
Lock Washer A-7653-3 12 A-7653-3 16 A-7653-4 16
Flat Washer A-7656-8 16 A-7656-8 16 A-9667-1 16
17 Bracket Mounting Fasteners - - - - -
Cap screw A-9680-1 25 8 A-9680-1 25 8 A-9626-150 8
Lock Washer A-7653-3 8 A-7653-3 8 A-7653-4 8
Flat Washer A-7656-8 8 A-7656-8 8 A-9667-1 8
18 Front Bracket B-525518A 1 B-525605A 1 B-525739A 1
19 PMG Bearing Cap B-525520A 1 B-525612A 1 B-525742A 1
20 Bearing Cap Fasteners - - - - - -
Cap screw A-9680-350 4 A-9680-400 4 A-9680-450 4
Lock Washer A-7653-3 4 A-7653-3 4 A-7653-3 4
21 Conduit Box D-525673 1 D-525680 1 D-525771 1
22 Conduit Box Mtg. Fasteners
Cap screw A-9680-75 8 A-9680-75 8 A-9626-75 8
Lock Washer A-7675-2 8 A-7675-2 8 A-7675-4 8
23 Snap Ring - Inner A-7610-275 1 — —
24 Loading Spring A-7661-45 1 A-7661-45 1 A-7661-45 1
25 PMG Rotor A-525529 1 A-525529 1 A-525529 1
26 Snap Ring-Outer A-7610-275 1 A-7610-275 1 A-7610-275 1
27 PMG Stator A-525548-1 1 A-525548-1 1 A-525548-1 1
28 PMG Stator Mtg. Fasteners
Cap screw A-9812-200 4 A-9812-200 4 A-9812-200 4
Belleville Washer A-9682-2 4 A-9682-2 4 A-9682-2 4
29 Exciter Stator A-400N-200A I A-400N-300A I See Table 9-2 1
30 Exciter Stator Fasteners - - - - - -
Cap Screw A-9626-300 4 A-9626-400 4 See Table 9-2 4
Belleville Washer A-9682-1 4 A-9682-1 4 A-9682-1 4
31 Exciter Rotor Assy. (IncI. 42) - - - - See Table 9-2
430 Frame - All B-525524-2 I — —
570 Frame - Low Voltage — — B-525524-3 1
570 Frame - Med. Voltage — — B-525524-10 1
32 Exciter Rotor Fastener - - - - - -
Cap screw A-9670A-200 1 A-9670A-200 1 A-9670A-200 1
Belleville Washer A-9682-1 1 A-9682-1 1 A-9682-1 1

63
TABLE 9-1 PARTS LIST
NOTE: The parts in this list are subject to change, model number and serial number must
accompany any parts order or inquiry.
Item Part Description 430 Frame Series 570 Frame Series 740 Frame Series
Part Number Qty. Part Number Qty. Part Number Qty.
33 Grounding Stud Assembly - - - - - -
Stud A-26937-300 1 A-26937-300 1 A-525574-400 I
Washer A-9787-1 2 A-9787-1 2 A-9787-3 2
Nut A-9786-1 1 A-9786-1 2 A-9786-3 2
34 Bus Bar Assembly REFER TO FACTORY
35 Voltage Regulator
PM100A C-512481 1 C-512481 1 C-512481 1
PM200A(optional) C-512482 1 C-512482 1 C-512482 1
36 Capacitor A-525582-1 1 A-525582-1 1 A-525582-1 1
37 Side Panels Blank B-525679A 1 B-525686A 1 B-525707A 1
Machined for AVR B-525679B I B-525686B 1 B-525707B 1
38 Fuse A-525698-1 1 A-525698-1 1 A-525698-1 1
39 Fuse Holder Cap A-525893 1 A-525893 1 A-525893 1
40 Solid Cover B-525676 1 B-525687 1 B-525706 1
41 Louvered Cover C-525562 1 C-525647 1 C-525670 1
42 Exciter Rectifier Assy. B-525528A 1 B-525528A 1 B-525528B 1
(Includes 43,44,45)
43 Diode Standard Polarity B-525570-1 3 B-525570-1 3 B-525570-2 3
44 Diode Reverse Polarity B-525571-1 3 B-525571-1 3 B525571-2 3
45 Surge Suppressor B-526482-1 1 B-526482-1 1 B-526482-2 1
46 Cover Mtg. Screws A-9646-75 33 A-9646-75 33 A-9646-75 33

