Vol3

Service Manual
K38, K50, QSK38 and QSK50

Volume 3
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Bulletin 4021528
Printed in U.S.A. 27-MARCH-2008
p174
Cummins Inc.
Box 3005
Columbus, Indiana, U.S.A., 47202
Registered Office
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright
2008
Cummins Inc.
281522_Cummins_CovV3.mpc:281522_Cummins_CovV3 3/28/08 7:07 AM Page 1
Service Manual
Volume 3
Copyright 2008 Bulletin 4021528
Cummins Inc. Printed 27-MARCH-2008
All rights reserved
Foreword
This manual contains instructions for troubleshooting and repairing this engine in the chassis, complete rebuild
procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing
of accessory and component suppliers is located in Section M - Component Manufacturers. Suppliers can be
contacted directly for any information not covered in this manual.
Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i
- Introduction.
The manual is organized to guide a service technician through the logical steps of identifying and correcting problems
related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment
manufacturer for repair procedures.
The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild
procedures require the use of special service tools. Make sure the correct tools are used as described in the
procedures.
When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used
in place of the recommended item.
A series of specific service manuals (for example: Troubleshooting and Repair, Specifications, and Alternative Repair)
are available and can be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office
listing is located in Service Literature (Section L).
Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement.
Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating
your comments.
The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between
your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS
(1-800-343-7357) toll free in the U.S. and Canada.
The latest technology and the highest quality components are used to manufacture Cummins engines. When
replacement parts are needed, we recommend using only genuine Cummins or ReCon exchange parts.
Table of Contents
Section
Cooling System Group 08 .................................................................................................................... 8
Drive Units Group 09 ........................................................................................................................... 9
Air Intake System Group 10 ................................................................................................................ 10
Exhaust System Group 11 ................................................................................................................... 11
Compressed Air System Group 12 ...................................................................................................... 12
Electrical Equipment Group 13 ............................................................................................................ 13
Engine Testing Group 14 ..................................................................................................................... 14
Mounting Adaptations Group 16 ......................................................................................................... 16
Miscellaneous Group 17 ...................................................................................................................... 17
Main Power Generator Group 21 ......................................................................................................... 21
Service Literature ..................................................................................................................................... L
Component Manufacturers ....................................................................................................................... M
Specifications ........................................................................................................................................... V
Back .......................................................................................................................................................... back
K38, K50, QSK38, and QSK50
Section 8 Cooling System Group 08 Page 8-a
Section 8 Cooling System Group 08
Section Contents
Page
Belt Guard .........................................................................................................................................................8-3
Clean and Inspect for Reuse.............................................................................................................................8-4
Install................................................................................................................................................................8-4
Remove............................................................................................................................................................8-3
Coolant Bypass Tube ......................................................................................................................................8-12
Clean and Inspect for Reuse...........................................................................................................................8-14
Industrial......................................................................................................................................................8-14
Marine Applications......................................................................................................................................8-14
Finishing Steps...............................................................................................................................................8-16
Install..............................................................................................................................................................8-15
Industrial......................................................................................................................................................8-15
Preparatory Steps...........................................................................................................................................8-12
Remove.......................................................................................................................................................... 8-12
Industrial......................................................................................................................................................8-12
Coolant Filter ...................................................................................................................................................8-17
Install..............................................................................................................................................................8-17
Remove.......................................................................................................................................................... 8-17
Coolant Temperature Gauge ...........................................................................................................................8-11
Inspect for Reuse............................................................................................................................................8-11
Coolant Thermostat .........................................................................................................................................8-18
Finishing Steps...............................................................................................................................................8-32
General Information.........................................................................................................................................8-18
Install..............................................................................................................................................................8-27
Conventional Aftercooling.............................................................................................................................8-27
LTA..............................................................................................................................................................8-28
with Electronically Actuated Injector............................................................................................................. 8-29
Gas Compression.........................................................................................................................................8-30
Leak Test........................................................................................................................................................8-24
LTA..............................................................................................................................................................8-26
Remove.......................................................................................................................................................... 8-19
LTA..............................................................................................................................................................8-20
Test................................................................................................................................................................ 8-23
Coolant Thermostat Housing Support ............................................................................................................8-32
LTA..............................................................................................................................................................8-37
Finishing Steps...............................................................................................................................................8-41
Install..............................................................................................................................................................8-37
LTA..............................................................................................................................................................8-37
Remove.......................................................................................................................................................... 8-33
Cooling System ...............................................................................................................................................8-42
Drain...............................................................................................................................................................8-42
Fill...................................................................................................................................................................8-44
Flush...............................................................................................................................................................8-42
Cooling System Diagnostics ...........................................................................................................................8-54
Inspect............................................................................................................................................................8-54
Cooling System - Air or Combustion Gas Test ..............................................................................................8-46
Test................................................................................................................................................................ 8-46
Overflow Method..........................................................................................................................................8-46
Page 8-b Section 8 Cooling System Group 08
Sight Glass Method......................................................................................................................................8-47
Air Compressor............................................................................................................................................8-48
Combustion Gas Leak..................................................................................................................................8-49
Cylinder Head and Cylinder Liner.................................................................................................................8-52
Drive Belt, Cooling Fan .....................................................................................................................................8-5
Adjust............................................................................................................................................................. 8-11
Inspect for Reuse..............................................................................................................................................8-7
Install................................................................................................................................................................8-8
Remove............................................................................................................................................................8-5
ECM Cooling Plate .........................................................................................................................................8-169
Assemble......................................................................................................................................................8-173
Clean and Inspect for Reuse.........................................................................................................................8-170
Disassemble..................................................................................................................................................8-169
Finishing Steps.............................................................................................................................................8-174
Install............................................................................................................................................................8-174
Preparatory Steps.........................................................................................................................................8-169
Remove.........................................................................................................................................................8-169
ECM Cooling Plate Lines ...............................................................................................................................8-175
Finishing Steps.............................................................................................................................................8-178
Inspect for Reuse..........................................................................................................................................8-176
Install............................................................................................................................................................8-177
Remove.........................................................................................................................................................8-175
Expansion Tank ...............................................................................................................................................8-75
Finishing Steps...............................................................................................................................................8-80
Install..............................................................................................................................................................8-78
Remove.......................................................................................................................................................... 8-75
Fan Clutch, Viscous ........................................................................................................................................8-55
Measure..........................................................................................................................................................8-55
Fan, Cooling ....................................................................................................................................................8-70
Finishing Steps...............................................................................................................................................8-71
Install..............................................................................................................................................................8-71
Remove.......................................................................................................................................................... 8-70
Fan Drive Idler Arm Assembly ........................................................................................................................8-56
Assemble........................................................................................................................................................8-60
Clean..............................................................................................................................................................8-59
Disassemble................................................................................................................................................... 8-58
Finishing Steps...............................................................................................................................................8-62
Install..............................................................................................................................................................8-62
Remove.......................................................................................................................................................... 8-57
Fan Hub Bracket ..............................................................................................................................................8-62
Install..............................................................................................................................................................8-64
Remove.......................................................................................................................................................... 8-63
Fan Hub, Belt Driven .......................................................................................................................................8-64
Assemble........................................................................................................................................................8-67
Disassemble................................................................................................................................................... 8-66
Finishing Steps...............................................................................................................................................8-70
Install..............................................................................................................................................................8-69
Remove.......................................................................................................................................................... 8-65
Fan Shroud Assembly .....................................................................................................................................8-70
Heat Exchanger ...............................................................................................................................................8-81
Assemble......................................................................................................................................................8-101
Tube Type..................................................................................................................................................8-101
Plate Type..................................................................................................................................................8-103
Section 8 Cooling System Group 08 Page 8-c
Box Type....................................................................................................................................................8-106
Clean..............................................................................................................................................................8-92
Tube Type....................................................................................................................................................8-92
Tube Type....................................................................................................................................................8-97
Plate Type....................................................................................................................................................8-98
Box Type......................................................................................................................................................8-99
Disassemble...................................................................................................................................................8-92
Tube Type....................................................................................................................................................8-92
Plate Type....................................................................................................................................................8-93
Box Type......................................................................................................................................................8-95
Exploded View................................................................................................................................................8-81
Finishing Steps.............................................................................................................................................8-121
Inspect..........................................................................................................................................................8-100
Tube Type..................................................................................................................................................8-100
Plate Type..................................................................................................................................................8-100
Box Type....................................................................................................................................................8-101
Install............................................................................................................................................................8-110
Tube Type..................................................................................................................................................8-110
Plate Type..................................................................................................................................................8-116
Box Type....................................................................................................................................................8-119
Pressure Test................................................................................................................................................8-108
Tube Type..................................................................................................................................................8-108
Box Type....................................................................................................................................................8-110
Remove..........................................................................................................................................................8-85
Tube Type....................................................................................................................................................8-85
Plate Type....................................................................................................................................................8-88
Box Type......................................................................................................................................................8-90
Low-Temperature Aftercooler (LTA) Water Pump ........................................................................................8-168
Maintenance Check.......................................................................................................................................8-168
with Mechanically Actuated Injector............................................................................................................8-168
Radiator ...........................................................................................................................................................8-72
Test................................................................................................................................................................8-72
Radiator Hoses ................................................................................................................................................8-74
Radiator Pressure Cap ....................................................................................................................................8-74
Pressure Test..................................................................................................................................................8-75
Sea Water Hoses ...........................................................................................................................................8-168
Inspect..........................................................................................................................................................8-168
Sea Water Pump ............................................................................................................................................8-121
Assemble......................................................................................................................................................8-128
Gear Driven................................................................................................................................................8-128
Spline Driven..............................................................................................................................................8-132
Gear Driven................................................................................................................................................8-127
Spline Driven..............................................................................................................................................8-128
Disassemble..................................................................................................................................................8-122
Gear Driven................................................................................................................................................8-122
Spline Driven..............................................................................................................................................8-125
Finishing Steps.............................................................................................................................................8-136
Spline Drive................................................................................................................................................8-136
General Information.......................................................................................................................................8-121
Gear Driven................................................................................................................................................8-121
Install............................................................................................................................................................8-136
Spline Drive................................................................................................................................................8-136
Spline Drive................................................................................................................................................8-121
Remove.........................................................................................................................................................8-122
Spline Drive................................................................................................................................................8-122
Sea Water Pump Support ..............................................................................................................................8-136
Page 8-d Section 8 Cooling System Group 08
with Electronically Actuated Injector............................................................................................................8-138
Finishing Steps.............................................................................................................................................8-140
Install............................................................................................................................................................8-139
Remove.........................................................................................................................................................8-137
Sea Water System Diagnostics .....................................................................................................................8-165
Inspect..........................................................................................................................................................8-165
Pressure Test................................................................................................................................................8-167
Test...............................................................................................................................................................8-166
Service Tools ....................................................................................................................................................8-1
Cooling System.................................................................................................................................................8-1
Supplemental Coolant Additive (SCA) ..........................................................................................................8-140
Maintenance Check.......................................................................................................................................8-140
Water Manifold ..............................................................................................................................................8-141
Water Pump ...................................................................................................................................................8-142
Assemble......................................................................................................................................................8-154
Disassemble..................................................................................................................................................8-149
Finishing Steps.............................................................................................................................................8-164
Inspect..........................................................................................................................................................8-152
Install............................................................................................................................................................8-160
Remove.........................................................................................................................................................8-145
K38, K50, QSK38, and QSK50 Service Tools
Section 8 Cooling System Group 08 Page 8-1
Service Tools
Cooling System
The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins Authorized
Repair Location.
Tool No. Tool Description Tool Illustration
ST-647
Gear Puller
Used to remove the water pump pulley and impeller.
3376326
Pulley Installation Tool
Used to install drive pulleys.
3375318
Water Pump Bearing Mandrel
Used to press the bearing and shaft into the water pump body.
3375319
Water Pump Bearing Mandrel
Used to install the front water pump oil seal into the water pump body.
3375326
Bearing Separator
Used to hold the bearing when removing it from the shaft.
3375411
Thermostat Seal Driver
Used to install thermostat seal.
Service Tools K38, K50, QSK38, and QSK50
Page 8-2 Section 8 Cooling System Group 08
3375066
Pipe Sealant
Used when installing pipe plugs or cup plugs on the engine in order
to prevent leaks.
3377462
Digital Optical Tachometer
Used to measure the rpm of the fan.
3377464
Reflective Tape
Used with optical tachometer, Part Number 3377462, to measure the
rpm of the fan.
CC-2602
Cooling System Test Kit - Fleetguard
Used to measure supplemental cooling additive (SCA) concentration.
1650
Snap-On Pry Bar
Used to remove thermostat seals.
3164794
Torque Wrench
Used to tighten capscrews 13 to 136 Nm [10 to 100 ft-lb].
K38, K50, QSK38, and QSK50 Belt Guard
Belt Guard (008-001)
Remove
Remove the two capscrews and washers connecting the
auxiliary drive guard from the vibration damper guard.
Loosen the two capscrews from the rear of the gear
housing securing the auxiliary drive guard to the gear
housing.
Remove the auxiliary drive guard.
Remove the four capscrews, washers, and isolators from
the vibration damper guard.
Remove the vibration damper guard.
Remove the capscrews and washers from the alternator
mounting bracket to the alternator belt guard.
Remove the two mounting capscrews and washers from
the front of the alternator belt guard to the front gear cover.
Remove the alternator belt guard.
Belt Guard K38, K50, QSK38, and QSK50
Clean and Inspect for Reuse
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use solvent to clean the belt guards.
Dry with compressed air.
Inspect the belt guards and brackets for cracks or other
damage. If damaged, they must be replaced.
Inspect the isolators for damage. If the isolators are hard
and brittle, they must be replaced.
Install
Install the two mounting capscrews, washers, and
alternator belt guard to the front gear cover.
Install the capscrews and washers to the alternator belt
guard through the alternator mounting bracket.
Operate the engine and check for proper operation.
K38, K50, QSK38, and QSK50 Drive Belt, Cooling Fan
Install the vibration damper guard, four capscrews,
washers, and isolators to the front gear cover.
Torque Value:
Vibration Guard
Capscrews
25 Nm [ 18 ft-lb ]
Install the auxiliary drive guard.
Install the two capscrews on the rear of the gear housing
securing the auxiliary drive guard to the gear housing.
Torque Value:
Rear Guard
Housing
Capscrews
40 Nm [ 30 ft-lb ]
Install the two capscrews and washers connecting the
auxiliary drive guard to the vibration damper guard.
Torque Value:
Auxiliary Drive
Guard
Capscrews
15 Nm [ 133 in-lb ]
Drive Belt, Cooling Fan (008-002)
Remove
NOTE: The back side idler system uses one of two types
of control rods (turnbuckles) or a shock absorber. Refer to
the OEM service manual for the instructions that apply to
the engine being serviced.
Remove the back side idler end of the shock absorber,
solid control rod (turnbuckle), or control rod tensioner
assembly.
Loosen the upper capscrew (31). Remove the lower
capscrew (31).
NOTE: One of the jam nuts on the solid control rod
(turnbuckle) 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).
Drive Belt, Cooling Fan K38, K50, QSK38, and QSK50
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 two jam
nuts (26), washers (25)(24), and spring (23).
Remove the following parts:
Capscrew (20)
Lock washer (19)
Washer (18)
Spacer (17)
Capscrew (14)
Lock washer (13)
Washer (12)
Control rod (15).
WARNING
The fan belt idler is under tension. Do not allow hands
to get between the idler, fan, or the fan hub. Failure
to do so can result in personal injury.
Use a 8-point socket and breaker bar or large wrench to
hold the idler in position against the spring tension.
Remove the capscrews from the spring cap.
Slowly turn the wrench until the spring tension is relieved.
Remove the fan belt.
NOTE: The fan center distance is the distance between
the crankshaft and fan center lines.
On systems that use a two pulley fan drive (without idler
pulley) with a 508 mm [20 in], 559 mm [22 in], or 610 mm
[24 in] fan center, loosen the bolts 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 711 mm [28
in] fan center distance, loosen the bolts that pass through
the slotted holes and fan hub bracket of the 711 mm [28
in] fan center system. The adjusting screw (16) is below
the fan hub. The locknut (17) must be loosened before
loosening the fan hub adjusting screw.
Remove the fan belt.
Inspect for Reuse
Inspect the fan belt for the following:
Cracks
Glazing
Tears or cuts.
Install
Install the belt on the crankshaft and fan hub pulley.
Align the grooves on the belt on the ribs of the pulley.
WARNING
After installing the fan belt, install the back side fan idler
system.
Rotate the idler against the spring tension until the
capscrew holes are aligned.
Install the lock washer and capscrew.
Torque Value: 45 Nm [ 35 ft-lb ]
Slowly turn the wrench until the idler is against the belt.
NOTE: The fan hub pulley and the fan belt are shown
removed for clarity.
When installing the solid control rod (turnbuckle) on older
engines, the capscrews (4)(7) are 64 mm [2-1/2 in] in
length. On the newer engines, the capscrew (4)(7) are 57
mm [2-1/4 in] in length. It is recommended that SAE Grade
8 capscrews that are 57 mm [2-1/4 in] be installed or the
capscrews can break.
Install a spacer (1), a heavy flat washer (2), and lock
washer (3).
Install a SAE Grade 8 capscrew (4), 57 mm [7/16-14 x 2-1/4
in] 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 heavy flat
washer (2).
Install a SAE Grade 8 capscrew (7), 57 mm [7/16-14 x 2-1/4
in] in the lower control rod end (8).
Install the lower control rod end on the idler arm (9).
Tighten the capscrews (4)(7).
NOTE: The fan belt must be 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.
Turn 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 handed threads.
Hold the adjusting screw and tighten the two jam nuts (11).
To install the control rod with spring, install the flat washer
(12), lock washer (13), and capscrews (14) in the upper
end of the control rod (15).
Install the control rod in the fan support (16).
Tighten the capscrew.
Install the spacer bushing (17), flat washer (18), lock
washer (19), and capscrew (20) in the lower end of the
control rod (21).
Install the lower end of the control rod on the fan idler are
(22).
Tighten the capscrews.
CAUTION
Do not tighten the inner fan nut excessively. If the jam
nut is to tight, the spring retainer will bend and the
control rod will fail.
Install the following parts:
Spring (23)
Spring retainer washer (24)
Flat washer (25)
Jam nuts (quantity 2)(26).
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.
CAUTION
The shock absorber must be installed with the larger
outer tube of the shock absorber attached to the fan
hub support. If the absorber is installed wrong, dirt
can enter the tube and cause the part to fail.
Install the following parts to install the shock absorber:
Spacer (28)
Flat washer (29)
Lock washer (30)
Capscrew (31)
Shock absorber (32).
Install the shock absorber (32) in the fan support (6).
Install the flat washer (29), lock washer (30), and capscrew
(31) in the lower end of the shock absorber.
Install the shock absorber on the fan idler arm.
Tighten the two capscrews (31).
The following step is for installing the two pulley fan drive
belt center 711 mm [28 in].
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) counterclockwise to
remove the slack from the belt.
The following step is for installing the two pulley fan drive
belt centers 508mm [20 in], 559mm [22 in], and 610 mm
[24 in].
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 the
slack from the belt.
K38, K50, QSK38, and QSK50 Coolant Temperature Gauge
Adjust
Only one method is acceptable for setting the two pulley
fan drive belt tension. The recommended method is to use
a belt tensioner gauge.
WARNING
CAUTION
Incorrect belt tension can cause component failure.
Install the belt tension gauge, Part Number 3823772, or
equivalent, on the belt in the middle between the two
pulleys. Continue tightening the adjusting capscrew to a
belt tension of 2668.9 to 2891.3 N [600 to 650 lbf] The belt
tension will increase when the capscrews tighten the fan
hub assembly to the fan support.
Remove the tension gauge and position the gauge on the
other side of the belt. Check to make sure the tension is
correct 2891.3 to 3336.2 N [650 to 750 lbf]. If the belt
tension is not correct, loosen the capscrews and adjust to
the correct tension again.
Coolant Temperature Gauge (008-004)
Inspect for Reuse
Check for a blown fuse.
Check the wiring from the gauge to the sending unit for
broken connection(s).
Coolant Bypass Tube K38, K50, QSK38, and QSK50
Use a temperature gauge of known accuracy to check the
existing gauge.
Replace the gauge or sending unit if faulty.
Coolant Bypass Tube (008-005)
Preparatory Steps
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Batteries cam emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To avoid
the possibility of arcing, remove the negative (-)
battery first, and attach the negative (-) battery cable
last.
Disconnect the battery cables. Refer to Procedure
013-009 (Batteries and Cable connections) in
Section 13.
Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
Remove
Industrial
Loosen the hose clamps (5).
Remove the four capscrews, the two tubes (2) and (6), and
the gaskets (1).
Remove the hose (4).
Discard the hose (4) and gaskets (1).
K38, K50, QSK38, and QSK50 Coolant Bypass Tube
Marine Applications
Remove the Straub coupling from the bypass line.
Remove the U-bolts from the bypass tube.
Remove the capscrews and washers from the lower flange
connecting the bypass tube to the water pump.
Remove the lower section of the bypass tube.
Discard the gasket.
Remove the capscrews and washers from the upper
flange connecting the bypass tube to the thermostat
housing.
Remove the upper section of the bypass tube.
Discard the gasket.
Industrial
WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to prevent personal injury when
using a steam cleaner or high-pressure water.
Use a gasket scraper and wire brush to clean the gasket
sealing surfaces.
Use steam to clean the tubes.
Check the tube gasket sealing face and tube for damage.
Replace if it is cracked or otherwise damaged.
Replace the hose and hose clamps.
Marine Applications
WARNING
Wear safety glasses or a face shield, as well as
protective clothing. Hot stem can cause serious
personal injury.
Use a gasket scraper and wire brush to clean the gasket
sealing surfaces.
Use steam to clean the tubes and Straub coupling.
Check the tube gasket sealing face and tube for damage.
Inspect the Straub coupling for wear or other damage.
Replace if cracked or otherwise damaged.
Replace the hose clamps.
K38, K50, QSK38, and QSK50 Coolant Bypass Tube
Install
Industrial
Install the gasket (1) and the lower end of the bypass tube
(2) on the water pump inlet housing (3) with lock washers
and capscrews.
Put the hose (4) and two clamps (5) on the tube (2).
Install the end of the tube (6) in the hose. Install the gasket
(7), lock washer, and capscrews that hold the tube to the
thermostat support.
Tighten the four capscrews
Check to be sure the hose (4) is the same length on both
tubes.
Tighten the two hose clamps (5).
Torque Value: 5 Nm [ 44 in-lb ]
Marine Applications
Install the upper section of the bypass tube.
Install the capscrews and washers to the upper flange
connecting the bypass tube to the thermostat housing.
Torque Value:
Upper Flange
Capscrews
38 Nm [ 28 ft-lb ]
Install the lower section of the bypass tube.
Install the capscrews and washers to the lower flange
connecting the bypass tube to the water pump.
Torque Value:
Lower Flange
Capscrews
28 Nm [ 20 ft-lb ]
Check the gap between the upper and lower bypass
tubes. The gap must not exceed 17 mm [0.70 in].
Install the U-bolts for the bypass tube.
Torque Value:
U-Bolts 21 Nm [ 186 in-lb ]
Install the Straub coupling onto the bypass line.
Torque Value:
Straub Coupling 30 Nm [ 22 ft-lb ]
Finishing Steps
WARNING
last.
Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
Connect the battery cables. Refer to Procedure
Section 13.
Operate the engine to normal operating temperature
and pressure, then check for leaks.
K38, K50, QSK38, and QSK50 Coolant Filter
Coolant Filter (008-006)
Remove
WARNING
Remove the pressure cap from the radiator.
WARNING
Turn valve (1) on the coolant filter head to the OFF position
to prevent water loss.
Remove the coolant filters.
Install
Clean the area around the coolant filter head. Clean the
gasket surface of the coolant filter head.
The o-ring can stick on the coolant filter head. Make sure
the o-ring is removed.
Discard the coolant filters.
CAUTION
When lubricating the seal on the coolant filter do not
allow oil to get into the coolant filter. It will adversely
affect the SCA.
Lubricate the seal on the coolant filter with clean engine
oil.
Coolant Thermostat K38, K50, QSK38, and QSK50
Install the coolant filter.
Turn the coolant filter clockwise until the seal touches the
coolant filter head.
Turn the coolant filter an additional to of a turn after
contact.
Turn the valve (1) on the coolant filter head to the ON
position.
Coolant Thermostat (008-013)
General Information
The K38 and K50 engines must have thermostats that do not have a vent.
The K50 thermostats contain a nitrile rubber seat vulcanized to the brass collar at the barrel seat. This seat prevents
coolant leakage and wear. The thermostat with the rubber seat must be used on K50 engines. The thermostat with
the rubber seat is not required for the K38 engine, but can be installed.
The Low Temperature Aftercooling (LTA) arrangement uses four coolant thermostats and one LTA thermostat, the
LTA thermostat has a knurled flange and is located in the center position between the engine coolant thermostats.
Thermostat, Part Number 3046191, must be used in all K50 engines to prevent premature thermostat failures.
This thermostat is designed to withstand the higher flow of the K50 engine and incorporates a nitrile rubber seal for
reduced leakage and improved seating. This thermostat was released in July, 1985, engine serial number first
33109759. The standard thermostat will fail at low hours if installed in the K50 engines.
This thermostat was fitted to all K38 engines from May, 1993, engine serial number first 33124382.
K38, K50, QSK38, and QSK50 Coolant Thermostat
Preparatory Steps
WARNING
WARNING
WARNING
Batteries can emit explosive gases. To reduce the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the negative
(-) battery cable first and attach the negative (-) battery
cable last.
Disconnect the batteries. Refer to Procedure
013-009 (Batteries and cable connections) in Section
13.
Remove the cooling fan (if installed). Refer to
Procedure 008-040 (Fan Cooling) in Section 8.
Remove the fan belt (if installed). Refer to Procedure
008-002 (Drive Belt, Cooling Fan) in Section 8.
Remove the fan hub (if installed). Refer to Procedure
008-036 (Fan Hub, Belt Driven) in Section 8.
Remove the fan hub bracket (if installed). Refer to
Procedure 008-035 (Fan Hub Bracket) in Section 8.
Remove the water filters (if installed). Refer to
Procedure 008-006 (Coolant Filter) in Section 8.
Remove the heat exchanger (if equipped). Refer to
Procedure 008-053 (Heat Exchanger) in Section 8.
Remove
Conventional Aftercooling
NOTE: Shown is the K38 and K50 thermostat housing.
Although different in appearance, the procedure remains
the same for the QSK series engines.
Remove both upper radiator hoses from the thermostat
housing.
Remove the 12 capscrews.
Remove the thermostat housing and gasket.
Discard the gasket.
Remove the thermostats and seals from the thermostat
housing.
LTA
Remove the pipe plug from the lower water transfer
connection on aftercooler core on each bank to drain the
aftercooler plumbing on engines equipped with LTA.
Remove the tube clamps (1) and the aftercooler plumbing
on both banks.
Loosen the capscrews (2) on the water transfer connection
to allow flexibility.
Remove the water transfer tubes.
Remove the radiator hoses from the thermostat housing.
Remove the vent lines from the thermostat housing (1).
Remove the four water bypass tube capscrews (2).
Remove the 14 capscrews and the heat shield.
Remove the thermostat housing and gasket.
Remove the four main thermostats and the one knurled
LTA thermostat in the center. The main and LTA
thermostats are not interchangeable.
with Electronically Actuated Injector
Remove the two Straub couplings on the thermostat outlet
tube on marine engines.
Remove the hose clamps and hoses for the industrial
engines (not shown).
Disconnect the vent line from the thermostat outlet tube.
Remove the capscrews and washers from the thermostat
outlet connections to the outlet tube tube.
Remove the outlet tube and discard the gaskets.
Remove the six capscrews, washers, cover plate, and
gaskets from the LTA thermostat housing.
Remove the LTA thermostats and seals from the
thermostat housing.
Inspect for Reuse
Check the thermostat for wear or damage. If the barrel of
the thermostat is worn or fretted, it must be replaced.
Test
Check the thermostat marking to see when the thermostat
is designed to open.
The rated nominal temperature is marked on the side of
the thermostat.
The design temperature of the thermostat is 82C [180
F].
Engine Thermostat Initial Opening Temperature
C F
82.2 MIN 180
94.4 MAX 202
LTA Thermostat Initial Opening Temperature
C F
73.8 MIN 165
86.1 MAX 187
Continue to apply heat until the water reaches the full
open temperature for the specific thermostat being tested.
The temperature is 12C [22F] above nominal opening
temperature. At that temperature, measure the open
distance of the thermostat.
The minimum open distance at full open temperature is
9.52 mm [0.375 in].
Remove the container from the heat.
With the thermostat open, check for wear or other
damage.
If the seat of the thermostat is worn or fretted, it must be
replaced.
Check to see if the thermostat returns to the closed
position.
If the barrel of the thermostat is worn or fretted, it must be
replaced.
Leak Test
WARNING
Complete this procedure with engine coolant
temperatures below 50C [120F]. Hot coolant or
steam can cause serious personal injury.
This procedure has been developed to troubleshoot a
thermostat failed in the open position, or experiencing
excessive leakage at the seat.
This problem is often verified by observing premature
warming of the thermostat housing coolant outlet pipes to
the radiators. These pipes must not warm previous to
coolant temperatures reaching the designated thermostat
opening temperature.
The following procedure outlines troubleshooting a
thermostat stuck in the open position:
NOTE: All troubleshooting procedures dealing with
thermostats stuck in the open position must take place
with coolant temperatures below the nominal opening
temperatures of the thermostats.
Two test procedures are included. One defines the
procedure for the standard cooling system, the second
describes engines equipped with LTA.
WARNING
Remove the upper radiator hoses from the thermostat
housing.
Coolant flowing from the thermostat housing with the
hoses removed signifies a thermostat stuck in the open
position. Remove the thermostat and test the operation as
described in the Test section.
Install two hoses of the same size on the thermostat
housing outlets long enough to reach a remote dry
container.
Install and tighten the hose clamps on the housing outlets.
Place the end of the hoses in two dry containers.
Operate the engine at rated rpm for 1 minute.
Shut the engine off, and measure the amount of coolant
collected in each container.
The amount of coolant collected in either container must
not exceed 200 cc [7 fluid oz].
If more than 200 cc [7 fluid oz] of coolant is collected from
either container, the thermostat or thermostat seal is
leaking.
Remove the thermostat and test operation as described in
the Test section.
LTA
Remove the LTA radiator inlet hose (1) and the two main
engine coolant outlet hoses (2) to the radiator.
Coolant flow from the thermostat housing indicates a
thermostat is stuck in the open position. Replace the
thermostats.
Install a hose from the LTA Thermostat housing to a
remote container (1). Install a hose from each of the main
engine thermostat coolant outlets to a common remote
container (2).
Partially fill each hose with coolant. Place the end of each
hose in their respective containers. Allow the hoses to
drain in this position. Remove the coolant from the
containers.
Operate the engine at rated rpm for 1 minute.
Turn off the engine and measure the amount of coolant in
the container.
The amount of coolant collected from the main engine
thermostats must not exceed 400 cc [14 fluid oz].
Remove the draincock (3). Use a gauge of 420 kPa [60 psi]
minimum capacity.
Remove any coolant from the container collecting the LTA
thermostat leakage.
Start the engine. Note the block coolant pressure.
Increase the engine speed until the coolant pressure
reaches 170 kPa [25 psi]. Maintain this engine speed for
1 minute. Shut the engine off and measure the amount of
coolant collected in the container.
The amount of coolant collected from the LTA thermostat
must not exceed 100 cc [3.5 fluid oz]. If more is collected,
the thermostat or thermostat seal is leaking. Remove the
thermostat(s) and test.
Install
The seal must be installed with the part number up.
Use a mallet and seal driver, Part Number 3375411. Install
the seal.
Install the seal no more than 0.51 mm [0.020 in] 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, be sure the
thermostat is installed.
The K50 thermostats contain a nitrile rubber seat
vulcanized to the brass collar at the barrel seat. This seat
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.
Install the thermostat housing.
Torque Value:
Thermostat
Housing
45 Nm [ 33 ft-lb ]
On K38 and K50 engines, install the two upper radiator
hoses.
Tighten the hose clamps.
On the QSK38 and QSK50 engines, connect the water
lines to the triangle, three bolt flanges, using new gaskets.
LTA
The seal must be installed with the part number up.
Use a mallet and seal driver Part Number, 3375411. Install
the seal.
Install the four main engine thermostats and the one
knurled LTA thermostat.
Install the radiator hoses at the thermostat housing.
Install the LTA thermostat seals and thermostats into the
thermostat housings.
Install the new gasket, thermostat cover, washers, and
capscrews into the LTA thermostat housing.
Tighten the capscrews
Install new gaskets and the thermostat outlet tube,
washers, and capscrews to the outlet connection of the
LTA thermostat housing.
Tighten the capscrews
Install the vent line to the thermostat outlet tube.
Install the two Straub couplings onto the thermostat outlet
tube on marine engines.
Install the hose and two hose clamps onto the thermostat
outlet tubes on industrial engines (not shown).
Gas Compression
NOTE: The seal must be installed with the part number
up.
Use a mallet and seal driver, Part number 3375411, to
install the seal.
The K50 thermostats contain a nitrile rubber seat
vulcanized to the brass collar at the barrel seat. This seat
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 KTA38GC
engine, but can be installed.
Coolant Thermostat Housing Support K38, K50, QSK38, and QSK50
Finishing Steps
WARNING
WARNING
cable last.
Install the fan hub bracket (if installed). Refer to
Install the fan hub (if installed). Refer to Procedure
Install the fan belt (if installed). Refer to Procedure
Install the cooling fan (if installed). Refer to
Procedure 008-040 (Fan Cooling) in Section 8.
Install the heat exchanger (if equipped). Refer to
Install the water filters (if installed). Refer to
Connect the batteries. Refer to Procedure 013-009
(Batteries and cable connections) in Section 13.
Operate the engine until the coolant temperature
reaches 70C [158F], and then check for leaks.
Coolant Thermostat Housing Support (008-015)
General Information
Thermostat Support
The thermostat support assembly contains a support and two thermostat housings. Each thermostat housing contains
two thermostats. The support assembly also provides for connection of the water outlet tubing for the cylinder head,
air compressor, aftercooler, and a mounting provision for coolant filters. The low temperature aftercooler thermostat
housing does not include a mounting provision for coolant filters.
A revised thermostat housing support with 6.35 mm [0.25 inch] vent holes located higher in the support for improved
venting replaced the previous housing in February of 1992, engine serial number first 33121370. The support housing
with 19.05 mm [0.75 inch] holes remained in production.
Thermostat Seal
Each thermostat housing contains two thermostat seals.
The thermostat seal for K38 and K50 engines was changed. The revised seal has a sealing element that is thicker.
This sealing element prevents fretting and leakage resulting from the higher coolant flow required in K38 and K50
engines. The thin seal is installed on other Cummins engines. The thick seal must be used on K38 and K50 engines.
Heat Shield
All KT38, KTA38, and KTA50 engines with a center mount aftercooler or air transfer housing must have a heat shield
installed on the right bank thermostat housing. This heat shield is required to prevent damage to the outlet hose from
the heat of the exhaust outlet of the turbocharger. KTA38 and KTA50 engines with outboard aftercoolers do not require
the heat shield. The thermostat housing mounted design replaced the coolant outlet hose mounted design in February
of 1983, engine serial number first 33107562, a revised thermostat housing was also released to accommodate the
revised heat shield. The older heat shield must not be installed again or failure of the right bank coolant outlet hose
will result.
K38, K50, QSK38, and QSK50 Coolant Thermostat Housing Support
Preparatory Steps
WARNING
WARNING
WARNING
last.
Section 13.
Drain the cooling system. Refer to Procedure Refer
to Procedure 008-018 (Cooling System) in Section 8..
Remove the air cleaner assemblies. Refer to
Procedure 010-013 (Air Cleaner Assembly (Engine-
Mounted) in Section 10.
Remove the cooling fan (if installed). Refer to
Procedure 008-040 (Fan, Cooling) in Section 8.
Remove the fan belt (if installed). Refer to Procedure
Remove the fan hub (if installed). Refer to Procedure
Remove the fan hub bracket (if installed). Refer to
Remove the water filters (if installed). Refer to
Remove the heat exchanger (if equipped). Refer to
Remove
WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
NOTE: Shown is the K38 and K50 thermostat housing and
support bracket. Although different in appearance, the
procedure remains the same for the QSK engines.
Remove the six support assembly to the cylinder block
mounting capscrews.
Remove the thermostat support assembly (5).
Remove the water transfer tubes (2) and (3). Remove the
o-rings.
Discard the o-rings.
Low Temperature Aftercooling Thermostat Support.
Remove the Straub coupling from the bypass line.
Remove the U-bolts from the bypass tube.
Remove the capscrews and washers from the upper
flange connecting the bypass tube to the thermostat
housing.
Remove the upper section of the bypass tube.
Discard the gasket.
NOTE: The following step must be carried out on both
engine banks.
Remove the capscrews and retaining clamps from the
water tubes to the aftercoolers.
engine banks.
Loosen the hose clamps connecting the transfer tubes to
the rubber tee between the aftercoolers.
Separate the transfer tubes from the rubber tees.
Remove the capscrew and clamp from the right bank
upper transfer tube on the LTA thermostat housing.
Remove the transfer tube and discard the o-rings.
Remove the two capscrews and upper half of the transfer
tube isolator.
Remove the one capscrew, washer, and clamp from the
left bank transfer tube.
Remove the transfer tube and discard the o-rings.
Remove the six capscrews, gasket, and thermostat cover.
Remove the LTA thermostats and seals.
Discard the cover gaskets and thermostat seals.
Remove the four mounting capscrews, washers, and LTA
thermostat housing.
Remove the transfer tube isolation bracket and water
outlets from the thermostat housing.
Discard the o-ring and gaskets.
LTA
WARNING
WARNING
personal injury.
Use a suitable scraper to clean all gasket surfaces.
Use a wire brush to clean the LTA thermostat support
housing.
Thoroughly clean the o-ring bores.
Check for cracks or corrosion damage around the o-ring
seal bores.
Check for damaged threads and gasket surfaces.
Install
LTA
Use new gaskets and o-rings and install the water outlets
and transfer tube isolation bracket onto the thermostat
housing.
Torque Value:
Water Outlet
Capscrews
38 Nm [ 28 ft-lb ]
Torque Value:
Transfer Tube
Capscrews
11 Nm [ 97 in-lb ]
Install the thermostat housing, washers, and capscrews.
Torque Value:
LTA Thermostat
Housing
Capscrews
38 Nm [ 28 ft-lb ]
Install new thermostat seals, thermostats, new cover
gasket, and cover. Install the six washers and capscrews.
Torque Value:
LTA Thermostat
Cover Capscrews
60 Nm [ 44 ft-lb ]
Install two new o-rings on the left bank transfer tube and
lubricate them with vegetable oil.
Install the transfer tube, clamp, and one washer and
capscrew.
Torque Value:
Left Bank
Transfer Tube
Capscrews
22 Nm [ 16 ft-lb ]
Install two new o-rings on the right bank transfer tube and
lubricate them with vegetable oil.
Install the transfer tube, clamp, and one washer and
capscrew.
Torque Value:
Right Bank
Transfer Tube
Capscrews
22 Nm [ 16 ft-lb ]
engine banks.
Install the transfer tubes into the rubber tees.
Tighten the hose clamps at the rubber tee between the
aftercoolers.
Torque Value:
Hose Clamps 8 Nm [ 71 in-lb ]
Install the upper half or the transfer tube isolator and two
capscrews.
Torque Value:
Upper Half
Transfer Tube
Capscrews
11 Nm [ 97 in-lb ]
engine banks.
Install the retaining clamps, washers, and capscrews to
the water tubes to the aftercoolers.
Torque Value:
Retaining Clamps 38 Nm [ 28 ft-lb ]
Use a new gasket and install the washers and capscrews
on the upper flange connecting the bypass tube to the
thermostat housing.
Torque Value:
Upper Flange
Capscrews
38 Nm [ 28 ft-lb ]
Install the U-bolts on the bypass tube.
Torque Value:
Bypass Tube U-
bolts
22 Nm [ 16 ft-lb ]
Install the Straub coupling on the bypass line.
Torque Value:
Straub Coupling 30 Nm [ 22 ft-lb ]
Finishing Steps
WARNING
WARNING
last.
Install the water filters (if installed). Refer to
Install the fan hub bracket (if installed). Refer to
Install the fan hub (if installed). Refer to Procedure
008-036 (Fan Hub, Belt Driven) in Section 8
Install the fan belt (if installed). Refer to Procedure
Install the cooling fan (if installed). Refer to
Procedure 008-040 (Fan, Cooling) in Section 8.
Install the air cleaner assemblies. Refer to
Procedure 010-013 Air Cleaner Assembly (Engine
Mounted) in Section 10.
Section 13.
Operate the engine to normal operating
temperatures and pressures. Check for leaks.
Cooling System K38, K50, QSK38, and QSK50
Cooling System (008-018)
Drain
WARNING
WARNING
Remove the radiator cap after the engine is cool.
Open the petcocks on each turbocharger.
Open the draincock at the bottom of the radiator.
Remove the lower radiator hose.
Open the aftercooler core drain valves.
Drain the cooling system.
Do not allow the cooling system to dry out.
Check for damaged hoses and loose or damaged hose
clamps. Replace as required.
Check the radiator for leaks, damage, and buildup of dirt.
Clean and replace as required.
Flush
RESTORE (cooling system cleaner) is a heavy-duty
cooling system cleaner that removes corrosion products,
silica gel, and other deposits. The performance of
RESTORE is dependent on time, temperature, and
concentration levels. An extremely scaled or flow-
restricted system, for example, can require higher
concentrations of cleaners, higher temperatures, or longer
cleaning times or the use of RESTORE Plus (cooling
system cleaner). Up to twice the recommended
concentration levels of RESTORE can be used safely.
RESTORE Plus must be used only at its recommended
concentration level. Extremely scaled or fouled systems
can require more than one cleaning.
K38, K50, QSK38, and QSK50 Cooling System
Do not remove the coolant filters.
CAUTION
Fleetguard Restore (cooling system cleaner)
contains no antifreeze. Do not allow the cooling
system to freeze during the cleaning operation.
Close all petcocks to avoid air entrapment in the cooling
system.
Immediately add 3.8 liters [1 gal] of Fleetguard Restore,
or equivalent, for each 38 to 57 liters [10 to 15 gal] of
cooling system capacity, and fill the system with plain
water.
Turn the heater temperature switch to HIGH to allow
maximum coolant flow through the heater core. The
blower does not have to be on.
Operate the engine at a coolant temperature of at least
85C [185F] for 1 to 1- hours.
Shut the engine off.
Fill the cooling system with clean water.
Operate the engine at high idle for 5 minutes with the
coolant temperature above 85C [185F].
Shut the engine off.
If the water drained is still dirty, the system must be
flushed again until the water is clean.
Install a new coolant filter.
Fill the cooling system with fully formulated coolant.
Use additional SCA to bring the coolant to the correct SCA
concentration level. Refer to Procedure 018-004 (Coolant
Recommendations and Specifications) in Section 18.
Install the pressure cap. Operate the engine until the
coolant reaches a temperature of 70C [158F] and check
for coolant leaks.
Minimum Cooling System Pressure Cap Capacity 48
kPa [ 7 psi ]
Fill
Make sure the radiator draincocks and aftercooler core
drain valves are closed.
Open the cooling system venting petcocks.
Install the lower radiator hose(s). Refer to Procedure
008-045 (Radiator Hoses) in Section 8.
Use fully formulated coolant to fill the cooling system.
Use the correct units of SCA to obtain the correct cooling
system protection. Refer to Procedure 018-004 (Coolant
Recommendations and Specifications) in Section V.
CAUTION
Fill the cooling system slowly to avoid trapping air in
the cooling system. Air trapped in the system can
cause water pump cavitation and inadequate coolant
level.
Begin filling the cooling system with coolant.
Fill until a continuous stream of coolant begins to flow from
each opened petcock in the coolant system.
Close each petcock as the continuous stream of coolant
begins to flow from that petcock.
Fill the system with the coolant to the bottom of the
radiator fill neck.
Install the cooling system pressure cap.
Operate the engine until the coolant reaches a
temperature of 85C [185F]. Check for leaks.
WARNING
Shut the engine off, and allow it to cool.
Check the coolant level.
Cooling System - Air or Combustion Gas Test K38, K50, QSK38, and QSK50
Cooling System - Air or Combustion
Gas Test (008-019)
Test
Overflow Method
WARNING
Wait until the temperature is below 50C [120F]
before removing the pressure cap. Heated coolant
spray or steam can cause personal injury.
Remove the cooling system pressure cap.
Install a radiator pressure cap that has had the spring and
pressure relief valve removed.
The pressure cap must make a tight seal.
Attach a rubber hose to the radiator overflow connection.
Put the free end of the hose in a container of water.
Operate the engine at rated rpm until it reaches a
temperature of 85C [185F] with the thermostat open.
Check for a continuous flow of air bubbles from the hose
in the water container.
A continuous flow of bubbles can be the result of:
Air compressor cylinder head leak
Cylinder head combustion gas leak
Incorrect cylinder protrusion
Cracked or broken cylinder liners.
If air is not in the system, perform the following:
Remove the test equipment
Check the coolant level and fill if necessary
Install the correct radiator pressure cap
Operate the engine to a temperature of 80C [180
F]
Check for coolant leaks.
K38, K50, QSK38, and QSK50 Cooling System - Air or Combustion Gas Test
Sight Glass Method
Install a clear Pyrex tube in the water connection
between the engine radiator and the thermostat housing.
If desired, the Pyrex tube can be installed in the vent line
between the thermostat housing and the radiator.
WARNING
Use wire lace to cover the tube and hose. Personal
injury can result if the Pyrex tube separates from the
hoses.
Use the appropriate sight glass for the hose size used.
Sight Glass Part
Number
Outside diameter
mm in
3377405 25.4 [1.00]
3377406 31.8 [1.25]
3377407 50.8 [2.00]
3377408 57.2 [2.25]
3377409 63.5 [2.50]
3377410 69.9 [2.75]
3377411 76.2 [3.00]
3377412 88.9 [3.50]
Shut off the coolant filter to avoid discoloration of coolant
and obscured visibility
WARNING
Use wire lace to cover the tube and hose. Personal
injury can result if the Pyrex tube separates from the
hoses.
Connect the tube and hose with a wire lace.
Operate the engine at 75 percent of rated rpm until it
reaches an operating temperature of 85C [185F].
Check for a continuous flow of air bubbles in the hose.
A continuous flow of air bubbles indicates excessive air in
the system. Continue to operate the engine for 25 minutes.
If the flow of bubbles does not stop, check for the
following:
Air compressor cylinder head leak
Cylinder head combustion gas leak
Incorrect cylinder protrusion
Cracked or broken cylinder liners.
If no air is found in the system or if the flow of bubbles
stops within 25 minutes, perform the following:
Remove the test equipment
Check the coolant level and fill if necessary
Install the correct radiator pressure cap
Operate the engine until it reaches a temperature of 85
C [185F], and check for coolant leaks.
Air Compressor
CAUTION
The air compressor discharge mustbe disconnected
at the compressor. This will allow the compressor to
discharge air to the atmosphere to prevent the
compressor from overheating during this test.
CAUTION
Do not operate the engine over 5 minutes with the
components isolated from the cooling system.
Component damage can result.
Disconnect the air compressor discharge line.
Disconnect and plug the coolant supply and coolant drain
lines, from the air compressor.
Repeat the sight glass method or overflow method test.
If air is not found in the cooling system with the air
compressor isolated, replace the air compressor cylinder
head gasket. See to the Holset Master Repair Manual,
Bulletin 3666121.
Combustion Gas Leak
Combustion Gas Test
Use Part Number 3822985 Combustion Gas Tester or
equivalent, to test for combustion gases in the cooling
system.
NOTE: It is recommended that the cooling system contain
a mixture of 50 percent antifreeze and 50 percent water
during the combustion gas leak test. The use of water
only can result in a color change in the test fluid from blue
to turquoise or light green during the test. This is not an
indication of a combustion gas leak.
Drain the coolant level down approximately 50 mm [2 in]
below the radiator cap seal ledge in the radiator fill neck.
Pour the test fluid into the combustion gas test instrument
until it is up to the yellow fill line on the instrument.
Insert the rubber tip of the combustion gas leak test
instrument in the radiator fill neck. Hold the instrument
down firmly and turn back and forth to make sure that an
air tight seal is formed between the tester and radiator fill
neck.
Start the engine and run at high idle for approximately 30
minutes. Monitor the engine temperature and color of the
test fluid during engine operation. Do not allow the engine
temperature to exceed 100C [212F) during the test.
If the color of the test fluid changes from blue to yellow
anytime during the test, combustion gases are leaking into
the cooling system. Discontinue the test if the color of the
test fluid changes from blue to yellow.
If the color of the test fluid does not change from blue to
yellow during the 30 minutes test period, return the engine
to low idle.
Check the test instrument to make sure that it is firmly
sealed in the radiator fill neck.
Insert the tip of the rubber ball into the hole in the top of
the test instrument. Squeeze the rubber ball 2 to 3 minutes
to draw air from the radiator through the test fluid.
If the color of the test fluid remains blue, combustion
gases are not entering the cooling system. If the color of
the test fluid changes from blue to yellow, combustion
gases are entering the cooling system and further
investigation is required to determine the source of the
combustion leak.
NOTE: As the cooling system warms up to operating
temperature air will be expelled through the combustion
gas tester in the form of bubbles in the test fluid. This is
due to normal expansion of the coolant. Do not mistake
the presence of air bubbles in the tester as combustion
gases or air leaks into the cooling system. A change in the
color of the test fluid from blue to yellow is the only
indication of combustion gas in the cooling system.
A positive result from the combustion leak tester indicates
one or more of the following problems:
Cylinder liner protrusion incorrect
Cracked cylinder liner
Cylinder head or gasket leakage
NOTE: Discard the tester fluid if it has indicated positive.
A negative result from the combustion leak tester coupled
with a continuous flow of air bubbles from the previous test
indicates the following:
Defective fan, shutter or heater air control valve
Air compressor head or head gasket leakage
Air entrained due to incorrect fill and inadequate
cooling system venting
Defective Air Control Valve
To check the air control valve perform the following:
Remove air pressure from the tank that supplies the
valve in question
Disconnect the air supply line from the valve. Install
a plug in the air supply line
Repeat the test. If no air is found in the cooling
system, the air control valve is defective and must
be replaced.
Cylinder Head and Cylinder Liner
A cracked or defective cylinder head will pressurize the
cooling system and force the coolant out the overflow
tube.
Check the cylinder head gasket. Refer to Procedure
002-004 (Cylinder Head) in Section 2.
A cracked or porous cylinder liner will pressurize the
cooling system and force coolant out the overflow tube.
To determine the cylinder liner that is leaking, perform the
following:
Remove the water pump. Refer to Procedure
008-062 (Water Pump) in Section 8.
Remove the collar.
Install the water pump without the collar (20).
WARNING
Wait until the temperature is below 50C [120F]
before removing the pressure cap. Heated coolant
WARNING
Drain the coolant down to where coolant is level with the
water manifold tubes.
Slide the water manifold tubes into the rocker lever
housing.
Operate the engine at low idle for a maximum of 4
minutes. Check inside the water passage of each rocker
lever housing for air bubbles. Air bubbles in the coolant
indicate a porous or cracked cylinder liner.
A defective cylinder liner must be replaced. Refer to
Procedure 001-028 (Cylinder Liner) in Section 1.
Cooling System Diagnostics K38, K50, QSK38, and QSK50
If bubbles are not detected, install the water tubes and
water pump collar.
Cooling System Diagnostics (008-020)
Inspect
WARNING
Check the coolant level if necessary.
NOTE: If coolant is added, additional DCVA4 (or
equivalent) is required.
K38, K50, QSK38, and QSK50 Fan Clutch, Viscous
Fan Clutch, Viscous (008-028)
Measure
WARNING
To reduce the possibility of personal injury, keep
hands, long hair, jewelry, and loose-fitting or torn
clothing away from fans and other moving parts.
Use an optical tachometer, Part Number 3377462, or a
strobe light to measure the fan rpm.
Mark a spot on the fan so the rpm can be measured.
