MAINTENANCE ROUTINES FOR

CUMMINS KTA50-G3 ENGINE

 MAINTENANCE ROUTINES FOR CUMMINS KTA50-G3 ENGINE

250 HRS MAINTENANCE

 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow
o Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check/Clean Crankcase breather tube/hose
 Check belt
 Check belt tension
 Check cooling system additives
 Check all belts
 Check cooling fan condition
Cant Description N/P
5 Oil Filter 3310169
ELEMENT, OIL BYPASS
2 3889311
FILTER
2 FUEL WATER SEPARATOR 4095189
2 Corrosion Resistor 4058965
2 Air Cleaner 3630751

1500 HOURS MAINTENANCE

 Steam clean engine
 Change engine oil
 Clean air pre-filter
 Replace filters:
 o Oil Full-flow
o Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check:
o Belt and belt tension
o Cooling system additives
o All belts (alternator)
o Cooling fan
o Engine protection system
o Batteries
 Check/replace hoses as required
 Check/Tighten mounting bolts
 Adjust fan idler pulley tensioner
 Grease:
o Fan idler pivot arm
o Front engine support
 Inspect crankshaft end clearance
 Clean/replace crankcase breather element
 Check/Clean Crankcase breather tube/hose
 Adjust valves and injectors** (This applies only to the first 1500 hours after
replacing injectors. After this adjustment, it’s recommended to calibrate at 3000
hours).

3000 HOURS MAINTENANCE

 Steam clean engine
 Adjust valves and injectors
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow
o Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check:
o Belt and belt tension
o Cooling system additives
o All belts (alternator)
o Cooling fan
o Engine protection system
o Batteries
 Grease:
o Fan idler pivot arm
o Front engine support
 Check/replace hoses as required
 Check/Tighten mounting bolts

6000 HOURS MANINTENANCE

 Steam clean engine
 Clean, calibrate and/or replace (if necessary) injectors
 Adjust valves
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow
 o Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check:
o Belt and belt tension
o Cooling system additives
o All belts (alternator)
o Cooling fan
o Batteries
 Grease:
o Fan idler pivot arm
o Front engine support
 Check/replace hoses as required
 Check/Tighten mounting bolts
 Clean an calibrate fuel pump
 Inspect and/or Replace as necessary:
o Turbocharger
 Measure turbocharger Axial Clearance
 Measure turbocharger Radial bearing Clearance
o Vibration Damper
 Thickness measurement, inspect for cracks, dents, bulges or leaks
o Water pump
 Clean and flush cooling system
 Change Coolant
 Calibrate Engine protection system
 Rebuild/replace:
o Fan hub
o Fan idler pulley
o Thermostat and seals
12.000 HOURS MAINTENANCE (IN-FRAME OVERHAUL)
 Steam clean engine
 Clean, calibrate and/or replace (if necessary) injectors
 Adjust valves
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow
o Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check:
o Belt and belt tension
o Cooling system additives
o All belts (alternator)
o Cooling fan
o Batteries
 Grease:
o Fan idler pivot arm
o Front engine support
 Check/replace hoses as required
 Check/Tighten mounting bolts
 Clean an calibrate fuel pump
 Change Anti-Coolant
 Calibrate Engine protection system
 Rebuild/replace:
o Fan hub
 o Fan idler pulley
 Check and Replace if necessary:
o Aftercooler
o Cam follower Assembly
o Camshaft
o Push rods or tubes
o Rocker lever Assembly
o Vibration Damper
 Thickness measurement, inspect for cracks, dents, bulges or leaks
 Replace:
o Thermostat and seals
o Cylinder heads
o Fuel line seals, NG
o Water pump
 Clean and flush cooling system
 Measure gear train backlash
 Inspect Exhaust Manifold - Air leaks, Air Intake and Exhaust System
 Inspect crankshaft end clearance
 Replace:
 Connecting Rods bearing
 Connecting Rod
 Cylinder liner
 Lubricating Oil Pump
 Piston rings
 Turbocharger