TABLE 9-2 : EXCITER ASSEMBLIES

Frame Type Insulation Exciter Stator Exciter Stator Exciter Rotor
Mtg. Cap screws
572 RSL Standard A-400N-2504 A-9626-350 B-526483-24
573.574 RSL Standard A-400N-300A A-9626-400 B-526483-3
572 RSL VPI A-400N-250AA A-9626-350 B-526483-25
573.574 RSL VPI A-400N-300AA A-9626-400 B-526483-9
573,574 FSM VPI A-400N-300AA A-9626-400 B-526483-10
741, 742 RSL Standard A-400N-500A A-9626-600 B-526483-5
741, 742, 743 RSL VPI A-400N-500A A-9626-600 B-526483-11
741, 742 FSM VPI A-400N-500A A-9626-600 B-526483-11
743 FSM VPI A-400N-600A A-9626-700 B-526483-12
744 RSL VPI A-400N-600A A-9626-700 B-526483-12
744 FSL VPI A-400N-650A A-9626-750 B-526483-13

The MagnaMAX generator is assembled

STANDARD TOOLS with American standard SAE hardware.

64
All fasteners should be properly torqued.
(See section 12). Torque wrenches ranging
from 25 in-lb. through 200 ft-lb. should be
available.
Electrical test equipment should include a
voltmeter or multimeter (VOM), clamp on
ammeter, accurate frequency meter or
tachometer, and a megohmmeter. See
section Generator Testing for more informa-
tion.
SPECIAL TOOLS
In addition to the standard tools mentioned
above, the following special tools would
facilitate removal and installation of large
and/or special parts. These tools can be
obtained from the Marathon Electric parts
department.
Exciter stator lifting fixture (Figure 10-1).
Figure 10-1
In cases where the exciter stator is to be
serviced without removing the generator
65
conduit box this fixture can be used with
overhead rigging to remove and reinstall the
exciter stator.
Exciter rotor puller bolt (Figure 10-2). The
exciter rotor has a built in pulling system.
With the use of this bolt, the rotor can be
easily removed from the shaft without
damage to the winding.
Figure 10-2
The PMG rotor is installed to the generator
shaft with a snap ring.
The nominal shaft diameter is 2-3/4 inches
and the ring must be spread approximately
3/4 inches for removal. To install the snap
ring, use a piece of pipe with a 2-3/4 inch
I.D. (Figure 10-4). Push the PMG rotor and
snap ring onto the shaft until the ring snaps
into the groove.
Figure 10-4
Rotor lifting fixture (Figure 10-5). The main
generator rotor is heavy (approximately 1/2
the weight of the generator) and difficult to
handle. The proper fixture should be used
whenever removing or installing the main
rotor into the main stator. Without proper
care and equipment, the windings can be
easily damaged.
Figure 10-5
MISCELLANEOUS
A selection of wiring devices such as
electric connectors, tape, cable ties,
crimping and stripping tools, etc., should
also be a part of the generator service tool
kit. The standard regulator uses flat 1/4 inch
female insulated terminals for AWG #14
wire.
PREPARATION FOR SHIPMENT
OR EXTENDED STORAGE
SHIPPING INSTRUCTIONS
Shipping and handling will be much easier if
the generator is fastened to a suitable
shipping skid that will allow handling by a
forklift. The skid should extend beyond the
generator in all directions. If the original
skid is available it should be used. Marathon
Electric will supply shipping skid drawings
upon request.
Overseas shipping may require special
export crating. Check with your freight
carrier.
66
When installed, single bearing generator
rotors are supported on the drive end by the
drive discs bolted to the engine flywheel.
When the engine is removed, the rotor must
be supported by an appropriate fixture to
prevent main rotor, main stator or exciter
damage (Figure 11-1). Before shipping any
single bearing generator, the main rotor
must be supported by the adapter using an
appropriate fixture.
Figure 11-1
STORAGE INSTRUCTIONS
If the generator is placed in storage, the
following precautions should be taken to
protect it:
A. Equipment must be kept clean.
1. Store indoors.
2. Keep covered to eliminate airborne dust
and dirt.
3. Cover openings for ventilation, conduit
connections, etc. to prevent entry of rodents,
snakes, birds, and insects, etc.
B. Equipment must be kept dry.
1. Store in a dry area indoor.