Mark another spot on the vibration damper to measure
engine rpm.
NOTE: When using the Cummins reflective optical
tachometer, use a piece of reflective tape Part Number
3377464, to mark the spot.
Measure the fan pulley diameter (A).
If the fan pulley diameter is 419 mm [16.50 inch], measure
the crankshaft pulley diameter (B).
Fan Drive Idler Arm Assembly K38, K50, QSK38, and QSK50
Operate the engine. Read and compare the fan rpm to
specifications.
Belt Driven Fan
Fan Pulley Diameter Crank Pulley
Diameter
Fan rpm
mm in mm in
419 [16.5] 163 [6.40] 0.4 x
engine
rpm
419 [16.5] 203 [8.00] 0.5 x
engine
rpm
406 [16.0] 0.5 x
engine
rpm
380 [14.94] 0.55 x
engine
rpm
317.5 [12.50] 0.64 x
engine
rpm
If the fan rpm is not correct, check the following:
Belt
Viscous fan element
Fan clutch thermal control valve.
Fan Drive Idler Arm Assembly
(008-029)
Preparatory Steps
NOTE: Not all engines are equipped with this option.
Remove the cooling fan. Refer to Procedure 008-040
(Fan, Cooling) in Section 8.
Remove the fan belt. Refer to Procedure 008-002
(Drive Belt, Cooling Fan) in Section 8.
K38, K50, QSK38, and QSK50 Fan Drive Idler Arm Assembly
Remove
NOTE: Two types of control rods or a shock absorber are
used. See the instructions that apply to the engine being
serviced.
Shock absorber: Remove the two capscrews (31) , the two
spacers (29), the spacer (28) and the shock absorber
Solid control rod: Loosen the 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).
NOTE: One of the jam nuts has left-hand threads.
Remove the capscrews (4) and (7), the washers (2) and (3)
and the spacers (1). Remove the control rod assembly.
Control Rod with Spring: Remove the two jam nuts (26).
Remove the washers (25) and (24) and the spring (23).
NOTE: This type of control rod is on engines that have an
adjustable fan hub only.
Remove the parts.
- (20) Capscrew
- (19) Washer, Lock
- (18) Washer
- (17) Spacer
- (14) Capscrew
- (13) Washer, Lock
- (12) Washer
- (15) Control Red
WARNING
Remove the three capscrews Remove the idler assembly.
NOTE: Engine with a 457 mm [18 inch] fan centre have
an adapter place between the idler and the front gear
cover.
Remove the adapter plate.
WARNING
Remove the three capscrews. Remove the idler arm
assembly.
NOTE: Engines with a 457 mm [18 inch] fan center have
an adaptor plate between the idler and the front gear
cover.
Remove the adaptor plate.
Disassemble
Remove the capscrews.
Remove the pulley assembly from the pivot arm assembly.
Rotate the cap until the pins (1) align with the slots (2) in
the cap.
Remove the cap.
Use a vise. Support the pivot arm assembly.
Capscrew (3)
Plain washer (4)
Thrust bearing (5)
Pivot arm (6)
Thrust bearing (7)
Spring (8).
NOTE: The pivot arm (6) contains an external wear sleeve
to prevent the spring from contacting the arm. The wear
sleeve can be replaced using the same method as the
coolant pump drive wear sleeve.
Remove the following parts.
Bushing (9)
O-ring (10).
Discard the o-ring.
Clean
WARNING
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers recommendations
Use solvent to clean the parts.
Check the shaft for wear. Make sure the shaft is tight in
the support.
If the shaft has grooves in the surface or is loose, the
support and the shaft must be replaced as an assembly.
Shaft Outside Diameter
mm in
38.087 MIN 1.4995
38.113 MAX 1.5005
Assemble
Install and position the bushings (9) even with the pivot
arm.
Use vegetable oil. Lubricate the o-ring (10).
Install the part.
Use a vise to hold the support as shown. Install the spring
on the support.
The end of the spring must be positioned on the spring
stop as shown.
Use water pump type grease. Lubricate the thrust
bearings (5) and (7).
Install the parts.
Align the pins (1) with the slots (2) in the cap.
Install the cap.
Use water pump type grease. Lubricate the pivot arm
assembly until the grease begins to come from under the
cap.
Install the pulley assembly to the pivot arm assembly.
Fan Hub Bracket K38, K50, QSK38, and QSK50
Install
NOTE: If the engine has two vibration dampers, a longer
idler arm than shown is required.
NOTE: If the engine has a fan hub with 457 mm [18 in]
center (low mount fan), an adapter plate is required
between the idler arm and the front gear cover.
NOTE: Check to be sure the spring on the idler arm is
not under tension. This will aid the future installation of
the fan hub.
WARNING
Install the fan belt idler assembly, the three lock washers,
and capscrews.
Finishing Steps
Install the belt. Refer to Procedure 008-002 (Drive
Belt, Cooling Fan) in Section 8.
Install the cooling fan. Refer to Procedure 008-040
(Fan, Cooling) in Section 8.
Fan Hub Bracket (008-035)
General Information
Two revised fan brackets for all two pulley fan drives on K2000, KTA50-C1800, KTTA50-C1800, and KTA50-C1600
engines were released in January, 1992, ESN 33121123.
The revised fan brackets are not interchangeable. The bolt span between them has increased, therefore, both revised
brackets must be used together with the correct hardware. These changes replace the original two pulley design that
was announced in July, 1989.
The security of the bolted joint between the fan bracket and fan bracket support was also improved. A revised clamping
plate is being used along with a 12 point capscrew and plain washer to improve the integrity. The torque value for the
12 point capscrew is 258 Nm [190 ft-lb]. The use of the clamping plate eliminates issues associated with a single
washer clamping over a single hole.
K38, K50, QSK38, and QSK50 Fan Hub Bracket
Remove
Fan Hub Bracket (Standard)
WARNING
Remove the capscrews. Remove the fan hub bracket.
Fan Hub Bracket (Revised)
Remove the mounting capscrews (15) and lock washers
(14).
Remove the fan hub bracket.
WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Clean the support with steam.
Check the support for cracks or fretting.
NOTE: If the support must be replaced, be sure to install
the correct part. All fan supports are not the same
because of fan center location and spacing from the
cylinder block.
Fan Hub, Belt Driven K38, K50, QSK38, and QSK50
Install
Two types of fan hub brackets are used on KV engines.
A one piece original standard bracket was first used. A two
piece bracket was introduced with the two pulley fan drive
system.
One Piece Bracket
Install guide pins in two of the fan support capscrew holes
in the cylinder block for alignment.
Install the fan hub bracket (14) over the guide pins. Install
the lock washers (15) and mounting capscrews (16).
Remove the guide pins and install the remaining lock
washers and capscrews.
Two piece bracket
Install the heavy nut (17) on the adjusting capscrew. Install
the adjusting capscrew into the bottom of the boss in the
fan bracket support (13).
Install the retaining ring (18) into the groove of the
adjusting capscrew.
Install guide pins in two of the six fan support capscrew
holes in the cylinder block for alignment.
Install the fan bracket support (13) over the guide pins.
Install the lock washers (14) and capscrews (15). Remove
the guide pins and install the remaining lock washers and
capscrews.
Fan Hub, Belt Driven (008-036)
Preparatory Steps
WARNING
This component weighs greater than 23 kg [50 lb]. To
prevent serious personal injury, be sure to have
assistance or use appropriate lifting equipment to lift
this component or assembly.
Remove the cooling fan. Refer to Procedure 008-040
(Fan Cooling) in Section 8.
Remove the fan belt. Refer to Procedure 008-002
K38, K50, QSK38, and QSK50 Fan Hub, Belt Driven
Remove
WARNING
NOTE: Make a note of the holes that are used for the fan
bracket. The holes that are used determine the different
fan center arrangements.
Remove the four SAE Grade 8 capscrews. Remove the
fan hub (1).
WARNING
WARNING
personal injury.
Use solvent to clean the fan hub.
Check the seal for leaks.
Check the shaft (1) for damage. Check the pulley exterior
(2) for damage.
If the shaft or pulley are damaged, the fan hub must be
rebuilt.
Poly Vee pulley groove wear can be measured by placing
a gauge ball or drill bit in the pulley groove and checking
the protrusion with a straight edge. If the gauge ball or drill
bit is below the pulley peaks, the pulley must be replaced.
All KV engines use either a K or L section pulley belt.
To determine which gauge ball or drill bit can be used,
measure the A dimension and compare to the dimensions
of K and L section pulleys.
Poly Vee - Pulley Reuse Guidelines
Belt Type A B
K-Section 3.56 mm [0.140
in]
3 mm [0.12 in]
gauge ball or a
number 31 drill
bit
L-Section 4.70 mm [0.185
in]
4 mm [0.16 in]
gauge ball or a
number 20 drill
bit
Check the clearance.
Bearing End Clearance
mm in
0.03 MIN 0.001
0.15 MAX 0.006
If the clearance is not within the specifications, the fan
hub must be rebuilt.
Rotate the pulley to check for rough or damaged bearings.
If the fan hub does not rotate freely, the fan hub must be
rebuilt.
Remove the pipe plugs (3) (if fitted). Install a grease fitting
in one of the holes.
Use a grease gun and water pump type grease. Pump
grease into the hub until it begins to come out of the open
plug hole.
Remove the grease fitting.
Install the pipe plugs (3).
Disassemble
Remove the following parts from the pulley (6).
1. Capscrews
2. Fan pilot
3. O-ring
4. Locknut
5. Plain hardened washer
Discard the o-ring.
NOTE: If force is required, use an arbor press. Support
the pulley (6) and push on the small end of the shaft (7).
Remove the pulley assembly (6) from the shaft (7).
Remove and tag the front roller bearing (8) for future
identification.
Remove the pipe plugs (9) (if fitted).
Turn the pulley assembly (6) over.
Remove the oil seal (10).
Remove the rear roller bearing (11) and tag for future
identification.
Remove the inner bearing spacer (12).
NOTE: Do not remove the outer bearing spacer.
Assemble
CAUTION
Do not lubricate the seal surface of the shaft. The seal
and seal surface must be clean and dry. Failure to do
so can result in seal failure.
NOTE: Excessive grease will affect the end float reading.
Lightly grease the bearing (11) with Mobiplex 48 grease,
or equivalent.
Install the bearing in the hub.
Apply Loctite 675, or equivalent, to the outside diameter
of the seal.
Install the seal (10), use a mandrel with the flat unseamed
face toward the shoulder of the driver and press the seal
in until it bottoms.
Install the fan hub seal end first over the shaft and make
sure no damage occurs to the seal.
The rear bearing must slide easily on the shaft. If it does
not, check for chips or burrs.
Install the inner bearing spacer (12). The following spacers
are available to provide correct end clearance when the
fan hub has been assembled.
The following listing is for two spacer style fan hubs:
3627681 - 63.906 mm [2.5160 in] length
3627682 - 63.995 mm [2.5195 in] length
3627683 - 64.084 mm [2.5230 in] length
3627684 - 64.173 mm [2.5265 in] length.
The following listing is for other fan hubs:
3627677 - 51.562 mm [2.0300 in] length
3627678 - 51.689 mm [2.0350 in] length
3627679 - 51.816 mm [2.0400 in] length
3627680 - 51.943 mm [2.0450 in] length
3628830 - 52.019 mm [2.0480 in] length
Lightly grease the front bearing (8).
Install the bearing.
The bearing must slide easily over the shaft. If it does
not, check for chips and burrs.
CAUTION
Remove all grease from the threads on the shaft
before installing the locknut. Grease on the threads
reduce the torque retention of the locknut.
Install the hardened washer (5).
Install the lock nut (4).
Use a dial indicator to measure the bearing end clearance.
mm in
0.025 MIN 0.001
0.150 MAX 0.006
If the clearance is not within specifications, rebuild the fan
hub with a suitable size spacer. Check the bearing end
clearance.
CAUTION
Do not use more grease than specified. Too much
grease will cause excessive heating and failure.
Use Mobiplex 48 grease, or equivalent, to fill the cavity
with 120 cc of grease. Grease the inner race, fit the
spacer, and inner race,
Install the hardened washer (5). Install the lock nut (4).
Check the bearing end clearance.
Install the o-ring (3) on the fan pilot (2).
Lubricate the o-ring with vegetable oil.
Install the fan pilot and o-ring.
Install the capscrews (1).
Install
WARNING
Install the fan hub, four SAE grade 8 capscrews, and lock
washers. Tighten the capscrews.
Fan, Cooling K38, K50, QSK38, and QSK50
Finishing Steps
WARNING
Install the fan belt. Refer to Procedure 008-002
Install the cooling fan. Refer to Procedure 008-040
(Fan Cooling) in Section 8.
Operate the engine and check for proper opertion.
Fan Shroud Assembly (008-038)
Inspect for Reuse
Inspect the fan shroud for the correct fan clearance. See
the vehicle manufacturer's specifications and the
appropriate installation recommendations bulletin.
Inspect the fan shroud for cracks, air leaks, or other
damage. Replace the part if damaged. Consult the
manufacturer's instructions.
Fan, Cooling (008-040)
Preparatory Steps
WARNING
cable last.
013-009 (Battery Connections and Cables) in Section
13.
Remove
WARNING
Do not rotate the engine by pulling or prying on the
fan. Do not straighten a bent fan blade or continue to
use a damaged fan. A bent of damaged fan blade can
fail during operation and cause serious personal
injury or property damage
K38, K50, QSK38, and QSK50 Fan, Cooling
Remove the fan
Install
CAUTION
Replace the original equipment fan with a fan of the
identical part number. Cummins Engine Co., Inc. must
approve any other fan changes. Using a fan with a
different part number can result in failure, causing
damage to personal injury.
Install the fan.
Tighten the mounting capscrews.
Finishing Steps
WARNING
cable last.
(Battery Connections and Cables) in Section 13.
Radiator K38, K50, QSK38, and QSK50
Radiator (008-042)
Test
On engines with standard cooling systems or when
checking for an obstruction in the main engine radiator on
engines equipped with LTA, start at engine radiator.
When checking for an obstruction of the high flow or LTA
radiator on engines equipped with low temperature
aftercooling, start with LTA.
Step 1
Use a pressure gauge designed to measure 0 to 100
kPa [0 to 15 psi].
Install a valve on each side of the gauge.
Step 2
Install line 1 into the water pump inlet connection and
line 2 into the thermostat return line or on top of the
radiator core.
Bleed the air from the gauge lines.
Step 3
Restrict the radiator airflow.
reaches 88 to 90C [190 to 195F].
K38, K50, QSK38, and QSK50 Radiator
Step 4
Use a pressure gauge designed to measure 0 to 345
kPa [0 to 50 psi].
Install a valve on each side of the gauge.
Step 5
Install a line from each valve into the top of the small,
front, high flow LTA radiator core. This is a dual pass
radiator.
Install one line on each side of the upper core
surface.
Step 6
Restrict the radiator airflow.
reaches 88 to 90C [190 to 195F].
Step 7
Operate the engine at rated rpm.
Close valve 1 and open valve 2. Record the
pressure at the top of the radiator.
Radiator Pressure Cap K38, K50, QSK38, and QSK50
Close valve 2 and open valve 1. Record the
pressure at the water pump inlet.
Compare the two pressure readings. If they differ by
more than 35 kPa [5 psi], the radiator core or piping
is obstructed.
Radiator Hoses (008-045)
Inspect for Reuse
WARNING
NOTE: Do not bend or deform the hoses during
inspection. This can cause the hoses to crack.
Inspect all hoses for cracks or cuts.
Inspect all hoses for signs of ballooning or collapsing.
Engine overheating or coolant overflow can result from
internal deterioration of the coolant hoses. See
troubleshooting symptom tree, Coolant Temperature
Above Normal in Section TS. Particles of deteriorating
hose can restrict or completely stop the coolant flow.
Radiator Pressure Cap (008-047)
Inspect for Reuse
Inspect the rubber seal of the pressure cap for damage.
Inspect the radiator fill neck for cracks or other damage.
Refer to the radiator manufacturer's operating instructions
if the fill neck is damaged.
Make sure the correct radiator cap is being used. The
pressure rating must be 48 kPa [7 psi] or greater.
K38, K50, QSK38, and QSK50 Expansion Tank
Pressure Test
Pressure-test the radiator cap.
The pressure cap must seal within 14 kPa [2 psi] of the
value printed on the cap, or it must be replaced.
Expansion Tank (008-052)
Preparatory Steps
WARNING
WARNING
WARNING
last.
013-009.
008-018.
Remove
Front Mounted Tank
Detach the coolant vent hoses (6) and (5).
Expansion Tank K38, K50, QSK38, and QSK50
Detach both ends of the coolant make-up hose (4).
Remove the hose.
Check the hose for damage. Discard the part if it is
damaged.
WARNING
Remove the four capscrews and washers.
Remove the cotter pins (3) and the two hinge pins (2).
Remove the expansion tank (1).
Top Mounted Tank
Detach the coolant vent hoses.
Remove the coolant make up lines.
Remove the coolant filter. Refer to Procedure 008-006.
WARNING
Remove the mounting capscrews and isolators.
Install the lifting straps and connect them to a lifting
device.
Remove the expansion tank.
WARNING
WARNING
personal injury.
NOTE: Shown in the clean and inspect step is only one
example of the expansion tank. Although different in
appearance the procedure remains the same.
Clean the inside and outside of the expansion tank using
steam cleaner or high pressure washer.
Cap off the vent line and makeup hose fitting.
Fill the expansion tank with clean water.
Install a pressure tester to the expansion tank and apply
a maximum of 172 kPa [25 psi] of pressure.
Check for leaks.
If any leaks are found they must be repaired.
Remove the caps from the vent and make up fittings and
drain the expansion tank.
Install
WARNING
Place the tank (1) in position and install the two hinge pins
(2). Install the cotter pins (3) in the hole in the hinge pins.
Install the four flat washers, lock washers, and capscrews
through the expansion tank to the brackets on the support.
Connect the coolant make-up hose (4) to the fitting on the
right bank side of the expansion tank and to the fitting in
the water pump inlet housing.
Connect the two coolant vent hoses (5) to the fittings in the
expansion tank and to the fittings on the top of the
thermostat housing.
If the engine is equipped with a center mount type
aftercooler, connect the two vent hoses (6) to the fittings
on the top of the aftercooler coolant outlet fittings and to
the fittings on the expansion tank.
WARNING
Top Mounted Tank
Install the lifting straps and connect them to a lifting
device.
Place the expansion tank into position on the top of the
engine.
Install the mounting capscrews.
Torque Value:
Expansion Tank
Capscrews
40 Nm [ 30 ft-lb ]
Install the coolant make up line.
Attach the coolant vent hoses.
Finishing Steps
WARNING
last.
Fill the cooling system. Refer to Procedure 008-018.
013-009.
Operate the engine to normal operating temperature
and check for leaks.
K38, K50, QSK38, and QSK50 Heat Exchanger
Heat Exchanger (008-053)
Exploded View
Figure 1, K38 Marine Plate Type Heat Exchanger Plate Orientation and Plate Location Numbers
Heat Exchanger K38, K50, QSK38, and QSK50
Exploded View
A. Lower Manifold B. Tank.
Exploded View
Figure 2, K50 Marine Plate Type Heat Exchanger Plate Orientation and Plate Location Numbers
Exploded View
A. Lower Manifold A. Tank
Preparatory Steps
WARNING
WARNING
Refer to Procedure 008-018.
Remove
Tube Type
Loosen the hose clamps.
Remove the upper heat exchanger outlet pipe (24) and
gaskets (23).
Discard the hose (22) and gaskets.
Remove the V-band clamp. Remove the right bank pump
inlet pipe (20) and the seal (21).
Discard the hose (19) and seal.
Loosen the hose clamps
Remove the four capscrews. Remove the upper heat
exchanger inlet pipe (15) and the gasket (17).
Discard the hose and gasket.
Remove the V-band clamp. Remove the right bank pump
outlet pipe (16) and seal (18).
Discard the seal.
Remove the four capscrews. Remove the lower heat
exchanger outlet pipe (13) and gasket (12).
Discard the hose (11) and gasket.
Remove the four capscrews. Remove the lower heat
exchanger inlet pipe (7) and gasket (6).
Remove the V-band clamp. Remove the left bank pump
outlet pipe (9) and the seal (10).
Discard the seal.
Remove the V-band clamp. Remove the left bank pump
inlet pipe (5).
Discard the seal (4).
Remove the four sea (raw) water manifold connections (2)
and the gaskets (1).
Discard the gaskets.
Heat Exchanger Pipes, Engine Water
If the pipe from the water pump inlet connection to the heat
exchanger outlet pipe (17) has not been removed, remove
the pipe now.
Remove the eight capscrews. Remove the outlet pipes
(17, 14) and gaskets (15, 18).
Remove the hose (16).
Loosen the eight hose clamps.
Remove the four capscrews.
Remove the pipes (8, 10) and the gasket (11).
Remove the hoses (9).
Discard the gasket and hoses.
Remove the four capscrews. Remove the pipe (5) and
gasket (6).
A portion of the heat exchanger support is not shown for
clarity.
Remove the two capscrews (3). Remove the engine outlet
pipes (2, 1).
Discard the hoses.
WARNING
This component weighs 23 kg [50 lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.
Remove the upper heat exchanger (2).
Remove the lower heat exchanger (1).
Plate Type
Remove the vent lines from the expansion tank.
Disconnect and remove the coolant outlet tube.
Disconnect the sea water pump prime discharge line from
heat exchanger sea water outlet connection.
Disconnect the sea water inlet and outlet tube.
Attach a chain fall or other lifting equipment with straps
around the heat exchanger assembly as shown.
Remove the six jacket water manifold bolts that hold the
jacket water manifold to the thermostat housing.
Remove the four LTA transfer tube mounting bolts that
hold the tubes to the thermostat housing.
Disconnect the lower mounting bracket bolts that fasten
the bracket to the engine block.
Lift the heat exchanger assembly away from the engine.
Box Type
Remove the vent lines.
Remove the coolant inlet connection.
Remove the sea water outlet connection and sea water
priming discharge hose.
Remove the sea water inlet connection.
Remove the coolant outlet tube.
Remove the Low Temperature Aftercooled (LTA) coolant
outlet tubes.
Attach the proper lifting equipment with straps around the
heat exchanger assembly as shown.
Remove the four heat exchanger support bracket
mounting bolts from engine block and lift the box type heat
exchanger away from the engine.
Clean
Tube Type
WARNING
can cause serious personal injury
Use a suitable scraper clean all gasket surfaces.
Use steam and clean the heat exchanger.
Flush the engine coolant and raw water passages of the
cooler.
Disassemble
Tube Type
CAUTION
Do not damage the housing or cover when separating
the parts. If the parts are damaged, a leak will result.
The closed end of the housing has two notches. Turn
the closed end cover so that the notches are not
aligned with the notches in the housing. Use a mallet
and brass drift to move the o-ring seal from the core.
Remove the 12 capscrews (2) and lock washers, the
closed end cover (3), and the gasket (4) from the housing
(5).
Remove the o-ring seal (6) from the cover. Discard the o-
ring seal.
Remove the six zinc electrode plugs (1).
CAUTION
Do not damage the housing or cover when separating
the parts. If the parts are damaged, a leak will result.
The open end of the housing has one notch. Turn the
open end cover so that the notch is aligned with the
notch in the housing. Use a mallet and brass drift to
move the o-ring seal from core.
Remove the 12 capscrews (7) and lock washers, open end
cover (8), and the gasket (9) from the housing (5).
Remove the cooler core (10) and the gasket (4) from the
housing (5).
Plate Type
Remove the two flange bolts from the drain tube. The drain
tube will stay in the expansion tank during the
disassembly process.
If installed, remove the support brackets from both sides
of the expansion tank.
More current versions of the heat exchanger assembly,
with cast front support brackets, do not have the side
brackets installed.
Remove the two end top spacer bolts from the top of the
expansion tank.
Loosen the bolts 1 through 6 that hold the expansion tank
against the plate pack, in the sequence shown.
CAUTION
Do not loosen each bolt completely. The expansion
tank must not be more than 12 mm [.50 in] from level;
as this will cause the plate pack and tank to bind on
the Low Temperature Aftercooled (LTA) tubes and the
drain tubes causing damage to them and the o-rings.
WARNING
Remove the tank from the assembly.
Remove the shield by removing the 10 capscrews that
mount the shield to the spacers.
Use a paint marker to draw a diagonal line across the plate
pack as shown.
The line will help identify plate arrangement and benefit
the assembly procedure.
WARNING
Wear protective gloves for protection against sharp
edges.
Remove the plates from the assembly.
The plates have sharp edges.
Box Type
This procedure can be performed with the heat exchanger
on or off the engine.
Drain the engine coolant if the heat exchanger is engine
mounted.
Remove the vent lines.
Remove the coolant inlet connection.
Remove the sea water outlet connection and pump
priming hose.
Remove the sea water inlet connection.
Remove the coolant outlet tube.
Remove the heat exchanger front cover.
WARNING
Remove the heat exchanger core.
Remove the Low Temperature Aftercooled (LTA) inlet and
outlet tubes.
Remove the heat exchanger rear housing.
Tube Type
WARNING
Use a suitable scraper, clean all gasket surfaces.
Use steam and clean the heat exchanger.
Flush the engine coolant and raw water passages of the
cooler.
Use a brass rod or a copper rod that has an outside
diameter of 8 mm [0.313 in]. Use the rod to clean the
tubes.
Plate Type
CAUTION
Incorrect orientation of the gaskets can cause
overheating and sea water to enter the cooling
system.
Observe the orientation of the gasket for assembly
accuracy.
Remove each gasket from the plate one at a time.
Clean each plate.
Clean the plate with a soft brush and running water.
If deposits are present that are difficult to remove, spray
the plate with a high pressure water hose.
If brushing and high pressure water does not properly
clean the plates, the deposits on the plates can be
evaluated.
Use the information in the following lists to determine what
solvents to use.
Incrustation
Calcium carbonate (corrosion products - clean with
nitric acid).
Calcium sulphate (metal oxides - clean with sulfamic
acid).
Silicates (silt - clean with citric acid, alumina - clean
with phosphric acid, diatomic organisms and their
excrement of various colors - clean with complexing
agents EDT, A, and NTA).
Biological Growth
Slime - Clean with alkaline cleaning agents.
Bacteria - clean with sodium hydroxide.
Nematodes - Clean with sodium hydroxide.
Protozoa - Cleaning effect can be considerably
increased by the addition of small quantities of
hypochlorite or agents for the formation of
complexes and surfactants.
Concentration maximum: Four Percent.
Temperature maximum: 60C [140 F].
Solvents That Can Not be Used
Ketones (acetone, methyletylketone,
methylisobutylketone)
Esters (ethylacetate, butylacetate)
Halogenated hydrocarbons (chloro-thene, carbon
tetrachloride, freons)
Aromatics (benzene, toluene).
Box Type
WARNING
Pressure wash, steam clean or flush the core with hot
water.
Inspect
Tube Type
Check the parts for cracks or other damage. Replace any
damaged parts.
To pressure test the cooler core, see the Pressure Test
step in this procedure.
Check the length of each electrode. If more than 1/2 of the
length is missing, the plug must be replaced.
If more than 5 percent of the tubes are plugged or have
been closed by an earlier repair, the core must be
replaced.
Plate Type
Inspect the gasket.
If gaskets are swollen, cracked, or deformed, they must
be replaced.
Box Type
Check for damaged tubes and eroded or corroded o-ring
sealing surfaces in the front cover and rear housing.
Assemble
Tube Type
CAUTION
One end of the housing has one notch, and one end
has two notches. The cooler core and the open end
cover must be installed on the end that has only one
notch. If the heat exchanger is not assembled
correctly, the engine will overheat because the water
pipe will not be connected correctly.
CAUTION
The notch in the core and the notch on the housing
must be in alignment. If the parts are not in alignment,
the coolant flow through the heat exchanger will be
faulty and the engine will overheat.
Install the gasket (4). Align a notch on the gasket with the
notch on the core. The capscrew holes will also be in
alignment.
Install the cooler core (10) in the housing (5).
Align the notches on the core, gasket, and housing.
CAUTION
A notch in the gasket and the notch on the cover must
be in alignment with the notch in the housing. If the
parts are not in alignment, the coolant flow through
the heat exchanger will be faulty and the engine will
overheat.
Install the gasket (9). Align the notches.
Check to be sure the center rib on the gasket is in proper
position on the center rib of the cover.
Install the open end cover (8). Align the notches.
Install the 12 capscrews (7) and lock washers.
NOTE: Install capscrews that are 44 mm [1.750 in] in
length for this end of the assembly.
Install the gasket (4) on the housing (5). Align the notch in
the gasket with the notch in the housing that will provide
for correct capscrew hole alignment.
Install the new o-ring seal (6) in the groove in the closed
end cover.
Use vegetable oil. Lubricate the o-ring seal.
Install the closed end cover (3) and o-ring seal on the
housing. Push the o-ring seal over the core until the cover
touches the gasket.
Align the two notches in the cover with the two notches in
the housing.
NOTE: Install capscrews that are 38 mm [1.500 in] in
length for this end of the assembly.
Install the 12 capscrews (2) and lock washers.
Install the six zinc electrode plugs (1).
Plate Type
Make sure the two guide pins are in place on the lower
manifold. Install the guide pin lower bolts with Nord-Lock
washers as sown.
The longer serrations, or cams, of each Nord-Lock
washer must be oriented toward the other in order for the
assembly to work properly.
Torque the bolts to the guide pins.
Torque Value:
Guide Pin Bolts 256 Nm [ 190 ft-lb ]
The orientation of the plates is different on a K38 engine
than it is on the K50 engine. See the10 digit I.D. number
(1).
See:
Figure 1 for K38 engines
Figure 2 for K50 engines.
During the plate assembly process, make sure the ribs on
alternating plates are pointing in opposite directions, as
shown in Figures 1 and 2.
CAUTION
Incorrect orientation of the gaskets can cause
overheating and sea water to enter the cooling
system.
Place the gaskets back onto the plates one at a time.
Make sure the tabs are locked into the slots and orientated
correctly.
Gaskets will always be facing up during the plate
assembly process.
See Figures 1 and 2 for plate orientation and identification
numbers.
After the plates are assembled in the engine, make sure
the profile shows a honey-comb pattern and the gasket
tabs alternate position.
If this pattern is not shown throughout the entire plate
pack, the plates must be rearranged.
Install the spacers and the shield.
Torque Value:
Shield capscrews 9 Nm [ 80 in-lb ]
CAUTION
Pushing the LTA tubes too deep into the expansion
tank, can damage the tube's o-ring.
Remove the drain and LTA tubes.
Install the o-ring and crevice seal onto the drain and LTA
tubes and install them into the expansion tank assembly
approximately 25 mm [1 in] deep.
WARNING
Place the expansion tank on top of the assembly.
Install the o-ring onto the bottom of the drain pipe flange.
Make sure the drain tube fits into the lower manifold as
the tank and plate pack are tightened down.
Install the six-plate pack clamping bolts with the Nord-
Lock washers as shown.
Finger tighten the bolts in the sequence pattern shown
until the plate pack begins to compress.
Tighten bolts, one through six, in 14 Nm [124 in-lb]
increments in the sequence shown so the expansion tank
comes down evenly.
Stop tightening bolts when expansion tank is touching all
6 spacers.
CAUTION
During the tightening process the expansion tank
must not be more than 12 mm [.5 in] from level;
otherwise the plate pack and tank may bind on the
Low Temperature Aftercooled (LTA) drain tubes and
damage the o-rings.
Measure the plate stack distance, as a double-check. The
plate stack distance should match what is on the data
sticker on the heat exchanger bracket.
K38 A Dimension 142 to 147 mm [ 5.6 to 5.8 in ]
K50 A Dimension 181 to 183 mm [ 7.0 to 7.3 in ]
Install two end-guide top bolts with Nord-Lock washers.
Tighten all eight top bolts.
Torque Value:
Tighten all 8 Top
Bolts
256 Nm [ 190 ft-lb ]
NOTE: Engines with cast iron front support brackets do
not need the side brackets installed.
Install the side brackets, if they were installed initially.
Torque Value:
Bracket
Capscrew
31 Nm [ 23 ft-lb ]
Box Type
WARNING
CAUTION
Apply a coating of high grade (nickel) anti-seize
compound to the bolt threads.
Install the rear heat exchanger housing onto the engine.
Connect LTA inlet and outlet tubes.
Tighten the bolts.
Install the sealing ring and the heat exchanger core into
the rear housing and tighten bolts.
Install the sealing ring and the heat exchanger front cover.
Install the coolant outlet tube.
Tighten the bolts.
Install the sea water inlet connection.
Tighten the bolts.
Install the sea water outlet connection and pump priming
hose.
Tighten the bolts.
Install the coolant inlet connection.
Install the vent lines.
Pressure Test
Tube Type
The most convenient method to pressure test the cooler
core is with the heat exchanger assembled. More items
must be fabricated to test the core separately. No tool is
available from Cummins, Inc., to test the core separately.
For both tests it is necessary to use two of the heat
exchanger piping connections (1), gaskets (2), hoses (3)
and hose clamps (4).
Install the connections, gaskets, and hoses on the open
end cover plate.
Install a plug (5) in one of the hoses using a hose clamp.
Install a reducer (6) to connect a source of compressed air
supply in the other hose.
Test the Heat Exchanger
Connect an air supply to a regulator and gauge assembly
(7). Connect the outlet hose of the regulator to the fitting
on the reducer.
Fill the heat exchanger with clear water.
Adjust the regulator to apply 275 kPa [40 psi] to core.
Check for air bubbles in engine coolant side of heat
exchanger.
If air bubbles are visible, core has leak and must be
replaced.
CAUTION
Install heavy washers between the nuts and the flange
on the core to prevent damage to the sealing surface
of the core.
Test the Heat Exchanger Cooler Core
Install the connections, hoses, clamps, plug, and reducer
on the open end cover.
The two capscrew holes that are 180 degrees apart
must remain open.
Install the cover (8) and gasket (9) on the flange of the core
using at least four capscrews, nuts, and washers.
Use two lengths of threaded rod (10), a plate with holes
for the rod (11), a piece of gasket material (12), and nuts
and flat washers to seal the open end of the core.
CAUTION
Tighten the nuts only enough to seal the gaskets. Do
not tighten the nuts excessively or damage to the core
will result, preventing its use.
Install the items as shown.
Connect a regulated compressed air supply to the fitting
in the reducer.
Some air will be trapped between the tubes of the core
when the core is immersed. Move the core around to allow
this trapped air to escape. If the core is leaking, a steady
stream of air bubbles will be visible.
Immerse the core and testing items in a container of water.
Adjust the regulator to apply 275 kPa [40 psi] to the core.
Check for air bubbles coming from the core. Be sure the
air bubbles are not coming from the area of the testing
plates.
If air bubbles are visible, the core is leaking and must be
replaced.
Box Type
Cap off the sea water inlet connection and install the test
fittings in the sea water outlet connection.
Immerse the core in the tank and apply 172 kPa [25 psi]
of shop air for a minimum of 10 minutes.
Check for air bubbles coming from the core.
If a continuous stream of bubbles appears during the last
5 minutes of the test, the core must be scrapped.
Install
Tube Type
WARNING
The component weights 23 kg [50 lb] or more. To
or get assistance to lift the component.
Install the lower heat exchanger (1) and the upper heat
exchanger (2) as shown. Install four lock washers and
capscrews in each heat exchanger.
Tighten the heat exchanger mounting capscrews.
The engine coolant pipes are always connected to the side
of the heat exchanger.
Always tighten the capscrews before tightening the hose
clamps.
Two clamps are installed on both ends of all hoses. Make
sure that the hoses are centered over the gap between the
pipes. Tighten the capscrews for the pipe before
tightening the clamps.
The upper heat exchanger and a portion of the heat
exchanger support are not shown for clarity.
Install the engine outlet pipes (1) and (2) on the outlets of
the thermostat housing, using the hoses and clamps.
Install a flat washer, lock washer, and capscrew (3)
through the tab on each pipe to the heat exchanger
support.
Tighten the clamps.
Connect the pipe (5) to the outlet pipe for the left bank as
shown. Install the gasket (6), and four lock washers and
capscrews to the upper heat exchanger (7) inlet.
Tighten the clamps.
Connect the pipe (8) to the outlet pipe for the right bank
as shown. Install the hose (9) and the pipe (10). Install the
gasket (11), and the four lock washers and capscrews to
the lower heat exchanger inlet.
Tighten the clamps.
Install the gasket (15), the upper heat exchanger outlet
pipe (14), the four lock washers and capscrews to the
upper heat exchanger outlet.
Install the hose (16) and clamps on the lower heat
exchanger outlet pipe (17). Install the hose on the upper
heat exchanger outlet pipe. Install the gasket (18), the four
lock washers and capscrews to the lower heat exchanger
outlet (19).
A large pipe (not shown) with a flange and a gasket
must be installed to the lower heat exchanger outlet pipe
(17) and to the engine water pump inlet. The pipe is
notinstalled at this time because the pipe is routed under
a crossmember of a base rail on engines equipped with
base rails.
If the engine being serviced has sea water pumps,
proceed to With Sea (Raw) Water Pumps.
Without Seal Water pumps
The sea water pipes are always connected to the ends of
the heat exchangers.
clamps.
Two clamps are on each end of each hose. Check to be
sure the hose is centered over the gap between the pipes.
Tighten the capscrews for the pipe before tightening the
hose clamps.
Install the four gaskets (1) and the four connections (2) to
the sea water manifold as shown.
Install the hose (3), the clamps, the gasket (4), and the
lower heat exchanger inlet pipe (5) as shown.
lower heat exchanger outlet pipe (8) as shown.
upper heat exchanger inlet pipe (11) as shown.
The pipe (14) must be routed between the pipe (15) and
upper heat exchanger outlet pipe (14) as shown.
The sea water pipes are always connected to the ends of
The inlet for a sea water pump mounted on the left bank
of an engine is nearest to the pump support. The inlet for
a sea water pump mounted on the right bank of an engine
is farthest from the pump support. The pumps rotate the
same direction as the camshafts.
clamps and the V-band clamps.
Always tighten the V-band clamps before tightening the
hose clamps
Torque the capscrews for the V-band clamps.
Tap on the V-band clamp with a mallet. Continue the
tapping and tightening process until the capscrews do
not turn at the specified torque.
Two hose clamps are on each end of each hose. Check to
be sure the hose is centered over the gap between the
pipes. Tighten the capscrews and the V-band clamps
before tightening the hose clamps.
Install the four gaskets (1) and the four connections (2) to
the sea water manifold as shown.
Install the hose (3), hose clamps, seal (4), and the left bank
pump inlet pipe (5). Install the V-band clamp.
Tighten the V-band clamps.
Install the gasket (6) and the lower heat exchanger inlet
pipe (7) as shown.
Install the hose (8), the hose clamps, the left bank pump
outlet pipe (9), the seal (10). Install the V-band clamp.
Tighten the V-band clamp.
Install the hose (11), the hose clamps, the gasket (12), and
the lower heat exchanger outlet pipe (13) as shown.
Install the hose (14) and hose clamps on the upper heat
exchanger inlet pipe (15). Install the right bank pump
outlet pipe (16) in the hose (14) as shown. Install the
gasket (17) and the pipe to the upper heat exchanger inlet
as shown.
Install the seal (18) and the V-band clamp to the right bank
pump outlet as shown.
Install the hose (19), the hose clamps, the right bank pump
inlet pipe (20), the seal (21), and the V-band clamp to the
right bank pump inlet as shown.
The pipe (24) must be routed between the pipe (25) and
Install the hose (22), the hose clamps, the gasket (23), and
the upper heat exchanger outlet pipe (24) as shown.
Install the gasket (6) and the lower heat exchanger inlet
pipe (7) as shown.
Install the hose (8), the hose clamps, the left bank pump
outlet pipe (9), the seal (10). Install the V-band clamp.
Plate Type
Use a chain fall or other lifting equipment to lift heat
exchanger into position in front of the engine with the
jacket water manifold over the thermostat housing.
Install the o-rings onto the bottom flange of the LTA tubes
and the jacket water manifold as the assembly is lowered
into place.
Install the lower mounting bracket bolts that fasten the
bracket to the engine block.
Torque Value:
Bolts, Lower
Bracket
35 Nm [ 25 ft-lb ]
Install the four bolts that hold the Low Temperature
Aftercooled (LTA) tube to the thermostat housing
Tighten the bolts.
Torque Value:
Bolts 78 Nm [ 57 ft-lb ]
Install the clips and bolt and tighten.
Install the ring retainer clip from the drain pipe and tighten
the bolts.
Torque Value:
Clips 17 Nm [ 144 in-lb ]
Install the jacket water manifold bolts that fasten the
manifold to the thermostat housing.
Tighten the bolts.
Torque Value:
Bolts, Jacket
Water Manifold
31 Nm [ 23 ft-lb ]
Connect the sea water pump prime discharge line from
the heat exchanger sea water outlet connection.
Connect the sea water inlet and outlet connections.
Connect the coolant outlet tube and connector.
Connect the vent lines to the expansion tank.
Box Type
Attach the proper lifting equipment with straps around the
heat exchanger assembly as shown.
Install the four heat exchanger support bracket mounting
bolts on the engine block.
Lift the heat exchanger assembly onto the engine.
Install the Low Temperature Aftercooled (LTA) coolant
inlet pipe.
Install the Low Temperature Aftercooled (LTA) coolant
outlet pipe.
Install the coolant outlet tube.
Install the sea water inlet connection.
Install the sea water outlet connection and pump priming
hose.
Install the coolant inlet connection.
Install the vent lines.
K38, K50, QSK38, and QSK50 Sea Water Pump
Finishing Steps
WARNING
WARNING
Fill the cooling system.
Sea Water Pump (008-057)
General Information
Gear Driven
Some K38 and K50 marine series engines are equipped with two sea water pumps. The pumps are mounted on
supports on the front gear cover. The supports for the left bank and the right bank are different. The sea water pumps
are the same for both the left and right banks. The sea water pump is a gear driven pump, that is driven by the camshaft
gear.
The sea water pump on K38 and K50 marine series engines contain a paddle type impeller that allows the pump to
function in either a clockwise or counterclockwise rotation. When viewed from the front of the engine. The sea water
pump on the right bank rotates in a counterclockwise direction. The sea water pump on the left bank rotates in a
clockwise direction. The inlet for the sea water pump is the port nearest to the front gear cover to the person's right.
The bearings in the sea water pumps on K38 and K50 marine series engines are lubricated by engine oil through
drillings in the front gear cover and the pump supports.
The sea water pumps on K38 and K50 marine series engines are limited to engine speeds of 2000 rpm or less.
Cummins Inc., does not provide sea water pump gears for engine speeds in excess of 2000 rpm. The sea water
pumps mounted on K38 and K50 marine series engines are Gilmec, Model 250/700, manufactured by:
Gilbert Gilkes & Gordon Ltd.
Kendal, Cumbria
England
LA9 7B2
Preparatory Steps
Spline Drive
Isolate the water supply to the sea water pump.
Disconnect the piping from the sea water pump.
Sea Water Pump K38, K50, QSK38, and QSK50
Remove
Spline Drive
WARNING
CAUTION
Do not support the weight of the sea water pump on
its shaft end. Damage to the shaft can result.
Place a strap around the pump to support the weight of
the pump during removal.
Remove the mounting capscrews.
Work the pump loose from gear housing and remove the
pump from the engine.
Disassemble
Gear Driven
Rotate the shaft to check for damaged bearings or parts
that are rubbing.
If the pump does not turn correctly, refer to Procedure
008-074.
While turning the shaft, put clean 15W-40 engine oil in the
oil passage to lubricate the bearings.
NOTE: This procedure can also apply to check or replace
the seal when the pump is installed on the engine. If the
work is being performed with the pump installed, the
hoses for the pump must be removed.
Remove the vee band clamp (1).
Use a scribe or a center punch. Put a mark on both ends
of the water pump bodies so that they can be assembled
correctly.
NOTE: The body is a tight fit. If necessary, use a wooden
wedge to aid in the separation of the parts. Put the wedge
in the space between the inlet and outlet ports.
Insert a wooden hammer handle through the part until the
handle is touching the end of the shaft.
Pry on the handle.
Remove the nondrive end of the body (2).
NOTE: The spacer ring (3) can be a tight fit in the nondrive
end of the body. It is not necessary to remove the spacer
ring if it is secure in the body (2).
Remove the o-ring seal (4).
Remove the cotter pin (5), slotted nut (6), and washer (7).
Use standard puller ST-647 or equivalent and two 8 - 1.25
x 70 mm capscrews (8).
Remove the impeller (9).
Use a drift and a mallet. Remove the key (10) from the
impeller.
Remove the shims (11). Keep the shims together for future
assembly. The thickness of the shims is critical for the
performance of the pump.
NOTE: The spacer ring can be a tight fit in the body. If
necessary, use two pry bars to remove the ring.
Remove the spacer ring (3).
Bend the lockplates. Remove the four nuts (12) and the
lockplates (13).
NOTE: It will be necessary to use a mallet to separate the
parts because of the tight fit between the shaft and the
water seal and spacer.
Remove the drive end of the body (14), and spacer (15),
from the bearing housing and shaft assembly (16).
NOTE: The port plate can be a tight fit in the body after
many hours of operation. If necessary, use the special tool
available from Gilkes.
NOTE: This tool can also be used to remove the port plate
from the nondrive end of the body.
Remove the port plate (17) and mechanical seal (18) from
the drive end of the pump body (14).
Use a press and an appropriate mandrel. Remove the
contact ring (19) from the body.
Spline Driven
Remove the eight suction bend mounting capscrews (6).
Remove the suction bend (15) from the pump case (13).
Remove the o-ring (26).
NOTE: The main impeller uses a left hand thread.
Restrain the shaft spline.
Use a strap wrench to unscrew the main impeller (27).
Remove the spacer (39).
Loosen and remove the three screws (12) that hold the
wear ring (11) into position.
Remove the wear ring and the visible port plate (9).
Rotate the assembly to remove the lip seal (17) and
bevelled circlip (18) from the drive end of the bearing
housing (3).
Stand the assembly in a press, supporting it on the square
drive end flange. Press down on the shaft end.
As the shaft is pressed through the intermediate body (8)
and the bearing housing (3), the priming impeller (25) will
be released.
Take care that the shaft does not fall.
Remove the distance ring (10).
Unscrew and remove the locknut (16).
Press the bearing (2) and seal collar (19) off the shaft. This
can be tight as it is secured with Loctite 574 threadlocker.
Remove the six screws (6) holding the bearing housing (3)
to the intermediate body (8). Be sure to catch the shims
(31), (32), (33), and (34).
Press the second port plate (9) out of the intermediate
body (8).
Remove the seal spacer (24).
Remove the loose rotating half of the mechanical seal (23)
and press out the stationary half.
Remove the seal collar (20), the lip seal (22), and remove
the circlip (21) from the bearing housing. The inner race
of the roller bearing (5) will drop out.
Press out the bearing outer race.
Remove the o-ring (1).
Gear Driven
WARNING
When using detergents for cleaning, follow the
manufacturers recommendations for use. Wear
goggles and protective clothing to reduce the risk of
personal injury.
Use a 5-percent detergent solution to clean the parts. It is
important to eliminate all of the grease and dirt from the
surfaces that contact the contact ring and the mechanical
seal.
Check the impeller (3) and port plate (2) for damage from
cavitation.
If necessary, replace the parts.
Gilkes recommends the replacement of the mechanical
seal only when the contact ring is replaced at the same
time.
NOTE: This is only a temporary repair for an emergency
situation. Cummins Inc., does not recommend the use of
this procedure for a permanent repair. The correct repair
procedures must be followed as soon as possible.
For an emergency repair, the contact ring (1) can be
reversed so that the side of the ring that is not worn
touches the mechanical seal.
Reverse the ring and install it in the rubber boot (2).
Spline Driven
WARNING
When using detergents for cleaning, follow the
manufacturers recommendations for use. To reduce
the possibility of personal injury, wear goggles and
protective clothing.
WARNING
personal injury.
Use a 5-percent detergent solution to clean the parts.
Visually inspect all sea water pump components for
evidence of cracks, pitting, and any obvious damage.
Replace any damaged parts as necessary.
Assemble
Gear Driven
Use a 5-percent detergent solution. Lubricate the rubber
boot. Do not use grease.
Use the special tool (22) that is available from Gilkes or
use your hands. Install the contact ring (19) in the drive
end of the body (14).
Be sure the ring touches the bottom of the bore in the
body.
Use a 5-percent detergent solution. Lubricate the inside
diameter of the contact ring.
Install the drive end of the body (14) on the bearing
housing and shaft assembly (16).
Install the lockplates (13) and the nuts (12).
Bend the lockplate tabs over the nuts and the edge of the
housing.
WARNING
CAUTION
Do not touch the sealing surface of the seal. The oil
from your hands can cause the seal to fail.
Use solvent to clean the shaft and the contact ring.
Use a 5-percent detergent solution to lubricate the shaft.
NOTE: The largest diameter of the seal must touch the
contact ring.
Install the mechanical seal (18).
Push the seal until it touches the contact ring.
CAUTION
The lugs on the back of the port plate must enter the
slots in the body.
NOTE: The port plates are identical and interchangeable.
Install the drive end of the port plate.
The port plate will be approximately 13 mm [0.500 in]
below the chamfer when the plate is installed correctly.
Install the spacer (15).
Install the shims (11). The shims must touch the drive end
of the port plate.
NOTE: The thickness of the shims is critical to the
performance of the pump.
Use a straight edge (23) or ring that will touch the step in
the shaft.
Use a feeler gauge (24), to measure the distance from the
step on the shaft and the shims (straight edge) to the port
plate.
This distance is the impeller side clearance.
Sea Water Pump Impeller Side Clearance
mm in
0.18 MIN 0.007
0.23 MAX 0.009
If the side clearance is not within specifications, remove
or install shims (11) until the side clearance is correct.
Be sure the contact ring, seal, and port plate are seated
properly.
Install the shaft key (10).
Apply Loctite 609 or equivalent, to the shaft and key.
CAUTION
Do not use a hammer and mandrel to install the
impeller. The bearings in the pump will be damaged.
NOTE: Be sure the puller holes in the impeller are
positioned toward the nondrive end of the pump.
Align the slot in the impeller with the key. Install the
impeller on the shaft.
Use a mallet with a soft nose. Tap the impeller (1) only
until it is straight on the shaft.
CAUTION
Do not use too much grease or antiseize compound.
If the grease touches the seal, the seal will fail.
Use water pump grease or antiseize compound. Apply a
light layer to the threads on the shaft.
Install the washer (7) and the nut (6).
Use the nut to push the impeller on the shaft. The impeller
will stop when it contacts the shims.
CAUTION
Use this illustration to identify the torque specification
for the nut being installed. If the older, smaller nut is
torqued to the higher specification, the nut will fail.
If the nut requires a [1.250 in] wrench:
If the nut requires a [1.125 in] wrench:
The larger nut is recommended.
CAUTION
Do not loosen the nut to align the slots in the nut with
the hole in the shaft. Tighten the nut no more than 10
degrees to align the holes. If the slots and holes are
not in alignment, change the washer or reduce the
thickness of the washer slightly so that a slot and the
hole are in alignment at the proper torque.
Install the cotter pin (5). Bend the ends of the pin over the
nut.
Install the o-ring seal (4) on the spacer ring (3).
Install the spacer ring and o-ring seal. Push the o-ring seal
under the lip for the vee-band clamp.
NOTE: If the nondrive end of the port plate was removed,
install the plate in the body so that the lugs on the plate
engage the slots in the body.
Install the nondrive end of the body (2).
Align the marks scribed on the bodies during disassembly.
The center of the inlet and outlet ports must be in
alignment within 3 degrees.
Install the vee-band clamp (1).
Tighten the clamp.
Use a plastic hammer. Tap around the vee-band clamp
completely. Torque the clamp fasteners again. Continue
this step until the fasteners remain at the correct torque
after tapping the clamp.
Spline Driven
Mechanical seals, lip seals, o-rings, spring washers and
bearings are not serviceable, and must always be
replaced.
NOTE: Whenever Loctite products are mentioned, all
surfaces must be clean and grease free in accordance
with Loctite brand recommendations.
Press the bearing (2) onto the shaft (4).
Press the shaft and bearing assembly into the bearing
housing (3) with bevelled circlip (18).