18.000 HOURS MAINTENANCE (MAJOR OVERHAUL)

 Steam clean engine
 Adjust valves
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow
o Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check:
o Belt and belt tension
o Cooling system additives
o All belts (alternator)
o Cooling fan
o Batteries
 Grease:
o Fan idler pivot arm
o Front engine support
 Check/replace hoses as required
 Check/Tighten mounting bolts
 Calibrate Engine protection system
 Rebuild/replace:
o Fan hub
o Fan idler pulley
 Inspect and replace if necessary:
o Cylinder heads
o Cylinder Package
o Thermostat and seals
o Connecting Rods bearing
o Connecting Rod
o Cylinder liner
 o Lubricating Oil Pump
o Piston rings
o Turbocharger
 Measure turbocharger Axial Clearance
 Measure turbocharger Radial bearing Clearance
o Fuel line seals, NG
o Connecting rod and bearing
 Replace:
o Aftercooler
o Main Bearings
o Thrust Bearings
o Cam follower Assembly
o Camshaft Bushing
o Camshaft Thrust Bearing
o Crankshaft front and rear seals
o Engine (Crankcase) breather
o Exhaust manifold
o Camshaft idle gear: left and right banks
o Lubricating oil cooler
o Fuel Injectors
o Fuel transfer pump
o Fuel primping pump
o Pistons
o Water Pump
o Replacement of auxiliary water pump
o Hydraulic Pump
o Lubricating oil cooler
o Vibration Damper
o Fuel Pressure-regulating valve
 Check Piston cooling Nozzle
 Clean and flush cooling system
 Change Coolant
 Measure gear train backlash
 Inspect crankshaft end clearance

Cummins has found that engines in most applications will not experience
significant valve/injector trail wear after initial adjustment is made at 1500 hours.
After this adjustment, it is recommended that the valves and injectors not be
adjusted again before injector calibration at 6000 hours or 2-year interval. Because
injector trail hardware is typically mixed between cylinders during injector
replacement, it is recommended to adjust valves and injectors 1500 hours after all
injector replacements.
MAINTENANCE ROUTINES FOR
CUMMINS QSK60-G5 ENGINE
MAINTENANCE ROUTINES FOR CUMMINS QSK60-G5 ENGINE

250 HRS MAINTENANCE

 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow/Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check/Clean Crankcase breather tube/hose
 Check Supplemental Coolant Additive (SCA) concentration
 Check pressure drop in Eliminator Filter (If it’s installed)
 Check:
o Belt and belt tension
o Fan idler pulley tensioner
o Cooling system additives and hoses
o Hoses, tubes, clamps
o Electrical connections
o Flexible hose
o Cooling fan

Cant Description N/P

4 Oil Filter 4920071
3 FUEL WATER SEPARATOR 4095189
2 Corrosion Resistor 3100308
4 Air Cleaner 4001508

.
1.500 HRS MAINTENANCE
 Steam clean engine
 Adjust valves and injectors** (This applies only to the first 1500 hours after
replacing injectors. After this adjustment, it’s recommended to calibrate at 3000
hours)
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow/Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check/Clean Crankcase breather tube/hose
 Check:
o Belt and belt tension
o Fan idler pulley tensioner
o Cooling system additives and hoses
o Hoses, tubes, clamps
o Electrical connections
o Flexible hose
o Cooling fan
o Check Supplemental Coolant Additive (SCA) concentration
o Check pressure drop in Eliminator Filter (If it’s installed)
o Check engine protection system
o Check batteries
 Check/replace hoses as required
 Inspect crankshaft end clearance
 Inspect Air leaks, Air Intake and Exhaust System
 Clean/replace crankcase breather element
 Clean centrifugal separator of Eliminator Filter (if it’s installed)

Cant Description N/P

4 Oil Filter 4920071
3 FUEL WATER SEPARATOR 4095189
2 Corrosion Resistor 3100308
4 Air Cleaner 4001508
1 Crankcase Beather 3636916
1 Colant Additive 3888399