2. Temperature swings should be minimal to
prevent condensation.
3. If stored in an unheated or damp building,
space heaters will be required to prevent
internal condensation.
4. Treat unpainted flanges, shafts, drive
discs, and fittings with a rust inhibitor.
5. Check insulation resistance of all
windings before starting the generator. If
readings are low, the windings must be
dried.
C. Keep bearings lubricated.
67
1. Every six months rotate shaft
several turns to distribute grease in bearings.
2. If unit has been stored more than
one year, add grease before start-up.
D. Review and follow instructions in
Sections 3 and 4 before putting the gen-set
into service.
CAUTION
DO NOT ATTEMPT TO TRANSPORT
ANYGENERATOR WITHOUT
PROPER ROTOR
SUPPORT, EXTENSIVE
EQUIPMENTDAMAGE CAN OCCUR.
TABLE 12-1: MAGNA MAX - FASTENER AND TORQUE SPECIFICATIONS
Part Fastener Spec. 430-570 Frames 740 Frames
Description
Size Dia.- Torque Ft-Lb. Size Dia.- Torque
Thread Thread Ft-Lb.
Front Bracket Grade 5 cap screws with 3/8 - 16 25 1/2 - 13 60
flat and lock washers
Bearing Caps Grade 5 cap screws with 3/8 - 16 25 3/8 - 16 25
lock washers
Drive Disc Grade 8 cap screws with 5/8 - 18 192 5/8 - 18 192
hardened washers
Adapter Grade 5 cap screws with 3/8 - 16 25 1/2-13 60
(or rear flat and lock washers
bracket)

Conduit Box Grade 5 cap screw with 3/8 - 16 25 1/2-13 60

star type lock washer
PMG Stator Grade 5 cap screws with 1/2-13 4 1/2-13 4
Belleville washers
Exciter Stator Grade 5 cap screws with 1/2-13 60 1/2-13 60
Belleville washers

Exciter Grade 8 cap screw with 1/2-13 84 1/2-13 84

Armature Belleville washer
(rotor)
Cooling Fan Grade 5 cap screws with 1/2-13 60 1/2-13 60
Belleville washers
Main Rotor Grade 8 cap screws with 5/16-18 19 3/8 - 16 35
Coil Supports Belleville washers
Rectifier Grade 5 cap screws 1/4-20 4 1/4-20 4
Assembly
Mounting
Drive Hub Set Socket head set screw 1/4 1/2-13 50 1/2-13 50
Screw in. hex key

NOTES: For table 12-1

All fasteners are SAE (American) standard.
All torque values are for plated hardware that is standard on the MagnaMAX.
If hardware is replaced with non-plated, refer to Table 12-2.
Always use quality hardware of the grade specified.
Main Rotor Coil Supports 570 and 740 frame only. Not used on 430 frames.