Press the inner race of the roller bearing (5) into position
on the shaft. Fully pack this bearing with Shell ALBIDA
2 grease.
Secure the bearing with circlip (21).
Apply Loctite 574 threadlocker to the face in contact with
the shaft.
Fit the seal collar (19) over the shaft.
Secure with a locknut (16).
Apply Loctite 641 retainer to the shaft where the seal
collar (20) will fit. Press the seal collar into position.
Be sure that no excess Loctite product enters the
bearing.
Press the lip seal (22) into position using grease to
lubricate the lips.
Fit the o-ring (1).
Press the stationary half of the mechanical seal (23) into
the intermediate body (8). Use a 5-percent detergent
solution to install the seal.
Secure the intermediate body to the bearing housing with
screws (6) and spring washers (7).
Do not fully tighten the screws.
Use the 5-percent detergent solution to fit the rotating half
of the mechanical seal (23) over the shaft.
NOTE: The seal faces must be clean and dry to operate
effectively.
Slide the seal spacer (24) over the shaft.
Install the drive end port plate (9) with the port at the 9
o'clock position.
NOTE: When pressing the priming impeller onto the shaft,
make sure that the shaft end is supported to avoid loading
the bearings.
Press the priming impeller (25) onto the shaft.
Install the distance ring (10), second port plate (9), and
wear ring (11).
NOTE: Be sure the port plate fitting rib is located at the 12
o'clock position so it locates between the two dowels on
the wear plate.
Lubricate the screw threads with Loctite 242
threadlocker.
Install the screws (12) and spring washers (37).
Install the spacer (39).
Screw the impeller (27) onto the shaft using Loctite 242
threadlocker and a strap wrench.
Wipe away the excess Loctite.
NOTE: When installing the suction bend and pump case
on the assembly, it is important that the sealing o-rings are
lubricated so as not to damage them during assembly.
Install a new o-ring (26).
Install the suction bend and pump case assembly (13)
using screws (6) and spring washers (7).
The side clearance of the priming impeller must be
equalized by fitting the appropriate shims (31), (32), (33),
and (34) between the bearing housing (3) and the
intermediate body (8).
Use a feeler gauge to check the maximum, then the
minimum clearance.
Select the correct shim(s) to equalize the side clearance.
Subtract the minimum clearance from the maximum
clearance. Add one-half of the difference to the minimum
to obtain the correct side clearance dimension.
Tighten the screws (6).
Install the rubber flap valve (40) into the machined bore.
The small plate side fits into the discharge bore.
Install the o-ring flange (30) and secure down with the
countersunk screws (38).
Sea Water Pump Support K38, K50, QSK38, and QSK50
Install
Spline Drive
WARNING
CAUTION
The sea water pump must be supported by hand or in
a sling until the mounting flange is fully engaged with
the engine. Do not support the weight of the sea water
pump on its shaft end. Damage to the shaft can result.
Install a new o-ring on the pump mounting flange.
Use a hoist to lift and support the pump weight, and install
the sea water pump.
Install and tighten the mounting capscrews.
Finishing Steps
Spline Drive
NOTE: The pump must be filled with water before its first
use, and after being deliberately drained for any reason.
Connect the pipework to the water pump. Be sure that no
loads are imposed on the pump.
Fill the pump with water.
Open the supply and return valves to the sea water pump.
Operate the engine and check for leaks.
Sea Water Pump Support (008-058)
Preparatory Steps
Close the water supply valve to the sea water pump.
Remove the sea water pump. Refer to Procedure
008-057.
K38, K50, QSK38, and QSK50 Sea Water Pump Support
Remove
with Mechanically Actuated Injector
Remove both of the sea water pump oil supply tubes right
bank and left bank (17).
WARNING
equipment to lift the component or assembly.
NOTE: A mallet is required to move the support from the
two dowel pins (4).
NOTE: One of the capscrews for the left bank support also
holds the valve and injector adjustment mark pointer.
Remove the capscrews, the support, (6) and the gasket.
Discard the gasket.
Remove the sea (raw) water pump drive ring gears.
Remove the eight 12-point capscrews (3) from each gear.
Remove the gears (1) from the camshaft gears (2).
Remove the four capscrews from the support bracket and
remove the bracket.
Sea Water Pump Support K38, K50, QSK38, and QSK50
WARNING
WARNING
personal injury.
Use solvent to clean the sea water pump support and
gear.
Inspect the sea water pump support components for
damage.
Replace if damage is found.
WARNING
WARNING
personal injury.
Use solvent to clean the sea water pump support.
Inspect the sea water pump support for damage.
Replace if damage is found.
K38, K50, QSK38, and QSK50 Sea Water Pump Support
Install
CAUTION
The capscrews (3) are SAE Grade 8. If a capscrew of
lower strength is installed, the part can fail.
NOTE: The engine requires one ring gear for each
camshaft.
Install the gear (1) in the camshaft (2).
Install the eight lock washers and 12-point capscrews (3).
Check to be sure the ring gear is flat against the camshaft
gear.
WARNING
NOTE: The supports and gaskets are different for the right
and left bank. The left bank support is shown.
Install the sea water pump support.
Check to be sure the dowel pins (4) are installed.
Install the gasket (5) and the support (6) on the dowels.
This illustration gives the capscrew lengths required for
the supports. Install the pointer (7) on the capscrew for the
left bank support as shown.
Reference Numbers Length
8 [7/16-14 x 3 inch]
8 [7/16-14 x 4 1/2 inch]
10 [7/16-14 x 1 3/8 inch]
Install the lock washers and capscrews.
NOTE: The tube for the left bank pump and the right bank
pump are different. The installation procedure is the
same.
Connect the tube (17) to the fitting (18) in the front gear
cover and the fitting (19) on the support.
Tighten the tube nuts.
Torque Value:
Tube nuts 35 Nm [ 25 ft-lb ]
Supplemental Coolant Additive (SCA) K38, K50, QSK38, and QSK50
Install the support bracket and four capscrews.
Torque Value:
Support Bracket
Capscrews
60 Nm [ 45 ft-lb ]
Finishing Steps
Install the sea water pump. Refer to Procedure
008-057.
Open the water supply valve to the sea water pump.
Supplemental Coolant Additive (SCA)
(008-060)
Maintenance Check
Supplemental coolant additives, or equivalent, are used to
prevent the buildup of corrosion and scale deposits in the
cooling system.
CAUTION
Inadequate concentration of coolant additives can
result in major corrosive damage to cooling system
components. Over-concentration can cause the
formation of gelatin (gel) that can cause restrictions
and plugging.
The SCA concentration must not fall below 1.2 units per
3.8 liters [1 gal] or exceed 3 units per 3.8 liters [1 gal].
When changing the coolant, the initial SCA, or equivalent
concentration, must be between 1.2 and 3 units per 3.8
liters [1 gal] of coolant (initial charge).
The cooling system must be clean before adding SCA, or
equivalent. Refer to Procedure 008-018 (Cooling System)
in Section 8.
K38, K50, QSK38, and QSK50 Water Manifold
DCA4 is compatible with all permanent-type antifreeze,
except methoxy propanol. If methoxy propanol antifreeze
is used, reduce the amount of DCA4 by one-third. This will
prevent inhibitor loss due to precipitation caused by
chemical incompatibility.
If coolant is added between drain intervals, additional
SCA, or equivalent, will be required.
Check the coolant just before changing the coolant filter.
Use only coolant test kit, Fleetguard Part Number
CC2602, to check the coolant additive concentration when
SCA is used.
Use the correct Fleetguard coolant filter to maintain the
correct SCA concentration in the system.
Maintain the correct concentration by changing the
maintenance coolant filter at each oil drain interval.
Water Manifold (008-061)
WARNING
reduce the risk of personal injury.
NOTE: It is not necessary to remove the manifold from the
support bracket.
Remove the plugs. It is not necessary to remove the
fittings.
Use solvent. Clean the water manifold.
Water Pump K38, K50, QSK38, and QSK50
Be sure the passages are open.
Compare the dimensions (1) and (2) to determine the top
(3) of the manifold. With the top of the manifold up, the
manifold inlet (4) is the lower passage and the outlet (5) is
the upper passage.
(1) 48 mm [1.875 in]
(2) 38 mm [1.500 in]
The manifold must be mounted on the bracket with the
top up.
Install the plugs.
Water Pump (008-062)
General Information
CAUTION
The seal will malfunction if the spring tension is not correct. One drop of Loctite 290, or equivalent, must
be applied on the joint between the seat and the shaft. More than one drop of the sealant can contact the
sealing surfaces and cause the seal to malfunction.
CAUTION
Use of the K50 water pump inlet connection on low temperature aftercooler (LTA) equipped engines will result
in excessive cooling system pressures and cooling system malfunctions.
The K38 and K50 water pumps are the same physical size but contain different parts. The correct water pump
must be installed. If the correct parts are not installed, the performance of the water pump will not be within
specifications.
The water pump is a centrifugal pump with cast iron impellers only. The water pump is gear driven by a spline coupling.
This coupling connects the pump to the water pump drive.
The water pump contains two ball-type bearings. The bearings are lubricated with pressurized engine oil. The new
K38 and K50 water pumps contain a front, large ball bearing that is a single row type bearing. Older pumps contain
a double row type bearing. The water pump body and the bearing spacer are different for the single and double row
bearings. If the front bearing is replaced, the same type of bearing must be installed.
The water pump shaft and impeller were changed to increase the torque capability of the shaft and impeller joint. The
bore in the impeller is smaller. The drive key, the notch for the drive key, and the self-locking capscrew in the impeller
were omitted. The older and the new shafts and impellers can be combined, but the torque capability of the joint will
not be increased. If the older and new parts are combined, the drive key and the self-locking capscrew must be
omitted.
The impeller and the water inlet connection have a machined angle that is critical to the performance of the pump.
The older and the new K38 parts do not have the same angle and are not to be combined. The K50 impeller and
water inlet connection are always machined to the same angle, but are different than the older and new K38 parts.
K38, K50, QSK38, and QSK50 Water Pump
The water pump shaft was also changed. The new shaft contains one retaining ring only and requires a spacer
between the two bearings. The spacer is different for the single row and double row, front, large bearing. The older
shaft contains two retaining rings and does not require a spacer. The older shaft can be installed only when the
double row bearing is required. If the older shaft is replaced, the correct bearing and spacer must be installed for the
water pump body.
The water pump contains an oil seal and a water pump seal. A revised water seal was introduced into production in
October, 1997 (Engine Serial Number First 33139138). The cavity between these seals has a vent. The vent prevents
contamination of the lubricant or coolant if a seal leaks. Oil and coolant seeping from the vent will not harm the
operation of the pump. Check the vent for any obstruction at each scheduled maintenance interval. The recommended
interval is 250 hours or 6 months of operation.
The water seal was changed from a two piece to a unitized, one piece design. The seal and seat are fastened together
in this design. This helps to prevent malfunctions caused by dirt or oil contacting the seal and seat surfaces during
installation. A special tool must be used to install the one piece seal so that the seat is installed at the correct dimension
from the water pump body. Correct installation results in proper spring tension.
Additional information regarding other parts of the cooling system can be found within this section.
K50 engines fitted with an low temperature aftercooler (LTA) system use the K38 water pump and water pump inlet
connection.
The water pump inlet connection is designed for optimum coolant flow split and decreases the possibility of reverse
flow through the main radiator core via the bypass tube. A revised larger diameter water bypass tube is also used.
The following table details the compatibility of the water pump parts.
NOTE: If the shaft does not contain threads in the end for the impeller, the drive key must be omitted.
NOTE: If the impeller does not contain a slot on the side that has vanes, the drive key and self-locking capscrew
must be omitted.
NOTE: If the shaft contains threads in the end for the impeller, and the impeller contains a slot on the side that has
vanes, the drive key and self-locking capscrew must be installed.
Engine
Model
Water Pump
Body
With Inlet
Connection
Install Impeller Install Shaft Install Spacer Spacer Length
mm [in]
K38 3030489 3001712 3050453 or
3001711
3050442 or
3175527
3030487 35.17 [1.385]
206456 3050455 or
3175069
3050442 or
3175527
3030487 35.17 [1.385]
3001317 3001712 3050453 or
3001711
3050442 or
3175527 If 206194
-->
3175570
NONE
23.68 [0.935]
206456 3050455 or
3175069
3050442 or
3175527 If 206194
-->
3175570
NONE
23.68 [0.935]
206192 3001712 3050453 or
3001711
3050442 or
3175527 If 206194
-->
3175570
NONE
23.68[0.935]
206456 3050455 or
3175069
3050442 or
3175527 If 206194
-->
3175570
NONE
23.68 [0.935]
K50 3030490 3002108 3050454 or
3002106
3050442 or
3175527
3030487 35.17 [1.385]
3002107 3002108 3050454 or
3002106
3050442 or
3175527
3175570
NONE
23.68 [0.935]
Preparatory Steps
WARNING
arcing, remove the negative (-) battery cable first, and
attach the negative (-) battery cable last.
WARNING
WARNING
013-009 (Battery and Cables Connections) in Section
13.
Remove the coolant bypass tube. Refer to Procedure
008-005 (Coolant Bypass Tube) in Section 8.
WARNING
WARNING
WARNING
13.
Remove the alternator drive belt. Refer to Procedure
013-005 Alternator Drive Belt) in Section 13.
Remove the alternator drive pulley. Refer to
Procedure 009-010 (Alternator Drive Pulley) in
Section 9.
Remove
Disconnect the lower radiator hose from the water pump
inlet.
NOTE: On low temperature aftercooler (LTA) equipped
engines, disconnect the water filter hoses.
Remove the two capscrews and heavy washers (6) that
hold the support bracket (4) to the cylinder block.
Remove the four capscrews that hold the housing (2) to
the water pump (3). Note that the two washers (5) are
heavy washers.
Remove the support bracket. Pull the housing from the
pump.
Remove and discard the o-ring (1).
WARNING
Remove the four capscrews that hold the adapter plate (2)
to the cylinder block.
Remove the four capscrews that hold the pump (3) to the
water pump drive (6). Remove the pump and the coupling
(4). Remove the plate (2) from the pump.
Remove and discard the o-ring seal (1), and the gasket (5).
NOTE: The procedure for the QSK60 engine is shown.
The procedure for the QSK38 and QSK50 engines are
similar.
Open the drain cock on the engine block (1) and the water
pump (2).
Remove the two brackets and U clamps (1) from the low
temperature aftercooler outlet (2) and jacket water bypass
pipes (3).
1. Remove the hose clamps (1) from the low
temperature aftercooler outlet (2) and the jacket
water bypass pipe (3).
2. Remove the U clamp (4) from the jacket water
bypass pipe (3).
3. Remove the four capscrews (5), low temperature
aftercooler outlet (2), and the gaskets.
4. Remove the four capscrews (6), the jacket water
bypass pipe (3), and the gaskets.
If equipped with Straub clamps, loosen the three
capscrews and slide the Straub clamp up onto the upper
portion of the low temperature aftercooler outlet and jacket
water bypass tubes.
Remove the bracket/clamp (1) from the low temperature
aftercooler bypass pipe (2).
Remove the hose clamp (3) from the low temperature
Remove the bypass pipe (2).
If equipped with Straub clamps, loosen the three
capscrews and slide the Straub clamp up onto the upper
half of the bypass tube.
Remove the four capscrews and jacket water radiator inlet
connection.
Remove the capscrews and jacket water inlet connection.
Remove the two capscrews (2) from the engine block (1)
and the water pump support bracket (3).
Remove the two capscrews (2) from the water pump (4),
and the water pump support bracket (3).
Remove the capscrews (2) and the water pump support
bracket (3) from the water pump (4), and the engine block
(1).
WARNING
Remove the six capscrews (1) from the water pump (2) and
the gear housing (3).
Remove the four capscrews (4) from the engine block (5).
Remove the water pump from the front gear housing.
WARNING
WARNING
personal injury.
Clean all gasket surfaces.
Use solvent to clean the drive shaft end of the pump.
Rotate the shaft to check the bearings for damage or wear.
An end clearance of 0.05 to 0.010 mm [0.002 to 0.004 in]
is required.
If the bearings are damaged or worn, the pump must be
rebuilt.
Check the splines on the shaft and the coupling for
damage or wear.
If the splines on the shaft are worn or damaged, the pump
must be rebuilt.
If the splines in the coupling are worn, the coupling
must be replaced.
If the splines that contact the water pump drive are worn,
check the shaft in the drive.
A minor chemical buildup or streaking at the water pump
weep hole (1) is normal. Do not repair or replace the water
pump unless an actual leak is confirmed. If a leak is
confirmed, contact a Cummins Authorized Repair
Location for replacement.
Disassemble
Spline coupling (1)
Mounting gasket (2)
Adapter plate (3)
O-ring (4)
Adapter plate gasket (5).
Discard the o-ring and gasket.
Water inlet connection (6)
Gasket (7)
Support bracket (8)
Draincock (9).
Discard the gasket.
Capscrews (10)
Water pump inlet connection (11)
O-ring seal (12).
Discard the o-ring.
NOTE: The latest water pumps and rebuilt water pumps
with revised shafts or impellers do not contain the drive
key and capscrew.
Self-locking capscrew (12)
Drive key (13).
CAUTION
The puller screw must pass easily through the
impeller bore to prevent damage.
CAUTION
The puller screw must not damage the threads in the
shaft if the shaft is to be installed again with an
impeller that has a slot for a drive key. Install a short
capscrew in the shaft to protect the threads.
Use a standard puller, Part Number ST-647, or equivalent.
Remove the impeller.
Clean and check the impeller for damage.
Remove the large retaining ring (14).
Use an arbor press to support the water pump body. Push
on the impeller end of the shaft. Remove the bearing and
shaft assembly.
Discard the water pump seal seat, if equipped.
Oil seal (15)
Water seal (16).
The bearing and shaft assembly can be one of two
different designs. The replacement procedure is different
for the two designs. The revised bearing and shaft
assembly (1), contains a retaining ring (2) nearest to the
impeller end of the shaft.
The previous bearing and shaft assembly (3), contains a
retaining ring (2) nearest to the end of the shaft that is
splined.
The revised assembly (1) can contain different large
bearings (4), and bearing spacers (5). The bearing (4) can
be a double or single row bearing. The spacer (5) for the
single row bearing is longer. The Water Pump, General
Information in this procedure list the correct parts.
The previous assembly (3) must contain the double row
bearing.
The following steps are for the revised design of the water
pump.
Remove the retaining ring (2).
CAUTION
Do not damage the end of the shaft if it is to be
installed again. Support the assembly as shown.
Use a hydraulic press to support the large bearing (4) as
shown.
Remove the small bearing (6), spacer (5), and the large
bearing (4) from the shaft (7).
The following step is for the previous design of the water
pump.
Remove the retaining ring (1).
Use a water pump bearing separator, Part Number
3375326, or equivalent. Disassemble the parts.
Remove the front, large bearing (2), spacer (5), and the
rear, small bearing (3)
Inspect
NOTE: Three different shafts have been used. The
outside diameter in the bearing area is the same.
Measure the outside diameter
Water Pump Shaft Outside Diameter (Bearing Area)
mm in
30.010 MIN 1.1816
30.020 MAX 1.1820
Water Pump Shaft Outside Diameter (Impeller End)
mm in
24.999 MIN 0.9842
25.009 MAX 0.9846
Measure the shaft outside diameter and the bearing inside
diameter
Maximum Clearance 0.003 mm [ 0.0001 in ]
Maximum Interference 0.018 mm [ 0.007 in ]
NOTE: The shaft outside diameter specifications are the
same as for the revised design shaft.
Measure the bore inside diameter of Part Numbers
3050454 and 3050455.
Water Pump Impeller Inside Diameter (17)
mm in
24.919 MIN 0.9811
24.945 MAX 0.9821
Measure the inside diameter. All other part numbers,
excluding those listed above are covered by this table.
Water Pump Impeller Bore Inside Diameter (17)
mm in
24.932 MIN 0.9816
24.958 MAX 0.9826
NOTE: The outside diameter is given for parts
identification only. It is not necessary to measure the part.
Water Pump Impeller Outside Diameter (18)
mm in
K38 146 NOM 5.75
K50 171 NOM 6.75
NOTE: The angle is given for parts identification only. It
is not necessary to measure the part.
NOTE: All K50 water pump impellers have a 78 degree
angle.
K38 Water Pump Impeller Angle (19)
Part Number Angle
3050455 74 degrees
3175069 74 degrees
3050453 67 degrees
3001711 67 degrees
Install an impeller with a 74 degree angle only with a water
pump inlet connection that has a 16 degree angle.
Install an impeller with a 67 degree angle only with a water
pump inlet connection that has a 23 degree angle.
The Water Pump, General Information in this procedure
lists the correct part numbers.
K38 and K50 Water Pump Body Bore Inside Diameter
mm in
Water Seal (21) 53.60 MIN 2.110
54.10 MAX 2.130
Oil Seal (22) 38.05 MIN 1.498
38.10 MAX 1.500
Water Seal (23) 61.997 MIN 2.4408
62.009 MAX 2.4412
Oil Seal (24) 71.996 MIN 2.8345
72.012 MAX 2.8351
NOTE: The depth of the bore is given for parts
identification only. It is not necessary to measure the part.
Front Water Pump Bearing Bore Depth in Water
Pump Body (25)
mm in
Body for single
row bearing
25.4 1.00
Body for double
row bearing
36.8 1.45
NOTE: The diameter is given for parts identification
only. It is not necessary to measure the part.
Water Pump Impeller Counterbore Inside Diameter in
Water Pump Body (26)
Engine Model mm in
K38 (revised) 147 5.8
K38 (previous) 160 6.3
K50 (all) 173 6.8
Assemble
CAUTION
Be sure the correct large bearing is installed. If the
wrong large bearing is installed, the pump will fail.
CAUTION
The mandrel must contact on the inner race of the
bearing to prevent damage.
NOTE: On the revised shafts, the bearing will not fit tightly
on the part of the shaft that is machined smaller (10).
The following steps are for the revised design shaft and
bearings.
Use a hydraulic press to support the shaft as shown.
Use a water pump bearing mandrel, Part Number
3375318 (8), or equivalent.
Push the large bearing (4) on the shaft until it touches the
step on the shaft (9).
CAUTION
The correct spacer must be installed or the bearing
assembly will not fit in the body correctly.
If the large bearing is a single row bearing (11), install the
long spacer (12).
If the large bearing is a double row bearing (13), install the
short spacer (14).
Install the correct spacer (5). Slide the spacer on the shaft
until it touches the large bearing.
CAUTION
Use a hydraulic press to support the shaft as shown.
3375318 (8), or equivalent.
Push the small bearing (2) on the shaft until it touches the
spacer (5).
Install the retaining ring (2).
CAUTION
NOTE: Only the large, double row front bearing can be
installed on the older design shaft.
The following steps are for the previous design shaft and
bearings.
3375318 (8), or equivalent. Use an appropriate mandrel
(4). Use an arbor press. Support the shaft.
Install the bearings.
Install the retaining ring.
The new oil seal must be installed with the part number
positioned down. Use a water pump seal driver, Part
Number 3375319, or equivalent. Install the seal.
The seal must be even with, or up to no more than 0.51
mm [0.020 in] below the top of the step in the body.
Use an arbor press to support the housing.
Use the water pump bearing driver, Part Number
3375318, or equivalent, or push on the end of the shaft.
Install the assembly.
The beveled edge must be positioned as shown. Install
the large retaining ring.
CAUTION
Support the water pump body for installation of the
water pump seal. Do not support the shaft. This will
prevent damage to the bearings.
Use a water pump seal driver, Part Number 3824836, or
equivalent (27). Install the new water seal (16).
Make sure the shoulder on the seal touches the housing.
The installed height of the seal (28) must be 21.36 to 21.87
mm [0.841 to 0.861 in].
CAUTION
The seal will malfunction if the spring tension is not
correct. One drop of Loctite 290 or equivalent, must
be applied on the joint between the seat and the shaft.
More than one drop of the sealant can contact the
sealing surfaces and cause the seal to malfunction.
Apply one drop only of Loctite 290, or equivalent, to the
seal and the parting line of the shaft.
CAUTION
If the impeller and shaft have a slot for the drive key,
the slots must be aligned before the impeller is
pushed on the shaft.
If either the impeller or shaft do not have a slot, omit this
step. Position the impeller on the shaft so that the slots
are aligned.
Apply a smooth coating of Loctite 609, or equivalent to
the impeller bore.
Use an arbor press and a flat steel plate to support the
shaft as shown.
Install the impeller until it is even with the end of the shaft.
NOTE: If either the shaft or the impeller does not have a
slot for the drive key, omit this step.
Install the drive key (13) and the self-locking capscrew
(12).
Use vegetable oil to lubricate the o-ring.
Install the parts. Install the top and right capscrews.
NOTE: Do not tighten the capscrews for the bracket until
the pump is installed on the engine.
Install the support bracket (8) and capscrews.
Install the new gasket (7), connection (6), and capscrews.
Install the draincock (9).
Use vegetable oil to lubricate the new o-ring (4).
Install the o-ring in the groove of the adapter plate (3).
Install the adapter plate on the body. The thinner side of
the plate must be nearest to the water pump body.
Use clean engine oil to lubricate the bearings while
rotating the shaft.
Use clean engine oil to lubricate the splines on the shaft.
Install the spline coupling (1).
Install
WARNING
Install the o-ring (1) in the groove in the water pump
adapter plate (2). Use vegetable oil to lubricate the o-ring.
NOTE: The adapter plate must be installed so the groove
in the plate is toward the pump.
Install the adapter plate on the water pump (3).
Install the spline coupling (4) and the water pump shaft.
Install the gasket (5) on the pilot on the water pump. Align
the holes.
Position the pump on the water pump drive (6). Rotate the
pump to align the spline coupling with the splines on the
water pump drive shaft. Install the four lock washers and
capscrews that hold the drive to the pump. Tighten the
capscrews only enough to hold the parts together.
Install the gasket (7) between the adapter plate and the
cylinder block. Install but do not tighten the four lock
washers and capscrews that hold the plate to the cylinder
block.
Rotate the pump housing so that the pump outlet and the
adapter plate are close to the cylinder block as possible.
Tighten the four pump to pump drive capscrews.
Tighten the four cylinder block capscrews to the adapter
plate.
Install the o-ring (1) in the groove on the inlet housing (2).
Use vegetable oil to lubricate the seal.
Install the housing in the bore in the water pump (3). Align
the holes. Install the two lock washers and capscrews in
the top and outside capscrew holes. Tighten the
capscrews only enough to hold the parts together.
Install the bracket (4) to the pump using two large flat
washers (6), lock washers and capscrews. Tighten the
capscrews only enough to hold the bracket to the housing.
Install the two large flat washers (5), lock washers and
capscrews that hold the bracket to the hand hole cover.
Tighten the capscrews only enough to hold the bracket to
the hand hole cover.
NOTE: Make sure the bracket remains flat against both
the housing and the hand cover while tightening the
capscrews. If the bracket does not remain flat, it will
malfunction and cause the pump or pump drive to also
malfunction.
Tighten the four capscrews that hold the bracket to the
inlet housing, and the inlet housing to the pump.
Tighten the capscrews that hold the bracket to the hand
hole cover.
Install the bypass connection gaskets. Tighten the
capscrews.
Tighten hose clamps.
Torque Value: 5.6 Nm [ 50 in-lb ]
Replace the coolant filter. Refer to Procedure 008-006
(Coolant Filter) in Section 8.
Connect the lower radiator hose to the water pump inlet.
Connect the water filter lines.
WARNING
Install the water pump (2) into the gear housing (3) use the
six capscrews (1) and a new gasket.
Install the four capscrews (4) to the engine block (5) use a
new gasket.
Torque Value:
Water Pump
Mounting
Capscrews
80 Nm [ 59 ft-lb ]
Install the capscrews (2) and the water pump support
bracket (3) to the water pump (4), and the engine block (1).
Install the two capscrews (2) to the water pump (4), and
the water pump support bracket (3).
Install the two capscrews (2) to the engine block (1) and
the water pump support bracket (3).
Torque Value:
Support Bracket
Capscrews
45 Nm [ 33 ft-lb ]
Lubricate the new o-ring on the jacket water inlet.
Install jacket water inlet and capscrews onto the water
pump.
Torque Value:
Jacket Water
Inlet Capscrews
45 Nm [ 33 ft-lb ]
Install the jacket water radiator inlet connection, gasket
and four capscrews.
Torque Value:
Jacket Water
Radiator Inlet
Capscrews
45 Nm [ 33 ft-lb ]
Install the bypass pipe (2).
Install the hose clamp (3) on the low temperature
Install the bracket/clamp (1) to the low temperature
aftercooler bypass Pipe (2).
If equipped with Straub clamps, slide the Straub clamp
down onto the lower half of the bypass tube.
Install the jacket water bypass pipe (3), gaskets and four
capscrews (6).
Install the low temperature outlet pipe (2), gasket and four
capscrews (5).
Install the U clamp (4) to the jacket water bypass pipe (3).
Install the hose clamps (1) to the low temperature
aftercooler outlet (2) and the jacket water bypass pipe (3).
If equipped with Straub clamps, slide the Straub clamp
down onto the lower portion of the low temperature
aftercooler outlet and jacket water bypass tubes.
Tighten the three capscrews.
Install the bracket and U clamps (1) to the low temperature
aftercooler outlet (2) and jacket water bypass pipe (3)
Tighten the U clamps.
Close the draincock on the engine block (1) and on the
water pump (2).
Finishing Steps
WARNING
WARNING
13.
Operate the engine to 70C [160F] coolant
temperature and check for leaks.
K38, K50, QSK38, and QSK50 Sea Water System Diagnostics
WARNING
WARNING
013-009 (Battery Cables and Connections) in Section
13.
Install the alternator drive pulley. Refer to Procedure
009-010 (Alternator Drivve Pully) in Section 9.
Install the alternator drive belt. Refer to Procedure
013-005 (Drive Belt, Alternator) in Section 13.
Sea Water System Diagnostics
(008-103)
General Information
Typical sea water cooling system:
1. Grate-type strainer located on the bottom of the
vessel hull
2. Vessel bottom/hull
3. Sea water inlet valve
4. Hose
5. Sea water strainer
6. Sea water pump tube
7. Sea tube pump
8. Sea water inlet
9. Heat exchanger
10. Sea water outlet.
Inspect
Locate and verify that the sea water inlet valve is in the
full-open position. If closed or partially closed, open the
valve and check the engine temperature.
Sea Water System Diagnostics K38, K50, QSK38, and QSK50
Test
Attach a vacuum gauge to the inlet side of the sea water
pump.
Start the engine.
Check the sea water restriction from idle to rated speed at
200-rpm increments while the vessel is in the dock. Sea
water restrictions must be less than 17 kPa [5 in-Hg]
under all operating conditions.
If the sea water inlet restriction is above specification, the
source of the restriction (1,2,3 or 4) must be found.
Troubleshooting and repair of excessive sea water
restriction is a vessel manufacturer or vessel owner
responsibility and not covered by Cummins warranty.
K38, K50, QSK38, and QSK50 Sea Water System Diagnostics
If the sea water restriction readings fluctuate, inspect the
sea water supply for leaks. These components are not
built or supplied by Cummins Inc. Troubleshooting and
repair of sea water aeration is not covered under
Cummins warranty.
It is possible that aeration (gauge fluctuation) will only
occur while the vessel is underway, due to the introduction
of air.
Pressure Test
Attach a pressure gauge to the outlet side of the sea water
pump to check pump outlet pressure. Check water pump
specifications for proper pressure. Record the pressure
reading for the next step.
Attach the pressure gauge to the discharge side of the
heat exchanger and check for pressure drop. Be certain
to check both pressures under the same operating
conditions - for instance, at idle or rated speed.
Low-Temperature Aftercooler (LTA) Water Pump K38, K50, QSK38, and QSK50
If the pressure drop between the inlet side of the heat
exchanger and the outlet side of the heat exchanger is
greater than specification, check for blockage in the heat
exchanger.
Sea Water Hoses (008-104)
Inspect
NOTE: Shown is a basic sea water system. Although
components will different in appearance, the procedure
remains the same.
Start the engine and inspect all hoses and connections for
deterioration. Particles of deteriorated hose can be carried
through the sea water system and restrict or clog small
passages (especially the heat exchanger) and partially
stop circulation. Replace as necessary.
Inspect the sea water system hoses and hose connections
for leaks. Replace damaged hoses and clamps, if
necessary.
Low-Temperature Aftercooler (LTA)
Maintenance Check
A minor buildup of streaking at the water pump weep hole
(1) is normal. Do not repair or replace the water pump (2)
unless an actual leak is confirmed. If a leak is confirmed,
contact a Cummins Authorized Repair Location for
replacement.
K38, K50, QSK38, and QSK50 ECM Cooling Plate
ECM Cooling Plate (008-128)
Preparatory Steps
Remove the ECMs. Refer to Procedure 019-031 in
the Troubleshooting and Repair Manual Electronic
Control System QSK50 and QSK60 Modular
Common Rail System Series Engines, Bulletin
4021533.
008-018.
Remove the ECM cooling lines. Refer to Procedure
008-130.
Remove
Remove the nuts and washers from the ECM cooling plate
mounting studs and remove the ECM cooling plate.
Remove the ECM mounting studs.
The upper stud is in the fuel block manifold and the bottom
studs are in the cylinder block.
Disassemble
Remove the vibration isolators from the ECM cooling
plate.
ECM Cooling Plate K38, K50, QSK38, and QSK50
Remove the tee adapter from the ECM cooling plate
coolant return port (lower).
Remove the drain cock from the tee adapter.
Remove the elbow adapter from the ECM cooling plate
coolant supply port (upper).
WARNING
WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before use.
Clean the ECM cooling plate, fittings and attaching
hardware with cleaning solvent, Cummins Part Number
3824510, or equivalent.
Inspect the ECM cooling plate for any signs of damage,
cracks, corrosion, and leaks. Replace if damaged.
Inspect the ECM's mounting threaded holes for any signs
of damage.
If damage is found, it can be repaired with a screw thread
insert, Cummins Part Number 3822699, or equivalent
(M8x1.25).
Inspect the threaded supply and return ports for damage
or stripped threads,
Replace the ECM cooling plate if ports are damaged or
stripped.
Inspect the tee adapter for signs of damage or stripped
threads. Replace the tee adapter if damaged.
Inspect the elbow adapter for cracks, damage, and
stripped threads. Replace the elbow adapter if damaged.
Inspect the drain cock for damage, seizure, and stripped
threads. Replace if damaged or seized.
Inspect the ECM mounting studs for corrosion and
stripped threads. Replace as necessary.
Inspect the vibration isolators for cracks, wear, or
damage. Replace if necessary.
Inspect the ECM coolant supply and return lines for
cracks, damage, age, wear, or leakage.
Inspect the fitting on each end of the cooling lines for
damage and stripped threads.
Replace damaged coolant lines.
Assemble
If reusing the drain cock, apply thread sealer, Part Number
3375066, or equivalent to the threads. If a new draincock
is to be used, the threads will already have sealant
applied.
Install the drain cock into the tee. Hand tighten.
Install new o-rings on the return tee adapter and install it
in the ECM cooling plate return port.
Torque Value:
Coolant Return
Tee
25 Nm [ 18 ft-lb ]
Install new o-rings on the supply elbow adapter and install
it in the ECM cooling plate supply port.
Torque Value:
Coolant Supply
Elbow
25 Nm [ 18 ft-lb ]
Install the vibration isolators on the ECM cooling plate.
Install
Install the cooling plate mounting studs onto the block
manifold and cylinder block.
Torque Value:
ECM Mounting
Studs
80 Nm [ 59 ft-lb ]
Install the ECM cooling plate and mounting nuts onto the
mounting studs.
Torque Value:
ECM Cooling
Plate Nuts
23 Nm [ 17 ft-lb ]
Finishing Steps
Install the ECM cooling lines. Refer to Procedure
008-130.
Install the ECMs. Refer to Procedure 019-031 in the
Troubleshooting and Repair Manual Electronic
4021533.
K38, K50, QSK38, and QSK50 ECM Cooling Plate Lines
ECM Cooling Plate Lines (008-130)
Preparatory Steps
WARNING
WARNING
coolant spray or steam can cause serious personal
injury.
008-018.
Remove
Remove the capscrews securing the clips which hold the
electronic control module (ECM) cooling plate lines to the
cam follower covers and the air compressor housing.
Remove the electronic control module (ECM) cooling plate
supply and return lines.
ECM Cooling Plate Lines K38, K50, QSK38, and QSK50
Remove the brackets from the coolant lines.
Remove the male connectors and adapters from the Low
Temperature Aftercooler lines. Discard the o-rings.
Inspect for Reuse
Inspect the coolant lines for cracks, damage, age wear, or
leakage.
Inspect the fittings on both ends of the coolant lines for
damage and stripped fittings. Replace if damage is found.
Inspect the connectors and adapters for cracks, damaged
and stripped threads. Replace if damage is found.
K38, K50, QSK38, and QSK50 ECM Cooling Plate Lines
Install
If the adapters are being reused, apply sealant, Cummins
Part Number 3375066, or equivalent, to the threads of the
adapter. If installing new adapters, sealant is already
applied to the threads.
If the male connectors are being reused, apply sealant,
Cummins Part Number 3375066, or equivalent, to the
threads of the connectors. If installing new male
connectors, sealant is already applied to the threads.
Install the male connectors into each of the adapters.
Install the electronic control module (ECM) coolant plate
supply and return lines.
Install the electronic control module (ECM) coolant line
brackets.
ECM Cooling Plate Lines K38, K50, QSK38, and QSK50
Attach the bracket to the cam follower cover and air
compressor housing.
Finishing Steps
Section 9 Drive Units Group 09 Page 9-a
Section 9 Drive Units Group 09
Section Contents
Page
Accessory Drive ................................................................................................................................................9-3
Assemble..........................................................................................................................................................9-8
with Mechanically Actuated Injector................................................................................................................9-8
Disassemble.....................................................................................................................................................9-4
Finishing Steps...............................................................................................................................................9-11
with Mechanically Actuated Injector..............................................................................................................9-11
Initial Check......................................................................................................................................................9-3
Inspect for Reuse..............................................................................................................................................9-6
Install..............................................................................................................................................................9-10
Preparatory Steps.............................................................................................................................................9-3
Remove............................................................................................................................................................9-3
Accessory Drive Bushing ................................................................................................................................9-11
Mechanically Actuated Injector.....................................................................................................................9-12
Install..............................................................................................................................................................9-13
Remove.......................................................................................................................................................... 9-11
Accessory Drive Cover ....................................................................................................................................9-79
Install..............................................................................................................................................................9-79
Accessory Drive Gear and Shaft .....................................................................................................................9-14
Assemble........................................................................................................................................................9-15
Disassemble................................................................................................................................................... 9-14
Accessory Drive Pulley ...................................................................................................................................9-16
Install..............................................................................................................................................................9-18
POSE...........................................................................................................................................................9-19
Remove.......................................................................................................................................................... 9-16
Accessory Drive Pulley Wear Sleeve ..............................................................................................................9-19
Install..............................................................................................................................................................9-21
Remove.......................................................................................................................................................... 9-19
Alternator Drive Pulley ....................................................................................................................................9-21
Finishing Steps...............................................................................................................................................9-23
Install..............................................................................................................................................................9-22
Remove.......................................................................................................................................................... 9-21
Fuel Pump Drive ..............................................................................................................................................9-23
Assemble........................................................................................................................................................9-30
Disassemble................................................................................................................................................... 9-25
Page 9-b Section 9 Drive Units Group 09
Finishing Steps...............................................................................................................................................9-36
Initial Check....................................................................................................................................................9-24
Install..............................................................................................................................................................9-35
Remove.......................................................................................................................................................... 9-24
Hydraulic Pump Drive ..................................................................................................................................... 9-37
Assemble........................................................................................................................................................9-40
Clean for Rebuild............................................................................................................................................9-39
Disassemble................................................................................................................................................... 9-38
Finishing Steps...............................................................................................................................................9-41
Inspect............................................................................................................................................................9-39
Install..............................................................................................................................................................9-41
Remove.......................................................................................................................................................... 9-37
Hydraulic Pump Drive Gear and Shaft ............................................................................................................9-42
Assemble........................................................................................................................................................9-43
Disassemble................................................................................................................................................... 9-42
Rear Gear Drive (Lower Assembly) ................................................................................................................ 9-43
Assemble........................................................................................................................................................9-49
Clean..............................................................................................................................................................9-45
Disassemble................................................................................................................................................... 9-46
Finishing Steps...............................................................................................................................................9-53
Inspect............................................................................................................................................................9-47
Install..............................................................................................................................................................9-51
Remove.......................................................................................................................................................... 9-44
Rear Gear Drive (Upper Assembly) .................................................................................................................9-53
Assemble........................................................................................................................................................9-61
Clean..............................................................................................................................................................9-58
Disassemble................................................................................................................................................... 9-55
Inspect............................................................................................................................................................9-59
Install..............................................................................................................................................................9-64
Remove.......................................................................................................................................................... 9-54
Rear Gear Drive Gear and Shaft (Upper Assembly) .......................................................................................9-65
Assemble........................................................................................................................................................9-66
Clean..............................................................................................................................................................9-65
Disassemble................................................................................................................................................... 9-65
Service Tools ....................................................................................................................................................9-1
Drive Units........................................................................................................................................................9-1
Water Pump Drive Bushing .............................................................................................................................9-68
Install..............................................................................................................................................................9-69
Remove.......................................................................................................................................................... 9-68
Section 9 Drive Units Group 09 Page 9-c
Water Pump Drive Gear and Shaft ..................................................................................................................9-70
Assemble........................................................................................................................................................9-71
Disassemble...................................................................................................................................................9-70
Water Pump Drive Pulley ................................................................................................................................9-71
Finishing Steps...............................................................................................................................................9-72
Install..............................................................................................................................................................9-72
Remove..........................................................................................................................................................9-71
Woodward Governor Drive ..............................................................................................................................9-72
Assemble........................................................................................................................................................9-77
Disassemble...................................................................................................................................................9-73
Inspect............................................................................................................................................................9-75
Page 9-d Section 9 Drive Units Group 09
This Page Left Intentionally Blank
Section 9 Drive Units Group 09 Page 9-1
Service Tools
Drive Units
Repair Location.
ST-647
Gear Puller
Used to remove drive pulleys and impellers.
3376663
Coupling Puller
Remove the spline coupling gear from the compressor drive.
3823154
AV Seal Removal/Installation Kit
Used to remove and install AV seals from oil drillings.
3376326
Pulley Installation Tool
Contains a variety of adaptors used to assemble pulleys onto shafts.
3824502
Pulley Adaptor Kit
Used with Pulley Installation Tool, Part Number 3376326, to
assemble pulleys onto shafts.
3824922
Accessory Drive Oil Seal Installer
Used to assemble accessory drive oil seals into the front gear cover
with the accessory drive installed to the front cover.
Page 9-2 Section 9 Drive Units Group 09
3377132
Sealant (RTV)
Applied to the portion of the cover that will be in the bore of the front
cover.
3164794
Torque Wrench
K38, K50, QSK38, and QSK50 Accessory Drive
Accessory Drive (009-001)
Preparatory Steps
WARNING
WARNING
If an air compressor is not mounted on the engine, it is
not necessary to drain the cooling system.
Drain the cooling system, if applicable. Refer to
Procedure 008-018.
Remove the fuel pump. Refer to Procedure 005-016.
Remove the air compressor, if applicable. Refer to
Procedure 012-014.
Remove the accessory drive pulley, if applicable.
Remove the accessory drive cover, if applicable.
Remove the accessory drive seal, if applicable.
Remove
Remove the six capscrews.
Remove the accessory drive assembly.
Remove and inspect gasket.
Initial Check
WARNING
Use solvent to clean the outer housing of the accessory
drive.
Accessory Drive K38, K50, QSK38, and QSK50
Use a dial indicator to measure the accessory drive shaft
end clearance.
Accessory Shaft End Clearance
mm in
0.05 MIN 0.002
0.30 MAX 0.012
Disassemble
CAUTION
To prevent damage to the shaft, the capscrew must
be installed into the drive shaft without the washer.
Remove the capscrew and washer.
Install the capscrew into the shaft.
Use a jaw puller to remove the lovejoy or spline type
coupling.
Remove the capscrew from the shaft.
WARNING
Remove the clamping washer (1).
Remove the gear and shaft assembly.
Remove the pipe plug from the housing.
Use solvent to clean the parts.
Measure the inside diameter of the busings.
Accessory Drive Bushing Inside Diameter
mm in
49.95 MIN 1.967
50.03 MAX 1.970
If the inside diameter of either bushing is not within
specification, both bushings must be replaced.
Check the grooved surfaces of the bushings (1) for
damage.
Measure the distance from the outside of the thrust faces
of the two bushings.
Accessory Drive Busing Thrust Face Distance
mm in
45.370 MIN 1.786
45.450 MAX 1.789
If the distance between the two thrust faces is not within
Remove the flanged bushing from the drive housing using
a brass drift (1), taking care not to damage the bushing
bore.
Only remove the gear from the shaft when the gear or the
shaft must be replaced.
Use an arbor press to remove the gear.
Inspect for Reuse
Check the inner diameter of the coupling for damage.
If damage is found the coupling must be replaced.
Measure the inside diameter of the coupling.
Accessory Drive Lovejoy Coupling Inside Diameter
mm in
25.377 MIN 0.999
25.407 MAX 1.000
Accessory Drive Spline Coupling Inside Diameter
mm in
25.255 MIN 0.994
25.278 MAX 0.996
If the inner diameter of the coupling is not within
specification the coupling must be replaced.
If the bushing was removed, inspect the housing for
scoring and other damage.
Replace the housing if damaged.
If the bushing was removed, measure the inside diameter
of the bushing bore.
Accessory Drive Bushing Bore Inside Diameter
mm in
60.00 MIN 2.362
60.05 MAX 2.364
Replace the housing if the bushing bore is not within
specifications.
Inspect the shaft in the gear fit area for fretting or burrs.
Clean burrs with emery cloth.
Measure the shaft outside diameter.
Accessory Drive Shaft Outside Diameter
Measurements
mm in
(1) 34.964 MIN 1.376
34.976 MAX 1.377
(2) 43.928 MIN 1.729
43.940 MAX 1.730
(3) 44.370 MIN 1.747
44.630 MAX 1.757
(4) 45.070 MIN 1.774
45.082 MAX 1.775
(5) 49.820 MIN 1.961
49.832 MAX 1.962
(6) 25.424 MIN 1.001
25.436 MAX 1.001
If the outside diameter is not within specification, the shaft
must be replaced.
Check the gear teeth and gear bore for damage.
Replace the gear if damaged.
Measure the gear inside diameter.
Accessory Drive Gear Inside Diameter
mm in
44.98 MIN 1.771
45.02 MAX 1.772
If the gear is not within specification, the gear must be
replaced.
Assemble
WARNING
Wear protective clothing to reduce the possibility of
personal injury from burns.
CAUTION
Do not exceed the specified time or temperature.
Damage to the gear teeth will result.
If an adequate press is not available, an oven can be
used.
Heat the gear at 235C [450F] for not less than one hour,
and not more than six hours.
WARNING
Support the gear.
Slide the shaft into the gear until the shoulder of the shaft
touches the gear.
If an arbor press is available, support the gear.
Lubricate the shaft with clean engine oil.
Press the shaft through the gear until the shoulder of the
shaft touches the gear.
CAUTION
If the heat method was used to install the gear, allow
the gear to air cool. Do not use water or oil to reduce
cooling time. Damage to the gear can result.
Use a feeler gauge to measure the distance between the
shoulder of the shaft and the gear.
Accessory Drive Gear to Shaft Distance
mm in
0.05 MAX 0.002
If the distance between the gear and the shaft is not within
specification, press the gear on until the specification is
met.
CAUTION
The bushings must be pressed in square to the bores
of the housing. The thrust faces of the two bushings
must be parallel and concentric. The bushing with the
center counterbored must have the pressure applied
to the counterbore face and not on the thrust bearing
face. Failure to comply can result in distortion of the
thrust face.
Support the housing.
The bushing with the smaller outside diameter is pressed
into the output side.
Using an arbor press and the shaft as a mandrel, press
the bushing into the housing.
Turn the housing over and press the remaining bushing
into place.
Lubricate the grooved surface of the thrust bearing with
Lubriplate 105, Part Number 3163086, 3163087 or
equivalent.
Install the gear and shaft assembly into the housing.
Install the clamping washer (1) with the beveled edge up.
Install the pipe plug into the housing.
Tighten the pipe plug.
Support the assembly on the gear or the shaft.
Use an arbor press and a mandrel to press the coupling
onto the shaft until it touches the clamping washer.
The clamping washer must be positioned tightly between
the coupling and the shoulder of the shaft.
The capscrew must contain an oil drilling if an air
compressor is to be mounted on the engine.
Install the washer and capscrew.
Torque Value:
9.525 mm [0.375
in] Capscrew
Length
45 Nm [ 35 ft-lb ]
12.7 mm [0.50 in]
Capscrew Length
100 Nm [ 75 ft-lb ]
Rotate the shaft, checking for correct assembly.
Use a dial indicator to measure the accessory drive shaft
end clearance.
Accessory Drive Shaft End Clearance
mm in
0.05 MIN 0.002
0.30 MAX 0.012
If the end clearance is not within specifications, make sure
the coupling is positioned tightly against the clamping
washer.
Install
CAUTION
Do not use sealants on the gasket. The gasket is
manufactured from material that sealants will
damage.
Lubricate the bushing in the front gear housing cover with
Lubriplate 105, Part Number 3163086, 3163087 or
equivalent.
Install the gasket onto the pilot of the drive housing cover.
K38, K50, QSK38, and QSK50 Accessory Drive Bushing
There is not a requirement to align the index on the drive
gear with the marks on the camshaft gear on QSK38 and
QSK50 engines.
Install the accessory drive assembly, turning the shaft as
necessary to engage the gears.
Install and tighten the six capscrews.
With the accessory drive installed, measure the end
clearance.
Accessory Drive End Clearance
mm in
0.13 MIN 0.005
0.29 MAX 0.011
Finishing Steps
Install the accessory drive seal, if applicable. Refer
to Procedure 001-003.
Install the accessory drive pulley, if applicable. Refer
Install the accessory drive cover, if applicable. Refer
Install the air compressor, if applicable. Refer to
Procedure 012-014.
Install the fuel pump. Refer to Procedure 005-016.
Fill the cooling system, if applicable. Refer to
Procedure 008-018.
reaches 71C [160F]. Check for coolant leaks.
Accessory Drive Bushing (009-002)
Remove
Mechanically Actuated Injector
Standard Bushing
Remove the accessory drive cover, if equipped.
Refer to Procedure 009-039 (Accessory Drive Cover)
in Section 9.
Use an arbor press. Support the housing. Use a
suitable mandrel. Push the bushing from the
housing.
Accessory Drive Bushing K38, K50, QSK38, and QSK50
Flanged Bushing
Remove the accessory drive cover, if equipped.
Refer to Procedure 009-039 (Accessory Drive Cover)
in Section 9.
Remove the bushing from the drive housing using a
brass drift (1). Take care not to damage the bushing
bore.
Inspect for Reuse
Inspect the housing for scoring or other damage.
Standard Bushing
Measure the inside diameter
Housing Inside Diameter
mm in
36.73 MIN 1.446
36.75 MAX 1.447
Flanged Bushing
Housing Inside Diameter
mm in
39.61 MIN 1.559
39.64 MAX 1.561
K38, K50, QSK38, and QSK50 Accessory Drive Bushing
Install
CAUTION
Align the oil hole in the bushing with the oil drilling in
the housing.
Standard Bushing
Use an arbor press. Support the housing.
Use a mandrel. Install the bushing.
Both ends of the bushing must be positioned even with,
or below the surface of the housing.
Use a 2.39 mm [0.094 in] diameter rod or a 2.39 mm [0.094
in] hexagon wrench. Check the position and the location
of the oil hole in the bushing and the accessory drive
housing.
The rod must pass through the oil holes in the bushing
and into the oil supply drillings in the accessory drive
housing.
Install the accessory drive cover, if removed. Refer to
Procedure 009-039 (Accessory Drive Cover) in Section 9.
CAUTION
of the support casting. The thrust faces of the two
bushings must be parallel and concentric. The
bushing with the center counterbored must have the
pressure put on the counterbore face and not just on
the thrust bearing face. Failure to do this could result
in distortion of the thrust face.