3.000 HRS MAINTENANCE

 Steam clean engine
 Adjust valves and injectors
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow/Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check/Clean Crankcase breather tube/hose
 Check/Tighten Engine mount (mounting bolts)
 Check:
o Belt and belt tension
o Fan idler pulley tensioner
o Cooling system additives and hoses
 o Hoses, tubes, clamps
o Electrical connections
o Flexible hose
o Cooling fan
o Check Supplemental Coolant Additive (SCA) concentration
o Check pressure drop in Eliminator Filter (If it’s installed)
o Check engine protection system
o Check batteries
o Fuel line seals
 Check/replace hoses as required
 Inspect crankshaft end clearance
 Inspect Air leaks, Air Intake and Exhaust System
 Clean/replace crankcase breather element
 Clean centrifugal separator of Eliminator Filter (if it’s installed)
Cant Description N/P
4 Oil Filter 4920071
3 FUEL WATER SEPARATOR 4095189
2 Corrosion Resistor 3100308
4 Air Cleaner 4001508
1 Crankcase Beather 3636916
1 Coolant Additive 3888399

6.000 HRS MAINTENANCE

 Steam clean engine
 Clean, calibrate and/or replace (if necessary) injectors
 Adjust valves
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
 o Oil Full-flow/Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check/Clean Crankcase breather tube/hose
 Check/Tighten Engine mount (mounting bolts)
 Check:
o Belt and belt tension
o Fan idler pulley tensioner
o Cooling system additives and hoses
o Hoses, tubes, clamps
o Electrical connections
o Flexible hose
o Cooling fan
o Check Supplemental Coolant Additive (SCA) concentration
o Check pressure drop in Eliminator Filter (If it’s installed)
o Check engine protection system
o Check batteries
o Fuel line seals
 Check/replace hoses as required
 Inspect crankshaft end clearance
 Inspect Air leaks, Air Intake and Exhaust System
 Clean/replace crankcase breather element
 Clean centrifugal separator of Eliminator Filter (if it’s installed)
 Inspect and/or Replace if necessary:
o Turbochargers
 Measure turbocharger Axial Clearance
 Measure turbocharger Radial bearing Clearance
o Vibration Damper
 Thickness measurement, inspect for cracks, dents, bulges or leaks
  Water pump
Cant Description N/P
4 Oil Filter 4920071
3 FUEL WATER SEPARATOR 4095189
2 Corrosion Resistor 3100308
4 Air Cleaner 4001508
1 Crankcase Beather 3636916
1 Colant Additive 3888399

12.000 HRS MAINTENANCE (IN-FRAME OVERHAUL)

 Steam clean engine
 Clean, calibrate and/or replace (if necessary) injectors
 Adjust valves
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow
o Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check/Replace
o Belt and belt tension
o Cooling system additives
o All belts (alternator)
o Cooling fan
o Batteries
 Grease:
 o Fan idler pivot arm
o Front engine support
 Check/replace hoses as required
 Check/Tighten mounting bolts
 Clean an calibrate fuel pump
 Change coolant
 Calibrate Engine protection system
 Rebuild/replace:
o Fan hub
o Fan idler pulley
 Check and Replace if necessary:
 Aftercooler
 Cam follower Assembly
 Camshaft
 Push rods or tubes
 Rocker lever Assembly
o Vibration Damper
 Thickness measurement, inspect for cracks, dents, bulges or leaks
 Replace:
o Thermostat and seals
o Cylinder heads
o Fuel line seals, NG
o Water pump
 Clean and flush cooling system
 Measure gear train backlash
 Inspect Exhaust Manifold
 Inspect crankshaft end clearance
 Inspect Air leaks, Air Intake and Exhaust System
 Clean centrifugal separator of Eliminator Filter (if it’s installed)
 Replace:
  Connecting Rods bearing
 Connecting Rod
 Cylinder liner
 Lubricating Oil Pump
 Piston rings
 Turbocharger