68
TABLE 12-2: CAPSCREW TORQUE VALUES
NOTES: Cap screws threaded into aluminum may require reductions in torque of 3O% or more.
Cap screw Diameter and Ultimate Tensile Strength (PSI)
To 1/2 - 69,000 PSI To 3/4 - 120,000 PSI 150,000 PSI
To 3/4 - 64,000 PSI To 1 - 115,000 PSI
To l - 55,000 PSI
SAE 1 OR 2 5 8
Grade
Size Torque Ft-LB (N-M) Torque Ft-Lb. (N-M) Torque Ft-LB (N-M)
(Inches) -
(Thread)
Dry Oiled Plated Dry Oiled Plated Dry Oiled Plated
1/4-20 5(7) 4.5 (6) 4(5) 8 (11) 7 (9) 6 (8) 12 (16) 11 (15) 10 (14 )
1/4-28 6(8) 5.4 (7) 4.8 (6) 10 (14) 9 (12) 8 (11) 14 (19) 13 (18) 11 (15)
5/16-18 11 (15) 10 (14) 9 (12) 17 (23) 15 (20) 14 (19) 24 (33) 22 (30) 19 (26)
5/16-24 13 (18) 12 (16) 10 (14) 19 (26) 17 (23) 15 (20) 27 (37) 24 (33) 22 (30)
3/8-16 18 (24) 16 (22) 14 (19) 31 (42) 28 (38) 25 (34) 44 (60) 40 (54) 35 (47)
3/8- 24 20 (27) 18 (24) 16 (22) 35 (47) 32 (43) 28 (38) 49 (66) 44 (60) 39 (53)
7/16 - 14 28 (38) 25 (34) 22 (30) 49 (66) 44 (60) 39 (53) 70 (95) 63 (85) 56 (76)
7/16-20 30 (41) 27 (37) 24 (33) 55 (75) 50 (68) 44 (60) 78 (106) 70 (95) 62 (84)
1/2-13 39 (53) 35 (47) 31 (42) 75 (102) 68 (92) 60 (81) 105 (142) 95 (129) 84 (114)
1/2-20 41 (56) 37 (50) 33 (45) 85 (115) 77 (104) 68 (92) 120 (163) 108 (146) 96 (130)
9/16-12 51 (69) 46 (62) 41 (56) 110 (149) 99(134) 88(119) 155 (210) 140 (190) 124 (168)
9/16-18 55 (75) 50 (68) 44 (60) 120 (163) 108 (146) 96 (130) 170 (230) 153 (207) 136 (184)
5/8-11 83 (113) 75 (102) 66 (89) 150 (203) 135 (183) 120 (163) 210 (285) 189 (256) 168 (228)
5/8-18 95 (129) 86 (117) 76 (103) 170 (230) 153 (207) 136 (184) 240 (325) 216 (293) 192 (260)
3/4-10 105 (142) 95 (130) 84 (114) 270 (366) 243 (329) 216 (293) 375 (508) 338 (458) 300 (407)
3/4-16 115 (156) 104 (141) 92 (125) 295 (400) 266 (361) 236 (320) 420 (569) 378 (513) 336 (456)
7/8-9 160 (217) 144 (195) 128 (174) 395 (535) 356 (483) 316 (428) 605 (820) 545 (739) 484 (656)
1-14 175 (237) 158 (214) 140 (190) 435 (590) 392 (531) 348 (472) 675 (915) 608 (824) 540 (732)
1 -8 235 (319) 212 (287) 188 (255) 590 (800) 531 (720) 472 (640) 910 (1234) 819 (1110) 728 (987)
1- 14 250 (339) 225 (305) 200 (271) 660 (895) 594 (805) 528 (716) 990 (1342) 891 (1208) 792 (1074)