Flanged Bushing
Using an arbor press, support the housing. Use the shaft
as a mandrel. Press the new bushing into place.
Invert the housing, press the other bushing into place. The
bushing with the smaller outside diameter is installed on
the output end.
Install the accessory drive cover, if removed. Refer to
Procedure 009-039 (Accessory Drive Cover) in Section 9.
Accessory Drive Gear and Shaft K38, K50, QSK38, and QSK50
Accessory Drive Gear and Shaft
(009-003)
Disassemble
CAUTION
Do not drop the shaft during removal from the drive
gear. Damage to the part or personal injury can result.
Use an arbor press. Support the gear.
Push the shaft from the gear.
Remove the groove pin. If the pin is damaged, it must be
replaced.
Inspect for Reuse
Inspect the gear for cracks and chipped, or broken teeth.
Measure the inside diameter of the drive gear.
Gear Inside Diameter
mm in
39.73 MIN 1.564
39.75 MAX 1.565
K38, K50, QSK38, and QSK50 Accessory Drive Gear and Shaft
Measure the drive shaft outside diameter at the gear fit
location.
mm in
39.789 MIN 1.5665
39.802 MAX 1.5670
Assemble
Use a soft faced hammer to install the keys (if removed)
in the shaft.
CAUTION
The jaws of the vise must have copper plates to
prevent damage to the shaft.
Put the accessory drive shaft in a vise.
Apply Lubriplate 105 or equivalent, to the gear fit area
before installing the gear.
Use an arbor press. Support the gear.
Apply Lubriplate 105 or equivalent to the shaft.
Align the key with the key slot in the gear. Press the shaft
through the gear until the shoulder of the shaft touches
the gear.
NOTE: If an adequate press is not available, the gear
should be heated in an oven.
Accessory Drive Pulley K38, K50, QSK38, and QSK50
WARNING
Wear protective clothing to reduce the risk of
CAUTION
Heat the gear in an oven for a minimum of 1 hour, but no
more than a maximum of 6 hours.
Heat the gear to 235C [450F].
WARNING
Wear protective clothing to reduce the risk of
CAUTION
To prevent engine damage, the part number on the
gear must be positioned opposite of the flange on the
accessory drive shaft when the gear is installed.
Align the key slot in the gear with the key in the shaft, then
slide the gear over the shaft.
CAUTION
Keep the accessory drive shaft in a vertical position
until the gear has cooled. Do not use water or oil to
reduce the cooling time. Damage to the gear can
result.
Use a feeler gauge. The distance between the shoulder of
the shaft and the gear must be no more than 0.05 mm
[0.002 in].
Clean the assembly.
Use clean engine oil. Lubricate the shaft.
Accessory Drive Pulley (009-004)
Remove
NOTE: Install a capscrew in the end of the shaft to prevent
damage to the threads.
Install the capscrew (1). Use a puller (2), ST-647, or
equivalent. Remove the pulley from the accessory drive
shaft.
NOTE: Some engines have an accessory drive cover
instead of a pulley. It is not necessary to remove the cover.
K38, K50, QSK38, and QSK50 Accessory Drive Pulley
Remove the woodruff key (3). Remove the oil slinger (4).
Discard the slinger.
WARNING
reduce the rick of personal injury.
Use solvent and a clean cloth. Clean the pulley wear
sleeve.
Check the grooves of the pulley for wear.
Check the wear sleeve on the accessory drive pulley for
damage. If the wear sleeve requires renewing, refer to
Procedure 009-005 (Accessory Drive Pulley Wear Sleeve)
in Section 9.
Check the bore of the pulley for damage.
Accessory Drive Pulley Inside Diameter
mm in
34.912 MIN 1.3745
34.938 MAX 1.3755
Accessory Drive Pulley K38, K50, QSK38, and QSK50
Check the bore of the pulley for damage.
Alternator Drive Pulley Inside Diameter
mm in
35.00 MIN 1.378
35.03 MAX 1.379
Install
Install the oil slinger.
Install the woodruff key.
CAUTION
Do not use a hammer to position the pulley. The thrust
bearings in the accessory drive can be damaged, and
the part can fail.
Use the pulley installation tool kit, Part Number 3376326.
Install the appropriate adapter (1) in the pusher (2).
K38, K50, QSK38, and QSK50 Accessory Drive Pulley Wear Sleeve
CAUTION
Do not lubricate the seal or the wear sleeve on the
pulley. The seal and sleeve must be clean and dry or
the seal can leak.
Use engine oil. Lubricate the outside diameter only of the
shaft. Lubricate only the inside diameter of the bore in the
pulley.
CAUTION
The dust lip on the seal must not be folded under
when the pulley is installed. To prevent the dust lip
(yellow lip) from folding under, bend the lip out by
running your finger around the lip 8 to 10 times,
applying gentle pressure. Be sure there is no oil on
your hand. Avoid touching the seal lip (black lip). The
dust lip will remain bent approximately 1 minute, then
return slowly to the operating position.
Position the pulley on the shaft. Align the keyway in the
pulley with the key in the shaft.
Use the tool to push the pulley on the shaft until the sleeve
on the tool touches the shaft. The pulley will then be even
with the end of the shaft.
POSE
Press-On Shaft Excluder (POSE) Seal
CAUTION
When installing a new POSE seal, the flat (closed) side
of the seal MUST be TOWARD the pulley for correct
installation.
NOTE: Do not use any kind of lubricant to install the
POSE seal.
Use your hand to push the POSE seal onto the wear
sleeve.
Push the POSE seal onto the wear sleeve until the seal is
approximately 9 mm [0.375 in] below the end of the wear
sleeve.
Accessory Drive Pulley Wear Sleeve
(009-005)
Remove
CAUTION
The jaws of the vise MUST have copper plates to
prevent damage to the pulley.
Put the accessory drive pulley in a vise.
Accessory Drive Pulley Wear Sleeve K38, K50, QSK38, and QSK50
Grind a 1.57 mm [0.062 in] radius on the cutting edge of
a 19.05 mm [0.75 in] chisel.
Position the chisel against the wear sleeve. Use a hammer
to moderately strike the chisel at four points on the outside
diameter of the wear sleeve to relieve the press fit.
After the press fit has been relieved, remove the wear
sleeve by hand.
Use Scotch-Brite 7448, Part Number 3823258, or
equivalent to remove any deposits from the seal area of
the pulley.
Clean the seal wear area with a clean cloth.
Inspect the seal wear area for damage.
K38, K50, QSK38, and QSK50 Alternator Drive Pulley
Install
Install the wear sleeve on the pulley seal wear surface with
the chamfer on the outside diameter of the wear sleeve
facing up (away from the pulley).
Use installer tool, Part Number 3824508, and an arbor
press or mallet. Press the sleeve on the pulley until the
installer contacts the pulley.
Inspect the wear sleeve for burrs or other damage.
Alternator Drive Pulley (009-010)
Preparatory Steps
Remove the alternator belt. Refer to Procedure
013-005 (Alternator Drive Pulley) in Section 9.
Remove
Using puller, Part Number ST-647, remove the pulley from
the alternator drive pulley shaft.
Remove the puller.
Alternator Drive Pulley K38, K50, QSK38, and QSK50
WARNING
WARNING
WARNING
personal injury.
Clean the alternator drive and accessory drive pulley with
steam or solvent .
Inspect the pulley for nicks, cracks, excessive wear, or
other damage in the belt grooves.
Install
CAUTION
Do not use a hammer to drive the pulley into position.
The thrust washers will be damaged.
Use the pulley pusher kit, Part Number 3376085, and
adapter, Part Number 3163272.
Install the correct adapter in the pusher.
Install the pulley on the shaft.
Remove the tool and adapter.
K38, K50, QSK38, and QSK50 Fuel Pump Drive
Finishing Steps
Install and adjust the alternator belt. Refer to
Procedure 013-005 (Alternator Drive Pulley) in
Section 9.
Fuel Pump Drive (009-011)
Preparatory Steps
WARNING
WARNING
Depending on the circumstance, fuel is flammable.
Keep all cigarettes, flames, pilot lights, arcing
equipment, and switches out of the work area and
areas sharing ventilation to reduce the possibility of
severe personal injury or death when working on the
fuel system.
NOTE: If an air compressor is not mounted on the engine,
it will not be necessary to drain the cooling system.
008-018.
Remove the air compressor. Refer to Procedure
012-014.
Remove the accessory drive pulley. Refer to
Procedure 009-004.
WARNING
Depending on the circumstance, fuel is flammable.
Keep all cigarettes, flames, pilot lights, arcing
equipment, and switches out of the work area and
areas sharing ventilation to reduce the possibility of
severe personal injury or death when working on the
fuel system.
Remove the accessory drive pulley. Refer to
Procedure 009-004.
Remove the accessory drive cover (if applicable).
Remove the accessory drive seal (if applicable).
Fuel Pump Drive K38, K50, QSK38, and QSK50
Remove
CAUTION
Make sure the Woodruff key has been removed before
attempting to remove the fuel pump drive assembly.
Damage to the bushing in the front gear housing
cover can result if the key is not removed.
Remove the oil slinger.
Remove the six capscrews from the drive housing flange.
Remove the drive and discard the gasket.
Remove the six capscrews from the fuel pump drive
housing flange.
Remove the fuel pump drive.
Remove and inspect the gasket.
Initial Check
WARNING
Use solvent to clean the outer housing of the fuel pump
drive.
Use a dial indicator to measure the fuel pump drive shaft
end clearance.
Fuel Pump Shaft End Clearance
mm in
0.14 MIN 0.006
0.27 MAX 0.011
Disassemble
Remove the straight thread o-ring plug from the fuel pump
drive.
Remove the mesh screen with a small flat tip screwdriver.
Remove the shaft from the fuel pump drive housing.
Use a press to remove the gear from the shaft.
Measure the inside diameter of the busings.
Fuel Pump Drive Bushing Inside Diameter
mm in
49.95 MIN 1.967
50.03 MAX 1.970
Check the grooved surfaces of the busings (1) for damage.
Measure the distance from the outside of the thrust faces
of the two bushings.
Fuel Pump Drive Busing Thrust Face Distance
mm in
45.370 MIN 1.786
45.450 MAX 1.789
If the distance between the two thrust faces is not within
Remove the flanged bushing from the drive housing using
a brass drift (1), taking care not to damage the bushing
bore.
WARNING
WARNING
personal injury.
Clean the fuel pump drive assembly and inspect it for
reuse.
Clean the pulley and inspect it for reuse.
Measure the end clearance.
Fuel Pump Drive End Clearance.
mm in
0.05 MIN 0.002
0.30 MAX 0.012
NOTE: Oversize thrust bearings are available to adjust the
end clearance.
The coupling washer must be clamped tightly between the
coupling and the shaft. If the washer is not tight, rebuild
the drive unit.
WARNING
WARNING
personal injury.
Use solvent to clean the fuel pump drive components.
Inspect the screen for cracks or damage.
If any damage is present, the screen must be replaced.
Check the inner diameter of the coupling for damage.
If damage is found the coupling must be replaced.
Measure the inside diameter of the coupling.
Fuel Pump Drive Spline Coupling Inside Diameter
mm in
25.255 MIN 0.994
25.278 MAX 0.996
If the inner diameter of the coupling is not within
specification the shaft must be replaced.
If the bushing was removed, inspect the housing for
scoring and other damage.
Replace the housing if damaged.
If the bushing was removed, measure the inside diameter
of the bushing bore.
Fuel Pump Drive Bushing Bore Inside Diameter
mm in
60.00 MIN 2.362
60.05 MAX 2.364
Replace the housing if bushing bore is not within
specifications.
Measure the shaft outside diameter.
Fuel Pump Drive Shaft Outside Diameter
Measurements
mm in
(1) 34.964 MIN 1.376
34.976 MAX 1.377
(2) 39.662 MIN 1.561
39.740 MAX 1.564
(3) 39.789 MIN 1.566
39.801 MAX 1.567
(4) 49.820 MIN 1.961
49.832 MAX 1.962
If the outside diameter is not within specification, the shaft
must be replaced.
Check the gear teeth and gear bore for damage.
Replace the gear if damaged.
Measure the gear inside diameter.
Fuel Pump Drive Gear Inside Diameter
mm in
39.725 MIN 1.564
39.751 MAX 1.565
If the gear is not within specification, the gear must be
replaced.
Assemble
WARNING
CAUTION
used.
Heat the gear 235C [450F] for not less than one hour,
WARNING
Support the gear.
Slide the shaft into the gear until the shoulder of the shaft
touches the gear.
CAUTION
Fuel Pump Drive Gear to Shaft Distance
mm in
0.05 MAX 0.002
met.
CAUTION
of the housing. The thrust faces of the two bushings
must be parallel and concentric. The bushing with the
center counterbore must have the pressure applied to
the counterbore face and not on the thrust bearing
face. Failure to comply can result in distortion of the
thrust face.
Support the housing.
The bushing with the smaller outside diameter is pressed
into the output side.
Using an arbor press and the shaft as a mandrel, press
the bushing into the housing.
Turn the housing over and press the remaining bushing
into place.
Lubricate the grooved surface of the thrust bearing with
Lubriplate 105 or equivalent.
Install the gear and shaft assembly into the housing.
Install the clamping washer (1) with the beveled edge up.
Support the assembly on the gear or the shaft.
Use an arbor press and a mandrel to press the coupling
onto the shaft until it touches the clamping washer.
The clamping washer must be positioned tightly between
the coupling and the shoulder of the shaft.
Install the pipe plug into the housing.
Tighten the pipe plug.
The capscrew must contain an oil drilling if an air
compressor is to be mounted on the engine.
Install the washer and capscrew.
Torque Value:
9.525 mm [0.375
in] Capscrew
Length
45 Nm [ 35 ft-lb ]
12.7 mm [0.50 in]
Capscrew Length
100 Nm [ 75 ft-lb ]
end clearance.
Fuel Pump Drive Shaft End Clearance
mm in
0.05 MIN 0.002
0.30 MAX 0.012
washer.
If the bushings where removed, use the shaft as a mandrel
and press one bushing into the housing until the underside
of the bushing head is flush with the counterbore in the
housing. Turn the housing over and press the remaining
bushing into place.
Install the shaft into the housing.
WARNING
CAUTION
used.
Heat the gear 204C [400F] for not less than one hour,
WARNING
Install the key onto the shaft.
Support the shaft and housing.
Slide the gear onto the shaft until the shoulder of the shaft
touches the gear.
Install the key onto the shaft.
CAUTION
mm in
0.05 MAX 0.002
met.
Install the screen into the housing by pushing the screen
in by hand.
Install the straight thread o-ring plug.
end clearance.
Fuel Pump Drive Shaft End Clearance
mm in
0.14 MIN 0.006
0.27 MAX 0.011
washer.
Install
NOTE: This procedure also applies to the drive installed
on engines that have a governor drive.
NOTE: There is no requirement to align the index on the
drive gear with the marks on the camshaft gear on the K38
and K50 engines.
Use Lubriplate. Lubricate the bushing in the front gear
housing cover.
NOTE: Do not use sealants on the gasket. The gasket is
manufactured from a material that sealants will damage.
Install the gasket (1) onto the pilot of the housing cover.
Install the drive assembly (2) , turning the shaft as
Install the six lock washers (3) and capscrews.
Capscrews Specifications:
4. [7/16-14 x 1 inch] (one each)
5. [7/16-14 x 1 1/4 inch] (one each)
6. [7/16-14 x 3 3/4 inch] (one each)
Tighten the capscrews alternately and evenly.
Install the oil slinger.
Install the Woodruff Key.
CAUTION
Do not use sealants on the gasket. The gasket is
manufactured from material that sealants will
damage.
Lubricate the bushing in the front gear housing cover with
Lubriplate 105.
Install the gasket onto the pilot of the drive housing cover.
There is not a requirement to align the index on the drive
gear with the marks on the camshaft gear on QSK38 and
QSK50 engines.
Install the fuel pump drive assembly, turning the shaft as
Install and tighten the six capscrews.
With the fuel pump drive installed, measure the end
clearance.
Fuel Pump Drive End Clearance
mm in
0.14 MIN 0.006
0.27 MAX 0.011
Finishing Steps
Install the accessory drive pulley. Refer to Procedure
009-004.
Install the air compressor. Refer to Procedure
012-014.
K38, K50, QSK38, and QSK50 Hydraulic Pump Drive
Install the accessory drive seal, if applicable. Refer
Install the accessory drive pulley, if applicable. Refer
Install the accessory drive cover, if applicable. Refer
reaches 71C [160F]. Check for coolant leaks.
Hydraulic Pump Drive (009-016)
General Information
A hydraulic pump can be mounted on the front or at the rear of the gear cover .
The SAE A two-bolt type flange is required to mount a hydraulic pump at the rear of the gear cover. The SAE B four-
bolt type flange is required for a hydraulic pump to be mounted on the front of the gear cover. There is a specific drive
required to match the different sizes of spline drives required for the optional hydraulic pumps.
Engines that do not have a hydraulic pump drive must have parts that block the oil holes in the gear cover and housing
for correct engine oil pressure. A four-bolt flange that has a blind plug welded to it must be installed on the front of
the gear cover. The blind plug will extend into the bushing, blocking the oil drilling. A three-bolt cover that has two o-
rings must be installed on the rear of the gear housing.
A hydraulic pump drive can be installed by removing the blind plug flange and the cover. If only the rear drive port is
used, a plain four-bolt cover and gasket must be installed on the front of the cover. If only the front drive port is used,
a two-bolt cover and gasket must be installed on the rear of the pump drive.
Preparatory Steps
Remove the hydraulic pump. Refer to the OEM
service manual for instructions.
Remove
The hydraulic pump drive is removed from the rear of the
gear housing.
Remove the capscrews and lock washers.
Remove the drive assembly, allowing the gear to turn
freely as it disengages with the water pump idler gear.
Hydraulic Pump Drive K38, K50, QSK38, and QSK50
Disassemble
Remove the locktight capscrews and if fitted the lock
washers. Remove the cover (if equipped).
Remove and discard the gasket.
Remove the retaining ring.
Remove the clamping washer. Remove the thrust bearing.
Remove the housing. Remove the thrust bearing.
WARNING
cleaning, follow the manufacturers recommendation
WARNING
personal injury.
Clean the hydraulic drive bushing bore in the front gear
cover and measure the inside diameter. If it is not within
specifications refer to Procedure 001-031 (Gear Cover,
Front) in Section 1.
Hydraulic Pump Drive Bushing Inside Diameter
mm in
38.13 MIN 1.501
38.25 MAX 1.506
Check the drive assembly. Replace if damage is found on
the housing or the gear is worn.
Clean for Rebuild
WARNING
Use solvent. Clean all the parts.
Inspect
Check the grooved surface of the thrust bearing for
damage.
Measure the thickness.
Thrust Bearing Thickness
mm in
2.273 MIN 0.0895
2.299 MAX 0.0905
NOTE: Two oversize thrust bearings, 0.03 mm [0.001 in]
and 0.05 mm [0.002 in], are available.
Hydraulic Pump Drive K38, K50, QSK38, and QSK50
Measure the outside diameter of the shaft.
Shaft Outside Diameter (1)
mm in
38.062 MIN 1.4985
38.075 MAX 1.4990
mm in
50.749 MIN 1.9980
50.762 MAX 1.9985
If either the gear or the shaft must be replaced. Refer to
Procedure 009-019 (Hydraulic Pump Drive Gear and
Shaft) in Section 9.
Measure the inside diameter of the bushing.
Hydraulic Pump Bushing Inside Diameter
mm in
50.813 MIN 2.0005
50.902 MAX 2.0040
If the bushing must be replaced. Refer to Procedure
009-019 (Hydraulic Pump Drive Gear and Shaft) in Section
9.
Assemble
Use Lubriplate Number 105 multi purpose lubricant, or
equivalent. Lubricate the grooved surface of the thrust
bearing.
Position the grooved surface of the thrust bearing as
illustrated (3).
Slide the shaft in the housing.
NOTE: The gear must touch the thrust bearing.
Use Lubriplate Number 105 multi purpose lubricant, or
equivalent. Lubricate the grooved surface of the thrust
bearing.
With the grooved surface positioned up, slide the thrust
bearing over the shaft.
The beveled edge of the clamping washer must be
positioned against the thrust bearing. Slide the clamping
washer over the shaft.
The beveled edge of the retaining ring must be positioned
as illustrated. Install the retaining ring.
Measure the end clearance.
End Clearance
mm in
0.10 MIN 0.004
0.48 MAX 0.019
If the end clearance is not within specifications, the
assembly must be rebuilt.
Install a new gasket. Install the cover (if equipped).
Install the locktight capscrews or if fitted, lock washers and
the capscrews.
Install
Install a new o-ring in the counterbore around the hole in
the gear cover housing.
Install a new large o-ring in the groove on the housing of
the drive.
Lubricate the o-ring with vegetable oil.
Install the pump drive, allowing the gear to turn as it
meshes with the water pump idler gear.
Align the capscrew holes. Install the capscrews and
tighten to specification.
Finishing Steps
Install the hydraulic pump. Refer to the OEM service
manual.
Hydraulic Pump Drive Gear and Shaft K38, K50, QSK38, and QSK50
Hydraulic Pump Drive Gear and Shaft
(009-019)
Disassemble
NOTE: Only remove the gear from the shaft when the
gear or the shaft must be replaced.
Install the shaft and gear in an arbor press as shown. Use
a suitable mandrel to push the shaft from the gear.
WARNING
Use solvent. Clean the shaft and gear.
Measure the inside diameter of the gear if it is to be
reused.
Hydraulic Pump Drive Gear Inside Diameter
mm in
44.399 MIN 1.7480
44.425 MAX 1.7490
Inspect the gear teeth for wear or damage.
Measure the outside diameter of the shaft at the gear
location if it is to be reused.
Hydraulic Pump Drive Shaft Outside Diameter
mm in
44.450 MIN 1.7500
44.463 MAX 1.7505
K38, K50, QSK38, and QSK50 Rear Gear Drive (Lower Assembly)
Assemble
NOTE: If replacing the shaft, make sure that the
replacement contains the same number of teeth.
Use Loctite 609 or the equivalent. Apply a smooth layer
on the inside diameter of the gear.
Use an arbor press. Support the gear as shown with the
part number facing down.
Press the shaft through the gear until the shaft shoulder
touches the gear.
Rear Gear Drive (Lower Assembly) (009-023)
General Information
Not all engines are equipped with this option. The rear gear drive consists of a lower unit. The total continuous drive
capacity of the rear gear drive is 300 kw (400 hp) at 2100 rpm.
Previous K38 and K50 engines contained the rear gear drive lower unit so that the customer had the option to install
the upper drive. Engines built after September, 1986 do not have this feature. A one piece flywheel housing is used
(See Rear Engine Power Takeoff - Shop and Installation Manual, Bulletin 3666040), which incorporates the rear oil
seal.
CAUTION
If the lower rear gear drive contains gears and shafts, but no upper unit, the engine oil must flow through the
oil drillings in the housing or failure of the gear bushing will result.
On previous engines that did not have an upper unit, a cover plate was installed. Some of these engines have a rear
gear housing with expansion plugs installed in the bores for the shafts. The oil drilling in the housing that aligns with
the cylinder block left bank oil drilling must have a pipe plug installed on these engines. The cover plate and the o-
ring will block the oil drilling on the right bank side of the housing for the rear gear drive upper unit.
On the K38 and K50 engines, the rear gear drive housing has been replaced by a housing that contains only the rear
crankshaft seal. These engines must have plates installed on the cylinder block to plug the oil drillings. Some cylinder
blocks do contain the oil drillings required for the rear gear drive. The rear gear drive is installed on the K38 and K50
engines only when the rear gear drive upper unit is to be installed at the factory or as a customer request.
Rear Gear Drive (Lower Assembly) K38, K50, QSK38, and QSK50
Preparatory Steps
WARNING
reduce the possibility of arching, remove the negative
cable last.
WARNING
Disconnect the air supply to the starter. Refer to
Procedure 012-022.
013-009.
Drain the engine with oil. Refer to Procedure
007-025.
Remove the full flow oil filters. Refer to Procedure
007-013.
On QSK50 engines equipped with electronically
actuated injectors, remove the engine speed sensor
using the special socket tool, Part Number 4918623
or equivalent. Refer to Procedure 019-042 in the
4021533.
Remove the transmission, clutch, and all related
components. See the equipment manufacturer's
instructions.
Remove the starter motor. Refer to Procedure
013-020.
Remove the flywheel housing.
Remove the oil pan adapter assembly. Refer to
Procedure 007-027.
Remove
NOTE: If the engine is equipped with a rear gear drive
upper unit, the cover plate (8) is not required.
Remove the capscrews, nuts, cover plate (8), gasket, and
the o-rings.
Discard the gaskets and seals.
WARNING
Remove the four SAE Grade 8 capscrews (4) and the
fourteen SAE Grade 8 capscrews (5).
Remove the lower unit (2) and the gasket (1).
Discard the gasket.
The dowel pins do not have to be removed unless they
are damaged.
Clean
WARNING
When using solvents, acids or alkaline materials or
steam for cleaning, follow the manufacturer's
recommendations for use. Wear goggles and
protective clothing to reduce the risk of personal
injury.
WARNING
Use solvent or steam. Clean the rear gear drive.
NOTE: Prevent one of the gears from turning to check to
gear backlash.
Check the gear backlash.
Gear Backlash
mm in
0.08 MIN 0.003
0.30 MAX 0.012
Check the gear end clearance.
Gear End Clearance
mm in
0.10 MIN 0.004
0.25 MAX 0.010
If any of the parts are damaged or not within
specifications, the gear drive must be rebuilt.
Disassemble
If necessary, remove the cover plate capscrews, the plate
(1), if fitted, the gasket (2), and the o-rings (3).
CAUTION
The housing must be level on the press or breakage
will result.
Support the housing in a hydraulic press around the shaft
bore on the rear seal side of the housing as illustrated.
Press on the shafts (4) from the cylinder block mounting
side of the housing.
Press both shafts (4) from the bores in the housing.
Remove and discard the o-rings (5).
Remove the upper (6) and lower (7) gears, and the four
thrust bearings (8).
Clean for Rebuild
WARNING
WARNING
personal injury.
Use solvent. Clean the parts and the oil drillings
thoroughly. Dry with compressed air.
Inspect
Measure the outside diameter of both shafts at the press
fit area (9) and the gear bushing area (10).
mm in
63.500 MIN 2.5000
63.513 MAX 2.5005
If the shafts are not within specifications, they must be
replaced.
Check the gear teeth for damage or wear.
The gear bushings are machined after installation in the
gear. Do not remove the bushings unless you have the
capability of machining the bushings to a precise
tolerance.
The center of the bore in the bushings must be concentric
with the pitch diameter of the gear within 0.066 mm
[0.0026 inch] total indicator reading (TIR). The bore
must be machined to the following specifications.
NOTE: There are two bushings in each gear.
Measure the inside diameter of the gear bushings.
Gear Bushing Inside Diameter
mm in
63.564 MIN 2.5025
63.627 MAX 2.5050
Measure the thrust bearing thickness.
mm in
2.36 MIN 0.093
2.41 MAX 0.095
If the thickness of the thrust bearing is not within
specifications, the bearing must be replaced.
NOTE: The shaft bores in the housing have different
specifications.
Measure the shaft bores on the cylinder block mounting
Cylinder Block Side Bore Inside Diameter
mm in
63.411 MIN 2.4965
63.449 MAX 2.4980
Measure the shaft bores on the rear seal side of the
housing.
Rear Seal Side Bore Inside Diameter
mm in
63.513 MIN 2.5005
63.538 MAX 2.5015
If either bore is not within specifications, the housing
must be replaced.
Assemble
With the cylinder block mounting side positioned down,
put the housing in a hydraulic press.
CAUTION
The thrust bearings must be installed with the oil
grooves touching the gear. If the steel portion of the
bearing is touching the gear, failure will result.
Use clean engine oil. Lubricate the thrust bearings.
Position a thrust bearing over the shaft bore in the
housing.
NOTE: The gears have different helix directions.
The gear with the teeth slanted to the left (7) must be
installed nearest to the rear seal bore in the housing (lower
gear).
The gear with the teeth slanted to the right (8) must be
installed nearest to the cover plate end of the housing
(upper gear).
The assembly will not fit on the engine if this installation
procedure is not followed.
CAUTION
The flat side of the gears (11) must be toward the
cylinder block mounting side of the housing. Failure
will result if this installation procedure is not followed
because the gears will not mesh correctly.
The protruding gear hub (12) must be toward the rear seal
Use clean engine oil. Lubricate the gear bushings.
Position the gears (7 and 8) in the housing so that the bore
in the gear is aligned with the bore in the housing.
Install the thrust bearings. The oil grooves in the thrust
bearings must touch the gear. Each gear has one thrust
bearing on each side of the gear.
CAUTION
The new o-rings must be installed in the groove in the
shafts that do not have an oil hole. An oil leak will
result because the gear bushings will not be
lubricated sufficiently if the o-rings are installed
wrong.
Install a new o-ring in the small groove on each shaft.
Use clean engine oil. Lubricate the o-rings and shafts.
With the oil groove positioned first, install the shaft into the
housing. The oil hole in the side of the shaft must be
toward the cover plate end of the housing.
Push the shaft through the thrust bearings and gear
bushing by hand to be sure they are in alignment.
Use a hydraulic press to push the shaft until it is even with
the cylinder block side of the housing. The shaft must
not protrude.
Install the other shaft through the thrust bearings and
gear. Press it into the housing until it is even with the
cylinder block side of the housing. The shaft must not
protrude.
Use a dial indicator. Measure the end clearance of both
gears.
Gear End Clearance
mm in
0.10 MIN 0.004
0.25 MAX 0.010
If the gear end clearance is not within specifications,
inspect housing for wear.
Use a dial indicator. Prevent one of the gears from turning
to obtain the correct gear lash measurement.
Gear Lash
mm in
0.08 MIN 0.003
0.30 MAX 0.012
If the gear lash is not within specifications, the gear is
worn and should be replaced.
If necessary, install the gasket (2), new o-rings (3), the
cover plate (1), and the capscrews.
Install
NOTE: Some engines are not equipped with this option.
CAUTION
Not all of the cylinder blocks contain the oil drillings required for the rear gear drive. Check the rear of the
block for the oil drillings. See the second part of the instructions for installing the rear seal housing for the
location of the drillings. If the block does not contain the drillings, the rear gear drive lower unit must not be
installed unless the gears have been removed. If the block does not have the drillings, the gear drive will fail
from lack of lubrication and cause the rear crankshaft gear to fail.
CAUTION
The rear gear drive lower unit that has the gears must be lubricated by engine oil even if a rear gear drive
upper unit is not installed.
CAUTION
Do not install a lower unit that has had one or both of the gears removed unless both of the oil drillings in
the housing have been plugged. If the holes are not plugged, the engine oil continues to flow through the
housing and shafts, and will result in the engine oil pressure being less than specification. If desired, a
housing that does not contain gears can be plugged by machining threads for pipe plugs in the holes in the
housing that align with the oil holes in the cylinder block. Check to be sure the installed pipe plugs are even
with, or below the surface of the housing, or the housing will be damaged when the capscrews are tightened
to the block.
CAUTION
If the shafts are removed from a rear gear drive lower unit that has either the oil drillings plugged or is to be
installed on a cylinder block that does not have the oil drillings, all four holes for the shaft must be plugged
to prevent contamination. If the holes remain open, the oil in the oil pan will be contaminated.
Check to be sure the correct rear crankshaft gear is installed. A gear that is 63 mm [2.5 in] wide must be installed
when a rear gear drive lower unit that has gears is installed. Refer to Procedure 001-026.
WARNING
Install the four SAE grade 8 capscrews (4) and the
fourteen SAE Grade 8 capscrews (5).
NOTE: The use of guide bolts will aid the assembly
procedure.
Check to be sure the mating surfaces of the block housing
are clean, dry, and free from nicks or burrs.
Install the gasket (1) on the cylinder block.
Install the rear gear lower unit (2).
Install the eighteen lock washers (3), the four capscrews
(4), and the fourteen capscrews (5).
If the engine does not have the rear gear drive upper unit,
install the parts.
1. Gasket
2. O-rings (2)
3. Cover plate
4. Lock washers
5. Capscrews
6. Nuts.
K38, K50, QSK38, and QSK50 Rear Gear Drive (Upper Assembly)
Finishing Steps
WARNING
WARNING
reduce the possibility of arching, remove the negative
cable last.
Install the oil pan adapter assembly. Refer to
Procedure 007-027.
Install the flywheel housing.
Install the starter motor. Refer to Procedure 013-020.
Install the transmission, clutch, and all related
instructions.
On QSK50 engines equipped with electronically
actuated injectors, install the engine speed sensor
using the special socket tool, Part Number 4918623
or equivalent. Refer to Procedure 019-042 in the
4021533.
Install new full flow oil filters. Refer to Procedure
007-013.
Fill the engine with oil. Refer to Procedure 007-025.
Connect the batteries. Refer to Procedure 013-009.
Connect the air supply to the air starter. Refer to
Procedure 012-022.
Rear Gear Drive (Upper Assembly) (009-024)
General Information
Not all engines are equipped with this option. The rear gear drive consists of a lower and an upper unit. The total
continuous drive capacity of the rear gear drive is 300 kw (400 hp) at 2100 RPM.
Engines built after September 1986 do not have this feature, a one piece flywheel housing is used. See Rear Engine
Power Takeoff - Shop and Installation Manual, Bulletin Number 3666040.
This assembly has several variations, depending on the type of equipment to be driven by the rear gear drive. The
gears and shafts will vary with the number of drive ports, the type of spline installed on the shafts, and the SAE type
bolt flange.
If an upper unit is installed on an engine that did not have one originally, two roll pins must be installed in the lower
unit to align the upper unit. If an upper drive is permanently removed from an engine, the roll pins must be removed
to allow the installation of the cover plate.
As many as three hydraulic pumps can be installed on the upper unit. In the left and right drive positions (facing the
flywheel), the drive ratio is 1:0 multiplied by the engine RPM, and the direction of rotation is counterclockwise. In
the center drive position, the drive ratio is 0.75 multiplied by the engine RPM, and the direction of rotation is
clockwise.
Rear Gear Drive (Upper Assembly) K38, K50, QSK38, and QSK50
Remove
Remove the capscrews (6) for the center drive support (7).
Remove the center drive support. The support contains an
o-ring seal (8) and a thrust bearing (9) between the support
and the gear. Removal of the seal and thrust bearing is
not required.
Remove the three SAE Grade 8 capscrews (5) and the lock
washers (4) from the inside of the upper unit housing.
WARNING
If the drive support (7) is not installed BEFORE lifting
the drive unit, the center drive gear can fall, causing
personal injury.
CAUTION
The grooves in the thrust bearing must be toward the
gear. If the thrust bearing is installed incorrectly,
failure can result.
Install the center gear drive support in the housing.
WARNING
The component or assembly weighs greater than 23
NOTE: The lifting bracket (3) for a Cummins 855 cubic
inch engine (NH and NT) can be attached to the upper unit
as shown to support the weight.
NOTE: The two roll pins (1) do not have to be removed
unless they are damaged.
Remove the 11 SAE Grade 8 capscrews (5) and the two
heavy nuts. Remove the upper unit and the two o-ring
seals.
Discard the seals.
Disassemble
WARNING
NOTE: This procedure illustrates a typical gear drive
assembly. The procedures to remove and install the parts
and specifications are the same for all drives. The quantity
of parts in the drive does not change the procedure.
NOTE: A lifting bracket (1), Part Number 170266 (a NT855
part), can be used to lift the drive assembly. Remove the
two center capscrews for the cover plate on the top of the
drive. Use two [0.375 x 16 x 1.250 inch] capscrews with
lock washers and flat washers to install the lifting bracket.
Remove the two center capscrews for the cover plate on
the top of the drive. Use two [0.375 x 16 x 1.250 inch]
capscrews with lock washers and flat washers to install
the lifting bracket.
CAUTION
The center gear in the drive protrudes from the
bottom of the housing. Use wood blocks (2) to level
the gear and to prevent the part from being damaged.
CAUTION
Do not damage the housing, port covers, or support
assemblies when separating the parts. An oil leak can
result.
NOTE: The port cover plates and support assemblies
contain an o-ring that secure the parts firmly in the
housing after the capscrews are removed. To separate the
parts, it will be necessary to carefully insert the end of a
pry-bar or a screwdriver between the parts.
Remove the cover plate (3) and the o-ring (4) from any port
that does not contain a shaft support. Discard the o-ring.
Remove any cover plates (5) and gaskets (6) from the
supports. Discard the gaskets.
CAUTION
result.
NOTE: Mark the supports to indicate the location in the
drive housing: left, center, or right. The supports can be
different to allow the mounting of drive units with different
mounting flanges.
Remove the parts.
Capscrews and lock washers (7)
Support and bushing assembly (8)
O-ring (9)
Rear thrust bearing (10)
Discard the o-ring.
NOTE: Record the number of splines in the end of the
shaft so that the part can be installed correctly.
Remove the shaft and gear assembly (11) and the thrust
bearing (12).
CAUTION
result.
Remove the parts.
Capscrews and lock washers (13)
Support and bushing assembly (14)
O-ring (15)
Thrust bearing (16)
Discard the o-ring.
Prevent the gear and shaft from turning when removing
the capscrews. Remove the capscrews (17) that secure
the shaft adapter in the gear.
CAUTION
The gear can fall out when the shaft is removed. Avoid
personal injury and damage to the parts.
Remove the center shaft and adapter (18) and the thrust
bearing (19).
Remove the center gear (20) as shown.
Remove the bushing cover plates (21) and the gaskets
(22).
NOTE: The plug (23) and the o-ring (24) are installed only
in the bores that do not contain a gear and shaft assembly.
Remove the plug (23) and the o-ring (24). Discard the o-
ring.
Remove the pipe plug (25) from the bottom of the housing.
Remove the upper cover plate (26) and the gasket (27).
Clean
WARNING
NOTE: A lifting bracket (1), Part Number 170266 (a NT855
part), can be used to lift the drive assembly. Remove the
two center capscrews for the cover plate on the top of the
drive. Use two [0.375 x 16 x 1.250 inch] capscrews with
lock washers and flat washers to install the lifting bracket.
CAUTION
The center gear in the drive protrudes from the
bottom of the housing. Use wood blocks (2) to level
the gear and prevent the part from being damaged.
WARNING
When using solvents, acids or alkaline materials or
steam for cleaning, follow the manufacturers
recommendations for use. Wear goggles and
protective clothing to reduce the risk of personal
injury.
WARNING
CAUTION
Do not use solvent that will harm the silicone rubber
o-rings in the drive.
Use solvent or steam. Clean the drive.
Inspect for Reuse
Check the parts for damage. Look for scratches or dents.
NOTE: Prevent one of the gears from turning to check to
gear lash.
Check the gear lash.
Gear Lash
mm in
0.08 MIN 0.003
0.30 MAX 0.012
If the gear lash is not within specifications, the drive must
be rebuilt. Refer to Procedure 009-023.
Check the gear end clearance.
Gear End Clearance
mm in
0.10 MIN 0.004
0.25 MAX 0.010
If any of the parts are damaged or not within
specifications, the gear drive must be rebuilt. Refer to
Procedure 009-023.
Clean for Rebuild
WARNING
Use solvent. Clean the parts.
Inspect
Check all parts for damage or wear.
NOTE: All three bushings in the housing have the same
specifications.
Measure the inside diameter of the bushings.
Bushing Inside Diameter
mm in
63.55 MIN 2.502
63.63 MAX 2.505
The bushings are machined after installation in the
housing. Do not attempt to replace the bushings unless
you have the capability of machining the bushing inside
diameter to a precise tolerance. If the bushings in the
housing are replaced, they must be machined within the
above specifications.
The bushings must have the same center as the large
bores in the housing within 0.10 mm [0.004 inch] total
indicator runout.
NOTE: All bushings in the supports have the same
specification.
Measure the inside diameter of the bushings.
Support Bushing Inside Diameter
mm in
63.55 MIN 2.502
63.63 MAX 2.505
The bushings are machined after installation in the
support. Do not attempt to replace the bushings unless
you have the capability of machining the bushing inside
diameter to a precise tolerance. If the bushings in the
support are replaced, they must be machined within the
above specifications.
The bushings must have the same center as the support
pilot (between the o-ring groove and mounting flange)
outside diameter within 0.05 mm [0.002 inch].
NOTE: All shafts have the same outside diameter
specifications.
Measure the outside diameter at each end.
mm in
63.500 MIN 2.5000
63.513 MAX 2.5005
If the shaft is not within specifications, or the gear is
damaged, the gear or shaft must be replaced. Refer to
Procedure 009-028.
Each shaft must contain a cup plug that has an orifice
installed in the bore of the shaft. If the plug is not installed,
a low flow of oil to the bushing in the support will result. If
the plug does not have an orifice, no oil to the spline will
result. Do not remove the plug. The shaft and plug are
available as an assembly only.
NOTE: The specification for the shaft protrusion is the
same for the adapter on the center shaft and gear
assembly (19) as for the shaft and gear on the outboard
assembly or assemblies (11).
NOTE: Measure from the end of the shaft that contains
the drive splines.
Measure the shaft protrusion from the gear to check the
gear movement on the shaft.
Shaft Protrusion
mm in
85.47 MIN 3.365
85.98 MAX 3.385
NOTE: All thrust bearings have the same thickness
specifications.
Measure the thickness of all the thrust bearings.
mm in
2.36 MIN 0.093
2.41 MAX 0.095
Oversize thrust bearings are available to adjust end
clearance.
Assemble
Install the pipe plug (25) in the bottom of the housing.
Install the cover plate gasket (27) and the cover plate (26)
on the top of the housing.
NOTE: Install the lifting bracket if desired.
Install the capscrews.
Install the center gear (20) through the slot in the bottom
of the housing.
Position the gear so that the bore in the gear is centered
over the center bushing bore in the housing.
Use clean engine oil. Lubricate the shaft, thrust bearing,
and the bushing.
CAUTION
The thrust bearing must be installed so that the oil
grooves are toward the gear. If the thrust bearing is
not installed correctly, failure will result.
Install the thrust bearing (19) on the shaft with the adapter
(18).
With the short end first, install the adapter and the shaft
assembly (18) through the bore of the gear and into the
housing.
Install the flat washers and capscrews.
Install a new o-ring (15) on the center support.
Use clean engine oil. Lubricate the o-ring, thrust bearing
(16), and the shaft and bushing.
CAUTION
The oil grooves in the thrust bearing must be toward
the gear. If the bearing is not installed correctly,
failure will result.
Install the thrust bearing on the shaft.
Install the center support (14). Install the flat washers and
capscrews.
Use clean engine oil. Lubricate the thrust bearing (12), the
shaft (11), and the bushing in the housing.
CAUTION
the gear. If the bearing is not installed correctly,
failure will result.
Install the thrust bearing (12) on the shaft (11).
With the short end first, install the shaft through the thrust
bearing and into the bushing.
Install a new o-ring (9) on the support (8).
Use clean engine oil. Lubricate the thrust bearing, the
bushing in the support, and the shaft.
CAUTION
the gear. If the thrust bearing is not installed
correctly, failure will result.
Install the thrust bearing (10) and the support (8). Install
the flat washers and capscrews (7).
NOTE: Prevent one of the gears from turning when
measuring the gear lash.
Use a dial indicator. Measure the gear lash on all gears.
Gear Lash
mm in
0.08 MIN 0.003
0.30 MAX 0.012
If any gear lash is not within specifications, the gear
must be replaced.
Use a dial indicator. Measure the end clearance of the
shafts on all gears through the bore on the cylinder block
side of the drive.
Shaft End Clearance
mm in
0.10 MIN 0.004
0.25 MAX 0.010
NOTE: Oversize thrust bearings are available to adjust the
end clearance. If the end clearance is not sufficient, check
for debris between the thrust bearings and their
connecting parts.
CAUTION
The plug and the o-ring must be installed in any
bushing bore that does not contain a shaft. If the plug
and o-ring are not installed, low oil pressure will
result.
Install a new o-ring (24) on the plug (23).
Use clean engine oil. Lubricate the o-ring.
Install the plug in the bore. Push the plug in the bore until
the step on the plug touches the bushing.
Install new cover plate gaskets (22) and the cover plates
(21). Install the flat washers and capscrews.
Install a new o-ring (4) on the cover for a port that does
not contain a drive.
Use clean engine oil. Lubricate the o-ring.
Install the cover plate (3). Install the lock washers, flat
washers, and capscrews.
Install a new cover plate gasket (6) and the cover plate (5).
Install the lock washers and the capscrews.
NOTE: If an alternator or a pump is to be installed on the
drive, tighten the capscrews to a torque of 366 Nm [270
ft-lb].
Install
Check to be sure the two roll pins (1) have been installed
in the lower unit housing.
Install the two o-ring seals (2) in the counterbores that are
around the oil holes on the lower housing.
WARNING
NOTE: The lifting bracket (3) for a Cummins 855 cubic
inch engine can be attached to the upper unit as shown
to lift the unit with a hoist.
Put the upper unit on the lower unit.
CAUTION
The capscrews (5) must be SAE Grade 8. If the Grade
8 capscrews are not installed, the threads can fail at
the torque required to hold the drive.
Install eleven of the lock washers (4) and capscrews (5).
Do not tighten the capscrews.
Remove the capscrews (6) from the center drive support.
Remove the center support (7). The center support
contains an o-ring seal (8), and a thrust bearing (9)
between the support and the gear. It is not necessary to
remove the seal and the thrust bearing, but they must be
installed correctly.
Install the three lock washers (4) and capscrews (5) in the
holes that are inside the upper unit.
Tighten the fourteen capscrews that connect the upper
unit to the lower unit.
K38, K50, QSK38, and QSK50 Rear Gear Drive Gear and Shaft (Upper Assembly)
CAUTION
The grooves in the thrust bearing must be toward the
gear. If the bearing is installed wrong, the part can fail
because of the lack of lubrication.
Use engine oil. Lubricate the thrust bearing (9) and o-ring
seals (8).
Install the thrust bearing. Install the o-ring seal on the
support.
Install the center support (7) and the flat washer and
capscrews (6).
Rear Gear Drive Gear and Shaft (Upper
Assembly) (009-028)
Disassemble
NOTE: This procedure illustrates replacing a gear or shaft
in the center drive port. The procedure and specifications
are the same for the other locations.
Support the gear as illustrated. Use a press. Push the
shaft (1) out of the gear (2).
Clean
Use clean engine oil. Clean the parts.
Inspect for Reuse
Check the parts for damage.
Measure the outside diameter of the gear step on the
shaft.
Gear Step Outside Diameter
mm in
63.627 MIN 2.5050
63.640 MAX 2.5055
Rear Gear Drive Gear and Shaft (Upper Assembly) K38, K50, QSK38, and QSK50
Measure the inside diameter.
Gear or Adapter Bore Inside Diameter
mm in
63.53 MIN 2.501
63.55 MAX 2.502
Assemble
WARNING
To reduce the possibility of severe burns, wear
protective gloves when installing the heated ring gear.
CAUTION
Damage to the gear and gear teeth will result.
CAUTION
Do not attempt to install the gear without the use of
heat.
Use an oven. Adjust the temperature to 235C [450F].
Heat the gear in the oven for a minimum of 1 hour, but a
maximum of 6 hours. The Inside Diameter of the gear will
become larger than the outside diameter of the shaft,
allowing the installation of the gear on the shaft.
The gear must be located on the shaft a specific distance
from the end of the shaft that has the splines. Because the
gear will be hot, it must be secured in the correct location
on the shaft until it cools and tightens on the shaft.
There are two methods for positioning and securing the
hot gear correctly.
Method One (Preferred):
Obtain a length of pipe or thick wall tubing that has an
inside diameter larger than the shaft and an outside
diameter smaller than the hub on the gear or adapter.
Cut the pipe or tube so that it is the same length as the
shaft protrusion specification.
The shaft can now be put spline end down in the pipe or
tube, and the gear or adapter installed until it touches the
pipe or tube. The tube will then secure the gear or adapter
at the proper location on the shaft until the gear or adapter
is cool.
K38, K50, QSK38, and QSK50 Rear Gear Drive Gear and Shaft (Upper Assembly)
Method Two:
Apply machinist dye to the gear step area of the shaft.
Measure the distance of the protrusion specification from
the end of the shaft that contains the splines.
Use a scribe (3) to mark a line in the dye that will indicate
where the gear is to be located to obtain the correct
protrusion.
When this method is used, the gear must be moved to the
scribed line, then the gear and shaft assembly placed on
its side using vee blocks so that the gear will remain in the
correct location until it is cool.
Use Lubriplate No. 105, or equivalent. Lubricate the
outside diameter of the shaft. Do not allow the lubricant
to obscure any gear position marks.
WARNING
CAUTION
Allow the air to cool the gear. Do not use water or oil
to reduce the cooling time. Cracks in the gear will
result.
Remove the gear from the oven. Either side of the gear
can be put on the shaft.
NOTE: The gear pilot (4) outside diameter is the largest
outside diameter of the adapter.
The adapter must be put on the center shaft so that the
pilot for the center gear (4) is nearest to the end of the shaft
that does not have the splines.
Install the gear (4). Move the gear or adapter on the shaft
until it touches the pipe (5) or the scribed line.
After the parts are cool, measure the shaft protrusion from
the end of the shaft that has the splines.
Shaft Protrusion
mm in
85.47 MIN 3.365
85.98 MAX 3.385
If the protrusion is not correct, the gear or adapter can be
moved on the shaft slightly using a press and a mandrel.
Support the gear or adapter as near to the shaft as
possible and push on the shaft.
Water Pump Drive Bushing K38, K50, QSK38, and QSK50
Water Pump Drive Bushing (009-030)
Remove
Standard Bushing
Use an arbor press. Support the housing as shown. Use
a mandrel. Remove the bushings.
Flanged Bushing
NOTE: Before removal from the housing measure the
bushing inside diameter
Use an arbor press. Support the housing as shown.
Remove the drive gear (1).
Remove the shaft (2).
Remove the pipe plug (3).
WARNING
WARNING
personal injury.
Standard Bushing
Use solvent to clean the housing.
K38, K50, QSK38, and QSK50 Water Pump Drive Bushing
Flanged Bushing
Clean and inspect all parts.
NOTE: The oil drillings must be open and free of any
blockage.
Standard and Flanged Bushing
Measure the inside diameter of the housing bore.
Housing Bore Inside Diameter
mm in
47.63 MIN 1.875
47.65 MAX 1.876
If the bore is not within specifications, the housing must
be replaced.
Flanged Bushing Only
NOTE: There are two bushings in the water pump support.
Measure the inside diameter of both bushings.
mm in
44.48 MIN 1.751
44.58 MAX 1.755
specifications, both bushings must be replaced.
Install
CAUTION
The bushings should not block the oil drilling in the
housing.
Standard Bushing
Use an arbor press. Support the housing.
Use a suitable mandrel. Install the bushings. The
bushings must be even with, or up to a maximum of 0.38
mm [0.015 in] below the housing surface.
Water Pump Drive Gear and Shaft K38, K50, QSK38, and QSK50
Flanged Bushing
Use an arbor press (1).
Use the shaft (2) as a mandrel.
Support the housing (5) and using a spacer (3), press the
bushing (4) into place.
Repeat the process for the remaining bushing.
NOTE: The bushings must be pressed in square to the
bores of the casting. The thrust faces of the two bushings
must be parallel and concentric.
Lubricate the bushing bores and thrust faces with
Lubriplate Number 105, or equivalent.
Water Pump Drive Gear and Shaft
(009-031)
Disassemble
Only remove the gear from the shaft when the gear or the
shaft must be replaced.
Use an arbor press. Support the shaft and gear assembly
as shown.
Push the shaft from the gear.
Inspect for Reuse
Measure the outside diameter of the shaft at the gear
location.
mm in
39.776 MIN 1.5660
39.802 MAX 1.5670
K38, K50, QSK38, and QSK50 Water Pump Drive Pulley
Measure the inside diameter of the gear.
Gear Inside Diameter
mm in
39.726 MIN 1.5640
39.751 MAX 1.5650
Assemble
Fit the shaft into the housing.
Apply Loctite 609, Part Number 3823718 or equivalent,
to the gear inside diameter
Support the gear in a press.