24.000 HRS MAINTENANCE (MAJOR OVERHAUL)

 Steam clean engine
 Adjust valves
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow
o Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check:
o Belt and belt tension
o Cooling system additives
o All belts (alternator)
o Cooling fan
o Batteries
 Grease:
o Fan idler pivot arm
o Front engine support
 Check/replace hoses as required
 Check/Tighten mounting bolts
 Calibrate Engine protection system
 Rebuild/replace:
o Fan hub
o Fan idler pulley
 Inspect and replace if necessary:
o Cylinder heads
o Cylinder Package
o Thermostat and seals
o Connecting Rods bearing
o Connecting Rod
o Cylinder liner
o Lubricating Oil Pump
o Piston rings
o Turbocharger
 Measure turbocharger Axial Clearance
 Measure turbocharger Radial bearing Clearance
o Fuel line seals, NG
o Connecting rod and bearing
 Replace: Aftercooler
o Main Bearings
o Thrust Bearings
o Cam follower Assembly
o Camshaft Bushing
o Camshaft Thrust Bearing
o Crankshaft front and rear seals
o Engine (Crankcase) breather
o Exhaust manifold
o Camshaft idle gear: left and right banks
o Lubricating oil cooler
o Fuel Injectors
 o Fuel transfer pump
o Fuel primping pump
o Pistons
o Water Pump
o Replacement of auxiliary water pump
o Hydraulic Pump
 Check Piston cooling Nozzle
 Clean and flush cooling system
 Change Coolant
 Measure gear train backlash
 Inspect crankshaft end clearance
 Inspect Air leaks, Air Intake and Exhaust System
 Clean centrifugal separator of Eliminator Filter (if it’s installed)
Cummins has found that engines in most applications will not experience
significant valve/injector trail wear after initial adjustment is made at 1500 hours.
After this adjustment, it is recommended that the valves and injectors not be
adjusted again before injector calibration at 6000 hours or 2-year interval. Because
injector trail hardware is typically mixed between cylinders during injector
replacement, it is recommended to adjust valves and injectors 1500 hours after all
injector replacements.
MAINTENANCE ROUTINES FOR
CUMMINS QSK60-G6 ENGINE
 MAINTENANCE ROUTINES FOR CUMMINS QSK60-G5 ENGINE

250 HRS MAINTENANCE

 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow/Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check/Clean Crankcase breather tube/hose
 Check Supplemental Coolant Additive (SCA) concentration
 Check pressure drop in Eliminator Filter (If it’s installed)
 Check:
o Belt and belt tension
o Fan idler pulley tensioner
o Cooling system additives and hoses
o Hoses, tubes, clamps
o Electrical connections
o Flexible hose
o Cooling fan

1.500 HRS MAINTENANCE

 Steam clean engine
 Adjust valves and injectors** (This applies only to the first 1500 hours after
replacing injectors. After this adjustment, it’s recommended to calibrate at 3000
hours)
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow/Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check/Clean Crankcase breather tube/hose
 Check:
o Belt and belt tension
o Fan idler pulley tensioner
o Cooling system additives and hoses
o Hoses, tubes, clamps
o Electrical connections
o Flexible hose
o Cooling fan
o Check Supplemental Coolant Additive (SCA) concentration
o Check pressure drop in Eliminator Filter (If it’s installed)
o Check engine protection system
o Check batteries
 Check/replace hoses as required
 Inspect crankshaft end clearance
 Inspect Air leaks, Air Intake and Exhaust System
 Clean/replace crankcase breather element
 Clean centrifugal separator of Eliminator Filter (if it’s installed)
3.000 HRS MAINTENANCE
 Steam clean engine
 Adjust valves and injectors
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow/Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check/Clean Crankcase breather tube/hose
 Check/Tighten Engine mount (mounting bolts)
 Check:
o Belt and belt tension
o Fan idler pulley tensioner
o Cooling system additives and hoses
o Hoses, tubes, clamps
o Electrical connections
o Flexible hose
o Cooling fan
o Check Supplemental Coolant Additive (SCA) concentration
o Check pressure drop in Eliminator Filter (If it’s installed)
o Check engine protection system
o Check batteries
o Fuel line seals
 Check/replace hoses as required
 Inspect crankshaft end clearance
 Inspect Air leaks, Air Intake and Exhaust System
 Clean/replace crankcase breather element
 Clean centrifugal separator of Eliminator Filter (if it’s installed)

6.000 HRS MAINTENANCE

 Steam clean engine
 Clean, calibrate and/or replace (if necessary) injectors
 Adjust valves
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow/Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check/Clean Crankcase breather tube/hose
 Check/Tighten Engine mount (mounting bolts)
 Check:
o Belt and belt tension
o Fan idler pulley tensioner
o Cooling system additives and hoses
o Hoses, tubes, clamps
o Electrical connections
o Flexible hose
o Cooling fan
o Check Supplemental Coolant Additive (SCA) concentration
o Check pressure drop in Eliminator Filter (If it’s installed)
o Check engine protection system
o Check batteries
o Fuel line seals
 Check/replace hoses as required
 Inspect crankshaft end clearance
 Inspect Air leaks, Air Intake and Exhaust System
 Clean/replace crankcase breather element
 Clean centrifugal separator of Eliminator Filter (if it’s installed)
 Inspect and/or Replace if necessary:
o Turbochargers
 Measure turbocharger Axial Clearance
 Measure turbocharger Radial bearing Clearance
o Vibration Damper
 Thickness measurement, inspect for cracks, dents, bulges or leaks
 Water pump