69
TABLE 12-3:EXCITATION DATA -60 HZ - 1800 RPM
Model Number Exciter Field Exciter Field Volts Fl No Load Output Voltage With
Low Volts Resistance-Ohms and F2 at regulator Fixed Excitation
@25°C No Load 240/480 High Wye Connection®
Volts
12V DC 24V DC
431RSL2004 22.5 10.4 500 595
431RSL2006 22.5 9.5 520 610
431RSL2008 22.5 10.4 500 595
432RSL2010 22.5 10.8 495 590
432RSL2012 22.5 13.5 460 550
432RSL2014 22.5 11.3 490 575
432RSL2016 22.5 15.3 440 530
432RSL2018 22.5 14.1 450 545
433RSL2023 22.5 16.9 425 520
433RSL2027 22.5 13.7 445 545
571RSL2020 23.0 8.1 540 640
571RSL2024 23.0 9.9 500 600
571RSL2028 23.0 10.6 500 590
572RSL2032 23.0 10.8 490 580
572RSL2037 23.0 12.0 480 560
572RSL2040 23.0 10.6 500 580
572RSL2045 23.0 12.7 470 560
573RSL2048 23.0 12.4 470 560
573RSL2052 23.0 13.3 465 550
573RSL2056 23.0 14.0 450 540
741RSL2060 22.5 10.8 500 600
741RSL2064 22.5 12.2 480 570
741RSL2068 22.5 12.8 465 575
741RSL2072 22.5 11.9 480 580
742RSL2076 22.7 13.0 460 570
744RSL2284 22.0 15.0 430 570
744RSL2288 22.0 16.0 410 540
Model Number Exciter Field Exciter Field Volts Fl No Load Output Voltage With Fixed
Medium Volts Resistance-Ohms and F2 at Regulator Excitation Wye Connection
@25°C No Load 4160 Volts 12V DC 24V DC
573FSM2328 23.0 16.3 3600 4700
573FSM2336 23.0 17.2 3500 4600
574FSM2340 23.0 14.9 3700 4800
574FSM2348 23.0 18.7 3400 4500
574FSM2352 23.0 17.5 3500 4600
741FSM2360 22.7 12.9 4000 5100
741FSM2364 22.7 12.9 4000 5100
741FSM2368 22.7 13.2 3900 5100
742FSM2372 22.7 15.9 3600 4700
742FSM2376 22.7 16.6 3600 4700
742FSM2380 22.7 16.8 3500 4600
743FSM2384 22.0 17.6 3300 4600
743FSM2388 22.0 16.9 3500 4600
For rated load exciter field volts - see generator nameplate.
For low wye connection: divide value shown in table by 2.
For high delta connection: divide value shown in table by 1 .732.
For delta connection: divide value shown in table by 1 .732.

70
TABLE 12-3:EXCITATION DATA -50 HZ - 1500 RPM
Model Number Exciter Field Exciter Field Volts Fl No Load Output Voltage With
Low Volts Resistance-Ohms and F2 at regulator Fixed Excitation
@25°C No Load 240/480 High Wye Connection
Volts
12V DC 24V DC
431RSL2004 22.5 12.2 415 495
431RSL2006 22.5 10.4 430 510
431RSL2008 22.5 12.4 410 490
432RSL2010 22.5 12.6 410 490
432RSL2012 22.5 15.8 380 455
432RSL2014 22.5 13.1 400 480
432RSL2016 22.5 18.5 360 440
432RSL2018 22.5 16.9 370 450
433RSL2023 22.5 20.7 335 430
433RSL2027 22.5 16.7 360 445
571RSL2020 23.0 9.2 440 530
571RSL2024 23.0 11.5 420 500
571RSL2028 23.0 12.0 410 490
572RSL2032 23.0 12.4 400 480
572RSL2037 23.0 13.8 390 470
572RSL2040 23.0 12.7 400 480
572RSL2045 23.0 15.0 380 460
573RSL2048 23.0 14.3 390 470
573RSL2052 23.0 15.4 380 455
573RSL2056 23.0 17.0 370 450
741RSL2060 22.5 12.4 405 500
741RSL2064 22.5 13.7 390 480
741RSL2068 22.5 14.6 380 470
741RSL2072 22.5 14.0 390 480
742RSL2076 22.7 14.9 380 470
744RSL2284 22.0 17.2 350 470
744RSL2288 22.0 18.9 340 440
Model Number Exciter Field Exciter Field Volts Fl No Load Output Voltage With Fixed
Medium Volts Resistance-Ohms and F2 at Regulator Excitation Wye Connection
@25°C No Load 3300 Volts 12V DC 24V DC
573FSM2328 23.0 15.0 3000 3900
573FSM2336 23.0 15.4 2900 3800
574FSM2340 23.0 12.8 3200 4000
574FSM2348 23.0 15.4 2900 3800
574FSM2352 23.0 16.1 2800 3800
741FSM2360 22.7 12.0 3300 4300
741FSM2364 22.7 11.8 3300 4300
741FSM2368 22.7 12.5 3300 4200
742FSM2372 22.7 15.2 2900 3800
742FSM2376 22.7 15.0 2900 3800
742FSM2380 22.7 16.1 2700 3800
743FSM2384 22.0 15.4 2900 3900
743FSM2388 22.0 15.4 2900 3800
For rated load exciter field volts - see generator nameplate.
For low wye connection: divide value shown in table by 2.
For high delta connection: divide value shown in table by 1 .732.
For delta connection: divide value shown in table by 1 .732.