Press the shaft into the gear.
Water Pump Drive Pulley (00-032)
Preparatory Steps
Remove alternator belt. Refer to Procedure 013-005.
Remove
NOTE: A capscrew fitted to the end of the shaft will
prevent damage to the threads.
equivalent. Remove the pulley from the water pump drive
shaft.
Woodward Governor Drive K38, K50, QSK38, and QSK50
Install
CAUTION
bearings in the water pump drive can be damaged and
the water pump drive can fail.
CAUTION
the seal can leak.
shaft and the inside diameter of the bore in the pulley.
CAUTION
running your finger around it 8 to 10 times, applying
gentle pressure. Be sure there is no oil on your hands.
Avoid touching the sealing lip (black lip). The dust lip
will remain bent approximately 1 minute, then return
slowly to the operating position.
Position the pulley on the shaft. Use the tool to push the
pulley on the shaft until the sleeve on the tool touches the
shaft. The pulley will then be even with the end of the
shaft.
Finishing Steps
Install alternator belt. Refer to Procedure 013-005.
Woodward Governor Drive (009-034)
General Information
This drive provides mechanical power to both the governor and the fuel pump.
The drive replaces the fuel pump/compressor drive on engines that have an additional governor installed between
the governor drive and the Cummins PT fuel pump. This drive is referred to as a Woodward Governor Drive. Other
types of governors are installed on the governor housing.
The drive support does not contain a bushing or thrust bearing. The drive contains a ball bearing at the rear. The
front of the shaft is supported by the bushing in the front gear cover of the engine.
The drive has a shaft seal that prevents engine oil from entering the oil sump in the governor drive housing.
K38, K50, QSK38, and QSK50 Woodward Governor Drive
The drive gear has stamped marks. The stamped marks do not have to be aligned with any marks on the left bank
camshaft idler gear. The gear has the stamped marks only because the same gear is installed on K19 engines that
have the valve and injector adjustment marks on the accessory drive pulley. The drive gear must be installed on the
shaft so that the marks are toward the end of the pulley shaft for correct bearing end clearance.
WARNING
WARNING
personal injury.
CAUTION
Do not use a solvent that will damage the silicone
rubber oil seal.
Remove all of the gasket material from the mounting
flanges.
Use solvent. Clean the drive. Dry with compressed air.
Check the parts for damage.
Use your hand to rotate the shaft. Check the bearing for
damage. Check the end clearance of the bearing.
mm in
0.05 MIN 0.002
0.10 MAX 0.004
If any of the parts are damaged or the bearing is not within
specifications, the drive must be rebuilt or replaced.
Disassemble
Remove the locknut (1) and the retaining washer (2).
Discard the locknut.
CAUTION
Do not damage the threads on the shaft.
Use a three-jaw puller. Remove the coupling (3). Remove
the governor gear spacer (4) and the key (5).
Use a three-jaw puller. Remove the governor gear (6).
Use an arbor press. Support the drive support (7). Push
the shaft and gear assembly out of the bearing and
support.
Remove the bearing spacer (8) from the shaft (9).
Remove the bearing retaining ring (10).
NOTE: The outside diameter of the bearing can be a
maximum of 0.008 mm [0.0003 in] larger than the inside
diameter of the bearing bore. An arbor press can be used
to push the bearing out of the bore.
Remove the ball bearing (11).
Use a hammer and a mandrel (12). Remove the oil seal
(13) from the housing. Discard the seal.
Clean for Rebuild
WARNING
WARNING
personal injury.
Use solvent. Clean the parts. Dry with compressed air.
Inspect
Measure the seal and bearing bores in the support (9).
Seal Bore Inside Diameter (14)
mm in
57.12 MIN 2.249
57.18 MAX 2.251
Bearing Bore Inside Diameter (15)
mm in
61.991 MIN 2.4406
62.017 MAX 2.4416
If either bore is not within specifications, the support
must be replaced.
Check the shaft and gear for damage. Measure the shaft
at the locations illustrated.
mm in
34.963 MIN 1.3765
34.976 MAX 1.3770
mm in
25.257 MIN 1.0050
25.540 MAX 1.0055
mm in
24.999 MIN 0.9842
25.009 MAX 0.9846
mm in
20.663 MIN 0.8135
20.676 MAX 0.8140
If the shaft is not within specifications, it must be
replaced. Refer to Procedure 009-003.
NOTE: The drive gear is identical to the gear that is used
on the fuel pump/compressor drive. The specifications
shown in the referenced procedure for the gear inside
diameter and the shaft outside diameter for the gear step
are the same for this gear and shaft.
NOTE: The shaft outside diameter at the drive step of the
hourmeter in the shaft (17) is critical only when the engine
is equipped with an hourmeter drive.
Governor Drive Gear Inside Diameter
mm in
24.971 MIN 0.9831
24.986 MAX 0.9837
Jaw Coupling Hub Bore Inside Diameter
mm in
20.625 MIN 0.8120
20.638 MAX 0.8125
If the bore is not within specifications, the coupling
must be replaced.
Check the surface of the bearing spacer (8) in the area
that contacts the oil seal.
If the spacer indicates wear, it must be replaced.
Assemble
CAUTION
The case of the seal must not block the oil passages.
Bearing failure will result.
Use a mandrel and an arbor press.
Install a new oil seal (13) in the bore of the support (7).
Push the seal until the seal case aligns with the oil hole in
the support (20) as illustrated.
CAUTION
The mandrel must contact the outer rim of the bearing
to prevent damage to the part.
CAUTION
The flat side of the retaining ring must touch the outer
bearing cage.
NOTE: The outside diameter of the bearing can be a
maximum of 0.008 mm [0.0003 in] larger than the inside
diameter of the bearing bore. A mandrel and an arbor
press can be used to install the bearing.
Push the bearing (11) in the bore until it touches the step
in the housing.
Install the retaining ring (10).
CAUTION
Be sure the sealing lips of the seal are not rolled.
Failure of the seal will result.
Install the bearing spacer (8) on the shaft (9).
NOTE: The inside diameter of the spacer can be the same
size or a maximum of 0.05 mm [0.002 in] larger than the
step outside diameter of the shaft. If the spacer and shaft
have a tight fit, use engine oil to lubricate the inside
diameter of the spacer. Then rotate it clockwise and
counterclockwise to install it on the shaft.
Use engine oil. Lubricate the seal.
Install the shaft, spacer, and the gear assembly through
the oil seal until the step on the shaft for the bearing
touches the bearing bore.
CAUTION
The mandrel inside diameter must contact the inner
race of the bearing to prevent damage to the part. The
mandrel inside diameter must be larger than the
outside diameter of the shaft to prevent damage to the
shaft.
Use a mandrel (21). Use an arbor press to support the
drive gear.
Push the bearing and support assembly on the shaft. Push
the bearing until the bearing spacer touches the bearing.
The bearing and shaft must rotate freely.
Measure the clearance.
End Clearance
mm in
0.05 MIN 0.002
0.10 MAX 0.004
Use Lubriplate Number 105 multipurpose lubricant or
equivalent, to lubricate the bore of the governor drive
gear.
Use an arbor press to support the assembly on the drive
gear.
Use a mandrel to push the governor drive gear on the
shaft. Push the gear until it touches the bearing.
K38, K50, QSK38, and QSK50 Accessory Drive Cover
Install the governor spacer (4) and the key (5) on the shaft.
Align the keyway in the jaw coupling (3) with the key in the
shaft (5).
Use a flat piece of steel, such as a mandrel. Use an arbor
press to support the shaft as illustrated.
Push the jaw coupling on the shaft. Push the coupling until
it touches the spacer. Clean away any metal removed by
the installation.
Install the retaining washer (2) and a new locknut (1).
Accessory Drive Cover (009-039)
Install
NOTE: The cover is installed only if the accessory drive
or the water pump drive does not have a pulley.
Use a sealant (RTV), Part Number 3377132. Apply a bead
of sealant to the portion of the cover that will be in the bore
of the front cover.
Position the cover in the bore.
NOTE: Do not bend the cover when pushing it into the
bore. If the cover is bent, an oil leak will result.
Use a mallet. Push the cover into the bore until the step
on the cover touches the front gear housing.
Check to be sure the cover is straight in the bore.
Accessory Drive Cover K38, K50, QSK38, and QSK50
Notes
Section 10 Air Intake System Group 10 Page 10-a
Section 10 Air Intake System Group 10
Section Contents
Page
Aftercooler .......................................................................................................................................................10-3
Exploded View................................................................................................................................................10-4
Aftercooler Assembly ....................................................................................................................................10-12
Assemble......................................................................................................................................................10-25
Clean and Inspect for Reuse......................................................................................................................... 10-24
Disassemble..................................................................................................................................................10-19
Finishing Steps............................................................................................................................................. 10-43
MAI............................................................................................................................................................10-43
Install............................................................................................................................................................10-33
Preparatory Steps......................................................................................................................................... 10-12
MAI............................................................................................................................................................10-12
Pressure Test................................................................................................................................................10-23
Remove.........................................................................................................................................................10-13
Aftercooler Assembly (Center-Mount) ..........................................................................................................10-45
Assemble......................................................................................................................................................10-49
Disassemble..................................................................................................................................................10-46
Finishing Steps............................................................................................................................................. 10-53
Install............................................................................................................................................................10-51
Pressure Test................................................................................................................................................10-48
Remove.........................................................................................................................................................10-45
Aftercooler Assembly (Outboard) .................................................................................................................10-53
Install............................................................................................................................................................10-54
Remove.........................................................................................................................................................10-53
Aftercooler Element ...................................................................................................................................... 10-56
Finishing Steps............................................................................................................................................. 10-61
Standard....................................................................................................................................................10-58
LTA............................................................................................................................................................10-58
Center-Mount.............................................................................................................................................10-59
Install............................................................................................................................................................10-59
Standard....................................................................................................................................................10-59
LTA............................................................................................................................................................10-60
Center-Mount.............................................................................................................................................10-61
Remove.........................................................................................................................................................10-56
Page 10-b Section 10 Air Intake System Group 10
Standard....................................................................................................................................................10-56
LTA............................................................................................................................................................10-57
Center-Mount.............................................................................................................................................10-58
Aftercooler Housing (Center Mount) ...........................................................................................................10-162
Modify.........................................................................................................................................................10-162
KTA50......................................................................................................................................................10-162
Aftercooler Water Inlet Tube .......................................................................................................................10-167
Clean and Inspect for Reuse........................................................................................................................10-167
Center-Mount...........................................................................................................................................10-167
Aftercooler Water Outlet Tube ....................................................................................................................10-167
Center-Mount...........................................................................................................................................10-167
Air Cleaner Assembly (Engine-Mounted) ......................................................................................................10-61
Install............................................................................................................................................................10-64
Remove.........................................................................................................................................................10-61
Air Cleaner Element ...................................................................................................................................... 10-66
Pressure Test................................................................................................................................................10-66
LTA............................................................................................................................................................10-66
Air Connection Pipe (Turbocharger to Turbocharger) .................................................................................10-67
Clean............................................................................................................................................................10-67
Air Crossover (Center-Mount Aftercooler) ....................................................................................................10-68
Finishing Steps............................................................................................................................................. 10-69
Install............................................................................................................................................................10-69
Remove.........................................................................................................................................................10-68
Air Intake Restriction .................................................................................................................................... 10-71
Measure........................................................................................................................................................10-71
Air Leaks, Air Intake and Exhaust Systems .................................................................................................10-69
Service Tools ...................................................................................................................................................10-1
Air Intake System............................................................................................................................................10-1
Turbocharger .................................................................................................................................................10-73
Assemble......................................................................................................................................................10-99
Clean............................................................................................................................................................10-91
Disassemble..................................................................................................................................................10-94
Finishing Steps............................................................................................................................................10-129
MAI..........................................................................................................................................................10-129
with Electronically Actuated Injector..........................................................................................................10-129
Install..........................................................................................................................................................10-101
with Mechanically Actuated Injector..........................................................................................................10-101
Measure........................................................................................................................................................10-98
MAI............................................................................................................................................................10-75
Remove.........................................................................................................................................................10-77
Turbocharger Axial Clearance ....................................................................................................................10-137
Finishing Steps............................................................................................................................................10-140
Measure......................................................................................................................................................10-138
Preparatory Steps........................................................................................................................................10-137
Section 10 Air Intake System Group 10 Page 10-c
Turbocharger Blade Damage ......................................................................................................................10-140
Inspect for Reuse........................................................................................................................................10-140
Turbocharger Compressor Seal Leaks .......................................................................................................10-141
Inspect........................................................................................................................................................10-141
Turbocharger Coolant Hoses ......................................................................................................................10-144
Finishing Steps............................................................................................................................................10-148
EAI...........................................................................................................................................................10-148
Inspect for Reuse........................................................................................................................................10-146
EAI...........................................................................................................................................................10-146
Install..........................................................................................................................................................10-146
Marine Applications..................................................................................................................................10-148
EAI...........................................................................................................................................................10-144
Remove.......................................................................................................................................................10-144
Turbocharger Oil Drain Line ........................................................................................................................10-148
Finishing Steps............................................................................................................................................10-153
Install..........................................................................................................................................................10-151
Remove.......................................................................................................................................................10-149
Single Stage.............................................................................................................................................10-149
Two Stage................................................................................................................................................10-149
Turbocharger Oil Supply Line .....................................................................................................................10-153
Finishing Steps............................................................................................................................................10-161
Install..........................................................................................................................................................10-158
Industrial Applications...............................................................................................................................10-158
Two Stage................................................................................................................................................10-158
Low Pressure Turbocharger......................................................................................................................10-159
Remove.......................................................................................................................................................10-154
Industrial Applications...............................................................................................................................10-154
Two Stage................................................................................................................................................10-155
Low Pressure Turbocharger......................................................................................................................10-155
Turbocharger Radial Bearing Clearance .....................................................................................................10-161
Finishing Steps............................................................................................................................................10-162
Measure......................................................................................................................................................10-161
Turbocharger, Water-Cooled .......................................................................................................................10-130
Finishing Steps............................................................................................................................................10-137
Install..........................................................................................................................................................10-134
Left Bank..................................................................................................................................................10-134
Right Bank...............................................................................................................................................10-136
Remove.......................................................................................................................................................10-131
Left Bank..................................................................................................................................................10-131
Right Bank...............................................................................................................................................10-132
Setup..........................................................................................................................................................10-133
Page 10-d Section 10 Air Intake System Group 10
Section 10 Air Intake System Group 10 Page 10-1
Service Tools
Air Intake System
Repair Location.
ST-537
Dial depth gauge
Used to check for proper nozzle ring crush or end clearance checks
on turbochargers.
3375275
Pressure Gauge (0 to 689 kPa [0 to 100 psi])
Used to check air cleaner elements for leaks.
3824783
Torque Wrench
An inch-pound dial-type torque wrench.
3164794
Torque Wrench
3824879
Anti-Seize Compound
Lubricant that speeds assembly and disassembly of studs, bolts,
capscrews, flanges, and fittings.
3824523
Black Light (AC)
Used to help identify the source of leaks in the lubricating system.
Page 10-2 Section 10 Air Intake System Group 10
3377394
Black Light (DC)
Used to inspect for oil or fuel leaks.
3376891
Fluorescent Tracer
Used to determine the source of oil leaks. It must be used with a
black light.
4918234
Exhaust Manifold Leak Tester Kit
Used to pressure test turbocharger gasket, exhaust bellows, exhaust
manifold gaskets, and exhaust manifold adapter gasket sealing areas
for leaks.
3164231
Air Pressure Regulator
Used with the exhaust manifold leak tester.
3375957
Nylon Lifting Sling (1 inch by 6 ft)
Used to aid in the removal and installation of heavy components.
3375958
Nylon Lifting Sling (2 inch by 6 ft)
K38, K50, QSK38, and QSK50 Aftercooler
Aftercooler (010-001)
General Information
Most K38 engines rated at 675 kW (900 HP) and lower are not aftercooled. All K38 engines rated 675 kW (900 HP)
and higher are aftercooled. All K50 engines are aftercooled.
Engines that are aftercooled can have one or four aftercooler assemblies. New KTA engines and all KTTA, K2000E,
K1800E and K1500E engines have four aftercooler assemblies that are located with the intake manifolds. These are
referred to as "outboard" or "low profile" aftercoolers. The aftercoolers on older engines are mounted on supports on
the top center of the engine. The older aftercoolers are referred to as "center mount" aftercoolers.
Center Mount Aftercooler
The center mount aftercooler housing for the K50 engine was improved. The housing was modified to allow the
installation of cross bolts that prevent leaks from the expansion of the housing from temperature and internal pressure.
A procedure to modify the housing for the cross bolts is included in this section of the manual.
The parts for the center mount aftercooler supports on K38 and K50 engines were changed. The number of fasteners
to mount the bracket to the supports and to the aftercooler housing was increased. A new aftercooler housing can be
mounted with the old supports and brackets. The old aftercooler housing can be mounted with the new supports and
brackets. Old and new supports and brackets must not be combined.
The aftercooler element was changed at the same time the parts for the center mount aftercooler supports were
changed. The new element has an end tank that is manufactured of steel. The older element has an end tank that
is manufactured from bronze. The old and new elements can be combined in an aftercooler assembly.
The side cover plate for the aftercooler was changed on K38 and K50 engines. The mounting flange on the new plate
is 25.4 mm [1.000 inch] thick. The mounting flange on the older plate is 13 mm [0.5 inch] thick. The new plate requires
[3/8 - 16 x 2.250 inch] capscrews with lock washers and flat washers to attach the plate to the aftercooler housing.
K38 and K50 engines manufactured after June 1977 contain different aftercooler elements than the engines
manufactured before that date. The new elements contain a water connection nipple that is 69.9 mm [2.75 inch] in
length. The nipple on the older elements is 31.8 mm [1.25 inch] in length. If the older elements must be replaced,
the aftercooler water inlet and outlet connections must be changed to allow for the longer length. An adapter
connection that has a hole is required to prevent coolant from a leaking o-ring seal to enter the cylinders of the engine.
The aftercooler water outlet tube must be modified to allow for the longer nipple length and the use of the older
thermostat housing support.
Outboard Aftercooler
Revised aftercooler elements and plumbing was released for all KTTA38, E.S.N. 33112184, and KTTA50, E.S.N.
33112203, engines in April, 1987. All original KTTA aftercooler plumbing was replaced.
Older engines can be upfitted by following the procedure in this section.
Low Temperature Aftercooling (LTA) System
The LTA system was introduced to improve serviceability and to commonize cooling system hardware.
LTA is used on KTA50-G3, KTA50-G4, KTTA50-G2, K2000E, K1800E and K1500E engines and utilizes a standard
flow cooling system. For a detailed description of the LTA cooling system refer to Section 08 of this manual.
An AiResearch Phase 2 aftercooler element replaced Phase 1 elements in September, 1987, E.S.N. 33112790.
A Modine Phase 3 aftercooler element replaced the Phase 2 element in September, 1988, on C1800 engines from
E.S.N. 33114675 and on all other engines from E.S.N. 33114695.
A Modine steel element replaced the copper element on K2000E and K1800E engines in January, 1992, E.S.N.
33121129 and on all other engines in May, 1993, E.S.N. 33124510.
A revised aftercooler seal was released for K2000E and K1800E engines that improve the sealing reliability. The new
sealing hardware is not interchangeable with intake manifolds. Both the revised seal and intake manifolds must be
installed as a package when performing a retrofit. This change took place on engines from January, 1992, E.S.N.
33121129.
A revised convoluted hump hose, with two stainless steel rings around the circumference of the hose, was released
for KTA/KTTA50 engines. The new hose helps prevent ballooning of the hose.
Since the revised hump hose is longer than the hose used previously, a revised air connection must be used. The
hose connection will provide a wider air gap between the two pieces of air connection. Do not lubricate the hose. This
change was effective from July, 1994, E.S.N. 33128112.
Aftercooler K38, K50, QSK38, and QSK50
Exploded View
Aftercooler, Center mount
Aftercooler, Center mount
Reference Quantity (per Engine)
Number Description K38 K50
1 Manifold, Air Intake (Refer to Note 1) (Refer to General
Information)
4 4
2 Gasket, Intake Manifold 12 16
3 Seal, Rectangular Ring 24 32
4 Gasket, Air Intake Connection 8 8
5 Connection, Air Crossover 4 4
6 Connection, Air Intake (Jumper) 2 2
7 Seal, Dust (Air Crossover Tube) 4 4
8 Seal, O-Ring (Air Crossover Tube) 8 8
9 Tube, Air (Air Crossover) 4 4
11 Gasket, Connection 4 4
12 Cover, Aftercooler Housing 2 2
13 Gasket, Cover and Element 4 4
14 Element, Aftercooler 2 2
15 Housing, Aftercooler (Refer to Note 1) 1 1
16 Seal, O-Ring (Adapter to the Element) 4 4
17 Gasket, Flange 4 4
18 Connection, Adapter 4 4
19 Connection, Water Outlet 2 2
20 Seal, Rectangular 6 6
21 Tube, Water Outlet Transfer (Refer to Note 1) 2 2
22 Brace, Retaining (Refer to Notes 1 and 2) 4 4
23 Turbocharger (Refer to Note 1) (See General Information) 2 2
24 Seal, O-Ring (Turbocharger Outlet Tube) (Refer to Note 2) 4 4
25 Tube, Air (Turbocharger Outlet) (Refer to Note 2) 2 2
26 Seal, Dust (Turbocharger Outlet Tube) (Refer to Note 2) 2 2
27 Gasket, Turbocharger 2 2
30 Connection, Water Inlet 2 2
31 Seal, O-Ring 6 6
32 Tube, Water Inlet Transfer 2 2
33 Connection, Water Inlet Transfer 2 2
34 Gasket, Connection (to the Water Header) 1 1
35 Support, Aftercooler Housing 4 4
36 Plate, Aftercooler Support 2 2
Note 1:K38 and K50 parts are different.
Note 2:Newer engines have a special hose and special clamps instead of these parts.
Aftercooler, Outboard
Aftercooler, Outboard
Reference Quantity (per Engine)
Number Description K38 K50
2 Clamp, Vee-Band 2 2
4 Seal, O-Ring 4 4
6 Seal, Dust 2 2
9 Cover, Aftercooler 4 4
10 Screw, Captive Spring Washer [3/8-16 x 1.06 Inch] 32 32
11 Element, Aftercooler 4 4
12 Gasket, Aftercooler Cover 4 4
13 Seal, O-Ring 16 16
14 Gasket, Flange 8 8
15 Adapter, Connection 8 8
16 Clamp, Hose 32 32
17 Hose, Elbow (Refer to Note 1) 12 4
18 Tube, Water Outlet (Right Bank Front) (Refer to Note 1) 1 1
19 Hose, Plain (Refer to Note 1) 3 11
20 Coupling, Hose (to the Thermostat Housing) 2 2
21 Cover, Thermostat Housing Support 2 2
22 Gasket, Cover 2 2
23 Gasket, Air Intake Manifold 12 16
24 Seal, Rectangular Ring 24 32
25 Coupling, Hose (to the Cylinder Block) 4 4
26 Tube, Water Inlet (Right Bank Front) (Refer to Notes 1 and
2)
1 1
27 Capscrew [3/8-16 x 5.25 Inch] 24 32
27 Capscrew [3/8-16 x 6.75 Inch] 24 32
29 Manifold, Air Intake ( Right Bank Front, Left Bank Rear)
(Refer to Note 1)
2 2
30 Manifold, Air Intake ( Right Bank Rear, Left Bank Front)
(Refer to Note 1)
2 2
31 Tube, Water Inlet (Right Bank Rear) (Refer to Notes 1 and
2)
1 1
32 Tube, Water Outlet (Right Bank Rear) (Refer to Notes 1
and 2)
1 1
33 Elbow, 90 Degree (to the Rocker Lever Housing) (Refer to
Note 2)
1 1
Note 1:K50 parts are different.
Note 2:The right bank is illustrated. The left bank part is different.
Aftercooler, Outboard K2000E and K1800E
Aftercooler, Outboard K2000E and K1800E
Reference
Number Description Quantity
1 Clamp, V Band 2
2 Connection, Air Crossover 1
3 Clamp, T-bolt 4
4 Hose, Plain 2
5 Capscrew, Hexagon Head 16
6 Pipe, Plug 8
7 Washer, Spring 96
8 Gasket, Connection 4
9 Clamp. T-bolt 8
10 Hose, Plain 2
12 Connection 2
17 Hose, Plain 2
18 Connection, Air Intake 4
23 Gasket, Intake Manifold 4
24 Seal, Rectangular Ring 32
25 Manifold, Air Intake RB Front & LB Rear 2
26 Manifold, Air Intake LB Front & RB Rear 2
Aftercooler, Outboard K1500E
Aftercooler, Outboard K1500E
Reference
1 Clamp, V Band 2
3 Clamp, T-bolt 4
4 Hose, Plain 2
6 Pipe, Plug 8
7 Washer, Spring 96
9 Clamp. T-bolt 8
10 Hose, Plain 2
12 Connection 2
17 Hose, Plain 2
23 Gasket, Intake Manifold 12
25 Manifold, Air Intake RB Front & LB Rear 2
26 Manifold, Air Intake LB Front & RB Rear 2
Element, Aftercooler K2000E, K1800E and K1500E
Element, Aftercooler K2000E, K1800E and K1500E
Reference
1 Element, Aftercooler 4
2 Seal, Aftercooler 4
3 Connection, Water Transfer 2
6 Seal, O-ring 8
9 Plug, Pipe 4
10 Seal, Rectangular Strip 4
12 Seal, Grommet 8
13 Capscrew, hexagon Head 50
14 Spacer, Mounting 50
15 Washer, Spring 8
16 Draincock 4
Aftercooler, Outboard KTA50-G3, G4 and KTTA50-G2
Aftercooler, Outboard KTA50-G3, G4 and KTTA50-G2
Reference
1 Manifold, Air Intake LB front & RB Rear 2
2 Manifold, Air Intake RB front & LB Rear 2
3 Element, Aftercooler 4
4 Gasket, Cover 4
5 Clamp, T-bolt 4
6 Hose, Plain 2
7 Crossover, Air 2
8 Clamp, V-band 2
Aftercooler Assembly K38, K50, QSK38, and QSK50
10 Clamp, T-bolt 4
11 Hose, Plain 2
12 Gasket 4
13 Capscrew 8
14 Washer 16
15 Connection, Air 2
16 Clamp, T-bolt 4
17 Connection, Air 2
18 Hose, Plain 4
19 Washer, Plain 8
20 Capscrew 8
21 Gasket 16
22 Pipe, Plug 2
23 Washer, Plain 64
24 Capscrew 32
25 Capscrew 32
26 Washer, Spring 64
27 Capscrew 50
29 Spacer 50
30 Capscrew 8
31 Gasket, Air Connection 4
35 Seal, Rectangular Strip 4
Aftercooler Assembly (010-002)
Preparatory Steps
MAI
WARNING
WARNING
WARNING
cable last.
13.
Drain the coolant. Refer to Procedure 008-018
K38, K50, QSK38, and QSK50 Aftercooler Assembly
WARNING
WARNING
Remove the aftercooler heat shields. Refer to
Procedure 010-129 (Aftercooler Heat Shield) in
Section 10 (marine only).
Remove the coolant bypass tube. Refer to Procedure
008-005 (Coolant Bypass Tube) in Section 8 (right
bank only).
Remove the exhaust gas temperature converters (if
equipped). Refer to Procedure 019-450 (Exhaust
Gas Temperature Sensor Convertor) in Section 19 in
the Troubleshooting and Repair Manual QSK38,
QSK50 and QSK60 Modular Common Rail System,
Bulletin 4021533.
Remove the intake manifold air. Refer to Procedure
019-059 (Intake Manifold Air Temperature Sensor) in
Section 19 in the Troubleshooting and Repair
Manual QSK38, QSK50 and QSK60 Modular
Common Rail System, Bulletin 4021533.
Remove the intake manifold air pressure sensor.
Refer to Procedure 019-061 (Intake Manifold
Pressure Sensor) in Section 19 in the
Troubleshooting and Repair Manual QSK38, QSK 50
and QSK60 Modular Common Rail System, Bulletin
4021533.
Remove
Remove the eight capscrews. Remove the two tubes (3).
Remove the rectangular ring seals (2).
Discard the seals.
Detach the AFC air tube (1) at the aftercooler.
NOTE: If the engine has a hose connection between the
turbocharger and aftercooler housing, remove the t-bolt
clamps and slide the hose back.
NOTE: If the turbocharger uses turbo retaining straps,
remove the turbocharger. Refer to Procedure 010-033
(Turbocharger) in Section 10.
NOTE: There are four air crossovers.
Remove the four capscrews. Pull the crossover (10) and
the tube (9) from the aftercooler.
Remove the gasket. Remove the tube from the crossover.
Remove the o-rings (7).
Remove the dust seal (8). If the dust seal is hard or soaked
with oil, discard the seal.
Remove the two capscrews (10). Remove the four
capscrews (7). Remove the water inlet connection
assembly (5).
Remove the two rectangular ring seals (4). Remove the
gasket (8).
Discard the gasket and seals.
WARNING
This assembly or component weighs greater than 23
NOTE: Older engines have eight support bracket to the
support leg capscrews (2)
Remove the 12 capscrews (2).
Remove the aftercooler assembly (3).
Outboard Aftercooling - Standard Cooling system
Old style plumbing with the hoses removed.
NOTE: Each of the four aftercoolers has a coolant inlet
and outlet tube. Only the tubes for the left bank front are
shown.
Remove both tubes from all four of the aftercoolers.
NOTE: The rocker lever housing end of the outlet tube for
the left bank rear aftercooler has a tube nut and a
rectangular seal instead of a hose and hose clamps.
Remove the capscrew for any support clamp (6).
Remove the inlet (11) and outlet (12) tubes. Remove the
hoses.
New Style Plumbing
NOTE: Each of the four aftercoolers has a coolant inlet
and outlet tube. Only the tubes for the left bank are shown
Remove both tubes from all four of the aftercoolers.
Remove the capscrews for any support clamp.
Loosen the tube nuts and seals (A). Discard the seals.
Loosen the hose clamps at the cylinder block connection
(C). Remove the inlet (8) and outlet (D) tubes. Remove the
hoses.
Type I - Crossovers with Turbo Retaining Straps
Remove the capscrews, the clamps (17) for the
turbocharger oil inlet hose and the retaining straps (16).
Remove the vee-band clamp (15). Pull the air crossover
(14) and tube (12) from the turbocharger. Remove the dust
seal (13), the tube (12) and the o-ring seals.
Remove the capscrews, the aftercooler-to-aftercooler
connection assembly and the gaskets.
Type II - Air Crossovers with Hose Connections
Loosen all of the hose clamps.
Remove the vee-band clamp (18). Pull the air crossover
(17) and the hose (16) from the turbocharger. Push the
hose (12) on the connection (13) as far as possible.
Remove the four capscrews. Remove the connection and
gasket. Remove the hose from the connection.
Discard the hoses and gasket.
WARNING
NOTE: If the aftercooler water tubes have not been
removed, remove them at this time
Remove all of the capscrews. Remove the aftercooler
assembly (40) and the gaskets. Remove the rectangular
seal sleeves (2).
Discard the seals and gaskets.
Outboard Aftercooler - LTA Cooling System
The following procedure should be used in both engine
banks.
Loosen capscrews on the water transfer connections to
create flexibility.
Remove the capscrews for any supporting clamp.
Remove the water transfer tubes.
Remove the capscrews on the water transfer connections
between the aftercooler cores.
Remove the water transfer connections.
Loosen all of the hose clamps.
Remove the vee-band clamp (1). Pull the air crossover (2)
and the hose (3) from the turbocharger. Push the hose (4)
on the connection (5) as far as possible.
Remove the four capscrews. Remove the connection and
gasket (6). Remove the hose from the connection.
Remove the four capscrews. Remove the flange (7) and
the gasket (8).
Discard the hoses and gaskets.
Loosen hose clamps (18).
WARNING
Remove all of the capscrews. Remove the aftercooler
assembly (2) and the gaskets.
Remove the rectangular seal sleeves (28).
Remove the hose clamps at the air crossover to
turbocharger hose connection and at the aftercooler cover
hose connections.
Remove the air crossover support capscrews. Slide the
hoses back from the air crossover and remove the air
crossover.
Remove the eight capscrews from the air transfer bellows.
Remove the bellows and discard the gaskets (marine
only).
Remove the hose clamps from the air connection tube at
the turbocharger connection tube and the aftercooler
cover. Slide the hoses onto the connection tube and
remove the tube (marine only).
Remove the hose clamps from the rubber tee coolant
connections.
Slide the air balance tube toward the adjacent aftercooler
housing.
WARNING
Remove a lower mounting capscrew at each end of the
aftercooler assembly and install guide pins long enough
to protrude from the housing.
Remove a cover mounting capscrew at each end of the
assembly and install lifting eyes.
Attach a sling to the lifting eyes and a suitable hoist.
Raise the hoist until tension is applied to the assembly.
Remove the remainder of the mounting capscrews.
Lift and move the assembly away from the cylinder head
and the adjacent aftercooler assembly. Be careful not to
damage the air balance tube and the rubber coolant
connections as the aftercooler assembly is removed.
Repeat the procedure for the remaining assemblies.
Disassemble
Remove the air tubes (1). Remove the o-rings (2). Discard
the o-rings.
Remove the dust seals (3). Check the dust seals for
excessive oil or hardness. Discard any dust seal that is
hard or soaked with oil.
Check for indications of gasket leaks.
NOTE: All K50 aftercoolers contain this connection.
Newer K38 aftercoolers contain a shorter connection.
Remove the four capscrews for each crossover
connection. Remove the connections (5) and gaskets (4).
Remove the water outlet connections (6). Remove the
rectangular ring or o-ring (7) from the connection. Discard
the o-ring.
Remove the four cover plates (4) and gaskets (5).
Remove the four air crossover connections (6), spacers
(7), and gaskets (8).
Remove both of the aftercooler covers (13) and gaskets
(14).
Remove the aftercooler elements (15) and the gaskets (14)
from the housing (16).
Standard System
NOTE: This procedure is performed while the intake
manifold (aftercooler housing) remains on the engine.
Remove the parts.
1. Capscrews, lock washers, and flat washers
2. Adapter connections
3. Gaskets
Remove the o-rings (6) from the inner adapters (4).
Remove the 21 capscrews and flat washers (5).
NOTE: Do not damage the gasket surfaces if it is
necessary to use a wedge to separate the parts.
Remove the aftercare cover (6). It will be necessary to
move the cover so that it will not hit the nipple on the
element.
Remove the gasket (7) from the intake manifold (8).
Remove the eight captive capscrews (9). Note that the
washers on the capscrews are spring-type washers.
Remove the element (10) from the intake manifold (8).
WARNING
Low Temperature Aftercooler (LTA) System
Remove the fourteen capscrews (27), washers (26), and
spacers (29).
Remove the aftercooler element from the housing.
Remove the rubber seal from the groove on the aftercooler
housing.
Inspect the seal. Discard if damaged.
Inspect the rectangular strip seal (3). Discard the seal if it
is ripped, cracked, or worn.
Remove the coolant connections from the aftercooler
cover and housing.
Discard the connection gasket.
Remove the aftercooler cover mounting capscrews, cover,
and gasket.
Discard the gasket, grommet seal, and o-ring seal.
Remove the aftercooler element and gasket.
Remove the aftercooler element and gasket.
Pressure Test
Plug one coolant connection with a hose and pipe plug.
Attach an air line with an air pressure regulator and gauge
to the other coolant connection.
Heating the tank of water to 50C [122F] will improve the
test conditions.
Place the aftercooler element into a tank of water and
apply regulated air pressure.
Test pressure 415 kPa [60 psi].
If leaks are detected, replace the element. Do not attempt
to repair the element.
WARNING
WARNING
WARNING
personal injury.
CAUTION
All solvent or steam must be drained from the
housing. Any liquid remaining in the housing can
enter the combustion chamber and damage the
engine.
Use solvent or steam.
Clean the exterior of the assembly. Flush the elements
through the bores of the water outlet connection at the top.
Clean all the bores and grooves for the o-rings. Clean all
gasket surfaces. Dry with compressed air.
Check the assembly for cracks or other damage. There
must be no cracks in the housing or cover.
Check the dust seals for excessive oil or hardness.
Discard any dust seal that is hard or soaked with oil.
If the parts are cracked or otherwise damaged, or there
are any indications of gasket leaks, the assembly must be
rebuilt.
NOTE: If the K50 aftercooler housing does not contain
cross bolts, or contains a rib in the center of the housing,
it is recommended that the housing be modified for the
cross bolts before it is installed again. Refer to Procedure
010-073 (Aftercooler Housing (Center Mount)) in Section
10.
WARNING
WARNING
Clean all gasket surfaces.
Use solvent or steam. Clean the parts.
Check the air passages for evidence of coolant leaks. If
there is any evidence of leaks, the assembly must be
rebuilt.
Check the parts for cracks or other damage.
Inspect the rectangular strip seal (3). Discard the seal if it
is ripped, cracked, or worn.
Assemble
Install the housing-to-element flange gasket (14). Be sure
the proper holes are aligned with the roll pin.
Install the cooler element (15).
Install a new cover-to-element flange gasket (14) and the
cover (13).
NOTE: Each cover contains 18 capscrews.
Install the flat washers, lock washers, and capscrews.
Repeat this step for the other side of the assembly.
Install the four air crossover connection gaskets (8), the
spacers (7), the gaskets (8), and the connection (6).
Install the new cover plate gaskets (5) and plates (4).
NOTE: The adapters must be installed so that the water
leakage hole is toward the bottom of the aftercooler
housing. This hole prevents any coolant leak from
entering the aftercooler housing at the water inlet or outlet
connections.
Install four new adapter connection gaskets (9) and
adapters (10) on the nipples for the element.
CAUTION
Make sure the correct seal is installed for the water
connection. If the wrong seal is installed, a leak will
result, leading to engine damage.
NOTE: This information applies to the water inlet and
outlet connections for the aftercooler.
If necessary, install a new rectangular seal ring or a new
o-ring on the water outlet connection. Look at the water
outlet connection.
Install the rectangular ring seal (17) with the connection
(18) that does not have the step at the end of the chamfer.
Install the o-ring (19) with the connection (20) that has a
step at the end of the chamfer.
NOTE: The rectangular seal ring is the same part number
as the seal on the water outlet tube. The o-ring is the same
part number as the seal (10) on the adapter connection
(8). The older connection (20) is not available for service.
Install both water outlet connection seals (7) and
connections (6). Install the lock washers and capscrews.
Install new air crossover connection gaskets (4) and
connections (5). Install the flat washers, lock washers, and
capscrews.
NOTE: Lubricate only the o-ring seals that are to be
installed immediately in the bore of the housing or
connection. This will prevent the exposed o-ring from
expanding and collecting dirt.
Install two new o-rings (2) on each air tube.
Install the dust seals (3) on the air tubes (1).
Use vegetable oil. Lubricate the o-ring.
Install the air tube in the bore of the housing or connection.
Standard System
Install the element (10) in the manifold (8). Install the eight
capscrews (9) that contain the captive spring washers.
Install a new gasket (7) and cover (6). Install the 21 captive
capscrews and flat washers (5).
Install two new o-rings (4) in each adapter (2).
Use vegetable oil. Lubricate the o-rings.
Install new gaskets (3) and the adapters (2).
Install the four capscrews with flat washers and lock
washers (1).
Low Temperature Aftercooler (LTA)
The intake manifolds serve as the aftercooler housing.
The element is installed through the cast opening in the
WARNING
Install the foam seal into the groove in the aftercooler
housing.
NOTE: Applying a small amount of (RTV) sealant into the
groove aids in holding the foam seal in place. Do not allow
sealant on the visible portion of the foam seal.
The length of the seal protruding from each end is then
bent and installed into the groove provided to obtain a
positive seal with the element mounting flange. The
protrusion must be 3 to 6 mm [0.125 to 0.250 inch] outside
the housing at both sides. If required, cut the length to this
specification.
Apply a light film of vegetable oil to the foam seal at the
ends of the housing to reduce drag of the element and
prevent damage to the foam seal during element
installation.
There are two methods of sealing the aftercooler to
element joint:
Gasket/Sealant
Rubber Seal.
Gasket/Sealant Installation
NOTE: The gasket was replaced with liquid sealant.
Apply two separate, continuous beads of liquid sealant
Loctite 509 (also called Loctite LMD127) directly to the
aftercooler housing. Each sealant bead is to be 1.5 mm
[0.060 inch] in diameter. This sealant replaced the
conventional gasket.
The sealant is an anaerobic substance and will only cure
(set up) in the absence of air. The sealant will not begin
to cure until the aftercooler element is clamped into the
housing.
The sealant beads must be continuous strips without
gaps, to prevent air leakage. Do not apply an excessive
amount of sealant. Extra sealant does not result in a
stronger joint.
Install two guide pins in the housing for installing the
aftercooler element into the housing. The guide plugs
allow installation of the heavy element without disturbing
the sealant, if used.
Guide pins can be made by cutting the head off a 3/8 inch
capscrew.
Install the aftercooler element into the aftercooler housing.
Install the 63 mm [2.50 inch] capscrews and washers into
the locations shown.
Tighten the capscrews just enough to hold the element in
place.
Remove the two guide pins.
Install the 171 mm [6.750 inch] capscrews and washers
into the locations as shown.
Tighten the capscrews just enough to hold the element in
place.
The two remaining holes will be used when the water
transfer connections are installed. Use the torque value
and sequence in this step.
The sealant cures to 80 percent strength 1 hour after the
aftercooler element capscrews are tightened. The sealant
is completely cured in 24 hours.
Once the engine is filled with coolant and the engine is
tested, a small amount of sealant will seep from the joint
during the first hour of engine operation. Remove this
excess sealant.
Rubber Seal Installation
Install the rubber seal into the groove on the aftercooler
housing. Make sure the seal is not twisted or damaged.
Install the aftercooler element into the housing. Make sure
not to dislocate either the foam seal or the rubber seal.
All aftercooler elements are identical and are inserted into
the housing with the water inlet and outlet just below the
air intake connection.
Install the washers (26) and spacers (29) on the fourteen
capscrews (27). Insert the capscrews into the holes
shown. The three capscrews (1) can only be installed in
the rear intake manifold assemblies at this time.
Capscrews will be inserted in the open positions either
during the installation of the aftercooler plumbing or the
intake manifold assembly.
Tighten all of the inserted capscrews just enough to hold
the aftercooler element in place.
Use the sequence shown. Tighten the capscrews.
WARNING
Check the four aftercooler element locating pins for proper
location.
Install the aftercooler element gasket.
Install the upper and lower grommet seals and o-ring seals
on the cooler connections.
Install the aftercooler element into the housing.
Apply a light coat of anti-seize lubricant, Part Number
3824759, to the aftercooler cover mounting capscrew
threads.
Install the aftercooler cover and mounting capscrews.
Tighten the capscrews in the sequence shown.
Lubricate the o-ring with Lubriplate 105, Part Number
3163087, multi-purpose lubricant
Install the connection gasket and the seal retainer.
Install the flange connector and the mounting capscrews.
Install
WARNING
NOTE: This procedure applies only to KTA38 and KTA50
engines with a center mount aftercooler. If a KT38 engine
is being serviced, omit this procedure and proceed to
install the air transfer housing. If an engine with outboard
aftercoolers is being serviced, proceed to Install the
Turbochargers.
NOTE: This procedure assumes that the aftercooler was
assembled previously. Refer to Procedure 010-999 (Air
Intake System - Overview) in Section F.
NOTE: Newer engines have three capscrews with lock
washers through the bracket to each support. Older
engines have two capscrews with lock washers.
Install the lock washers (1) and capscrews (2) in the holes
in the bracket. Put the aftercooler assembly (3) on the
supports and install the capscrews in the supports.
CAUTION
Newer engines have rectangular ring seals (4)
between the water inlet connections and the tubes on
the aftercooler elements. Older engines have o-rings.
Determine if seals are required. If the correct seals are
not installed, a leak could result leading to engine
damage.
NOTE: Assemble the aftercooler water inlet connection (5)
as shown. Refer to Procedure 010-999 (Air Intake System
- Overview) in Section F.
Install the seals (4) on the aftercooler element tubes.
Use vegetable oil. Lubricate the seals.
Install the water inlet connection (5). Push the connection
over the seals until the connection touches the aftercooler
housing. Install, but do not tighten, the four lock washers
(6) and capscrews (7).
Install the gasket (8), the lock washers (9), and the
capscrews (10).
Tighten the four capscrews (7).
If the turbocharger uses a hose connection, slide the hose
forward on the connection and tighten the t-bolt clamps.
NOTE: Installation of the air tube for the AFC (1) is not as
difficult if completed before the installation of the water
tubes.
NOTE: Two aftercooler water outlet tubes are required
Install two rectangular seal rings (2) on the water outlet
tube. Install the tube, lock washers, and capscrews.
NOTE: Engines that are equipped with a center mount
aftercooler have four air crossover assemblies. Use this
procedure to install the parts.
Install the two o-rings (7) and the dust seal (8) on the tube
(9) for the air crossover.
Use engine oil or Lubriplate 105, Part Number 3163087,
multi-purpose lubricant. Lubricate the seals.
Install the tube in the air connections on the aftercooler or
the air transfer housing.
Install the air crossover (10) on the tube. Push the
crossover on the tube as far as possible.
NOTE: The raised bead on the gasket must be toward
the air crossover.
Install the gasket (11) and the four lock washers, flat
Outboard Aftercooler - Standard Cooling Systems
WARNING
Install the long capscrews, lock washers, flat washers (1)
and the rectangular seal sleeves (2) in the row of capscrew
holes that is nearest to the top of the aftercooler assembly.
The sleeves prevent dirt and water from damaging the
threads of the capscrews.
NOTE: The use of guide pins installed in the row of
capscrew holes at the bottom of the cylinder head will aid
the assembly procedure.
NOTE: The raised bead of the gasket (3) must be toward
the cylinder head.
Install a gasket (3) on each cylinder head.
Install the aftercooler assembly (4), lock washers, flat
washers and the capscrews.
Use the following steps to tighten the capscrews in the
sequence shown.
Torque Value: Step1 25 Nm [ 20 ft-lb ]
Step2 45 Nm [ 35 ft-lb ]
Type 1- Air Crossovers with Retaining Straps
NOTE: The engine has two air jumper tube assemblies.
The assembly for the left bank is shown. The assembly for
the right bank must be installed so that the opening for
the air crossover is nearest to the rear of the engine.
Install the 2 gaskets (10) and the air jumper tube assembly
with the 12 flat washers, 12 lock washers and 12
capscrews.
Install two o-ring seals (11) on the tube (12) for the air
crossover. Install the dust seal (13) on the tube.
Install the tube in the turbocharger. Install the air
crossover (14) on the tube. Push the crossover on the tube
as far as possible.
NOTE: Check to be sure the crossover and turbocharger
compressor housing are aligned properly. If the gap
between the compressor housing and the crossover are
not the same as the top and the bottom, adjust the
turbocharger compressor housing alignment.
Install the vee-band clamp (15). Tighten the clamp.
Use a mallet. Tap around the clamp to be sure it is seated.
Tighten the clamp nut.
Continue tapping and tightening the clamp nut until it does
not turn at the specified torque after tapping.
NOTE: Some engines have clamps (17) for the
turbocharger oil inlet hose. The hose must be clamped
to the outside of the retainer plates (16).
Install the two retainer plates (16), the large flat washers,
lock washers and capscrews.
Type II - Air Crossover with Hoses
Install the hose (12) on the connection (13). Push the hose
on the connection as far as possible.
Insert the connection and the hose between the two
manifold assemblies. Fit the hose over the manifold cover.
Install the gasket (14), the four flat washers, lock washers
and capscrews.
Push the hose on the manifold cover until the ends of the
hose are the same distance from the gap between the
connection and the cover.
Install the two t-bolt clamps (15).
NOTE: Check to be sure the crossover and the
turbocharger compressor housing are aligned properly.
Put the crossover in position on the connection (13). Look
at the gap between the crossover and the turbocharger
housing. If the gap is not the same at the top and bottom,
the turbocharger compressor housing must be adjusted
Install the hose (16) on the crossover (17). Install the hose
and tube on the turbocharger housing.
Install the vee-band clamp (18).
Tighten the nut on the clamp.
Continue tapping and tightening the clamp nut until it does
not turn at the specified torque after tapping.
Install the two t-bolt clamps (19).
Old Style Plumbing with Hoses
Install the hoses and clamps on the inlet tube 4 and the
outlet tube (5). Connect the tubes to the aftercooler, the
fitting in the cylinder block and the fitting in the thermostat
support as shown.
Install the support clamp (6) on the tube with one of the
aftercooler mounting capscrews.
NOTE: Only one of the four connections is shown here.
New Style Plumbing
Install the hoses on the water transfer tube (C). Install the
o-rings and rectangular seal in the core connections.
Lubricate with engine oil or vegetable oil.
Tighten the connecting capscrews.
Install the clamps. Install inlet tubes (B).
WARNING
NOTE: The aftercooler housings for the left bank front and
right bank rear are the same. The left bank rear and the
right bank front are also the same.
NOTE: Guide pins installed in the row of capscrew holes
at the bottom of the cylinder heads will aid in installation.
NOTE: The raised bead other gasket (21) must be toward
the cylinder head.
Install the aftercooler assembly (2), conical washers (23)
and the capscrews (25).
Install the longer capscrews (25) and conical washers (23)
and the rectangular seal sleeves (28) in the row of
capscrews holes that are nearest the top of the aftercooler
assembly. The sleeves will prevent dirt and water from
damaging the threads of the capscrews.
Insert the shorter capscrews (24) and conical washers (23)
in the lower row of the assembly.
Tighten the capscrews in the sequence shown.
Install the hose (11) and the two t-bolt clamps (10) on the
two air intake connections (9).
Install gaskets (12) and connections on the intake
manifolds. Insert the long capscrews (13) and the short
capscrews (30) with washers (14). Tighten the capscrews
(13) and (30).
Tighten the t-bolt clamps.
Do not position the clamps over the hose beads. The
clamps must be positioned between the hose beads and
the end of the hose. A portion of the hose must extend
outside the clamp.
Tighten the t-bolt clamps.
Install the two clamps (16) and the hose (18) over the
connections (15 and 17). Do not tighten the clamps at this
time.
Install the gaskets (31), eight capscrews (20) and washers
(19). Tighten the capscrews.
Center the hose (18) over the gap between the
connections (15 and 17).
NOTE: Do not position the clamps over the hose beads.
The clamps must be positioned between the hose beads
and the end of the hose. A portion of the hose must
extend outside the clamp.
Position the clamps between the end of the hose and bead
on the connection. Tighten the clamps.
The crossover (7) and the turbocharger must align
properly. Put the crossover in position on the connection
(17). Check the gap between the crossover (7) and the
turbocharger housing. If the gap is not the same at the top
and bottom, rotate the crossover connection (17). If this
does not provide proper alignment, the turbocharger
compressor housing must be adjusted.
If the gap is not the same at the front and rear, rotate the
crossover to the position that provides the best possible
alignment.
Install the hose (6) on the crossover (7). Then install the
crossover on the turbocharger and the flanged
connection.
Install and tighten the vee-band clamp (8).
Tighten the nut on the clamp.
Tap and tighten the clamp nut until it will not turn at the
specified torque after tightening.
Install the two t-bolt clamps.
and the end of the hose. A portion of the hose must
extend outside the clamp
Position the hose (6) in the center of the connection and
tighten the clamps (5).
Install the tube clamps (7) and (8) on water transfer tubes
(5) and (6). Install capscrews (9).
Check dust seals (29).
Install the vent line on the upper water transfer connection
on each bank.
NOTE: The lines must route horizontal or inclined toward
the thermostat housing at all times. Any humps or sags
will prevent aftercooler core venting and cause core
damage. The length of the short hose between the two
manifolds is critical. It must not sag or put excessive
stress on the fittings
Install the vent lines from each bank to the cross
connection on the thermostat housing.
WARNING
Use a hoist and sling to lift the aftercooler assembly.
Install guide studs long enough to protrude from the
housing.
Install guide studs into the cylinder head in the lower row
of mounting holes.
Lubricate the air balance tube o-rings with Lubriplate
105, Part Number 3163087, multi-purpose lubricant
Install the air balance tube.