12.000 HRS MAINTENANCE (IN-FRAME OVERHAUL)

 Steam clean engine
 Clean, calibrate and/or replace (if necessary) injectors
 Adjust valves
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow
o Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check:
o Belt and belt tension
o Cooling system additives
o All belts (alternator)
o Cooling fan
 o Batteries
 Grease:
o Fan idler pivot arm
o Front engine support
 Check/replace hoses as required
 Check/Tighten mounting bolts
 Clean an calibrate fuel pump
 Change coolant
 Calibrate Engine protection system
 Rebuild/replace:
o Fan hub
o Fan idler pulley
 Check and Replace if necessary:
 Aftercooler
 Cam follower Assembly
 Camshaft
 Push rods or tubes
 Rocker lever Assembly
o Vibration Damper
 Thickness measurement, inspect for cracks, dents, bulges or leaks
 Replace:
o Thermostat and seals
o Cylinder heads
o Fuel line seals, NG
o Water pump
 Clean and flush cooling system
 Measure gear train backlash
 Inspect Exhaust Manifold
 Inspect crankshaft end clearance
 Inspect Air leaks, Air Intake and Exhaust System
 Clean centrifugal separator of Eliminator Filter (if it’s installed)
 Replace:
 Connecting Rods bearing
 Connecting Rod
 Cylinder liner
 Lubricating Oil Pump
 Piston rings
 Turbocharger

24.000 HRS MAINTENANCE (MAJOR OVERHAUL)

 Steam clean engine
 Adjust valves
 Adjust fan idler pulley tensioner
 Change engine oil
 Clean air pre-filter
 Replace filters:
o Oil Full-flow
o Oil by-pass
o Fuel filter
o Coolant filter
o Air cleaner element
 Check:
o Belt and belt tension
o Cooling system additives
o All belts (alternator)
o Cooling fan
o Batteries
 Grease:
o Fan idler pivot arm
o Front engine support
 Check/replace hoses as required
 Check/Tighten mounting bolts
 Calibrate Engine protection system
 Rebuild/replace:
o Fan hub
o Fan idler pulley
 Inspect and replace if necessary:
o Cylinder heads
o Cylinder Package
o Thermostat and seals
o Connecting Rods bearing
o Connecting Rod
o Cylinder liner
o Lubricating Oil Pump
o Piston rings
o Turbocharger
 Measure turbocharger Axial Clearance
 Measure turbocharger Radial bearing Clearance
o Fuel line seals, NG
o Connecting rod and bearing
 Replace: Aftercooler
o Main Bearings
o Thrust Bearings
o Cam follower Assembly
o Camshaft Bushing
o Camshaft Thrust Bearing
o Crankshaft front and rear seals
o Engine (Crankcase) breather
o Exhaust manifold
o Camshaft idle gear: left and right banks
 o Lubricating oil cooler
o Fuel Injectors
o Fuel transfer pump
o Fuel primping pump
o Pistons
o Water Pump
o Replacement of auxiliary water pump
o Hydraulic Pump
 Check Piston cooling Nozzle
 Clean and flush cooling system
 Change Coolant
 Measure gear train backlash
 Inspect crankshaft end clearance
 Inspect Air leaks, Air Intake and Exhaust System
 Clean centrifugal separator of Eliminator Filter (if it’s installed)

Cummins has found that engines in most applications will not experience
significant valve/injector trail wear after initial adjustment is made at 1500 hours.
After this adjustment, it is recommended that the valves and injectors not be
adjusted again before injector calibration at 6000 hours or 2-year interval. Because
injector trail hardware is typically mixed between cylinders during injector
replacement, it is recommended to adjust valves and injectors 1500 hours after all
injector replacements.