71
TABLE 12-5: RESISTANCE VALUES - MAIN WINDINGS
NOMINAL COLD (25°C) RESISTANCE IN OHMS
Base Model Winding Main Main
Low Voltage H-SG- Stator Rotor
431RSL2004 430011 .1160 .139
431RSL2006 430012 .0898 .149
431RSL2008 430013 .0685 .160
432RSL2010 430014 .0534 .170
432RSL2012 430018 .0389 .186
432RSL2014 430015 .0353 .189
432RSL2016 430017 .0245 .225
432RSL2018 430016 .0228 .226
433RSL2023 430042 .0144 .286
433RSL2027 430039 .0137 .297
571RSL2020 570020 .0316 .306
571RSL2024 570021 .0253 .322
571RSL2028 570022 .0214 .328
572RSL2032 570023 .0159 .363
572RSL2037 570024 .0144 .374
572RSL2040 570025 .0109 .402
572RSL2045 270026 .0092 .419
573RSL2048 570027 .0082 .457
573RSL2052 570028 .0068 .490
573RSL2056 570029 .0054 .542
741RSL2060 740021 .0061 .609
741RSL2064 740022 .0046 .647
741RSL2068 740023 .0042 .679
741RSL2072 740024 .0037 .718
742RSL2076 740025 .0032 .750
744RSL2284 740026 .0026 .892
744RSL2288 740027 .0018 1.044
Base Model Winding Main Main
Medium Voltage H-SG- Stator Rotor
573FSM2328 570201 1.249 .383
573FSM2336 570202 .837 .424
574FSM2340 570203 .694 .458
574FSM2348 570204 .526 .498
574FSM2352 570205 .410 .553
741FSM2360 740201 .462 .609
741FSM2364 740202 .380 .662
741FSM2368 740203 .297 .694
742FSM2372 740204 .223 .768
742FSM2376 740205 .185 .825
742FSM2380 740206 .151 .888
743FSM2384 740207 .127 .954
743FSM2388 740208 .101 1.053
Main stator values shown are line to line on the high wye connection. For low wye connection
divide value shown in table by 4.

72
 TABLE 12-6: RESISTANCE VALUES - EXCITER WINDINGS
NOMINAL COLD (25°C) RESISTANCE IN OHMS
Low Voltage Exciter Stator Exciter Rotor PMG
(Field) (Armature) Stator
430 Frames 22.5 0.023 2.0
570 Frames 23.0 0.045 2.0
741 Frames 22.5 0.043 2.0
742 Frames 22.7 0.048 2.0
744 Frames 22.0 0.066 2.0
Medium Exciter Stator Exciter Rotor PMG
Voltage (Field) (Armature) Stator
570 Frames 23.0 0.070 2.0
741 Frames 22.7 0.048 2.0
742 Frames 22.7 0.048 2.0
743 Frames 22.0 0.065 2.0

73