Install the rubber tee coolant connectors.
Install new intake manifold gaskets, with the raised bead
of the gasket toward the cylinder head. Use heavy grease
to hold in place.
Install the aftercooler assembly with a hoist.
Align the rubber water connectors and air balance tube
while the assembly is being installed over the guide studs.
Install the top row of the aftercooler mounting capscrews
(long capscrews). Do not tighten the capscrews.
Remove the guide studs and install the lower aftercooler
mounting capscrews.
Tighten the aftercooler mounting capscrews in the
sequence shown.
Torque Value:
Cast Iron Housing
Capscrews
65 Nm [ 48 ft-lb ]
Torque Value:
Aluminum
Housing
Capscrews
53 Nm [ 39 ft-lb ]
Install and tighten the coolant connection hose clamps.
Torque Value:
Coolant
Connection
Clamps
5 Nm [ 44 in-lb ]
Inspect the air crossover, turbocharger connection and
the hoses to make sure they are clean.
Install the air crossover, hoses and the hose clamps.
Install the air crossover support capscrews.
Position the hose clamps 10 mm [0.25 in] from the raised
bead on the turbocharger outlet and the air crossover.
Tighten the air crossover support capscrews.
Install the air connection bellows and two new gaskets
(marine only).
Install and tighten the eight mounting capscrews.
Install the air transfer tube between the aftercooler and the
turbocharger (marine only).
Install and tighten the hose clamps.
Finishing Steps
MAI
WARNING
WARNING
cable last.
(Battery Cables and Connections) in Section 13.
WARNING
WARNING
cable last.
Install the exhaust gas temperature converters (if
equipped). Refer to Procedure 019-450 (Exhaust
Gas Temperature Sensor Convertor) in Section 19 in
the Troubleshooting and Repair Manual QSK38,
QSK 50 and QSK60 Modular Common Rail System,
Bulletin 4021533.
Install the intake manifold air temperature sensor.
Refer to Procedure 019-059 (Intake Manifold Air
Temperature Sensor) in Section 19 in the
Troubleshooting and Repair Manual QSK38, QSK 50
and QSK60 Modular Common Rail System, Bulletin
4021533.
Install the intake manifold air pressure sensor. Refer
to Procedure 019-061 (Intake Manifold Pressure
Sensor) in Section 19 in the Troubleshooting and
Repair Manual QSK38, QSK 50 and QSK60 Modular
Install the coolant bypass tube. Refer to Procedure
008-005 (Coolant Bypass Tube) in Section 8 (right
bank only).
Install the aftercooler heat shields. Refer to
Procedure 010-129 (Aftercooler Heat Shield) in
Section 10 (marine only).
K38, K50, QSK38, and QSK50 Aftercooler Assembly (Center-Mount)
Aftercooler Assembly (Center-Mount)
(010-003)
Preparatory Steps
WARNING
not reused, dispose or in accordance with local
WARNING
Drain the coolant. Refer to Procedure 008-018.
Remove the coolant outlet pipes. Refer to Procedure
010-075.
Remove
Remove the eight capscrews. Remove the two tubes (3).
Remove the rectangular ring seals (2).
Discard the seals.
Detach the AFC air tube (1) at the aftercooler.
NOTE: If the engine has a hose connection between the
turbocharger and aftercooler housing, remove the t-bolt
clamps and slide the hose back.
NOTE: If the turbocharger uses turbo retaining straps,
remove the turbocharger. Refer to Procedure 010-033.
NOTE: There are four air crossovers.
Remove the four capscrews. Pull the crossover (10) and
the tube (9) from the aftercooler.
Remove the gasket. Remove the tube from the crossover.
Remove the o-rings (7).
Remove the dust seal (8). If the dust seal is hard or soaked
with oil, discard the seal.
Aftercooler Assembly (Center-Mount) K38, K50, QSK38, and QSK50
Remove the two capscrews (10). Remove the four
capscrews (7). Remove the water inlet connection
assembly (5).
Remove the two rectangular ring seals (4). Remove the
gasket (8).
Discard the gasket and seals.
WARNING
NOTE: Older engines have eight support bracket to the
support leg capscrews (2)
Remove the 12 capscrews (2).
Remove the aftercooler assembly (3).
Disassemble
Remove the air tubes (1). Remove the o-rings (2). Discard
the o-rings.
Remove the dust seals (3). Check the dust seals for
excessive oil or hardness. Discard any dust seal that is
hard or soaked with oil.
Check for indications of gasket leaks.
Remove the four capscrews for each crossover
connection. Remove the connections (5) and gaskets (4).
Remove the water outlet connections (6). Remove the
rectangular ring or o-ring (7) from the connection. Discard
the o-ring.
Remove the four cover plates (4) and gaskets (5).
Remove the four air crossover connections (6), spacers
(7), and gaskets (8).
(14).
Remove the aftercooler elements (15) and the gaskets (14)
Pressure Test
NOTE: Pressure test both aftercooler cores.
Use a hose plugged with a pipe plug. Plug one of the core
nipples as illustrated. Attach an air line and gauge to the
remaining nipple. Pressure test the core.
Apply air pressure. Check for leaks.
Air Pressure: 448 kPa [65 psi]
If the part leaks, it must be replaced.
WARNING
WARNING
WARNING
personal injury.
CAUTION
All solvent or steam must be drained from the
housing. Any liquid remaining in the housing can
enter the combustion chamber and damage the
engine.
Use solvent or steam.
Clean the exterior of the assembly. Flush the elements
through the bores of the water outlet connection at the top.
Clean all the bores and grooves for the o-rings. Clean all
gasket surfaces. Dry with compressed air.
Check the assembly for cracks or other damage. There
must be no cracks in the housing or cover.
If the parts are cracked or otherwise damaged, or there
are any indications of gasket leaks, the assembly must be
rebuilt.
cross bolts before it is installed again. Refer to Procedure
010-073.
Assemble
Install the housing-to-element flange gasket (14). Be sure
the proper holes are aligned with the roll pin.
Install the cooler element (15).
Install a new cover-to-element flange gasket (14) and the
cover (13).
Install the flat washers, lock washers, and capscrews.
Install the four air crossover connection gaskets (8), the
spacers (7), the gaskets (8), and the connection (6).
Install the new cover plate gaskets (5) and plates (4).
NOTE: The adapters must be installed so that the water
leakage hole is toward the bottom of the aftercooler
housing. This hole prevents any coolant leak from
entering the aftercooler housing at the water inlet or outlet
connections.
Install four new adapter connection gaskets (9) and
adapters (10) on the nipples for the element.
CAUTION
Be sure the correct seal is installed for the water
connection. If the wrong seal is installed, a leak will
result, leading to engine damage.
NOTE: This information applies to the water inlet and
outlet connections for the aftercooler.
If necessary, install a new rectangular seal ring or a new
o-ring on the water outlet connection. Look at the water
outlet connection.
Install the rectangular ring seal (17) with the connection
(18) that does not have the step at the end of the chamfer.
Install the o-ring (19) with the connection (20) that has a
step at the end of the chamfer.
NOTE: The rectangular seal ring is the same part number
as the seal on the water outlet tube. The o-ring is the same
part number as the seal (10) on the adapter connection
(8). The older connection (20) is not available for service.
Install both water outlet connection seals (7) and
connections (6). Install the lock washers and capscrews.
Install new air crossover connection gaskets (4) and
connections (5). Install the flat washers, lock washers, and
capscrews.
NOTE: Lubricate only the o-ring seals that are to be
installed immediately in the bore of the housing or
connection. This will prevent the exposed o-ring from
expanding and collecting dirt.
Install two new o-rings (2) on each air tube.
Install the dust seals (3) on the air tubes (1).
Install the air tube in the bore of the housing or connection.
Install
WARNING
NOTE: This procedure applies only to KTA38 and KTA50
engines with a center mount aftercooler. If a KT38 engine
is being serviced, omit this procedure and proceed to
install the air transfer housing. If an engine with outboard
aftercoolers is being serviced, proceed to Install the
Turbochargers.
NOTE: This procedure assumes that the aftercooler was
assembled previously. If the aftercooler is not assembled,
refer to Procedure 010-999.
NOTE: Newer engines have three capscrews with lock
washers through the bracket to each support. Older
engines have two capscrews with lock washers.
Install the lock washers (1) and capscrews (2) in the holes
in the bracket. Put the aftercooler assembly (3) on the
supports and install the capscrews in the supports.
CAUTION
Newer engines have rectangular ring seals (4)
between the water inlet connections and the tubes on
the aftercooler elements. Older engines have o-rings.
Determine if seals are required. If the correct seals are
not installed, a leak could result leading to engine
damage.
NOTE: If the aftercooler water inlet connection (5) is not
assembled as shown, refer to Procedure 010-999.
Install the seals (4) on the aftercooler element tubes.
Use vegetable oil. Lubricate the seals.
Install the water inlet connection (5). Push the connection
over the seals until the connection touches the aftercooler
housing. Install, but do not tighten, the four lock washers
(6) and capscrews (7).
Install the gasket (8), the lock washers (9), and the
capscrews (10).
Tighten the four capscrews (7).
If the turbocharger uses a hose connection, slide the hose
forward on the connection and tighten the t-bolt clamps.
NOTE: Installation of the air tube for the AFC (1) is not as
difficult if completed before the installation of the water
tubes.
NOTE: Two aftercooler water outlet tubes are required
Install two rectangular seal rings (2) on the water outlet
tube Install the tube, lock washers, and capscrews.
NOTE: Engines that are equipped with a center mount
aftercooler have four air crossover assemblies. Use this
procedure to install the parts.
Install the two o-rings (7) and the dust seal (8) on the tube
(9) for the air crossover.
Install the tube in the air connections on the aftercooler or
the air transfer housing.
Install the air crossover (10) on the tube. Push the
crossover on the tube as far as possible.
NOTE: The raised bead on the gasket must be toward
the air crossover.
Install the gasket (11) and the four lock washers, flat
K38, K50, QSK38, and QSK50 Aftercooler Assembly (Outboard)
Finishing Steps
WARNING
not reused, dispose or in accordance with local
Install the aftercooler water outlet tubes. Refer to
Procedure 010-075.
Aftercooler Assembly (Outboard)
(010-004)
Remove
Remove the aftercooler coolant plumbing. .
Remove the capscrews and spring washers.
Remove the aftercooler element (3), gasket (4), and
rectangular strip seal (35).
Discard the gasket.
Inspect for Reuse
Clean and check the element for reuse. Refer to
Procedure 010-001.
Aftercooler Assembly (Outboard) K38, K50, QSK38, and QSK50
Visually inspect the rectangular strip seal (35). Discard the
seal if it is ripped, cracked or worn.
Install
Install the seal (35) into the groove in the air intake
manifold housing (2). If a new seal has been installed,
check the length that is protruding outside the housing.
This protrusion must be flush to 3 mm [1/8 inch] in length
outside the housing at both sides. If required, clip the seal
to this length. Install the gasket (4) and the aftercooler core
(3).
NOTE: All aftercooler cores are identical and are inserted
into the housing with the water inlet and outlet just below
the air intake connection.
Install the 3 inch capscrews (27) and spring washers (26)
into the holes shown.
Capscrews at position 1 can only be placed in the rear
intake manifold assemblies at this time.
Tighten the inserted capscrews just enough to hold the
aftercooler element in place.
Install the 6.75 inch capscrews (29) and spring washers
the aftercooler core in place.
K38, K50, QSK38, and QSK50 Aftercooler Assembly (Outboard)
Install the aftercooler plumbing. Refer to Procedure
010-001.
Aftercooler Element K38, K50, QSK38, and QSK50
Aftercooler Element (010-008)
Preparatory Steps
WARNING
WARNING
WARNING
cable last.
This procedure describes several arrangements.
Outboard Aftercooler - Standard Cooling System
13.
Remove air coolant plumbing. Refer to Procedure
010-002 (After Cooler Assembly) in Section 10.
Remove
Standard
Remove the 21 capscrews and flat washers (5).
NOTE: Do not damage the gasket surfaces if it is
necessary to use a wedge to separate the parts.
Remove the aftercooler cover (6). It will be necessary to
move the cover so that is will not hit the nipple on the core.
Remove the gasket (7) from the intake manifold (8).
K38, K50, QSK38, and QSK50 Aftercooler Element
WARNING
WARNING
CAUTION
Use a solvent that will not harm copper.
Remove the eight captive capscrews (9). Notice that the
washers on the capscrews are spring-type washers.
Remove the core (10) from the intake manifold (8).
Clean the element.
Use solvent or steam. Clean the remaining parts.
Check for damage.
LTA
Remove the capscrews and spring washers.
Remove the aftercooler element (3), gasket (4) and
rectangular strip seal (35).
Discard the gasket.
Center-Mount
WARNING
WARNING
(14).
Remove the aftercooler cores (15) and the gaskets (14)
Clean all o-ring bores and grooves. Clean all gasket
surfaces.
Use solvent and steam. Clean the parts.
Check the parts for cracks or damage.
cross bolts before it is installed again.
Refer to Procedure 010-002 (Aftercooler Assembly) in
Section 10.
Inspect for Reuse
Standard
Clean and check element for reuse. Refer to Procedure
010-002 (Aftercooler Assembly) in Section 10.
LTA
Clean and check the element for reuse.
K38, K50, QSK38, and QSK50 Aftercooler Element
Inspect the rectangular strip seal (35). Discard the seal if
it is ripped, cracked or worn.
Center-Mount
Clean and check the element for reuse. Refer to
Procedure 010-002 (Aftercooler Assembly) in Section 10.
Install
Standard
Install the core (10) in the manifold (8). Install the eight
capscrews (9) that contain the captive spring washers.
Install a new gasket (7) and cover (6). Install the 21 captive
capscrews and flat washers (5).
LTA
Install the seal (35) into the groove in the air intake
manifold housing (2). If a new seal has been installed,
check the length that is protruding outside the housing.
This protrusion must be flush to 3 mm [1/8 inch] in length
outside the housing at both sides. If required, clip the seal
to this length. Install the gasket (4) and the aftercooler core
(3).
NOTE: All aftercooler cores are identical and are inserted
into the housing with the water inlet and outlet just below
the air intake connection.
Install the 3 inch capscrews (27) and spring washers (26)
Capscrews at position 1 can only be placed in the rear
intake manifold assemblies at this time.
Tighten the inserted capscrews just enough to hold the
aftercooler element in place.
Install the 6.75 inch capscrews (29) and spring washers
the aftercooler core in place.
K38, K50, QSK38, and QSK50 Air Cleaner Assembly (Engine-Mounted)
Center-Mount
Install the housing-to-core flange gasket (14). Be sure the
proper holes are aligned with the roll pin.
Install the cooler core (15). Install a new cover-to-core
flange gasket (14) and the cover (13).
Install the flat washers, lock washers and capscrews.
Finishing Steps
WARNING
WARNING
cable last.
Install air and coolant plumbing. Refer to Procedure
010-002.
Air Cleaner Assembly (Engine-
Mounted) (010-013)
Remove
Remove the air restriction indicator and fitting.
Air Cleaner Assembly (Engine-Mounted) K38, K50, QSK38, and QSK50
Remove the air cleaner air inlet tube support brackets and
mounting hardware.
Loosen the T-bolt clamps at the air cleaner connection.
Slide the air cleaner inlet hose and T-bolt clamps onto the
air inlet tube. This will allow access clearance to the air
cleaner.
WARNING
Remove the air filter assembly from the air cleaner
bracket.
Remove the air cleaner strap retaining bolts and nuts.
WARNING
Slide the air cleaner out of the retaining straps.
Remove the right bank air cleaner support bracket from
the rear of the engine.
Remove the left bank air cleaner support bracket from the
rear of the engine.
Air Cleaner Assembly (Engine-Mounted) K38, K50, QSK38, and QSK50
WARNING
Remove the left bank air cleaner support bracket from the
rear of the engine.
CAUTION
The air cleaner elements can not be pressure washed
or submerged in water.
Check all hose connections and T-bolt clamps for damage
or failures.
Check the air cleaner canister and the tubes for any
obstructions or damages.
Inspect the restriction indicator for any damage.
Clean the inside of the air filter canister before installing a
new element.
Install
WARNING
Install the main air cleaner support bracket to the rear of
the engine, use a bolt and washer.
Install the vibration isolators to the air cleaner strap.
Tighten the nuts.
Install the support brackets on the engine.
Install the lock washers and capscrews in the support
brackets.
Torque Value: 41 to 47 Nm [ 30 to 35 ft-lb ]
Install the air cleaner straps around the air cleaner and
position for correct orientation.
Install retaining bolts and nuts at the end of the air cleaner
straps.
CAUTION
Inspect the internal area of air filters and each
connecting air supply component for damage or
debris. The air supply path must be smooth and free
of debris. Turbocharger failure and major engine
damage could occur.
Position the air inlet tubing, elbows, hoses, and T-bolt
clamps before tightening the T-bolt clamps.
Tighten the T-bolt clamps.
Install all remaining air cleaner air inlet tube support
brackets and mounting hardware.
Air Cleaner Element K38, K50, QSK38, and QSK50
Install the air restriction indicator and fitting.
Hand tighten only.
Air Cleaner Element (010-014)
Pressure Test
WARNING
personal injury.
Standard System
Use a hose plugged with a pipe plug. Plug one of the water
nipples as illustrated. Attached an air line and a gauge to
the other nipple. Pressure check the element.
Apply air pressure. Check for leaks.
Air Pressure 448 kPa [ 65 psi ]
If the part leaks, it must be replaced.
LTA
Low Temperature Aftercooled system
Use a hose plugged with a pipe plug. Plug one of the
element nipples. Attach an air line equipped with a gauge
and a regulator valve to the remaining nipple.
Submerge the core in a tank of water heated to 50 C
[120 F]. Do not apply air pressure yet. Check the tank for
bubbles. Note the location and rate of bubbles. These
bubbles are the air entrapped behind the silicone bead.
K38, K50, QSK38, and QSK50 Air Connection Pipe (Turbocharger to Turbocharger)
Leave the element submerged for five minutes to allow the
temperature of the element to stabilize. Apply air
pressure. Check for leaks. The element leaks when
bubbles form faster or from a new location while the tank
is pressurized.
Air Pressure 448 kPa [ 65 psi ]
Replace the element if leaks are discovered.
NOTE: A failed aftercooler element will often be coated on
the outside with coolant deposits.
Air Connection Pipe (Turbocharger to
Turbocharger) (010-018)
Clean
1. T-bolt clamps
2. Hose
3. O-ring seal
4. O-ring seal
5. Dust seal
6. Connection
WARNING
WARNING
personal injury.
Inspect for Reuse
Check the dust seal for excessive oil or hardness. Discard
any dust seal that is hard or soaked with oil.
Check the hoses for tears or separation. Discard the part
if it is damaged.
Check the pipe for damage, cracks, and fretting near the
o-ring seal groove. Replace the part if it is damaged.
Air Crossover (Center-Mount Aftercooler) K38, K50, QSK38, and QSK50
Air Crossover (Center-Mount
Aftercooler) (010-020)
Preparatory Steps
WARNING
Steam clean the area around the air crossover.
Remove
Remove the mounting flange capscrews and discard the
gasket or remove the flange clamp and retaining straps.
Remove the air crossover seals and tubes.
WARNING
WARNING
for use.
WARNING
Wear goggles and protective clothing to reduce the
possibility of personal injury. Wear appropriate eye
and face protection when using compressed air.
Flying debris and dirt can cause personal injury.
Use solvent or steam. Clean the parts. Be sure all gasket
material is removed. Use compressed air to dry the parts.
K38, K50, QSK38, and QSK50 Air Leaks, Air Intake and Exhaust Systems
Remove the o-rings (1). Discard the o-rings.
Remove the dust seals (2).
Check the bore of the air crossover. Check the o-ring
grooves of the tube.
Install
CAUTION
Lubricate only the o-ring that will be installed
immediately in the bore. Do not lubricate the other o-
ring until the part is to be installed on the engine.
Use vegetable oil. Lubricate the new o-rings.
Install the o-rings, tubes, and dust seals.
Tighten the mounting capscrews or clamp.
Finishing Steps
Air Leaks, Air Intake and Exhaust
Systems (010-024)
Inspect for Reuse
CAUTION
The engine air intake must be filtered to prevent dirt
and debris from entering the engine. If intake air
piping is damaged or loose, unfiltered air can enter
the engine and cause premature wear.
Inspect the system for damaged or loose intake piping.
Replace damaged pipes.
Tighten loose clamps.
Air Leaks, Air Intake and Exhaust Systems K38, K50, QSK38, and QSK50
Stall speed is not full power.
Operate the engine at rated rpm and load.
Listen for a high-pitched noise from the turbocharger.
This type of noise can be caused by an air leak from the
following:
Turbocharger-to-aftercooler air supply hose leak
Air crossover-to- aftercooler connection leak
Air crossover-to-intercooler connection leak
Turbocharger-to-exhaust manifold gasket leak
Turbine housing-to-bearing housing sealing surface
leak
Compressor housing-to-bearing housing sealing
surface leak.
If a turbocharger-to-aftercooler air supply hose leak is
found, inspect the hose for damage.
Replace damaged hose. Refer to Procedure 010-008
(Aftercooler Element) in Section 10.
If a air crossover-to-aftercooler connection leak is found,
replace the air crossover gasket.
If a air crossover-to-intercooler connection leak is found,
inspect for damaged hoses or loose hose clamps.
Replace damaged hoses.
Tighten loose clamps.
K38, K50, QSK38, and QSK50 Air Intake Restriction
If a turbocharger-to-exhaust manifold gasket leak is found,
replace the turbocharger base gasket.
If a turbine housing-to-bearing housing sealing surface
leak is found, tighten any loose capscrews.
If an air leak is still present, replace the turbocharger.
If a compressor housing-to-bearing housing sealing
surface leak is found, tighten the V-band clamps.
If an air leak is still present, replace the turbocharger.
Air Intake Restriction (010-031)
Measure
Install a vacuum gauge or water manometer, Part Number
3164875 or equivalent, in the intake air piping between the
turbocharger and the air filter. The gauge must have a
capacity of 1270 mm [50 in-HO].
Air Intake Restriction K38, K50, QSK38, and QSK50
NOTE: The gauge adapter (or fitting) must be installed at
a 90 degree angle to the air flow in a straight section of
pipe. The adapter location must be at least one pipe
diameter before the turbocharger.
The adapter must not extend through the wall of the air
intake tubing.
If the adapter must be located in a curve section of tubing,
locate it on the flat side of the curve, not in the radius.
Operate the engine at full throttle and rated rpm with
maximum load.
Record the reading of the gauge or manometer.
Vacuum Gauge or Water Manometer Restrictions
mm H
2
O in H
2
O
635 MAX 25
If restrictions exceeds specifications, do the following:
Replace or clean the air filter element. See the equipment
Inspect the intake air piping for damage. See the
equipment manufacturer's instructions.
NOTE: If no damage is visible, check the size of the intake
air piping. See the Installation recommendations.
K38, K50, QSK38, and QSK50 Turbocharger
Remove the test equipment.
Turbocharger (010-033)
General Information
All K38 and K50 engines are turbocharged. All turbochargers on K38 and K50 engines are oil cooled and lubricated.
The engine can have two or four turbochargers.
If the engine has four turbochargers, the two that are mounted on the exhaust manifold are the high pressure
turbochargers, and the two that are mounted on the support brackets are the low pressure turbochargers.
The correct turbocharger assembly must be installed. Many turbochargers appear the same physically, but contain
different internal parts. If the wrong turbocharger assembly is installed, the performance of the engine will be less
than specification, or the engine will be damaged due to excessive pressure and temperature in the cylinders.
K38 and K50 engines can contain turbochargers that are manufactured by Holset, Brown Boveri, or AiResearch.
In some cases turbochargers from two different vendors are on the same engine. One of the dataplates that is attached
to the turbocharger identifies the vendor, the turbocharger model, and the Cummins part number. Cummins Inc.
identifies the turbocharger by the part number, not the model nomenclature.
This manual does not contain information to rebuild the turbocharger. See the following turbocharger rebuild manuals:
Manufacturer Bulletin Model Number and Description
Holset 3810243 Model HC5, HC5A, HX80 and HX85
Turbocharger Shop Manual
Holset 3810386 Model HT100 Turbocharger Shop
Manual
Brown Boveri 3810325 Model RR-151-12, Brown Boveri
Turbocharger Shop Manual
Brown Boveri 3810325 Model RR-153, Brown Boveri Exhaust
Gas Turbocharger Shop Manual
AiResearch 3379091 Model T-18A, Turbocharger Rebuild
Manual
Two oil supply hoses are installed on K38 and K50 engines. The length of the hose for KT38, KTA38, and KTA50
engines is 1295 mm [51 in]. The length of the hose for KTTA38 and KTTA5O engines is 1092 mm [43 in].
The turbocharger oil drain assembly for the K38 is shorter on engines with dry type exhaust manifolds than on engines
with wet type exhaust manifolds. The turbocharger oil drain assembly for the K50 is the same as that installed on the
K38 with a wet type exhaust manifold.
The method for connecting the turbocharger oil drain to the cylinder block was changed. Engines with an ESN of
33106693 and greater have a flange and an o-ring seal type connection that is secured with a capscrew. Engines with
an ESN of 33106692 and lower have a 90 degree fitting with pipe threads.
A revised turbocharger compressor wheel was released for KTA50-G engines in September, 1985, ESN 33110070.
Turbochargers with a hose nipple on the compressor discharge and a hose type air crossover were released for use
in production on the KTA38 engines in September 1986, ESN 33111500.
Turbocharger K38, K50, QSK38, and QSK50
A chamfer was added to the diffuser plate on HC5A turbochargers to allow oil drain back to the sump in February,
1987, ESN 33111870.
A revised profile, turbocharger mounting gasket was released in August, 1987, ESN 33112713.
A turbocharger oil drain hose that is manufactured of flexible hose is available for engines built previously with a one
or two piece steel tube for the oil drain hose. The two piece steel tube that is connected by a hump hose is available
for service on engines that have AiResearch turbochargers only.
The KTTA50 low pressure turbocharger oil drain hose and drain location was changed in 1988, to provide a better
downhill return to the cylinder block. The revised oil drain hose routing also requires a revised turbocharger support,
which is modified to provide clearance for the new oil drain hose and a different clamp to retain the oil drain hose.
The revised hose drains the oil to drillings on the top deck at the front of the right bank and the left of the rear bank
of the cylinder block. The holes used are partially covered by the turbocharger support, this support requires
modification or replacement.
The mounting capscrew for the flange and o-ring seal type turbocharger drain hose connection was changed from
[0.250 inch -20 UNC] to [0.375 inch -16 UNC]. The cylinder block with the smaller holes require a spacer, Part Number
3177195, between the connection flange and the cylinder block at the left bank rear location. If the spacer is not
installed, an oil leak will result because the o-ring seal will not be in the bore correctly.
The flange on the turbocharger oil drain hose that fits to the turbocharger is different for Holset and AiResearch
turbochargers. The oil drain hose flange is different for the Brown Boveri type turbocharger. If the model of
turbocharger is changed, the oil drain hose must be changed.
A K50 turbine housing with a thickened flange between the capscrew holes to reduce flange distortion was released
in February 1988, ESN 33114833. This is for the K50 pulse exhaust manifolds only.
Longer studs, nuts and spacers were released for the K50 pulse exhaust manifold in May, 1989, ESN 33115948.
The K50 turbocharger mounting flange was completely thickened to improve gasket reliability, the spacer is no longer
required for K50 pulse exhaust manifold engines produced in February, 1990, ESN 33117281.
The K50 pulse exhaust manifold received a boss to allow use of capscrews in place of studs on engines produced
from February, 1990, ESN 33117392.
A steel oil supply fitting replaced the brass fitting to prevent torque loss/loosening on engines produced from
September 1990, ESN 33118322.
The Holset HT100 low pressure turbocharger replaced the Brown Boveri RR151 turbocharger for C1800B and K2000
engines in January 1991, ESN 33119163.
NOTE: The HT100 turbocharger can not be used to replace the Brown Boveri Model RR153 that is used on the
KTTA50-C1800A engines.
The Holset HX80 water-cooled turbocharger design was revised in 1997, to allow for the use of GAS fittings on all
coolant passage openings in the casting. O-ring seal fittings are less prone to leakage, and are easier to remove and
install. The diffuser plate was also changed to a sunk wheel design.
Preparatory Steps
MAI
WARNING
cable last.
WARNING
WARNING
WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
013-009.
Turn the air off to the air starter (if equipped) and tag
the valve closed. Refer to Procedure 012-022
Drain the cooling system to a point below the
turbochargers. Refer to Procedure 008-018.
Remove the coolant supply and return lines. Refer to
Procedure 010-041.
WARNING
cable last.
WARNING
WARNING
WARNING
013-009.
Turn the air off to the air starter (if equipped) and tag
the valve closed. Refer to Procedure 012-022
Drain the cooling system to a point below the
turbochargers. Refer to Procedure 008-018.
Remove the coolant supply and return lines. Refer to
Procedure 010-041.
Remove the oil supply lines. Refer to Procedure
010-046.
Remove the oil drain lines. Refer to Procedure
010-045.
Remove
NOTE: The turbochargers, mounting hardware, and
connections are not the same for all models of K38 and
K50 engines. Because the parts are different, procedures
are given for removal of the following turbochargers.
KT38, KTA38, and KTA50 with Center Mount
Aftercooler
KTTA38 Low Pressure
KTTA50 Low Pressure
K2000E Low Pressure
KTTA38, KTTA50, K1500E, K1800E and K2000E
High Pressure, and KT38, KTA38, and KTA50 with
Outboard Aftercoolers
NOTE: The oil inlet and drain hose routing and clamps can
be different than shown, depending on the age of the
engine.
KT38, KTA38, and KTA50 with Center Mount Aftercooler
NOTE: The illustrations show a KTA38. The KTA50 has a
longer connection between the turbocharger and the
aftercooler.
Older engines can have a spacer for the capscrew (23).
Keep the spacer for future assembly.
Detach the oil drain hose from the cylinder block. Remove
the o-ring seal (21).
Discard the seal.
Detach the oil drain hose from the turbocharger. Remove
the gasket (17).
Discard the gasket.
Check the hose (18) for damage. Discard the part if it is
damaged.
Detach the oil inlet hose (16). Removal of the fitting (15)
and the o-ring seal (14) is not required unless they are
damaged.
Remove any support clamps from the hose.
Remove the hose. Check the hose for damage. Discard
the part if it is damaged.
Newer engines have a hose and clamps between the
turbochargers and air transfer housings.
The clamps are special high strength parts.
Loosen the hose clamps (2).
Older engines have retaining straps.
Remove the capscrews and the retaining straps (10).
Check the straps for damage. Discard the part if it is
damaged.
WARNING
Remove the four capscrews (8) and nuts (9).
Remove the turbocharger and gasket.
Discard the gasket.
On newer engines, remove the clamps and the hose.
Discard the hose.
Check the clamps for damage. Discard the part if it is
damaged.
On older engines, remove the tube (5). Remove the o-ring
seals (4).
Discard the seals.
Remove the dust seal (3).
If the dust seal is hard or soaked with oil, discard the part.
KTTA38 Low Pressure:
Remove the oil drain hose (30). Remove the gasket (29)
and the o-ring seal (33).
Discard the gasket and seal.
damaged.
Detach the oil inlet hose (16). The removal of the fitting
(15) and the o-ring seal (14) is not required unless
damaged.
Remove any support clamps from the hose. Remove the
hose.
damaged.
WARNING
Remove the four capscrews (27) and the nuts (28).
Remove the turbocharger and the gasket.
Discard the gasket.
Loosen the hose clamps (24). Remove the clamps and the
hose (23) from the high pressure turbocharger air
connection.
Remove the air connection (21) from the high pressure
turbocharger. Remove the o-ring seals (19).
Discard the seals.
Remove the dust seal (22). If the dust seal is hard or
soaked in oil, discard the part.
Remove the four capscrews (12) and nuts (18). The heavy
washers (13) and capscrews are special heat resistant
parts.
Remove the exhaust connection (11) and the exhaust
outlet pipe (10).
Remove the vee-band clamp (8) and the exhaust outlet
connection (9).
Remove the six capscrews (7). The heavy flat washers (5)
are special. Remove the support plate (4).
Remove the socket head capscrew (3). Remove the
turbocharger support legs (1).
KTTA50 Low Pressure
The Brown Boveri, Model RR151, turbochargers contain
metric fasteners for the oil connection plates.
Remove the oil drain hose (48).
Remove the gasket (47) and o-ring seal (51).
damaged.
Some Brown Boveri turbochargers do not contain the
adapter plates for the oil inlet.
Detach the oil inlet hose. The adapter plates (44) and
fittings do not require removal.
Remove any support clamps. Remove the hose.
damaged.
Remove the four capscrews (40) and nuts (42). Remove
the gasket.
Discard the gasket.
Remove the two capscrews (35) that hold the exhaust side
of the turbocharger to the support bracket.
Remove the two capscrews (31) and nuts (34) that hold the
intake support bracket to the turbocharger support
bracket.
WARNING
Remove the low pressure turbocharger (16).
Loosen the hose clamps (12). Pull the intake connection
pipe (15) from the high pressure turbocharger. Remove
and discard the o-ring seals (13) and the hose (11).
Remove the dust seal.
If the dust seal is hard or soaked with oil, discard the part.
Remove the exhaust connection (11) and outlet pipe (10).
Remove the vee-band clamp (8) and the exhaust outlet
connection (9).
Remove the six capscrews (7). Remove the turbocharger
support bracket (4).
Remove the socket head capscrews (3). Remove the
turbocharger bracket support legs (1).
K2000E Low Pressure
Remove the oil drain hose (60). Remove the gasket (59)
and o-ring seal (63).
damaged.
Detach the oil inlet hose. Removal of the fitting, plate, (56)
and gasket (55) is not required.
Remove any support clamps from the hose. Remove the
hose.
damaged.
Remove the heat shield (blanket) from the interstage air
hose.
Loosen the two t-bolt clamps (45) on the air intake pipe
(47) and the compressor inlet.
Remove the four capscrews (49) and nuts (52) that hold
the air intake pipe (47) to the turbocharger compressor
outlet.
Remove the air intake pipe (47).
Check the pipe for damage. Discard the part if it is
damaged.
Loosen the vee-band clamp (8).
the two exhaust connections (9 and 11).
the exhaust connection to the turbine housing.
Remove the exhaust connection.
bracket (32) to the connection (26).
Remove the two capscrews (43) and the nuts (34) that hold
the bracket (32) to the support bracket (4).
WARNING
turbocharger exhaust outlet connection to the bracket.
Remove the turbocharger.
KTTA38, KTTA50, K1500E, K1800E and K2000E High
Pressure, and KT38, KTA38, and KTA50 with Outboard
Aftercoolers
If the engine being serviced is a KT38, KTA38, or KTA50,
write a note to detail the direction of the turbocharger
exhaust outlet and mark the exhaust manifolds for
location. This will aid the assembly process as the exhaust
can be either front out or rear out.
Detach the oil drain hose from the cylinder block. Remove
the o-ring seal (9).
Discard the o-ring seal.
damaged.
Detach the oil drain hose from the turbocharger. Remove
any support clamps and the hose. Remove the gasket (5).
Discard the gasket.
damaged.
Removal of the fitting (15) and the o-ring (14) is not
required.
Detach the oil inlet hose. Remove any support clamps.
Remove the hose.
damaged.
WARNING
Remove the four capscrews (3) and the nuts (4). Remove
the turbocharger and gasket.
Discard the gasket.
Remove the low pressure turbocharger air intake and
bracket.
Remove the low pressure turbocharger exhaust adapter
and bracket.
Remove the eight nuts, plain washers, nuts, capscrews
and p-clips from the air transfer connections.
Remove the air transfer connections and discard the
gaskets.
NOTE: Note the orientation of the capscrews and nuts in
the transfer tube prior to removal. The capscrews must be
installed in the same orientation during installation.
Remove the eight nuts, plain washers, nuts, capscrews
and remove the air transfer piping. Discard the gaskets.
WARNING
Remove the low pressure turbochargers.
Loosen and remove the clamps and hoses connecting the
turbochargers to the intake manifold.
Remove the clamps from the high pressure turbocharger
and air transfer connection.
Remove the air transfer from the high pressure
turbocharger.
Remove the four capscrews, nuts and washers and
remove the exhaust outlet connection from the high
pressure turbocharger.
Remove the exhaust outlet clamp and outlet connection
from the turbocharger.
Remove the four mounting capscrews, nuts and washers
from each high pressure turbocharger.
WARNING
Remove the mounting capscrews and lock washers.
Remove the turbocharger and gasket.
Discard the gasket.
Clean
CAUTION
Tape or plug all openings to prevent solvent or steam
from entering the oil cavities in the turbocharger.
This procedure applies to all models of turbocharger on
K38 and K50 engines. See General Information at the
beginning of this section.
WARNING
WARNING
Use solvent or steam. Clean the exterior of the
turbocharger.
Inspect for Reuse
Inspect the turbine and compressor wheels for fretting and
broken vanes.
Holset, model HC5, HC5A, HX80 or HX85
Measure the turbocharger shaft end clearance with a dial
depth gauge, Part Number ST-537.
Holset HC5, HC5A, HX80 or HX85 End Clearance
mm in
0.05 MIN 0.002
0.13 MAX 0.005
If the end clearance exceeds the specifications, the
turbocharger must be replaced or rebuilt. See HC5,
HC5A, HX80 or HX85 Turbocharger Shop Manual,
Bulletin 3810243, for rebuild instructions.
Use your hand to push the compressor impeller end of the
shaft toward the housing.
Use a feeler gauge that is not more than 13 mm [0.5 in]
wide. Measure the clearance between the impeller and the
housing at the minimum clearance point.
Holset HC5, HC5A, HX80 or HX85 Compressor
Impeller Radial Clearance
mm in
0.15 MIN 0.006
0.46 MAX 0.018
Perform the same measurement procedure for the turbine
wheel.
Holset HC5, HC5A, HX80 or HX85 Turbine Wheel
Radial Clearance
mm in
0.20 MIN 0.008
0.53 MAX 0.021
If the clearance exceeds the specifications, the
turbocharger must be replaced or rebuilt. See HC5,
HC5A, HX80 or HX85 Turbocharger Shop Manual Bulletin
3810243, for rebuild instructions.
Holset, Model HT100
Holset HT100 End Clearance
mm in
0.05 MIN 0.002
0.15 MAX 0.006
Measure the turbocharger shaft end clearance with a dial
depth gauge, Part Number ST-537.
turbocharger must be replaced or rebuilt. See HT100
Turbocharger Shop Manual Bulletin 3810386, for rebuild
instructions.
shaft toward the housing.
Holset HT100 Compressor Impeller Radial Clearance
mm in
0.25 MIN 0.010
0.46 MAX 0.018
wheel.
Holset HT100 Turbine Wheel Radial Clearance
mm in
0.38 MIN 0.015
0.53 MAX 0.021
turbocharger must be replaced or rebuilt. See HT100
Turbocharger Shop Manual Bulletin 3810386, for rebuild
instructions.
AiResearch Method One:
Check the radial clearance of both the compressor
impeller and turbine wheel.
Use your hand to push the compressor impeller or turbine
wheel toward the housing.
AiResearch T-18A Impeller and Turbine Wheel Radial
Clearance
mm in
0.08 MIN 0.003
0.18 MAX 0.007
turbocharger must be replaced or rebuilt. See
Turbocharger Component Shop Manual Bulletin 3379091,
for rebuild instructions.
AiResearch Method Two:
To measure the direct bearing radial clearance on the
T-18A, place a dial indicator through the oil drain hole as
illustrated. Be sure the indicator touches the highest part
of the shaft.
Move the turbine and compressor wheels by hand to the
upper and lower limits.
AiResearch T-18A Bearing Radial Clearance
mm in
0.20 MIN 0.008
0.46 MAX 0.018
turbocharger must be replaced or rebuilt. See
Turbocharger Component Shop Manual Bulletin 3379091,
for rebuild instructions.
All models:
After the turbocharger has been checked:
Lubricate the bearings with engine oil through the oil
inlet fitting
Cover all openings to prevent entry of dirt until
installed on the engine.
Disassemble
Remove the o-ring and discard.
If the compressor cover has an inlet baffle it can be
removed with a flat tip screwdriver. Pry the retaining ring
up and remove the retaining ring.
CAUTION
Use caution in handling the turbine blades. The
turbine blades can be easily damaged when the
turbine housing is removed.
Remove the turbine housing by bending the lock plate
tabs away from the capscrew heads.
Make sure the turbine wheel rotates freely inside the
turbine housing. Tap on the turbine housing with a mallet
to separate the turbine housing from the bearing housing.
Remove the oil supply fittings and the coolant lines from
the center housing assembly.
WARNING
manufacturer's instructions before using.
WARNING
Clean the compressor cover and turbine housing in parts
cleaner to loosen deposits.
WARNING
personal injury.
Dry the compressor housing with compressed air.
Use a soft bristle brush to remove heavy scale deposits.
Wash and dry the parts after brushing.
CAUTION
Do not use compressed air to dry or spin the turbine
wheel as this can cause damage to the turbocharger
bearing system.
If chemical and brush cleaning is not effective, bead blast
with plastic abrasive media, Part Number 3822735, or
equivalent.
Wash and dry parts after bead blasting.
The center housing rotating assembly can be cleaned with
contact cleaner, Part Number 3824510, or equivalent.
Do not spray contact cleaner into the oil and coolant ports.
Inspect the compressor cover for cracks, dents, and other
damage.
Inspect the inside of the compressor cover for signs of
scoring or damage from the compressor wheel. Replace
the compressor cover, if damaged.
Inspect the turbine housing for cracks and damage.
Cracks larger than 10 mm [0.39 in] can cause an exhaust
leak. Replace the turbine housing if damage is found.
Follow the criteria shown in the illustration.
Minor cracks in the turbine housing internal wall, where
exhaust gas flow enters the turbine wheel, is an
acceptable condition. The turbine housing can be reused.
Inspect the turbine housing for signs of contact with the
turbine wheel. Damaged turbine housings must be
replaced.
Inspect the center housing rotating assembly for any signs
of cracks, damaged threads, or other damage.
Rotate the turbine wheel by hand to make sure it spins
freely.
Replace the center housing rotating assembly if it is
damaged or does not spin freely.
Inspect the compressor wheel for damage, broken, or bent
blades.
Do not attempt to repair or straighten the blades. Instead,
replace the center housing rotating assembly.
Inspect the turbine wheel for damaged, broken, or bent
blades.
Do not attempt to repair or straighten the blades. Instead,
replace the center housing rotating assembly.
Measure
Measure the axial clearance with a dial indicator.
Replace the center housing rotating assembly if the axial
clearance is not within specification:
Axial Clearance 0.025 to 0.152 mm [ 0.001 to 0.006 in ]
Measure the radial clearance with a dial indicator.
Replace the center housing rotating assembly if the radial
clearance is not within specification:
Radial Clearance 0.254 to 0.787 mm [ 0.010 to 0.031
in ]
Assemble
CAUTION
Use caution when handeling the turbine blades. The
turbine blades can be easily damaged when installing
in the turbine housing.
Assemble the center housing rotating assembly on to the
turbine housing.
Lubricate the threads of the new capscrews with anti-seize
compound, Part Number 3824732, or equivalent.
Install the capscrews, with new lock plates, to the
turbocharger turbine housing.
Torque Value: 20.3 Nm [ 180 in-lb ]
Use a hammer and punch to fold the locking plate onto
the flat of the capscrew, to prevent loosening.
Assemble the inlet baffle into the compressor cover and
secure with a retaining ring. Hold one end of the retaining
ring in the groove. Press the remainder of the retaining
ring into position. Use a flat tip screwdriver to make sure
the retaining ring is correctly seated in the compressor
cover groove.
NOTE: The HX83 Turbocharger uses a titanium
compressor wheel. The edge of the wheel is very sharp.
Handle the compressor wheel with care.
Assemble the compressor housing new o-ring on the
turbocharger.
CAUTION
Do not damage the compressor wheel blades during
assembly.
Assemble the vee-band clamp and compressor cover onto
the turbocharger.
Place the vee-band clamp in position.
Tighten the vee-band clamp.
Make sure the compressor wheel and turbine wheel rotate
freely.
Install
CAUTION
Check to be sure the correct turbocharger assembly
is installed. The turbocharger assembly number is on
the dataplate that is mounted on the turbocharger.
Compare the assembly number with the number in the
CPL Manual with the corresponding CPL for the
engine being serviced. Many turbochargers appear
the same physically, but contain different parts. If the
wrong turbocharger assembly is installed, the
performance of the engine will be less than
specification, or damage can result to the engine due
to excessive cylinder pressure and temperature.
The turbochargers, mounting hardware, and connections
are different for various models of K38 and K50 engines.
Because of the different parts, installation procedures are
given for:
KT38, KTA38, and KTA50 Turbochargers with
KTTA38 and KTTA50 High Pressure, and KT38,
KTA38, and KTA50 Turbochargers with Outboard
Aftercoolers
KTTA38 Low Pressure Turbochargers
K2000E, K1800E and K1500E High Pressure
Turbochargers
K2000E Low Pressure Turbochargers
During turbocharger installation, it is often necessary to
adjust the angle of the bearing housing oil drain and the
angle of the compressor housing outlet. Instructions for
these adjustments are described following the procedure
for the KTTA50 Low Pressure Turbocharger.
Oil inlet and drain hose routing and clamps can be
different than shown because of the age of the engine. Be
sure the oil hoses have the correct clamps installed to
prevent damage from vibration or heat from another part.
KT38, KTA38, and KTA50 Turbochargers with Center
Mount Aftercooler
NOTE: The illustrations show a KTA38. The KTA50 has a
longer connection between the aftercooler housing and
the turbocharger. The procedure is the same for these
models.
Newer engines have a hose and clamps to connect the
turbocharger to the aftercooler connection. Older engines
have a tube with a dust seal and two o-ring seals to
connect the turbocharger to the aftercooler connection.
The clamps are special to allow a higher torque. Standard
t-bolt type clamps can loosen and allow an air leak.
Newer Engines:
Install the hose (1) and clamps (2) on the aftercooler
connection. Do not tighten the clamps.
Some of the newer K50 engines have a hose and heavy
duty clamps installed over the tube and o-ring as shown
in the next picture.
Older Engines:
Install the dust seal (3) and o-ring seals (4) on the tube (5).
Use vegetable oil. Lubricate the o-ring seals.
Install the tube in the bore of the aftercooler housing. Push
the tube into the bore until it touches the step in the bore.
WARNING
Install the gasket (6) on the exhaust manifold. The gasket
must be installed so that the raised bead on the gasket is
toward the turbocharger.
Install the turbocharger (7). Push the compressor housing
into the hose or on the hose.
The capscrews (8) with nuts (9) are manufactured from
heat resistant material. If heat resistant capscrews are
not installed, the parts will fail, causing an exhaust leak.
Apply an anti-seize compound on the threads of the
capscrew.
Install the four capscrews (8) with the nuts (9).
Torque Value:
Capscrews 40 Nm [ 30 ft-lb ]
Some of the compressor housing is not shown removed
for clarity.
Check the angle of the oil drain and the alignment of the
compressor housing to the aftercooler connection. If the
angle or alignment is not correct, adjust the turbocharger
oil drain angle, or adjust the turbocharger compressor
housing alignment, described later in this section.
Newer Engines:
Tighten the clamps (2).
Torque Value:
K38 9 Nm [ 80 in-lb ]
K50 15 Nm [ 133 in-lb ]
The K50 requires a special clamp.
Older Engines:
Install the parts.
10. Retaining plates
11. Flat washers
12. Lock washers
13. Capscrews.
Torque Value:
Capscrews 16 Nm [ 142 in-lb ]
NOTE: Holset turbochargers have a fitting that has
straight threads and requires an o-ring seal. AiResearch
turbochargers have a fitting with pipe threads. The torque
value is the same for both types of the fittings.
Install the o-ring seal (14) on the oil inlet fitting (15). Install
the fitting.
Torque Value:
Oil Inlet Fitting 35 Nm [ 26 ft-lb ]
Connect the turbocharger oil inlet hose (16) to the fitting.
Install the clamps for the oil inlet hose.
The other end of the oil inlet hose must be connected to
a fitting in the cylinder block. Refer to Procedure 001-026.
Install the parts.
17. Gasket
18. Hose
19. Lock washers
20. Capscrews
Torque Value:
Newer engines have a flange and an o-ring seal type oil
drain hose as shown. The newer hose connects to the
cylinder block with a capscrew. Older engines have a hose
that has a tubing nut and connects to the block with a
fitting that has pipe threads.
If a flange and an o-ring type connection is installed on an
older block, a spacer is required between the hole in the
block for the capscrew and the flange. If the spacer is
not installed, an oil leak will result.
Install the o-ring seal (21) on the hose flange.
Use vegetable oil. Lubricate the seal.
Install the flange, the lock washer (22), and the capscrew
(23).
Torque Value:
Flange
Capscrews
40 Nm [ 30 ft-lb ]
Repeat this procedure to install the other turbocharger
and connect the oil hoses.
KTTA38 and KTTA50 High Pressure, and KT38, KTA38,
and KTA50 Turbochargers with Outboard Aftercoolers
The turbochargers must be mounted on the correct
engine bank.
KTTA38 and KTTA50 High Pressure:
The turbocharger on the left bank must be installed with
the compressor housing pointed toward the front of the
engine. The turbocharger on the right bank must be
installed with the turbine housing pointed toward the front
of the engine.
KT38, KTA38, and KTA50 with Outboard Aftercoolers:
The turbine housing on both turbochargers must point the
same direction, either toward the front of the engine or
toward the rear of the engine so that the exhaust piping
will fit the application.
WARNING
NOTE: The turbochargers for the K50 engine with pulse
type exhaust manifolds are to be mounted with four studs
and nuts, not capscrews and nuts. The torque value is the
same. Some K38 engines do not require the nuts.
The gasket must be installed so that the raised bead on
the gasket is toward the turbocharger.
Install the gasket (1) on the exhaust manifold.
capscrews.
Install the turbocharger (2), the capscrews or studs (3),
and the nuts (4) if required.
Torque Value:
Turbocharger
Capscrews
40 Nm [ 30 ft-lb ]
NOTE: Some of the compressor housing is shown
Check the angle of the oil drain. The alignment of the
compressor housing to the air crossovers can not be
checked until the aftercooler assembly is installed. If the
angle is not correct, adjust the turbocharger oil drain
angle, described later in this section.
value is the same for both types of fittings.
the fitting.
Torque Value:
Connect the turbocharger oil inlet hose (16) to the fitting.
Install the parts.
5. Gasket
6. Hose
7. Lock washers
8. Capscrews.
Torque Value:
Install the flange in the bore of the block. Install the lock
washer (10) with the capscrew (11).
Torque Value:
Flange
Capscrews
40 Nm [ 30 ft-lb ]
Repeat this procedure to install the other turbocharger
and connect the oil hoses.
NOTE: The engine has two low pressure turbochargers.
The illustrations show the installation of one turbocharger.
It is recommended that the two low pressure
turbochargers be installed at the same time.
The engine has six turbocharger supports. Two are
mounted on the front of the right bank and two on the rear
of the left bank. One is mounted on the front of the left
bank and one on the rear of the right bank.
Install the turbocharger supports (1), the lock washers (2),
with the socket head capscrews (3).
Torque Value:
Turbocharger
Support
Capscrews
270 Nm [ 199 ft-lb ]
Do not tighten the clamps or fasteners to final torque until
the torque value is given. Tighten the parts enough to hold
them together, but loose enough to allow the parts to be
moved for alignment.
Install the parts.
4. Bracket
5. Flat washers, heavy (six)
6. Lock washers (six)
7. Capscrews (six).
Install the vee-band clamp (8) and the exhaust outlet
connection (9).
Apply an anti-seize compound to the slip-joints of the
exhaust outlet connection (9), exhaust outlet pipe (10),
and the turbocharger connection (11).
Install the pipe (10) to the connection (9). Install the
connection (11) in the pipe (10).
capscrews (12).
Install the four capscrews (12) through the connection and
bracket.
Install the heavy flat washers (13), the lock washers (17),
and the nuts (18).
Install the large o-ring seal (19) and the small o-ring seal
(20) on the air inlet pipe (21).
Install the dust seal (22) on the air inlet pipe.
Install the air inlet pipe in the high pressure turbocharger.
air inlet pipe and high pressure turbocharger.
WARNING
the gasket is toward the turbocharger
Install the gasket (25).
Install the low pressure turbocharger (26). Push the
compressor housing on the air inlet pipe.
Apply an anti-seize compound to the threads of the
capscrews (27).
Install the four capscrews (27) and lock nuts (28).
Check the angle of the oil drain. Check the alignment of
the compressor housing to the air inlet pipe. If the angle
or alignment is not correct, see Turbocharger, Oil Drain
Angle, Adjust, or Turbocharger, Compressor Housing
Alignment, Adjust, described in this section.
Tighten the six capscrews (7) that hold the bracket to the
supports.
Torque Value:
Bracket to
Supports
90 Nm [ 66 ft-lb ]
Tighten the four capscrews (12) and nuts (18) that hold the
connection to the bracket.
Torque Value:
Connection to
Bracket
90 Nm [ 66 ft-lb ]
turbocharger to the connection.
Torque Value:
Turbocharger
Connection
40 Nm [ 30 ft-lb ]
Tighten the vee-band clamp (8).
Torque Value:
Vee-band Clamp 7 Nm [ 62 in-lb ]
Torque the clamp nut to the same torque value.
Continue tapping and tightening the clamp until the nut
does not turn at the specified torque after tapping.
Tighten the two t-bolt clamps (24).
Torque Value:
T-bolt Clamps 9 Nm [ 80 in-lb ]
value is the same for both types of fittings.
the fitting.
Torque Value:
Install the parts.
29. Gasket
30. Hose
31. Lock washers
32. Capscrews.
Torque Value:
NOTE: Some older KTTA38 engines equipped with
AiResearch low pressure turbochargers have a drain
hose that has two pieces connected by a temperature
resistant hump hose.
Install the flange, the lock washer (34), and the capscrew
(35).
Torque Value:
Flange
Capscrews
40 Nm [ 30 ft-lb ]
NOTE: The engine has two low pressure turbochargers.
The illustrations show the installation of one turbocharger.
It is recommended that the two low pressure
turbochargers be installed at the same time.
The engine has six turbocharger supports. Two are
mounted on the front of the right bank, and two are on the
rear of the left bank. One is mounted on the front of the
left bank, and one on the rear of the right bank.
Install the turbocharger supports (1), the lock washers (2),
and the socket head capscrews (3).
Torque Value:
Turbocharger
Support
Capscrews
270 Nm [ 199 ft-lb ]
Do not tighten the clamps or fasteners to final torque until
the torque value is given. Tighten the parts enough to hold
them together, but loose enough to allow the parts to be
moved for alignment.
Install the bracket (4), the six lock washers (6), and the six
capscrews (7).
connection (9).
Apply an anti-seize compound to the slip-joints of the
exhaust outlet connection (9), the exhaust outlet pipe (10),
and the turbocharger connection (11).
Install the pipe (10) on the outlet connection (9). Install the
connection (11) in the pipe (10).
high pressure turbocharger.
Install the two o-ring seals (13) and the dust seal (14) on
the air inlet pipe (15).
Install the air inlet pipe in the high pressure turbocharger.
CAUTION
KTTA50 engines equipped with LOG type exhaust
manifolds must have Brown-Boveri Corporation
(BBC), Model Number 153, turbochargers. KTTA50
engines with PULSE type exhaust manifolds must
have BBC, Model Number RR 151, turbochargers. Be
sure the correct turbochargers are installed, or
damage to the engine can result.
CAUTION
Newer BBC RR 153 turbochargers have fastener
threads that are U.S. Customary inch. Older BBC RR
153 turbochargers have fastener threads that are
metric millimeter. The fastener threads in all BBC RR
151 are metric millimeter. Be sure the correct
fasteners are installed or the parts can be damaged.
NOTE: The exhaust and intake adapters for the BBC RR
153 and RR 151 appear the same, but have different
dimensions. Be sure to install the correct part.
Apply an anti-seize compound to the bore of the low
pressure turbocharger (16) for the exhaust outlet
connection (17), and the threads of the capscrews (19) and
(20).
The connection must be installed as shown so that the
flange with two holes aligns with the bracket.
The two capscrews (19) are longer than the six capscrews
(20).
Install the exhaust outlet connection (17), the lock washers
(18), and the capscrews (19) and (20).
Torque Value:
Exhaust Outlet
Connection
Capscrews
40 Nm [ 30 ft-lb ]
Install the parts on the air intake connection (26).
21. Capscrews (two)
22. Bracket
23. Flat washers, heavy
24. Lock washers
25. Nuts.
Install the o-ring seal (27) in the groove on the connection
(26).
Use engine oil or lubriplate to secure the seal in the
groove.
Install the parts on the low pressure turbocharger (16).
26. Connection
27. Flat washers (four)
28. Lock washers (four)
29. Capscrews (four).
Tighten only the capscrews (30).
Torque Value:
WARNING
Use a hoist and lifting strap. Put the turbocharger (16) in
position and push the compressor housing on the air pipe.
Install the capscrews (31) through the heavy flat washers
(32), and the brackets (22) and (4).
Install the heavy flat washers (32), lock washers (33), and
the nuts (34).
capscrews (35).
Install the two capscrews (35) through the exhaust outlet
connection (17) and the bracket (4).
Install the heavy flat washers (36), the lock washers (37),
and the nuts (38).
the gasket is toward the turbocharger.
Install the gasket (39) between the turbocharger turbine
housing and the exhaust connection.
capscrews (40).
Install the four capscrews (40) through the holes in the
turbine housing, the gasket, and the connection.
Install the lock washers (41) and the nuts (42).
the compressor housing to the air inlet pipe. If the angle
or alignment is not correct, see Turbocharger, Oil Drain
Angle, Adjust, or Turbocharger, Compressor Housing
Alignment, Adjust, described in this section.
supports.
Torque Value:
Bracket to
Supports
90 Nm [ 66 ft-lb ]
Tighten the two capscrews (35) and nuts (36) that hold the
Torque Value:
Exhaust Outlet
Connection to
Bracket
90 Nm [ 66 ft-lb ]
NOTE: Be sure the bracket (32) is flat against the flange
on the air inlet connection.
Tighten the two capscrews (43) and the nuts (34) that hold
the air intake connection (32) to the bracket (4).
Torque Value:
Air Intake
connection to
bracket
40 Nm [ 30 ft-lb ]
Tighten the two capscrews (31) and the nuts (25) that hold
the bracket (32) to the connection (26).
Torque Value:
Bracket
Capscrews
40 Nm [ 30 ft-lb ]
exhaust connection to the turbine housing.
Torque Value:
Exhaust
Connection
Capscrews
90 Nm [ 66 ft-lb ]
Tighten the vee-band clamp (8).
Torque Value:
Vee-band Clamp 7 Nm [ 62 in-lb ]
does not turn at the specified torque after tapping.
Tighten the two t-bolt clamps (45) on the air inlet pipe.
Torque Value:
T-bolt clamps 7 Nm [ 62 in-lb ]
CAUTION
Be sure the correct capscrews are installed. If the
wrong capscrews are installed, failure of the part can
result.
NOTE: Newer BBC RR153 turbochargers have a fitting
that is threaded directly into the bearing housing. Older
BBC RR 153 turbochargers require an adapter plate,
Part Number 3176567, and a gasket, Part Number
3176568, attached to the bearing housing with two
capscrews.
NOTE: All BBC RR 151 turbochargers have an adapter
plate and gasket. The adapter plate and gasket are
different than on the older BBC RR 153 turbochargers.
Install the parts for the turbocharger oil inlet.
55. Gasket
56. Plate
57. Lock washers
58. Capscrews.
Torque Value:
Oil Inlet
Capscrew
40 Nm [ 30 ft-lb ]
If the fitting is not installed in the plate, install the oil inlet
fitting.
Torque Value:
Fitting Torque 35 Nm [ 26 ft-lb ]
Connect the turbocharger oil inlet hose.
Install the parts for the turbocharger oil drain.
47. Gasket
48. Hose
49. Lock washers
50. Capscrews.
Torque Value:
Oil Drain
Capscrews
40 Nm [ 30 ft-lb ]
Install the flange, the lock washer (52), and the capscrews
(53) in the proper holes in the cylinder block.
Torque Value:
Oil Drain Flange
Capscrews
40 Nm [ 30 ft-lb ]
K2000E and K1800E High Pressure Turbochargers
The K2000E uses Holset HC5A high pressure
turbochargers (2), the HT100 Low Pressure
Turbochargers (1) installation is described later in this
section.
The K1800E engine is single stage turbocharged and
does not use the turbocharger interstage connections or
assembly procedures as does the K2000E.
The K1800E engine uses Holset HX85 turbochargers (1).
NOTE: The high pressure turbochargers (2) are mounted
to the exhaust manifold using four capscrews (3) and nuts
(4). These capscrews and nuts are manufactured from
high strength stainless steel that has high temperature
capability. Do not substitute with lower quality parts.
The gasket must be installed with the raised bead (2)
toward the turbocharger.
Install the gasket (1) on the exhaust manifold.
Coat the threads of the capscrews with anti-seize
compound.
Install the turbocharger (2), capscrews (3) and nuts (4).
Torque Value:
Turbocharger
Mounting
Capscrews
40 Nm [ 30 ft-lb ]
NOTE: Some of the compressor housing has been
Check the angle of the oil drain and the alignment of the
compressor housing to the air crossovers (this can not be
checked until the aftercooler assemblies are installed).
If the angle is not correct, the bearing housing must be
rotated in relation to the turbine housing. Adjust the
turbocharger oil drain angle.
If the alignment is correct or after the adjustment, lock the
bearing housing to the turbine casing lockplate tabs.
Connect the turbocharger oil inlet hose to the fitting.
Install the gasket (5), the hose (6), the lock washers (7) and
the two capscrews (8) to the turbocharger oil drain.
Install the o-ring seal (9) on the hose flange. Use engine
oil to lubricate the seal. Install the flange in the bore of the
block. Install the lock washer (10) and the capscrew (11).
Torque Value:
Oil Inlet
Capscrews
40 Nm [ 30 ft-lb ]
Repeat the procedure to install the other turbocharger and
connect the oil supply and the drain hose.
K2000E Low Pressure Turbochargers
The K2000E engine contains two low pressure
turbochargers. This illustration shows the installation of
only one turbocharger. The recommendation is to install
both low pressure turbochargers at the same time.
The K2000E engine contains six turbocharger supports.
Two of each of the supports are mounted on the front of
the right bank and rear of the left bank. One of each of the
supports is mounted on the front of the left bank and rear
of the right bank.
Install the turbocharger supports (1), and the lock washers
(2), and the socket head capscrews (3).
Torque Value:
Turbocharger
support
capscrews
270 Nm [ 199 ft-lb ]
NOTE: From this point on, do not tighten the clamps or
fasteners to their final torque unless the torque value is
given. Tighten only enough to allow the parts to move for
alignment.
Install the bracket (4), the six lock washers (6), and the six
capscrews (7).
connection (9).
Apply anti-seize compound to the threads of the
capscrews (12). Install the gasket (10), capscrews (12),
lock washers (13), and nuts (14).
Use anti-seize compound to coat the slip joints of the
exhaust pipe (11) and the turbocharger connection (16).
Install the turbocharger connection (16) on the exhaust
pipe (11).
After all interstage connections are in place, there must
be a minimum of 3.18 mm [0.125 inch] expansion space
between connections (11 and 16).
The gap can be adjusted by moving the low pressure
turbocharger or low pressure turbocharger mounting
bracket.
Use anti-seize compound to coat the bore on the low
pressure turbocharger (22) for the exhaust outlet
connection (17), and the threads of the capscrews (19 and
20).
The bracket (21) must be oriented to provide proper
turbocharger alignment.
NOTE: The two capscrews (19) are longer than the six
capscrews (20).
Install the exhaust outlet connection (17), the lock washers
(18), and the capscrews (19 and 20).
Torque Value:
Exhaust Outlet
Capscrews
40 Nm [ 30 ft-lb ]
Install the two capscrews (31), the bracket (32), the heavy
flat washer (23), the lock washers (24), and the nuts (25)
on the air intake connection.
Install the o-ring seal (27) in the groove on the connection
(26). Use engine oil or Lubriplate to hold the seal in the
groove.
Install the connection (26), the four flat washers (28), lock
washers (29), and the capscrews (30), on the low pressure
turbocharger. Tighten only the four capscrews (30).
Torque Value:
Air Intake
Connection
Capscrews
40 Nm [ 30 ft-lb ]
Use a hoist and lifting strap to position the turbocharger
and to align the capscrew holes in the brackets.
Install the capscrews (43) through the heavy flat washer
(44) and both brackets (32 and 4). Install the heavy flat
washers (44), lock washers (33) and the nuts (34).
Use anti-seize compound to coat the threads of the
capscrews (35).
Install the two capscrews (35) through the exhaust outlet
connection (17) and the bracket (4). Install the heavy flat
washers (36), the lock washers (37), and the nuts (38).
The raised bead on the gasket (39) must be toward the
turbocharger.
Install the gasket (39) between the turbocharger turbine
housing and the exhaust connections (16).
Use anti-seize compound to coat the threads of the
capscrews (40).
Install the four capscrews (40) through the holes in the
turbine housing, the gasket, and the connection.
Install the lock washers (41) and the nuts (42).
Slide one t-bolt clamp (45) and hose (46) over the end of
the intake pipe (47). Slide the hose on far enough to install
the pipe. Install the second clamp (45) over the
compressor outlet.
Position the intake pipe (47) between the turbochargers
and insert the gasket (48). Secure the flanges with four
bolts (49), flat washers (50), lock washers (51), and nuts
(52).
NOTE: Some of the compressor housing has been
the compressor housing to the air inlet pipe.
If the angle or alignment is not correct, the bearing
housing must be rotated in relation to the turbine housing.
See Turbocharger, Compressor Housing Alignment,
Adjust and Turbocharger, Oil Drain Angle Alignment,
Adjust, described in this section.
Prior to any of the capscrews being tightened, check to be
sure there is a minimum of 3.18 mm [0.125 in] expansion
space at the slip joints on both exhaust interstage
connections.
supports.
Torque Value:
Support Bracket
Capscrews
95 Nm [ 70 ft-lb ]
Torque Value:
Bracket
Capscrews
95 Nm [ 70 ft-lb ]
The bracket (32) must be flat against the flange on the air
inlet connection.
bracket (32) to the support bracket (4).
Torque Value:
Air Inlet
Connection
Capscrews
40 Nm [ 30 ft-lb ]
bracket (32) to the connection (26).
Torque Value:
Bracket
Connection
Capscrews
40 Nm [ 30 ft-lb ]
exhaust connection to the turbine housing.
Torque Value:
Exhaust
Connection
Capscrews
95 Nm [ 70 ft-lb ]
Tighten the three capscrews (19) that hold the bracket (21)
to the exhaust outlet connection (17).
Torque Value:
Exhaust Outlet
Connection
Capscrews
40 Nm [ 30 ft-lb ]
two exhaust connections (9 and 11).
Torque Value:
Exhaust Outlet
Connections
95 Nm [ 70 ft-lb ]
Tighten the vee-band clamp.
Torque Value:
Vee-Band 9 Nm [ 80 in-lb ]
Use a mallet. Tap all around the clamp to make sure it is
seated.
will not turn at the specified torque after tapping.
air intake pipe (47) to the turbocharger compressor outlet.
Torque Value:
Intake Pipe
Capscrews
40 Nm [ 30 ft-lb ]
CAUTION
The hoses and t-bolt clamps of the air intake system
are of heavy duty design to withstand temperatures
and pressures to which they are exposed. Only
specified parts are to be used. The clamps can be
removed and tightened again a maximum of three
times. The torque retention on the nut will be beyond
reuse after this. At this time, a second nut MUST be
added to double lock the nut or a new clamp MUST be
used.
Center the hose (46) over the high pressure turbocharger
compressor inlet and the pipe (47). Secure the two t-bolt
clamps (45).
and the end of the hose. A portion of the hose must extend
outside the clamp.
Tighten the two t-bolt clamps (45) on the air intake pipe
(47) and the turbocharger compressor inlet.
Torque Value:
Intake Pipe
Clamps
8 Nm [ 71 in-lb ]
These clamps need to be tightened again after the engine
has operated a few hours.
Wrap the interstage air hose with a heat shield (blanket).
The blanket is secured by placing the eyelets that are
located on each end of the blanket over the hose clamp t-
bolts. Use flat washers and nuts on the t-bolts to retain the
heat shield (blanket).
Install the gasket (55), the plate (56), the lock washers (57),
and the capscrews (58) for the low pressure turbocharger
oil inlet.
Torque Value:
Low Pressure
Turbocharger Oil
Inlet
25 Nm [ 18 ft-lb ]
Install the oil inlet fitting.
Torque Value:
Connect the turbocharger oil inlet hose.
Install the gasket (59), the hose (60), the lock washers (61),
and the capscrews (62) for the low pressure turbocharger
oil drain.
Torque Value:
Turbocharger Oil
Drain
25 Nm [ 18 ft-lb ]
Install the seal (63) on the hose flange. Use engine oil to
lubricated the seal. Install the flange, the lock washer (64)
and the capscrews (65) in the proper holes in the cylinder
block.
Torque Value:
Hose Flange 40 Nm [ 30 ft-lb ]
NOTE: The turbocharger oil drain line must run downhill
from the turbocharger to the cylinder block.
WARNING
NOTE: The word OUT, or raised bead on the gasket
must be positioned toward the turbocharger.
Lift the high pressure turbochargers, using approved
lifting straps, and place them onto the middle mounting
pads with the air outlets facing outboard.
Install the capscrews, washers and nuts and tighten.
Torque Value:
Turbocharger
Mounting
Capscrews and
Nuts
45 Nm [ 33 ft-lb ]
Install the exhaust outlet and clamp.
Apply anti-seize compound, Part Number 3824397, or
equivalent to both ends of the exhaust inter-stage piping
flanges.
Install both halves of the exhaust inter-stage using new
gaskets.
equivalent to the mounting capscrews.
Tighten the exhaust outlet connection clamp.
Torque Value:
Hose Clamp 8 Nm [ 71 in-lb ]
Install the capscrews, washers and nuts finger tight to
allow for alignment.
Install the hose and clamps (with tightening screws facing
downward) to the inlet side of the turbocharger.
Tighten the hose clamp closest to the turbocharger inlet.
Torque Value:
Install the intake air piping into the hose and loosely
tighten the clamp to allow for alignment.
WARNING
Lift the low pressure turbochargers, using approved lifting
straps, onto the mounting pads and align them with the
inter-stage air transfer connections.
Install a new steel gaskets between the outer low pressure
turbocharger and the outer low turbocharger exhaust
connection. Check that the raised beads on the gaskets
are facing the outer turbocharger.
Install the capscrews, washers and nuts in the same
orientation noted prior to removal and hand tighten.
Check the alignment and tighten the capscrews.
Torque Value:
Exhaust
Connection
Capscrews and
Nuts
95 Nm [ 70 ft-lb ]
Install a new paper gasket between the air intake
connection and the turbocharger and install the
capscrews, washers and nuts. Hand tighten only to allow
for alignment.
Add the p-clip to the top right capscrew. Do not tighten
this bolt until the oil supply line is installed.
Once alignment is checked, tighten the capscrews.
Torque Value:
Air Intake
Connection
Capscrews and
Nuts
48 Nm [ 35 ft-lb ]
Check that all air transfer connections are aligned and
tighten the interstage hose clamps.
Torque Value:
Interstage Hose
Clamp
8 Nm [ 71 in-lb ]
Install the air intake and bracket onto the low pressure
turbocharger and trolly assembly.
equivalent, to the mounting capscrews and install.
Tighten all capscrews with the exception of the two
capscrews not connected to the mounting bracket.
Torque Value:
Air Intake
Capscrews
48 Nm [ 35 ft-lb ]
equivalent, to the rear turbocharger outlet flange and
install the exhaust adapter and bracket onto the low
pressure turbocharger and trolly assembly.
equivalent, to the eight mounting capscrews and install.
Torque Value:
Exhaust Adapter
Capscrews
48 Nm [ 36 ft-lb ]
Finishing Steps
MAI
WARNING
cable last.
WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
WARNING
Turn the air on to the air starter (if equipped). Refer
to Procedure 012-022
WARNING
cable last.
Install the oil drain lines. Refer to Procedure 010-045.
Install the coolant supply and return lines. Refer to
Procedure 010-041.
Turn the air on to the air starter (if equipped). Refer
to Procedure 012-022
Turbocharger, Water-Cooled K38, K50, QSK38, and QSK50
Turbocharger, Water-Cooled (010-037)
Preparatory Steps
WARNING
cable last.
WARNING
WARNING
CAUTION
Use caution when draining oil or replacing filters that
the oil is not spilled or drained into the bilge area. The
oil and oil filters must be disposed of in accordance
with local environmental regulations.
CAUTION
Use caution when draining coolant that the coolant is
not spilled or drained into the bilge area. Do not pump
coolant overboard. If the coolant is not reused, it must
be disposed of in accordance with local
013-009.
008-018.
Remove the exhaust piping. Refer to the OEM
service manual
Remove the air intake filter assemblies. Refer to
Procedure 010-013.
Remove the exhaust connection pipe. Refer to
Procedure 011-001.
Remove the exhaust bellows. Refer to Procedure
011-018.
Remove the turbocharger oil supply line. Refer to
Procedure 010-046.
Remove the turbocharger coolant hoses. Refer to
Procedure 010-041.
K38, K50, QSK38, and QSK50 Turbocharger, Water-Cooled
Remove
Remove the turbocharger coolant vent lines.
Left Bank
Loosen the hose clamp connecting the flexible hose
between the sections of the air crossover tube.
Remove the eight capscrews and washers connecting the
air crossover tube to the turbocharger.
Remove the air crossover tube and discard the gasket.
Remove the Straub coupling from the water transfer tube.
Disconnect the water transfer tube from the turbocharger
and remove.
Remove the six capscrews, washers, and nuts from the
turbocharger to exhaust manifold flange.
WARNING
Use lifting straps and a hoist to support the weight of the
turbocharger.
Remove the four capscrews and washers from the center
section of the turbocharger and lift the turbocharger off the
turbocharger center support/drain assembly.
Right Bank
Loosen the hose clamp connecting the flexible hose
between the sections of the air crossover tube.
Remove the eight capscrews and washers connecting the
Remove the air crossover tube and discard the gasket.
Remove the Straub coupling from the water transfer tube.
Disconnect the water transfer tube from the turbocharger
and remove.
Remove the six capscrews, washers, and nuts from the
turbocharger to exhaust manifold flange.
WARNING
Remove the four capscrews and washers from the center
section of the turbocharger and lift the turbocharger off the
turbocharger center support/drain assembly.
Setup
NOTE: All views showing the clock marks have been
simplified for clarity.
Verify the correct clocking of the turbocharger.
If the turbocharger requires clocking, set the turbocharger
on a bench with the turbine housing against the bench and
loosen the V-band clamp.
The turbocharger can be used in different applications
and has three clock marks on the turbine housing.
1. 19 casting line
2. Left bank
3. Right bank
The bearing housing has a machined surface on the top,
creating an alignment mark.
Rotate the bearing housing, aligning the mark with the 19
casting line on the turbine housing.
Apply anti-seize compound to the V-band threads.
Torque Value: Step1 20 Nm [ 177 in-lb ]
Step2 Loosen 2 to 3 turns
Step3 18 to 20 Nm[ 160 to 177
in-lb ]
Install
Left Bank
WARNING
Lubricate and install a new o-ring into the machined
groove on the turbocharger center support/drain
assembly.
Install the turbocharger and exhaust manifold gasket.
Remove the lifting straps.
Install the six capscrews, washers, and nuts.
Tighten the nuts
Torque Value:
Turbocharger
Capscrews
136 Nm [ 100 ft-lb ]
Install the turbocharger to center section mounting
capscrews and washers and tighten.
Torque Value:
Turbocharger to
Center Section
Mounting
Capscrews
102 to 115
Nm
[ 75 to 85 ft-
lb ]
Install the water transfer tube to the turbocharger.
Install the Straub coupling to the water transfer tube.
Use a new gasket and install the air crossover tube
between the turbocharger and forward section for the air
crossover tube.
Install the eight capscrews and washers connecting the
Tighten the hose clamp on the flexible hose between the
sections of the air crossover tube.
Install the turbocharger coolant vent lines.
Right Bank
WARNING
Lubricate and install a new o-ring into the machined
groove on the turbocharger center support/drain
assembly.
Install the turbocharger and exhaust manifold gasket.
Install the six capscrews, washers, and nuts.
Tighten the nuts
Torque Value:
Turbocharger
Capscrews
136 Nm [ 100 ft-lb ]
Install the turbocharger to center section mounting
capscrews and washers and tighten.
Torque Value:
Turbocharger to
Center Section
Mounting
Capscrews
102 to 115
Nm
[ 75 to 85 ft-
lb ]
Install the water transfer tube to the turbocharger.
Install the Straub coupling to the water transfer tube.
K38, K50, QSK38, and QSK50 Turbocharger Axial Clearance
Use a new gasket and install the air crossover tube
between the turbocharger and forward section of the air
crossover tube.
Install the eight capscrews and washers connecting the
Tighten the hose clamp on the flexible hose between the
sections of the air crossover tube.
Finishing Steps
WARNING
cable last.
WARNING
Install the turbocharger coolant hoses. Refer to
Procedure 010-041.
Install the turbocharger oil supply line. Refer to
Procedure 010-046.
Install the exhaust bellows. Refer to Procedure
011-018.
Install the exhaust connection pipe. Refer to
Procedure 011-001.
Install the air intake filter assemblies. Refer to
Procedure 010-013.
Install the exhaust piping. Refer to the OEM service
manual
Turbocharger Axial Clearance
(010-038)
Preparatory Steps
Remove the intake and exhaust piping from the
turbocharger.
Turbocharger Axial Clearance K38, K50, QSK38, and QSK50
Measure
NOTE: Check the model of turbocharger fitted to the
engine, this is for: Holset, Model HC5
To measure axial clearance, use Part Number ST-537 Dial
Depth Gauge or a dial indicator. Measure the axial motion.
Holset HX5 - Axial Clearance
mm in
0.05 MIN 0.002
0.13 MAX 0.005
turbocharger must be replaced or rebuilt. See Bulletin
Number 3810243, HC5 Series Turbocharger Shop
Manual, for rebuild instructions.
shaft towards the housing.
Use a wire - type feeler gauge or a feeler gauge no
wider that 13 mm [1/2 inch]. Measure the clearance
between the impeller and the housing at the minimum
clearance point.
Holset HX5 - Compressor Impeller Radial Clearance
mm in
0.15 MIN 0.006
0.46 MAX 0.018
wheel.
Holset HX5 - Turbine Wheel Radial Clearance
mm in
0.20 MIN 0.008
0.53 MAX 0.021
If the clearance exceeds the specification, the part must
be replaced or rebuilt. See Bulletin Number 3810243, HC5
or HC5A turbocharger manual for rebuild instructions.
K38, K50, QSK38, and QSK50 Turbocharger Axial Clearance
engine, this is for: Brown Boveri, Model RR-153 and
RR-151
To measure axial clearance, use Part Number ST-537 Dial
Depth Gauge or a dial indicator. Measure the axial motion.
BBC (RR-151) and (RR-153) End Clearance
mm in
0.09 MIN 0.004
0.13 MAX 0.005
Number 3810235, Exhaust - Gas Turbocharger RR-153,
Instructions for Operation and Maintenance or Bulletin
Number 3810325, Exhaust - Gas Turbocharger,
RR151-12, Instructions for operation and Maintenance.
NOTE: The compressor and turbine casings do not
require removal to measure the radial clearance. The
parts shown are removed for clarity.
Use 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
If the clearance exceeds the specification, the part must
be replaced or rebuilt. See Bulletin Number 3810235,
Exhaust - Gas Turbocharger, RR-153, Instructions for
operation and Maintenance or Bulletin Number 3810315,
Exhaust - Gas Turbocharger, RR-151-12, Instructions for
Operation and Maintenance.
engine, this is for: AiResearch, Model T-18A
Use a dial indicator . Measure the clearance.
AiResearch T-18A End Clearance
mm in
0.10 MIN 0.004
0.23 MAX 0.009
Number 33379091, Turbocharger Component Shop
Manual, for rebuild instructions.
Turbocharger Blade Damage K38, K50, QSK38, and QSK50
Finishing Steps
Install the intake and exhaust piping to the
turbocharger.
Turbocharger Blade Damage (010-039)
Inspect for Reuse
Remove the intake and exhaust pipes from the
turbochargers.
Inspect the turbocharger compressor impeller blades for
damage.
Remove and rebuild or replace the turbocharger if
damage is found. Refer to Procedure 010-033
If the impeller is damaged, inspect the intake air piping
and the air filter element for damage and cause of leaks.
Inspect the compressor cover for any debris.
Repair any damage before operating the engine.
K38, K50, QSK38, and QSK50 Turbocharger Compressor Seal Leaks
Inspect the turbine wheel for damage.
Check for debris stuck in the turbine housing.
Remove and rebuild or replace the turbocharger if
damage is found. Refer to Procedure 010-033
Turbocharger Compressor Seal Leaks
(010-040)
Inspect
Remove the air intake piping from the turbocharger.
Remove the hose and two clamps between the air
crossover and the turbocharger.
Remove the clamp between the air crossover and the
aftercoolers or intercoolers.
Remove the air crossover.
Examine the compressor discharge and air crossover
piping for oil.
Turbocharger Compressor Seal Leaks K38, K50, QSK38, and QSK50
If oil is in the compressor discharge or crossover piping,
check the axial clearance of the turbocharger. Refer to
Procedure 010-038 (Turbocharger Axial Clearance) in
Section 10.
Check the radial clearance of the turbocharger. Refer to
Procedure 010-047 (Turbocharger Radial Bearing
Clearance) in Section 10.
Check for intake restriction. Refer to Procedure 010-031
(Air Intake Restriction) in Section 10.
If the restriction exceeds specifications, replace or clean
the air filter element; refer to the OEM's instructions.
Disconnect the oil drain hose from the cylinder block.
Remove and discard the o-ring seal (9).
Disconnect the oil drain hose from the turbocharger.
Remove any support clamps and the hose.
Remove and discard the o-ring gasket (5).
Clear any restrictions found in the hose.
Discard the hose if it is cracked, frayed, or will not bend
without cracking.
K38, K50, QSK38, and QSK50 Turbocharger Compressor Seal Leaks
Check the angle of the drain tube.
NOTE: The angle of the tube must be within 35 degrees
of vertical. Adjust the turbocharger, if necessary. Refer to
Procedure 010-033 (Turbocharger) in Section 10.
If the drain tube is free of restrictions and at the correct
angle, check the crankcase breathers and tubes to make
sure they are not plugged or restricted.
If these checks do not reveal the problem, measure the
crankcase pressure (blowby). Refer to Procedure 014-005
(Engine Testing (Engine Dynamometer)) in Section 14.
Turbocharger Coolant Hoses K38, K50, QSK38, and QSK50
Turbocharger Coolant Hoses (010-041)
Preparatory Steps
EAI
WARNING
WARNING
WARNING
cable last.
13.
Remove the turbocharger heat shield (marine
applications only).
Remove
NOTE: Shown is the Two Stage turbocharger, the Single
Stage is similar.
NOTE: The following procedure applies to both high
pressure turbocharger locations.
Disconnect the coolant supply hose from the turbocharger
and water manifold.
Stage is similar.
Remove the supply union fittings on the turbocharger and
water manifold. Discard the o-rings.
K38, K50, QSK38, and QSK50 Turbocharger Coolant Hoses
Remove the capscrews, washers, cover plate, and water
tube brackets supporting the turbocharger drain tube.
Disconnect and remove the coolant return hose from the
turbocharger and the thermostat housing connection.
Remove the drain fittings from the thermostat housing and
turbocharger.
Marine Applications
Disconnect the coolant supply and return hoses from the
turbocharger, coolant supply, and return water manifolds.
Turbocharger Coolant Hoses K38, K50, QSK38, and QSK50
Remove the fittings from the turbocharger, and from the
supply and return manifolds. Discard the o-rings.
Inspect for Reuse
EAI
Inspect the coolant supply and return hoses for cracks or
other damage.
Inspect the unions, elbows, t-fittings, reducer nuts, and
drain cocks for stripped threads, cracks, and other
damage.
Install
Stage is similar.
Install new o-rings on the supply union fitting on the
turbocharger and the elbow on the water manifold.
Torque Value:
Water and
Turbocharger
Fittings
57 Nm [ 42 ft-lb ]
K38, K50, QSK38, and QSK50 Turbocharger Coolant Hoses
Install the turbocharger coolant supply lines to the union
fittings on the turbocharger and the water manifold.
Tighten the supply line fittings.
Torque Value:
Turbocharger
Supply Line
Fittings
54 Nm [ 40 ft-lb ]
Install new o-rings on the drain union fittings on the
turbocharger and thermostat housing.
Tighten the fittings.
Torque Value:
Thermostat
Housing and
Turbocharger
Fittings
57 Nm [ 42 ft-lb ]
Install the turbocharger coolant drain lines to the union
fitting on the turbocharger and thermostat housing.
Torque Value:
Turbocharger
Drain Line
Fittings
54 Nm [ 40 ft-lb ]
Install the water tube bracket, cover plates, washers and
capscrews on the turbocharger supply and drain hoses.
Torque Value:
Bracket
Capscrews
9 Nm [ 80 in-lb ]
Turbocharger Oil Drain Line K38, K50, QSK38, and QSK50
Marine Applications
Install new o-rings on the fittings and the elbow fittings.
Install the fittings.
Tighten the fittings.
Install the coolant supply and return hoses on the
turbocharger and water manifolds.
Tighten the hoses.
Finishing Steps
EAI
WARNING
Install the turbocharger heat shields (marine
applications only).
Turbocharger Oil Drain Line (010-045)
Preparatory Steps
Remove the turbocharger heat shields (marine
applications only).
K38, K50, QSK38, and QSK50 Turbocharger Oil Drain Line
Remove
Single Stage
Remove the capscrews, washers, and p-clips securing the
turbocharger oil drain lines.
Remove the capscrews and washers connecting the oil
drain lines to the turbochargers and to the engine block.
Discard gaskets and o-ring.
Two Stage
Remove the capscrews, washers and p-clips securing the
turbocharger oil drain lines.
Remove the capscrews and washers connecting the oil
drain lines to the engine block and to the high pressure
turbochargers.
Discard the gaskets and o-rings.
Remove the capscrews and washers that secure the oil
drain line to the engine block and the capscrews
connecting the oil drain line to the front and rear low
pressure turbochargers.
Discard the gaskets and o-rings.
Marine Applications
Remove the turbocharger oil drain line mounting
capscrews from the turbocharger mounting base and the
flywheel housing.
Remove the oil drain and discard the gaskets.
WARNING
WARNING
WARNING
personal injury.
Use solvent to clean the turbocharger oil drain tubes and
male union adapter elbow.
K38, K50, QSK38, and QSK50 Turbocharger Oil Drain Line
Inspect the turbocharger oil drain tubes for signs of
damage.
If damage is found, the tubes must be replaced.
Install
Single Stage
CAUTION
Do not use sealant or gasket adhesive on the gasket
as this can contaminate the lubricating oil system.
Install a new turbocharger oil drain line gasket and install
the turbocharger oil drain line to the turbocharger with the
Lubricate the new o-rings and install them on the ends of
the turbocharger oil drain lines.
Install the turbocharger oil drain lines to the engine block
with the washers and capscrews.
Install the turbocharger oil drain line p-clips, washers, and
capscrews.
CAUTION
Two Stage
On the high pressure turbochargers, install a new
turbocharger oil drain line gasket and install the
turbocharger drain line to the turbochargers with the
Lubricate the new o-rings and install them on the ends of
the high pressure turbocharger oil drain lines.
Install the high pressure turbocharger oil drain lines to the
engine block with the washers and capscrews.
Install the high pressure turbocharger oil drain lines, p-
clips, washers, and capscrews.
CAUTION
On the low pressure turbochargers, install a new
turbocharger oil drain line gasket and install the front and
rear low pressure turbocharger oil drain lines to the
turbochargers with the washers and capscrews.
Lubricate new o-rings and install them on the ends of the
front and rear low pressure turbocharger oil drain lines.
Install the low pressure turbocharger drain lines to the
engine block with the washers and capscrews.
Install the turbocharger heat shield (marine applications
only).
K38, K50, QSK38, and QSK50 Turbocharger Oil Supply Line
Marine Applications
Install new gaskets on the oil drain line.
Install the oil drain line and the mounting capscrews.
Finishing Steps
Turbocharger Oil Supply Line
(010-046)
Preparatory Steps
Remove the turbocharger heat shield (marine
applications). Refer to the OEM manual.
Turbocharger Oil Supply Line K38, K50, QSK38, and QSK50
Remove
Industrial Applications
WARNING
WARNING
used engine oil can be a carcinogenic and cause
Single stage turbocharger, remove the oil supply tubes
from the male unions on the turbochargers. Discard the o-
rings.
Remove the capscrews, washers, and p-clips from the oil
supply tubes.
Remove the oil supply tubes from the male unions on the
engine. Discard the o-rings.
Two Stage
High pressure turbocharger, remove the oil supply tubes
from the male unions on the high pressure turbochargers.
Remove the capscrews, washers, p-clips, and mounting
spacers securing the turbocharger oil supply tubes for the
high pressure turbochargers.
Remove the oil supply tubes from the male unions on the
engine. Discard the o-rings.
Low Pressure Turbocharger
Remove the turbocharger oil supply tubes from the male
unions on the low pressure turbochargers. Discard the o-
rings.
Remove the p-clips, capscrews, mounting spacers and
washers, securing the turbocharger oil supply tubes for
the low pressure turbochargers.
unions on the engine for the low pressure turbochargers.
Marine Applications
NOTE: Shown is the right bank oil supply tube. The
procedure is the same for the left bank.
unions on the engine.
Remove the capscrews, washers, and p-clips securing the
turbocharger oil supply tubes.
Remove the oil supply tube from the turbocharger.
Remove the oil supply line.
WARNING
WARNING
WARNING
compressed air. Flying debris or dirt can cause
personal injury.
Clean the turbocharger oil supply lines and components
with solvent. Dry with compressed air.
Inspect the turbocharger oil supply lines for cracks, other
damage, or restrictions. Replace the line if damaged.
Inspect the p-clips. Replace if damage is found.
Install
Industrial Applications
Install new o-rings on the male unions.
Install the turbocharger oil supply tubes to the male unions
on the turbochargers.
Torque Value:
Oil Supply Tube
Fitting to
Turbocharger
35 Nm [ 26 ft-lb ]
on the engine.
Torque Value:
Oil Supply Tube
Fitting to Male
Union
35 Nm [ 26 ft-lb ]
Attach the p-clips to the turbocharger oil supply tubes.
Attach the p-clips to the engine with the capscrews,
washers, and mounting spacers.
Torque Value:
P-clip to Cylinder
Head Capscrews
20 Nm [ 15 ft-lb ]
Torque Value:
P-clip to Injector
Cover Plate
Capscrews
42 Nm [ 31 ft-lb ]
Two Stage
CAUTION
Do not use sealant or gasket adhesive on gaskets as
this can contaminate the oil system causing engine
damage.
High Pressure Turbochargers
Install new o-rings on the male unions on the
turbocharger.
Install the turbocharger oil supply tubes to the male
unions.
Torque Value:
Oil Supply Tube
Fitting to
Turbocharger
35 Nm [ 26 ft-lb ]
Install new o-rings on the male unions on the engine.
Install the turbocharger oil supply tubes to the male
unions.
Torque Value:
Oil Supply Tube
Fitting to Male
Union
35 Nm [ 26 ft-lb ]
Torque Value:
P-clip to Cylinder
Head Capscrews
20 Nm [ 15 ft-lb ]
Torque Value:
P-clip to Injector
Cover Plate
Capscrews
42 Nm [ 31 ft-lb ]
Low Pressure Turbocharger
CAUTION
Do not use sealant or gasket adhesive on gaskets as
this can contaminate the oil system, causing engine
damage.
Low pressure turbochargers, install new o-rings on the
male unions.
on the turbocharger.
Torque Value:
Oil Supply Tube
Fitting to
Turbocharger
35 Nm [ 26 ft-lb ]
on the engine.
Torque Value:
Oil Supply Tube
Fitting to Male
Union
35 Nm [ 26 ft-lb ]
Torque Value:
P-clip to Cylinder
Head Capscrews
20 Nm [ 15 ft-lb ]
Torque Value:
P-clip to Injector
Cover Plate
Capscrews
42 Nm [ 31 ft-lb ]
Marine Applications
NOTE: Shown is the right bank oil supply line. The
procedure is the same for the left bank.
Install the oil supply hose.
Install the capscrews, washers, and p-clips securing the
turbocharger oil supply tubes.
Use new o-rings and install the turbocharger oil supply
tubes to the male unions on the turbochargers.
Use new o-rings and install the turbocharger oil supply
tubes to the male unions on the engine.
K38, K50, QSK38, and QSK50 Turbocharger Radial Bearing Clearance
Finishing Steps
Install the turbocharger heat shield (marine
applications). Refer to the OEM manual.
Turbocharger Radial Bearing
Clearance (010-047)
Preparatory Steps
WARNING
cable last.
13.
Remove the intake and exhaust piping from the
turbocharger.
Measure
Check the radial clearance of both compressor impeller
and turbine wheel.
Use your hand to push the compressor impeller or turbine
wheel toward the housing.
Use a wire type feeler gauge or feeler gauge that is not
more than 13 mm [1/2 inch] wide. Measure the clearance
between the impeller and the housing at the minimum
clearance point.
AiResearch T-18A Impeller and Turbine Wheel Radial
Clearance
mm in
0.08 MIN 0.003
0.18 MAX 0.007
If the radial bearing clearance is not within specification,
the turbocharger must be replaced. See Bulletin Number
3379091, Turbocharger Component Shop Manual, for
rebuild instructions.
Aftercooler Housing (Center Mount) K38, K50, QSK38, and QSK50
Finishing Steps
WARNING
cable last.
Install the intake and exhaust piping to the
turbocharger.
Aftercooler Housing (Center Mount) (010-073)
Modify
KTA50
This procedure provides the steps required to modify a K50 center mount aftercooler housing to allow the installation
of cross bolts.
The cross bolts increase the stability of the housing and reduce failures caused by cyclic loading of the parts that
have different rates of thermal expansion.
This procedure represents the aftercooler housing that contains a rib in the center of the housing. The procedure
and specifications are also recommended for the K50 aftercooler housing that does not contain the rib.
This modification applies only to the aftercooler housing on K50 engines. The modification is not required for the
aftercooler housing on K38 engines. Some K50 engines contain aftercoolers that have the cross bolts installed.
Tools Required:
Band saw (with blade-welding attachment), hand-type reciprocating saw, end mill, or hand drill and bits to remove
the center rib that is 11 mm [0.43 in] thick
Hand grinder to smooth the surface created when the rib is removed
Radial drill or drill press with sufficient throat clearance to drill the holes for the cross bolts
A 14 mm [17/32-in] drill bit to drill the holes for the cross bolts
A 38 mm [1 1/2-in] diameter spot-face tool or end mill to machine clearance for the flat washers installed on the
cross bolts.
Parts Required:
NOTE: All the parts required, except the sealant, are available in a kit, Part Number 3176123.
3 each - Part Number 3176117, Stud
12 each - Part Number S-264, Flat Washer
12 each - Part Number S-200, Nut [1/2-13 UNC]
6 each - Part Number S-608, Lock Washer
1 each - Part Number 3177132, RTV Sealant
If the stud, Part Number 3176117, is not available, a part
can be fabricated to the dimensions illustrated and
specified.
Reference No. mm in
1 350 13-0.75
2 12 0.5
3 114 4-0.5
4 M12x1.75 1/2-13 UNC
K38, K50, QSK38, and QSK50 Aftercooler Housing (Center Mount)
NOTE: The front to the rear hole center dimension can
be determined by using the three threaded holes for the
cover, marked "+", that are nearest to the center of the
housing.
Use a center punch and a hammer. Mark the location for
the holes on the top (9) of the housing.
Reference No. mm in
5 248 MIN 9.770
250 MAX 9.830
6 361 MIN 14.210
362 MAX 14.270
7 474 MIN 18.650
475 MAX 18.710
8 99 MAX 3.90
Use a center punch and a hammer. Mark the location for
the holes on the bottom (10) of the housing.
The specifications are the same as for the top of the
housing.
NOTE: This step is not required if the housing contains a
rib in the center of the casting.
CAUTION
The covers must be installed on housings that do not
contain a rib to prevent the housing from bending
during the drilling operation.
Install the aftercooler covers. Install a minimum of six
capscrews in the holes illustrated.
Put the housing on the table of the radial drill or drill press.
Be sure the housing is secured to the table of the drill to
prevent movement during the drilling process.
NOTE: If a metric cross bolt is installed, use the correct
size drill bit. Use the drill size given for the stud from the
kit or a stud fabricated from a [0.5 in] rod.
Use a 14 mm [17/32] drill bit. Drill three holes in the
bottom or top of the housing.
Repeat this step to drill the three holes in the other side of
the housing.
NOTE: The spot-face must only be of sufficient depth to
be sure the flat washer will have full contact with the
housing and will be 90 degrees from the centerline of the
drilled hole.
Use a 38 mm [1.5 in] spot-face tool or end mill.
Spot-face each of the six holes on the top and bottom of
the housing. Remove the housing from the drill press.
Remove the covers from the housing that do not have a
rib.
CAUTION
Do not use a large hammer, or a hammer and chisel
to remove the rib. The housing will be damaged.
Use a band or a hand saw. Remove the center rib.
NOTE: If a saw is not available, drill several holes as near
together as possible in the rib near the walls of the
housing. Then very carefully break or saw the material to
connect the holes.
K38, K50, QSK38, and QSK50 Aftercooler Housing (Center Mount)
NOTE: If a saw was used, it is possible that this step is
not necessary.
Use a hand-type grinder. Remove all sharp edges and
burrs that remain on the housing from the rib.
Check the six holes on the inside of the housing. Be sure
the washer (9) can be placed flat on the surface of the
housing.
If the remainder of the rib causes the washer not to be flat
on the surface, use the spot-face tool or end mill to remove
the material so that the washer can be placed flat on the
housing.
CAUTION
Be sure there is no oil around the holes that were
drilled. Any oil will prevent the proper curing of the
RTV sealant.
NOTE: Refer to the following steps to install the three
studs.
NOTE: When installing the stud, Part Number 3176117,
the end of the stud with the longest thread length must
be inserted first, or there will not be sufficient clearance
to install the second stud.
Insert one end of the stud through the hole.
Install a nut (10). Turn the nut until it is on the last thread,
nearest to the center of the stud.
Install the flat washer (11).
Insert the stud through the hole in the other side of the
housing.
Install a nut (10) and a flat washer (11).
Turn both nuts until they are approximately 25 mm [1 in]
from the surface of the housing.
Apply the RTV sealant to the surface of the housing where
the washer will touch, and in the hole around the stud.
CAUTION
Do not use a wrench to turn the nuts on the inside of
the housing. If the nuts on the inside of the housing
are too tight, the housing will bend, causing failure.
Use your hand. Turn the nuts until the washers touch the
housing.
Be sure the stud protrudes the same length at the top and
the bottom of the housing.
Apply sealant to the outside of the housing at the top and
the bottom where the flat washer touches, and in the hole
around the stud.
Install the flat washers (10), lock washers (12), and the
nuts (11) on the studs.
Turn each nut until the flat washer touches the housing.
Tighten the nuts alternately and evenly.
K38, K50, QSK38, and QSK50 Aftercooler Water Outlet Tube
Aftercooler Water Inlet Tube (010-074)
Center-Mount
WARNING
WARNING
WARNING
personal injury.
Check the parts for damage. Any parts that are damaged
must be replaced.
Aftercooler Water Outlet Tube
(010-075)
Center-Mount
NOTE: Two water outlet tubes are required for each
engine.
WARNING
WARNING
Use solvent or steam. Clean the tube.
Aftercooler Water Outlet Tube K38, K50, QSK38, and QSK50
Check the tube for cracks or damage from corrosion.
Check to be sure the tube is not restricted because of
mineral deposits. Remove any mineral deposits.
Section 11 Exhaust System Group 11 Page 11-a
Section 11 Exhaust System Group 11
Section Contents
Page
Bellows ..........................................................................................................................................................11-36
Finishing Steps............................................................................................................................................. 11-37
Install............................................................................................................................................................11-36
Remove.........................................................................................................................................................11-36
Exhaust Connection Pipe ................................................................................................................................11-2
Finishing Steps...............................................................................................................................................11-3
Install..............................................................................................................................................................11-3
Remove..........................................................................................................................................................11-2
Exhaust Manifold (Wet) Water Connections .................................................................................................11-33
MAI............................................................................................................................................................11-34
Finishing Steps............................................................................................................................................. 11-35
MAI............................................................................................................................................................11-35
Install............................................................................................................................................................11-34
MAI............................................................................................................................................................11-34
Remove.........................................................................................................................................................11-33
MAI............................................................................................................................................................11-33
Exhaust Manifold, Dry .....................................................................................................................................11-4
Assemble........................................................................................................................................................11-9
Disassemble...................................................................................................................................................11-7
Finishing Steps............................................................................................................................................. 11-23
Install............................................................................................................................................................11-10
KT38 and KTA38 with Dry Exhaust Manifolds.............................................................................................11-10
KTTA38 with Dry Exhaust Manifolds...........................................................................................................11-11
KT38 and KTA38 with Dry Exhaust Manifolds.............................................................................................11-11
KTA50 Dry Exhaust Manifolds....................................................................................................................11-13
KTTA50 Dry Exhaust, Log Type Manifolds..................................................................................................11-14
K50 Dry Exhaust, Pulse Type Manifolds......................................................................................................11-15
K38 and K50 Bellows Manifold....................................................................................................................11-20
Remove..........................................................................................................................................................11-6
Exhaust Manifold, Wet ..................................................................................................................................11-24
EAI.............................................................................................................................................................11-26
Finishing Steps............................................................................................................................................. 11-31
EAI.............................................................................................................................................................11-31
Install............................................................................................................................................................11-28
EAI.............................................................................................................................................................11-28
EAI.............................................................................................................................................................11-24
Remove.........................................................................................................................................................11-25
EAI.............................................................................................................................................................11-25
Exhaust Restriction .......................................................................................................................................11-31
Measure........................................................................................................................................................11-31
Service Tools ...................................................................................................................................................11-1
Exhaust System Dataplate...............................................................................................................................11-1
Page 11-b Section 11 Exhaust System Group 11
Section 11 Exhaust System Group 11 Page 11-1
Service Tools
Exhaust System Dataplate
Repair Location.
ST-1111-3
Manometer (Mercury Filled Slack Tube)
Used to measure exhaust restriction.
3824879
Anti-Seize Compound
Used to speed asembly and disassembly of studs, bolts, capscrews,
flanges, and fittings.
3375958
Nylon Lifting Strap 2 in by 6 ft
3375957
3164794
Torque Wrench
3164798
Torque Wrench
Exhaust Connection Pipe K38, K50, QSK38, and QSK50
Page 11-2 Section 11 Exhaust System Group 11
Exhaust Connection Pipe (011-001)
Preparatory Steps
Remove the bolts securing the OEM exhaust
connection pipe. Refer to manufacturer's installation
instructions.
Remove
Remove the eight nuts and bolts from each flange
connecting the exhaust connection pipe to the exhaust
bellows.
WARNING
Remove the four capscrews connecting the exhaust
connection pipe to the support bracket.
Remove the exhaust connection pipe.
WARNING
WARNING
can cause personal injury.
Use solvent to clean the exhaust connection pipe.
Clean the exhaust connection pipe with a steam cleaner
to remove any remaining residue.
K38, K50, QSK38, and QSK50 Exhaust Connection Pipe
Inspect the exhaust connection pipe for any signs of
damage or deterioration.
If damage is found that will allow exhaust gas leakage,
replace the exhaust connection pipe.
Install
WARNING
Use new gaskets and install the exhaust connection pipe.
Install the four capscrews connecting the exhaust
connection pipe to the support bracket.
Install the eight nuts and bolts on each flange connecting
the exhaust connection pipe to the exhaust bellows.
Finishing Steps
Install the bolts securing the OEM exhaust
connection to the exhaust connection pipe. Refer to
the manufacturer's installation instructions.
Exhaust Manifold, Dry K38, K50, QSK38, and QSK50
Exhaust Manifold, Dry (011-007)
General Information
The manifold parts and mounting hardware are not the
same for all K38 and K50 engines. Because the parts are
different, procedures are described for installation of the
exhaust manifolds for:
KT38 and KTA38 Dry Exhaust Manifolds
KTTA38 Dry Exhaust Manifolds
KT38 and KTA38 Dry Exhaust Manifolds with Center
Mount Turbochargers (Outboard aftercoolers)
KT38, KTA38, and KTA50 Wet Exhaust Manifolds
KTA50 Dry Exhaust Manifolds
KTTA50 Dry Exhaust, Log Type Manifolds
KTA50, KTTA50, K1500E, K1800E and K2000E Dry
Exhaust, Pulse Type Manifolds
K38 and K50 Bellows Manifolds.
The marine exhaust system is used on the K38 M0/M1/
M2/D(M1) and the K50M2/D(M1) engines.
The marine exhaust manifold side profile is shown.
The marine exhaust manifold bellows has a different
design than the industrial exhaust manifold bellows.
The marine exhaust manifold bellows is shown.
K38, K50, QSK38, and QSK50 Exhaust Manifold, Dry
The exhaust manifold bellows gasket, Part Number
3966350, is located in the end of the bellows.
The bellows will not seal without the gasket in place.
The illustration shows the marine exhaust manifold
bellows with the gasket fitted in place.
Preparatory Steps
WARNING
[120F] before servicing the pressure cap. Heated
WARNING
WARNING
Remove the turbochargers. Refer to Procedure
010-033 (Turbocharger) in Section 10.
Remove the air inlet and crossover connections.
Refer to Procedure 010-021 (Air Crossover
(Outboard Aftercooler)) in Section 10.
Remove the wet manifold coolant supply tubes.
Refer to Procedure 011-016 (Manifold (Wet) Water
Connections) in Section 11.
Remove the center mounted aftercooler. Refer to
Procedure 010-002 (Aftercooler Assembly) in
Section 10.
On KTTA engines, remove the low pressure turbocharger
support brackets.
Remove
Use a drift and hammer to bend the lock plates away from
the capscrew heads.
NOTE: All engines do not contain this type of lockplate.
Some engines contain a lockplate that snaps over the
capscrew head. Some engines have locking capscrews
that do not require lockplates.
WARNING
NOTE: The dry manifold shown is a typical type. The
exhaust manifolds for the K38 and K50 engines are
different. The disassembly procedure, however, is the
same.
There are four capscrews at each cylinder head exhaust
port.
Remove the lockplates (5).
Remove the capscrews and spacers.
Remove both exhaust manifolds.
Remove the gaskets (3).
Disassemble
Use a mallet to separate the manifold sections.
WARNING
WARNING
Use steam or solvent to clean the manifold.
Use a wire brush to remove any scale from the inside and
outside diameters of the sealing joints.
Use 240 grit emery cloth and clean all of the exhaust
manifold gasket surfaces.
WARNING
WARNING
NOTE: This procedure applies to all K38 and K50 dry
manifolds. Only one style is illustrated.
Check the manifold for cracks, warping, or leaks at the
joints.
If any of the sections leak or are damaged, the manifold
section must be replaced.
Check for cracks in the areas shown.
Check all turbocharger mounting studs for damage.
If a manifold section is to be installed again, measure the
inside diameter (1) and the outside diameter (2) of the
connecting manifold section.
The inside diameter can be a maximum of 0.063 mm
[0.0025 in] larger than the outside diameter. The inside
diameter and the outside diameter can be the same size.
WARNING
NOTE: This procedure applies to all K38 and K50 dry
manifolds. Only one style is illustrated.
Use solvent or steam to clean the parts.
Assemble
Use an anti-seize compound to lubricate the outside
diameter of the sections in the area that slides into the
connecting manifold section.
Use a mallet to install the section to the connecting
section.
Install
KT38 and KTA38 with Dry Exhaust Manifolds
WARNING
CAUTION
Do not use gasket adhesives. The adhesive can cause
the molybdenum disulfide coating on the gasket to
lose its effectiveness and cause a gasket or capscrew
failure.
NOTE: The manifolds can be installed on either engine
bank.
NOTE: Install the mounting capscrews (2) that are 76 mm
[3 in] in length and spacers (1) that are 42.4 mm [1.67 in]
in length for all applications except generator sets. Install
capscrews that are 38 mm [1.5 in] in length and hardened
washers for manifolds on generator set applications.
Install the spacers (1) on the capscrews (2). Apply an anti-
seize compound on the threads of the capscrews.
the gasket is toward the manifold.
Install the gaskets (3), manifold (4), and capscrews. Check
to be sure the gasket is aligned properly with the manifold
and the cylinder head.
Torque Value:
38 mm [1.5 in]
capscrew
60 Nm [ 44 ft-lb ]
Torque Value:
76 mm [3 in]
capscrew with N
stamped on head
55 Nm [ 41 ft-lb ]
Torque Value:
76 mm [3 in]
capscrew without
N stamped on
head
80 Nm [ 59 ft-lb ]
NOTE: Capscrews without the N stamped on the head
have special threads to lock the capscrew and are not
available for service. The torque value is included in case
they are used again.
NOTE: Lockplates are not required on capscrews with
locking threads.
Use a 5/8 inch 12 point socket and a mallet to install each
lockplate (5) on the heads of two capscrews. Do not break
the lockplate.
KTTA38 with Dry Exhaust Manifolds
WARNING
CAUTION
failure.
bank.
Install the mounting capscrews (2) that are 114 mm [4.5
in] in length and hardened washers (1) for the center
section of the manifold. Install mounting capscrews (4)
that are 76 mm [3 in] in length and the spacers (3) that are
42.4 mm [1.67 in] for the end sections.
Install the washers (1) on the capscrews (2). Install the
spacers (3) on the capscrews (4). Apply an anti-seize
compound on the threads of the capscrews.
the gasket is toward the manifold.
Install the gaskets (5), the manifold (6), and the
capscrews. Check to be sure the gasket is aligned
properly with the manifold and the cylinder head.
the lockplate.
KT38 and KTA38 with Dry Exhaust Manifolds
WARNING
CAUTION
failure.
NOTE: The following information applies to center-mount
turbochargers with outboard aftercoolers only.
The manifold center section must be installed on the
correct engine bank for the engine exhaust piping to fit the
application.
If the exhaust is to be toward the rear of the engine, the
center section (8) with the smallest angle must be
installed on the right bank.
If the exhaust is to be toward the front of the engine, the
center section (8) with the smallest angle must be
installed on the left bank.
Install the mounting capscrews (2) that are 114 mm [4.5
in] in length and hardened washers (1) for the center
section of the manifold. Install the mounting capscrews (4)
that are 76 mm [3 in] in length and the spacers (3) that are
42.4 mm [1.67 in] for the end sections.
Install the washers (1) on the capscrews (2). Install the
spacers (3) on the capscrews (4). Apply an anti-seize
compound on the threads of the capscrews.
NOTE: The gasket must be installed so the raised bead
on the gasket is toward the manifold.
the lockplate.
KTA50 Dry Exhaust Manifolds
WARNING
CAUTION
failure.
bank.
Install capscrews (3) that are 140 mm [5.5 in] in length.
Install hardened washers (1) on all the capscrews except
at the end of the closed-end section. Install spacers (2)
that are 105.64 mm [4.159 in] in length on the capscrews
at the end of the closed-end section.
NOTE: Older engines contained a 38 mm [1.5 in]
capscrew and a hardened washer (1) at the end of the
closed-end section. These capscrews had special threads
and are no longer available for service. If the older
capscrew is replaced, the capscrew (3) and spacer (2)
must be installed.
Install the hardened washers (1) and spacers (2) on the
capscrews (3). Apply an anti-seize compound on the
Torque Value:
140 mm [5.5 in]
capscrew with N
stamped on head
55 Nm [ 41 ft-lb ]
Torque Value:
140 mm [5.5 in]
and 38 mm [1.5
in] capscrews
without N
stamped on head
80 Nm [ 59 ft-lb ]
have special threads to lock the capscrew and are no
longer available for service. The torque value is included
in case they are used again.
special threads.
the lockplate.
KTTA50 Dry Exhaust, Log Type Manifolds
WARNING
CAUTION
failure.
bank.
Install capscrews (3) that are 140 mm [5.5 in] in length.
Install hardened washers (1) on all the capscrews except
at the end of the closed-end section. Install spacers (2)
that are 105.64 mm [4.159 in] in length on the capscrews
at the end of the closed-end section.
Older engines contained a 38 mm [1.5 in] capscrew and
a hardened washer (1) at the end of the closed-end
section. These capscrews had special threads and are no
longer available for service. If the older capscrew is
replaced, the capscrew (3) and spacer (2) must be
installed.
Install the hardened washers (1) and spacers (2) on the
capscrews (3). Apply an anti-seize compound on the
Torque Value:
140 mm [5.5 in]
capscrew with N
stamped on head
55 Nm [ 41 ft-lb ]
Torque Value:
140 mm [5.5 in]
and 38 mm [1.5
in] capscrews
without N
stamped on head
80 Nm [ 59 ft-lb ]
have special threads to lock the capscrew and are no
longer available for service. The torque value is included
in case they are used again.
special threads.
the lockplate.
K50 Dry Exhaust, Pulse Type Manifolds
This procedure applies to the KTA50, KTTA50, K1500E,
K1800E, 2000E manifolds also.
KTA50 engines with pulse-type manifolds contain a
straight center section (1) on one bank and a curved
center section (2) on the other bank. The manifold center
sections must be installed on the correct engine bank for
the engine exhaust piping to fit the application. If the
exhaust is to be toward the rear of the engine, the manifold
with the straight center section (1) must be installed on
the left bank. If the exhaust is to be toward the front of the
engine, the straight center section must be installed on
the right bank.
KTTA50 engines with pulse-type manifolds contain a
straight center section (1) in both banks. These manifolds
can be installed on either engine bank.
A variety of changes were made to the K50 pulse-type
exhaust manifolds (1, 2, and 3) and manifold mounting
parts (7, 8, and 9).
A revised straight center section, Part Number 3630241,
replaced the previous straight center section, Part
Number 3626757 or 3628682.
This revised straight center section is to be used on non-
uprate K50 engines that require a pulse manifold
(example: KTA50C-1600 engine).
This manifold, Part Number 3630241, can be identified by
a notch in the exhaust port nearest to the two exhaust
inlets or double end. The previous manifold, Part Number
3626757 or 3628682, did not have a notch.
The notch can also be seen in the lower exhaust inlet.
Uprate construction K50 exhaust manifold center sections
require a higher thermal fatigue strength material (Ni-
Resist).
The distance between the two exhaust inlets or the double
end has increased.
A dogleg exhaust manifold section, Part Number
3627878, was released for use on uprate K50 construction
engines to accommodate this increased distance.
The uprate construction straight center section, Part
Number 3629532, is to be used on the K2000E, KTTA50-
C1800-B version, and on the left bank of the K1800E.
The construction uprate curved center section is to be
used on the right bank of the K1800E.
The K1800E right-bank center section allows for rear-out
exhaust.
Engine Serial Number First for Sections
Serial Number Section Part Number
33122641 3627877
33122641 3627878
33124817 3630241
* 3629532
* Engine serial number first build date is March 1994.
The manifolds have been changed by increasing the size
of the dowel hole (A) to the same diameter, 15 mm [0.591
in], as the other seven mounting holes within each section.
The smaller dowel hole was used to locate the manifold
front to rear to make sure the slip joint was properly
positioned.
CAUTION
Guide pins or studs must be used or the manifolds will
not be positioned properly, causing the manifold
cylinder head capscrews to break.
Use locating pins to position the new manifolds properly.
Use one pin in each section.
The diameter of the pin provides the proper manifold
position and alignment.
The locating pin dimensions are listed below so they can
be locally manufactured.
(A) Diameter:
13.8 mm to 14.0 mm [0.543 in to 0.551 in].
(B) Undercut to thread root diameter
(C) Thread size 0.438 in x 14 in x 0.50 in long
(D) Unthreaded length 99.2 mm [3.91 in].
NOTE: Wrench flats are optional on unthreaded end.
Inadequate clearance between exhaust manifold sections
(A and B) will result in failed capscrews, exhaust
manifolds, or cylinder heads. Use guide pins or studs to
make sure the manifolds have proper clearance (C and D).
The typical manifold clearance (C) ranges from 4.0 to 9.5
mm [0.158 to 0.374 in].
Longer exhaust manifold mounting capscrews and
spacers provide improved gasket sealing while permitting
slippage or movement at the cylinder head and exhaust
manifold interface.
Part Name Old Dimension New Dimension
Spacer-A 42.4 mm [1.67 in] 105.6 mm [4.16 in]
Spacer-B 76.2 mm [3.00 in] 139.7 mm [5.50 in]
NOTE: The longer capscrews and spacers can be used in
all positions except the left-bank front without any
component changes. Installation of longer capscrews and
spacers in the left-bank front position requires a new
thermostat housing support and water transfer tube. New
capscrews and spacers can be used on any K50 pulse-
type manifold part number.
WARNING
CAUTION
Do not use gasket adhesives. The adhesives can
cause the molybdenum disulfide coating on the
gasket to lose its effectiveness and cause a gasket or
capscrew failure.
capscrews.
Install the gaskets, manifold, and mounting capscrews
and spacers. Check to be sure that the gasket is aligned
properly with the manifold and the cylinder head.
NOTE: When installing the lockplate over the capscrew
head, install the plate to approximately one-half of the
head height. Installing the lockplate until it bottoms will
cause it to break.
In order to obtain clearance (A) for the longer capscrews
and spacers, three other component changes have been
made.
1. A clearance (A) has been cast into the thermostat
housing support to permit wrench and lockplate
clearance.
2. The water transfer tube (A) from the front of the V-
cavity to the thermostat housing support interferes
with the capscrew lockplate (B).
A flat has been added to the water transfer tube (A) to help
prevent interference with the capscrew lockplate (B) when
the longer spacers are used. The dotted line (C)
represents the flat added to the tube.
NOTE: Do not install the old lockplate, Part Number
3043912, upside down to clear the water tube. The
lockplate will either break or not be retained properly on
the capscrew head.
3. To increase the water-tube-to-lockplate clearance
even more, a new lockplate was released. The new
lockplate has the V-bend pointed downward toward
the manifold, rather than upward.
These changes were introduced in November 1994 (ESN
first 33128992).
K38 and K50 Bellows Manifold
Install the bellows to both sides of the bolt-together
manifold sections. Securing the bellows with V-band
clamps, install the clamps with the tightening screw on the
topside of the exhaust facing inboard.
NOTE: Bellows must be installed correctly to prevent
damage from the gas flow.
The arrow in the picture indicates the correct direction of
gas flow through the bellows.
Install additional bellows to the single inlet side of the
center turbocharger mounting section, securing the
bellows V-clamp, as above.
Install the exhaust outlet adapter with the gasket.
Starting on the left bank of the engine, install gaskets of
the correct thickness and install the bolt-together pulse
section to cylinder heads 5 and 6. Leave the clamps loose
at this point.
After installing the correct thickness gaskets, install the
rear exhaust section while securing it to the bellows of the
bolt-together section just installed.
If the rocker housings are on the engine, then it will be
necessary to loosen the bolt-together pulse section
capscrews to allow the V-clamp to be fitted. Leave the
capscrews loose at this point.
Install the center turbocharger mounting section while
securing it to the two bellows of the bolt-together pulse
section. Leave the main securing capscrews loose at this
point.
Install the final end section of the exhaust system, leaving
the capscrews loose at this point.
Remove two upper capscrews from the center sections of
the exhaust system. Make sure the exhaust section is
centered with the tapped holes in the cylinder heads.
Tighten the main securing capscrews.
Move either direction to the next section and remove two
capscrews. Center the exhaust manifold over the tapped
holes.
Tighten the main capscrews.
NOTE: It is important that each section of the exhaust
system be centralized to the tapped holes in the cylinder
head before tightening mounting capscrews and V-band
clamps. It is also important that the bellows be installed
correctly for the gas flow direction.
Position the V-band clamps at approximately 110 degrees
to the exhaust mounting face.
Torque Value:
Tighten the
marine
application V-
band clamp
17 Nm [ 150 in-lb ]
Torque Value:
Tighten the
industrial
application V-
band clamp
5 Nm [ 44 in-lb ]
Repeat the above installation instructions on right bank.
CAUTION
Installing the lockplate until it bottoms will cause it to
break.
NOTE: When installing the lockplate over the capscrew
head, install the plate to approximately one-half of the
head height.
Install lockplates on the heads of all exhaust manifold
capscrews.
Finishing Steps
On KTTA engines, install the low pressure turbocharger
support brackets.
WARNING
WARNING
Install the center mounted aftercooler. Refer to
Procedure 010-002 (Aftercooler Assembly) in
Section 10.
Install the turbochargers. Refer to Procedure
Install the wet manifold coolant tubes. Refer to
Procedure 011-016 (Exhaust Manifold (Wet) Water
Connections) in Section 11.
Install the air inlet and crossover connections. Refer
to Procedure 010-021 (Air Crossover (Outboard
Aftercooler)) in Section 10.
Exhaust Manifold, Wet K38, K50, QSK38, and QSK50
Exhaust Manifold, Wet (011-008)
Preparatory Steps
EAI
WARNING
WARNING
WARNING
cable last.
CAUTION
13
Remove the air intake filter assemblies. Refer to
Mounted)) in Section 10.
Remove the expansion tank. Refer to Procedure
008-052 (Expansion Tank) in Section 8.
Procedure 011-001 (Exhaust Connection Pipe) in
Section 11
Remove the exhaust bellows. Refer to Procedure
011-018 (Exhaust Manifold, Dry) in Section 11.
010-037 (Turbocharger, Water-Cooled) in Section
10.
K38, K50, QSK38, and QSK50 Exhaust Manifold, Wet
Remove
EAI
NOTE: Shown in this procedure is the QSK50 engine.
the same for the QSK38.
Remove the water hoses from the transfer tubes to the
inlet elbows.
Remove the elbows from the exhaust manifold.
Remove the hose clamps from the front of the water
transfer tubes.
Remove the capscrews, the top halves of the isolators,
and the transfer tube.
Remove the lower halves of the transfer tube isolators.
WARNING
equipment to lift this component of assembly.
Install approved lifting straps and use an approved hoist.
Remove the capscrews from the bottom two holes of each
cylinder head exhaust port; replace with guide studs.
Remove the upper capscrews connecting the exhaust
manifold to the cylinder heads.
Lift and remove the exhaust manifold.
EAI
Use a wire brush or scraper to clean the cylinder head to
exhaust manifold surface.
Remove the guide studs, if necessary replace after
cleaning.
WARNING
Wear safety glasses of a face shield, as well as
protective clothing, to prevent personal injury when
using a steam cleaner or high-pressure water.
Use a steam cleaner or high pressure water to clean the
exhaust manifold.
Use a wire brush or scraper to remove any scale on the
exhaust manifold sealing joint inside and outside
diameters.
Inspect the exhaust manifold turbocharger mating flange
for cracks.
If cracks or other damage is found, replace the exhaust
manifold.
Inspect the mounting capscrew holes and water transfer
elbow mounting area for damage.
If cracks or other damage is found, replace the exhaust
manifold.
Inspect the elbows and hoses for signs of damage or wear.
If damage is found, replace the elbows and/or hoses.
Inspect the water transfer tubes for leakage or other signs
of damage.
Inspect the isolators and capscrews for damage or wear.
Inspect the capscrews for damaged threads or corrosion.
Install
EAI
With the guide studs still in the bottom two holes of each
cylinder head exhaust port, install the exhaust gaskets.
Start the exhaust manifold onto the guide studs. Push the
exhaust manifold in until it contacts the cylinder head.
Apply anti-seize compound to the exhaust mounting
capscrews and install the washers and capscrews into the
top row of mounting holes. Hand tighten the capscrews.
Remove the guide studs, apply anti-seize compound to
the exhaust mounting capscrews, and install the washers
and capscrews.
Tighten the capscrews in the sequence illustrated.
Install the lower half of the transfer tube isolators.
Install the transfer tube, top half of the isolators, and the
capscrews.
Install the Staub clamps on the front of the water transfer
tubes.
Use new o-rings and install the elbows on the exhaust
manifold.
Install the water hoses from the transfer tubes to the inlet
elbows.
Align the fittings and hose connections.
Tighten the fittings and hose connections.
K38, K50, QSK38, and QSK50 Exhaust Restriction
Finishing Steps
EAI
WARNING
WARNING
cable last.
CAUTION
010-037.
Install the exhaust bellows. Refer to Procedure
011-018.
Procedure 011-001.
Install the expansion tank. Refer to Procedure
008-052.
Install the air intake filter assemblies. Refer to
Mounted)) in Section 10.
Exhaust Restriction (011-009)
Measure
Connect a pressure gauge in the exhaust piping. The
gauge must have a capacity of 75 mm Hg [3 inch Hg] or
1270 mm H2O [50 inch H2O]
Exhaust Restriction K38, K50, QSK38, and QSK50
The pressure gauge adapter, or fitting, must be installed
at a 90-degree angle to the exhaust flow in a straight
section of pipe. The adapter location must be a minimum
of 254 mm [10 in] after the turbocharger.
The adapter must not extend through the wall of the
exhaust tubing.
If the adapter must be located in a curved section of
tubing, locate it on the flat side of the curve, not in the
radius, or the measured valve will not be accurate.
Connect a 305 mm [12 in] piece of metal tubing between
the gauge adapter and the gauge hose. This will prevent
damage to the hose from extreme heat.
Operate the engine at rated rpm and load; record the
manometer reading.
NOTE: Exhaust pressure must not exceed 7.5 cm [3.0
Hg].
If the exhaust restriction exceeds the specification,
inspect the exhaust piping for damage. Refer to the
OEM's instructions.
If damage is not visible, check the size and routing of the
exhaust piping. Refer to the installation recommendation
bulletin.
Remove the test equipment.
K38, K50, QSK38, and QSK50 Exhaust Manifold (Wet) Water Connections
Exhaust Manifold (Wet) Water
Connections (011-016)
Preparatory Steps
WARNING
WARNING
WARNING
WARNING
cable last.
13.
Remove the air inlet and crossover connections.
Refer to Procedure 010-020 (Air Crossover (Center-
Mount Aftercooler)) in Section 10.
Remove the center mounted aftercooler. Refer to
Procedure 010-003 (Aftercooler Assembly (Center-
Mount)) in Section 10.
Remove
MAI
NOTE: There are connections at the front and rear of the
engine.
Remove the capscrews (5). Pull the water tube from the
exhaust manifold.
Remove the capscrews (4) and the capscrews (2). Pull the
water tubes from the connection (1). Remove the
connection and the gasket.
Discard the gasket.
Remove the capscrew (9), the spacer (8), the plug (7), and
the o-ring (6).
Discard the o-ring.
Exhaust Manifold (Wet) Water Connections K38, K50, QSK38, and QSK50
MAI
Clean and check the water connections for reuse.
Install
MAI
NOTE: The engine has two water connections. The
installation procedure is the same for both.
NOTE: If the o-rings have not been installed on the water
tubes, install them.
Use vegetable oil. Lubricate the o-rings.
Position the connection (1) between the water tubes. Push
the tubes into the bore of the connection. Install the two
flat washers, lock washers, and capscrews (2).
Install the gasket (3), the three lock washers, and the
capscrews (4).
Install the flat washers, lock washers, and capscrews (5)
through the tab on the tube to the exhaust manifold.
NOTE: The plug (7) is to be installed only on the exhaust
manifold at the left bank rear of the engine.
Install the o-ring (6) on the plug (7).
Install the plug in the bore in the exhaust manifold.
Install the spacer (8), lock washer, and capscrew (9). The
spacer will hold the plug in the bore.
K38, K50, QSK38, and QSK50 Exhaust Manifold (Wet) Water Connections
NOTE: The plug is to be installed only on the exhaust
manifold at the left bank rear of the engine.
Install the o-ring on the plug.
Install the plug in the bore in the exhaust manifold.
Install the spacer, lock washer, and capscrew. The spacer
will hold the plug in the bore.
Finishing Steps
MAI
WARNING
WARNING
WARNING
cable last.
Install the center mounted aftercooler. Refer to
Procedure 010-003 (Aftercooler Assembly (Center-
Mount)) in Section 10.
Install the water transfer inlet and outlet connections.
Refer to Procedure 010-020 (Air Crossover (Center-
Mount Aftercooler)) in Section 10.
Bellows K38, K50, QSK38, and QSK50
Bellows (011-018)
Preparatory Steps
WARNING
WARNING
cable last.
13.
Remove the bolts securing the OEM exhaust
the manufacturer's instructions.
Section 11.
Remove
WARNING
Remove the eight capscrews and washers to each flange
connecting the exhaust bellows to the turbochargers.
Remove the exhaust bellows and gaskets.
Install
WARNING
Use new gaskets and install the exhaust bellows.
Install the eight capscrews and washers to each flange
connecting the exhaust bellows to the turbochargers.
K38, K50, QSK38, and QSK50 Bellows
Finishing Steps
WARNING
WARNING
cable last.
Section 11.
Install the bolts securing the OEM exhaust
the manufacturer's instructions.
Bellows K38, K50, QSK38, and QSK50
Notes
Section 12 Compressed Air System Group 12 Page 12-a
Section 12 Compressed Air System Group 12
Section Contents
Page
Air Compressor ............................................................................................................................................. 12-13
Finishing Steps............................................................................................................................................. 12-18
Install............................................................................................................................................................12-16
Remove.........................................................................................................................................................12-14
Air Compressor (Oil Carryover) .................................................................................................................... 12-22
Air Compressor Carbon Buildup .....................................................................................................................12-4
Inspect............................................................................................................................................................12-4
Air Compressor Pin Bore Wear .......................................................................................................................12-6
Initial Check....................................................................................................................................................12-6
Air Compressor Unloader and Valve Assembly .............................................................................................12-9
Assemble......................................................................................................................................................12-11
Holset QE230, QE296, and QE338 A/C Model.......................................................................................... 12-11
Disassemble..................................................................................................................................................12-10
Holset QE230, QE296, and QE338 A/C Model.......................................................................................... 12-10
Finishing Steps............................................................................................................................................. 12-13
Initial Check....................................................................................................................................................12-9
Air Governor (Air Compressor Pumps Continuously) ..................................................................................12-19
Initial Check..................................................................................................................................................12-19
Air Governor (Air Compressor Will Not Pump) .............................................................................................12-18
Initial Check..................................................................................................................................................12-18
Air Leaks, Compressed Air System ..............................................................................................................12-21
Initial Check..................................................................................................................................................12-21
Air Starting Motor ..........................................................................................................................................12-23
Service Tools ...................................................................................................................................................12-1
Compressed Air System..................................................................................................................................12-1
Page 12-b Section 12 Compressed Air System Group 12
Section 12 Compressed Air System Group 12 Page 12-1
Service Tools
Compressed Air System
Repair Location.
ST-302
Ball Joint Vise
Used to hold the air compressor for disassembly or assembly.
ST-647
Standard Puller
Used to pull the drive gear. Use with puller capscrews that have M8
x 1.25-6H thread.
ST-749
Mounting Plate
Used to mount the air compressor to the vise.
3823596
Mounting Plate
Used to mount the air compressor to the vise.
3375182
Valve Spring Tester
Used to check the exhaust valve, intake valve, and unloader valve
cap springs.
3376663
Coupling Puller
Used to remove the spline coupling hub.
Page 12-2 Section 12 Compressed Air System Group 12
3377415
Air Compressor Seat Installation Tool
Used to install exhaust valve seats.
3377416
Air Compressor Seat Removal Tool
Used to remove exhaust valve seats.
3823528
Air Compressor Seat Socket
Used to remove and install exhaust valve seats and the inlet valve
cages.
ST-544
Valve Seat Puller
Used to remove exhaust valve seats on older compressors, where
the head is mounted on the air compressor.
3822674
Compressor Exhaust Valve Seat Kit
Tools used to pull and install the press fit nine hole exhaust seats in
single cylinder Cummins air compressors.
3822681
Compressor Exhaust Valve Seat Kit
Kit that converts Compressor Exhaust Valve Seat Kit, Part Number
3822674, into a two cylinder air compressor kit.
3824879
Anti-Seize Compound
Lubricant that speeds assembly and disassembly of studs, bolts,
capscrews, flanges, and fittings.
3824783
Torque Wrench
An inch-pound dial-type torque wrench
3164794
Torque Wrench
Air Compressor Carbon Buildup K38, K50, QSK38, and QSK50
Air Compressor Carbon Buildup
(012-003)
Inspect
WARNING
personal injury.
Shut off the engine.
Open the drain cock on the wet tank to release
compressed air from the system.
Remove the air inlet and outlet connections from the air
compressor.
Measure the total carbon deposit thickness inside the air
discharge line as shown.
The carbon deposit thickness must not exceed 1.6 mm
[0.06 in].
WARNING
The air discharge line must be capable of
withstanding extreme heat and pressure to prevent
personal injury and property damage. See to the
manufacturer's specifications.
If the total carbon deposit thickness exceeds specification,
remove and clean, or replace the air discharge line. See
to the manufacturer's material specifications.
K38, K50, QSK38, and QSK50 Air Compressor Carbon Buildup
WARNING
The air discharge line must be capable of
withstanding extreme heat and pressure to prevent
personal injury and property damage. See to the
Continue to check for carbon buildup in the air discharge
line connections up to the first connection, or wet tank.
Clean or replace all lines and fittings with carbon deposits
greater than 1.6 mm [0.06 in]. See to the manufacturer's
specifications for cleaning or replacement instructions.
CAUTION
Do not use a sharp object to remove carbon. The
sealing surfaces can be damaged.
Remove the air compressor head and valve assembly; see
to the Master Repair Manual, Holset Air Compressors,
Bulletin 3666121.
Clean the compressor head and valve assembly
components with solvent and a nonmetallic brush to
remove carbon.
Inspect the valve assembly components for reuse; see to
the Master Repair Manual, Holset Air Compressors,
Bulletin 3666121.
Assemble the air compressor using new gaskets and o-
rings; see to the Master Repair Manual, Holset Air
Compressors, Bulletin 3666121.
Install and tighten the air inlet and outlet connections.
Close the wet tank drain cock.
Operate the engine and check for air leaks.
Air Compressor Pin Bore Wear K38, K50, QSK38, and QSK50
On upright two cylinder air compressors, replace the air
compressor.
Air Compressor Pin Bore Wear
(012-010)
Initial Check
WARNING
The unloader valve body is installed with spring
tension. Use care when removing to reduce the
possibility of personal injury. Always wear protective
eye wear.
NOTE: This procedure applies to SS and ST models
only.
Hold the unloader valve body down, and remove the two
captive washer capscrews and the two plain washers.
Remove the unloader valve body.
Remove the o-ring.
Remove the rectangular ring seal.
CAUTION
To reduce the possibility of damage to the air
compressor, do not allow any debris to fall into the air
compressor cylinder.
NOTE: Disassembly of the center unloader valve on
Cummins Turbo Technologies two-cylinder air
compressors is similar to the single-cylinder unloader
valve.
Remove the unloader valve cap and the unloader valve
spring.
Remove the intake valve seat and valve.
Remove the intake valve spring.
K38, K50, QSK38, and QSK50 Air Compressor Pin Bore Wear
CAUTION
Do not use a screwdriver. A screwdriver can gouge
the top of the piston.
Insert the small end of a 3/8-inch drive socket extension
152 to 254 mm (6- to 10-inches long) through the exhaust
valve seat onto the top of the piston.
Bar the crankshaft over until the compressor piston
reaches top dead center and the extension starts to move
downward approximately 3 to 6 mm [1/8 to 1/4 in].
CAUTION
To prevent damage to the top of the piston, do not use
a hammer.
Give a quick, hard push, downward on the extension, and
listen for a metallic click as wear clearance is taken up.
If significant piston motion is felt or a metallic click is
heard, the pin bores can be worn, and the compressor
must be examined further.
Air Compressor Pin Bore Wear K38, K50, QSK38, and QSK50
All air compressors will not exhibit pin bore wear.
If no motion or sound is heard, the compressor is in
satisfactory condition and does not need to be replaced.
Remove the extension.
Install the intake valve spring with the tang down.
Install the intake valve.
Install the intake valve seat with the flange side up.
Install the unloader valve cap spring.
Install the unloader valve cap.
Use high-temperature grease (Accrolube lubrication
Teflon grease, or equivalent) to lubricate the outside
diameter of the cap.
Install the rectangular ring seal with the grooved side up.
Install the o-ring.
Use clean engine oil to lubricate the o-ring seal.
Install the unloader valve body.
Press the unloader valve body down to be sure the tangs
of the unloader valve cap are in the three slots of the intake
valve seat.
K38, K50, QSK38, and QSK50 Air Compressor Unloader and Valve Assembly
CAUTION
Do not overtighten the unloader body capscrews.
Compressor damage will result.
Hold the unloader body down and install the two plain
washers and captive washer capscrews.
Air Compressor Unloader and Valve
Assembly (012-013)
Initial Check
WARNING
Air pressure must be released from system before
removing the air governor to reduce the possibility of
personal injury.
NOTE: The illustrations shown will be of the SS model
single-cylinder air compressor. Differences in procedures
for SS, QE, and ST model Cummins Turbo Technologies
air compressors will be shown where necessary.
Remove the air governor or air governor hose from the air
compressor unloader body.
Operate the engine to activate the air compressor.
If the air compressor is not pumping, the unloader valve
is malfunctioning and must be repaired or replaced.
Air Compressor Unloader and Valve Assembly K38, K50, QSK38, and QSK50
Disassemble
WARNING
tension. To reduce the possibility of personal injury,
always wear protective eye wear and use care when
removing the unloader valve body.
The following steps are for the Cummins Turbo
Technologies SS, E-Type, and ST models.
Hold the unloader valve body down, and remove the two
captive washer capscrews and the two plain washers.
Remove the unloader valve body.
Remove the o-ring.
Remove the rectangular ring seal.
NOTE: Disassembly of the center unloader valve on
Cummins Turbo Technologies two-cylinder air
compressors is similar to the single-cylinder unloader
valve.
Remove the unloader valve cap and the unloader valve
spring.
Remove the intake valve seat and valve.
Remove the intake valve spring.
Holset QE230, QE296, and QE338 A/C Model
WARNING
tension. To reduce the possibility of personal injury,
always wear protective eye wear and use care when
removing the unloader valve body.
Hold the unloader valve body down and remove the
capscrews.
Remove the unloader body, unloader cap, and spring.
CAUTION
Do not use caustic cleaners. Caustic cleaners can
cause damage to component parts.
Remove all carbon and varnish from the unloader valve
cap body.
K38, K50, QSK38, and QSK50 Air Compressor Unloader and Valve Assembly
For Cummins Turbo Technologies two-cylinder air
compressors, check both cylinder and center unloader
springs. Cummins Turbo Technologies recommends that
new springs be installed during rebuild.
Use a valve spring tester to check the unloader spring.
See the Compressor Spring Force Specifications chart in
the Cummins Turbo Technologies Air Compressor
Master Repair Manual, Bulletin 3666121.
Replace the unloader spring if it does not meet the
specifications shown, or if the wrong spring has been
used.
If the compressor has a flat hat type of unloader cap (1),
it must use an unloader spring and valve seat different
from that used with the three-prong unloader.
Assemble
The following steps are for the Cummins Turbo
Technologies SS, E-Type, and ST models.
Apply high-temperature grease (Accrolube lubrication
teflon grease or equivalent) to the rectangular ring seal,
unloader cap, and unloader body bore.
Install the unloader spring, cap, and valve body.
Holset QE230, QE296, and QE338 A/C Model
Install the new rectangular V-seal into the unloader body
with the grooved side up.
Liberally lubricate the unloader valve bore above and
below the rectangular ring seal with high-temperature
grease (Accrolube lubrication Teflon grease, or
equivalent).
Air Compressor Unloader and Valve Assembly K38, K50, QSK38, and QSK50
Install a new o-ring on the unloader valve body.
Use clean 15W-40 oil or Accrolube lubrication Teflon
grease (or equivalent) to lubricate the seal.
Liberally lubricate the unloader valve body bore and
unloader cap with high-temperature grease (Accrolube
lubrication Teflon grease, or the equivalent).
Install the unloader cap.
Install the unloader spring.
Lubricate the unloader capscrew threads and underhead
with clean engine oil (SAE 15W-40) before installation.
NOTE: The two unloader body screws must not be used
to attach any brackets.
K38, K50, QSK38, and QSK50 Air Compressor
The longer capscrews are used to mount the manifold to
the air compressor.
Assemble the unloader components and attach the
unloader assembly to the valve plate with the four
capscrews and washers.
Finishing Steps
Air Compressor (012-014)
Preparatory Steps
WARNING
cable last.
WARNING
WARNING
013-009.
008-018.
Disconnect the coolant lines from the air
compressor. Refer to Procedure 012-014.
Air Compressor K38, K50, QSK38, and QSK50
Remove
Remove the air inlet and outlet connections from the air
compressor.
NOTE: A Cummins Two cylinder air compressor is
shown.
Remove the air compressor coolant inlet tube. Remove
and discard the rectangular seals.
Remove the two capscrews (7) that hold the support
bracket to the cylinder block. The heavy washers (5) are
special.
WARNING
Remove the capscrews (3). Remove the air compressor.
Remove the spline coupling (1). Remove the gasket (2).
Discard the gasket.
WARNING
Use solvent and clean the exterior of the air compressor.
Inspect the compressor housing for cracks or other
damage.
Inspect the splined coupling for cracks or other damage.
Use a dial indicator and magnetic base, Part Numbers
3376051 and 3377399, to check the crankshaft end
clearance.
End Clearance
mm in
0.04 MIN 0.0015
0.24 MAX 0.0095
Air Compressor K38, K50, QSK38, and QSK50
Install
WARNING
CAUTION
The gasket (2) must be installed with the sealing bead
toward the drive. If the bead is toward the
compressor, an oil leak can result.
NOTE: Not all engines are equipped with an air
compressor. The Cummins Two Cylinder air compressor
is shown. The engine can be equipped with a Cummins
Single Cylinder compressor or a compressor from another
supplier. All of the compressors have a support bracket,
but the bracket is different on each type of compressor.
The installation procedure is the same.
Install the spline coupling (1) on the accessory drive shaft.
Install the gasket (2) on the pilot on the air compressor.
Install the compressor, four lock washers, and four 12-
point capscrews (3). Tighten the capscrews only enough
to hold the parts together. You must be able to move the
compressor to align the support properly to the cylinder
block.
CAUTION
Be sure the six capscrews that hold the support (4) to
the compressor are loose enough to allow the support
to be moved.
Install the two large flat washers (5), lock washers (6), and
capscrews (7) through the support bracket to the cylinder
block. Tighten the capscrews only enough to pull the
support to the cylinder block.
Check to be sure the compressor is positioned so it is flat
against the accessory drive and the support bracket is flat
against the block.
Tighten the four capscrews (3) that hold the compressor
to the accessory drive.
Tighten the six capscrews (4) that hold the support to the
air compressor.
Tighten the two capscrews (7) that hold the support to the
cylinder block.
Install the rectangular seals on the air compressor water
inlet tube. Install the water inlet tube to the fittings on the
front of the air compressor and the side of the engine
cylinder block.
NOTE: The air compressor water outlet tube is to be
installed after the thermostat support is installed.
NOTE: The air compressor oil drain tube is to be installed
after the oil pan and adapter assembly has been installed.
Install the air inlet and outlet connections to the air
compressor.
Tighten the clamps.
Air Governor (Air Compressor Will Not Pump) K38, K50, QSK38, and QSK50
Finishing Steps
WARNING
WARNING
last.
Connect the coolant lines to the air compressor.
Air Governor (Air Compressor Will Not
Pump) (012-017)
Initial Check
Remove the air governor or air governor line from the air
compressor unloader body.
CAUTION
Without the air signal from the air governor, the air
compressor will continue to pump. Do not continue to
operate the air compressor at pressures greater than
930 kPa [135 psi] air pressure. If the pressure is
exceeded, air hoses or tanks may rupture suddenly,
causing damage.
If the air compressor is pumping, the air governor is
malfunctioning and must be repaired or replaced. See the
K38, K50, QSK38, and QSK50 Air Governor (Air Compressor Pumps Continuously)
If the air compressor does not pump, remove, clean, and
inspect the air compressor unloader valve assembly.
Air Governor (Air Compressor Pumps
Continuously) (012-018)
Initial Check
NOTE: If the air govenor is remote mounted, do not
disconnect the line from the air compressor unloader
valve.
Remove the air accessory air lines from the air
compressor governor.
Install pipe plugs in the air governor unloader ports where
accessory air lines were removed.
If the air compressor stops pumping (air pressure stops
rising) at the governed air pressure, there is a leak in an
accessory or an accessory air line. See to the equipment
manufacturer's instructions for troubleshooting and
repair.
If the air compressor does not stop pumping (air pressure
continues to rise) at the governed air pressure, connect a
regulated shop air pressure line to one of the following:
The air compressor unloader valve port
One of the air governor unloader valve ports.
Air Governor (Air Compressor Pumps Continuously) K38, K50, QSK38, and QSK50
Make sure the air pressure gauge is accurate, and the
supply lines and fittings are in good condition, before
performing any air pressure checks.
Use a master gauge of known accuracy to check the air
pressure gauge.
Apply 690-kPa [100-psi] air pressure to the unloader port.
If the air compressor stops pumping (air pressure stops
rising), the air governor is malfunctioning and must be
repaired or replaced, or the air governor mounting gasket
is leaking. See to the OEM's instructions.
If the air compressor continues to pump (air pressure
continues to rise), the unloader valve is malfunctioning
and must be repaired or replaced.
Remove the pipe plugs from the unloader ports used for
accessory air lines.
Install and tighten the accessory air lines.
Connect the line to the unloader valve.
K38, K50, QSK38, and QSK50 Air Leaks, Compressed Air System
Air Leaks, Compressed Air System
(012-019)
Initial Check
WARNING
compressed air. Fly debris and dirt can cause
personal injury.
NOTE: The illustrations shown will be of the single-
cylinder air compressor. Differences in procedures for SS,
QE, and ST model Cummins Turbo Technologies air
compressors will be shown where necessary.
Shut off the engine.
Open the drain cock on the wet tank to release air from
the system. Close the drain cock after the pressure is
released.
With the air compressor pumping between 550 to 690 kPa
[80 to 100 psi], use a solution of soapy water to check for
air leaks in the following areas:
Air compressor cover gasket
Unloader body o-ring
Air compressor head gasket
Air compressor valve plate gasket (QE models
only)
Hose and fitting leaks.
If air leaks are found, replace the leaking gasket or o-ring.
Refer to the Master Repair Manual, Holset Air
Compressors, Bulletin 3666121.
Air Compressor (Oil Carryover) K38, K50, QSK38, and QSK50
Air Compressor (Oil Carryover)
(012-020)
Inspect for Reuse
NOTE: The illustrations shown will be of the single-
cylinder air compressor. Differences in procedure for one-
or two-cylinder Cummins air compressors will be shown
where necessary.
Cycle the air compressor five times while viewing the
discharge from the air dryer. If the discharge appears
excessively oily, perform the following check.
Remove the air compressor line from the air compressor.
Apply regulated air pressure to the air governor unloader
port.
Air Pressure: 690 kPa [ 100 psi ]
Operate the engine at low idle for 10 minutes with the air
compressor unloaded (shop air applied to the unloader
port).
Remove the shop air pressure from the unloader port.
Operate the engine at low idle for 10 minutes with a white
cloth over the air compressor discharge port.
Remove the white cloth, and check the cloth for
contamination.
If the cloth indicates more than a trace of gray, the air
compressor is using an excessive amount of oil and
must be replaced. Refer to Procedure 012-014.
K38, K50, QSK38, and QSK50 Air Starting Motor
Install and tighten the air discharge line.
Air Starting Motor (012-022)
General Information
An engine air starting motor is shown in the illustration.
The air starting motor system (tanks, line sizes, and
valves) is designed and installed by the OEM and the
starting motor suppliers. Refer any questions about the air
starting systems to the manufacturer.
Do not operate the air starting motor with air pressure
lower than 480 kPa [70 psi].
Maintain the air compressor according to the
recommendations outlined in the component
manufacturer's manual.
For maximum efficiency, the hoses, tubes, and lines must
not leak.
Refer to the OEM and starting motor manufacturer's
manuals for specific information regarding the starting
motors, valves, and systems.
Air Starting Motor K38, K50, QSK38, and QSK50
Notes
Section 13 Electrical Equipment Group 13 Page 13-a
Section 13 Electrical Equipment Group 13
Section Contents
Page
Alternator .........................................................................................................................................................13-3
Finishing Steps...............................................................................................................................................13-6
Install..............................................................................................................................................................13-4
Remove..........................................................................................................................................................13-3
Alternator Adjusting Link ..............................................................................................................................13-22
Adjust............................................................................................................................................................13-23
Alternator Pulley ............................................................................................................................................13-10
Finishing Steps............................................................................................................................................. 13-11
Install............................................................................................................................................................13-11
Remove.........................................................................................................................................................13-10
Alternator Bracket ...........................................................................................................................................13-7
Finishing Steps...............................................................................................................................................13-8
Install..............................................................................................................................................................13-8
Remove..........................................................................................................................................................13-7
Batteries ........................................................................................................................................................ 13-12
Inspect..........................................................................................................................................................13-12
Battery Cables and Connections .................................................................................................................. 13-13
Initial Check..................................................................................................................................................13-13
Drive Belt, Alternator ......................................................................................................................................13-9
Finishing Steps............................................................................................................................................. 13-10
Install..............................................................................................................................................................13-9
Remove..........................................................................................................................................................13-9
Service Tools ...................................................................................................................................................13-1
Electrical Equipment.......................................................................................................................................13-1
Starter Magnetic Switch ................................................................................................................................13-14
Starter Solenoid .............................................................................................................................................13-17
Voltage Check...............................................................................................................................................13-17
Starter Switch ................................................................................................................................................13-16
Test...............................................................................................................................................................13-16
Starting Motor ................................................................................................................................................13-20
Finishing Steps............................................................................................................................................. 13-21
Install............................................................................................................................................................13-21
Remove.........................................................................................................................................................13-20
Page 13-b Section 13 Electrical Equipment Group 13
Section 13 Electrical Equipment Group 13 Page 13-1
Service Tools
Electrical Equipment
Repair Location.
ST-1193
Belt Tensioner Gauge
Used to measure alternator belt tension.
3164488
Digital Multimeter
This is an auto-ranging digital multimeter that includes functions of
DC and AC voltage, current, resistance, continuity, and diode test. It
comes with test leads and a protective boot that surrounds the meter.
3164489
Automotive Meter
This auto-ranging digital multimeter includes the functions of
frequency, capacitance, and temperature (with a built-in temperature
module). Also included are the functions: RPM, Dwell, Duty Cycle,
and Pulse Width.
3377193
Inductive Charging - Cranking Systems Analyzer
Used to test generators, alternators, relays, starters, regulators, and
batteries. Contains built- in voltmeter and ammeter.
3164794
Torque Wrench
3164798
Torque Wrench
Page 13-2 Section 13 Electrical Equipment Group 13
4918793
Spark Plug Socket
Removes spark plugs. The CSA application uses a 22 mm [0.875 in]
thread size plug. The non-CSA application uses a 21 mm [0.8125 in]
thread size plug.
K38, K50, QSK38, and QSK50 Alternator
Alternator (013-001)
Preparatory Steps
WARNING
cable last.
Disconnect batteries. Refer to Procedure 013-009
(Battery and Cable Connections) in Section 13.
Disconnect the wiring from the alternator.
Remove
Alternator without a guard.
Loosen the capscrew (2) and the nut (4). Loosen the
capscrews (6) and (9). Loosen the two jam nuts. Turn the
adjusting link (11) to loosen the belt.
NOTE: The three capscrews are SAE Grade 8 and the
three spacers are hardened. Keep the parts together to
aid the assembly procedure.
Remove the parts as shown.
Alternator with a guard.
Remove the alternator brace to the front gear cover.
Remove the two capscrews, four plain washers, and two
lock washers.
Alternator K38, K50, QSK38, and QSK50
Inspect for Reuse
Remove the nut and pulley from the alternator.
Clean and check the pulley for reuse.
Install
Alternator without a guard.
Lubricate the shaft with engine oil.
Install the pulley and nut on the alternator shaft.
Tighten the pulley mounting nut.
NOTE: New alternators will not operate correctly until the
pulley mounting nut is correctly torqued.
NOTE: The belt must be installed and adjusted before the
capscrews are tightened.
NOTE: The end of the adjusting link with the largest area
at the capscrew hole must be nearest to the alternator.
Install the alternator and the adjusting link as shown.
CAUTION
To avoid damage to the alternator belt, do not pry the
belt onto the pulley.
Install the belt.
Turn the adjusting screw counterclockwise to shorten
the link if necessary.
K38, K50, QSK38, and QSK50 Alternator
Alternator with a guard.
Install the alternator brace to the front gear cover using
two capscrews, four plain washers, and two lock washers
(9).
The plain washers act as spacers and must be installed
between the alternator brace and the front gear cover. Use
two spacers per capscrew.
The lock washers are installed between the capscrew and
alternator brace.
The alternator must swing through the same arc as the
machined slot in the alternator brace. Fasten the
alternator to the alternator brace using the capscrew.
Install the belt.
Adjust the belt tension. Refer to Procedure 013-022
(Alternator Adjusting Link) in Section 13.
Install the vibration isolators (3 and 4) between the bottom
bracket (6) and the main guard.
Install the plain washer (2) and nut (1).
Do not overtighten the isolators.
The compressed thickness of the vibration isolator must
be approximately 13 mm [0.5 in].
Alternator K38, K50, QSK38, and QSK50
Install a vibration isolator between the top bracket and the
main guard.
Install the assembled belt guard onto the brace and
alternator support bracket with three capscrews.
NOTE: The belt and pulleys must not contact the guard
or brackets.
Loosen the three capscrews and adjust the guard if an
interference is detected. The alternator brace has slotted
holes that allow a small amount of vertical movement.
Finishing Steps
WARNING
cable last.
Adjust the belt tension (if needed). Refer to
Procedure 013-022 (Alternator Adjusting Link) in
Section 13.
Connect the wiring to alternator.
K38, K50, QSK38, and QSK50 Alternator Bracket
Alternator Bracket (013-003)
Preparatory Steps
WARNING
cable last.
13.
Remove the alternator. Refer to Procedure 013-001
(Alternator) in Section 13.
Remove
NOTE: The two capscrews are SAE Grade 8 and the
washers are hardened. Keep the parts together to aid the
assembly procedure.
Remove the parts as shown.
Make sure the hardened sleeves (1) do not fall out of the
bracket.
WARNING
WARNING
WARNING
personal injury.
Alternator Bracket K38, K50, QSK38, and QSK50
Check the threads of the capscrews for damage.
Check the bracket for cracks. Check the bores for wear.
Replace any parts that are damaged or worn.
Install
Check to be sure the two sleeves (1) are installed in the
bracket. The sleeves move in the bracket as the
capscrews are tightened to the front gear cover and
housing.
NOTE: The capscrews (4) are SAE Grade 8. The heavy
flat washers (3) are hardened. The washers have a notch
for identification. These parts are used because they
must clamp the gear cover and housing properly, while
withstanding the torque and vibration of the alternator.
Install the bracket (2), the flat washers (3), and the two
capscrews (4).
Finishing Steps
WARNING
cable last.
Install the alternator. Refer to Procedure 013-001
(Alternator) in Section 13.
Start the engine and check for proper alternator
operation.
K38, K50, QSK38, and QSK50 Drive Belt, Alternator
Drive Belt, Alternator (013-005)
Preparatory Steps
Loosen the alternator adjusting link. Refer to
Section 13.
Remove
Remove the alternator drive belt.
Inspect for Reuse
Check the belt for wear or other damage.
If the belt indicates any wear or other damage, it must be
replaced.
Install
Install the alternator belt.
Alternator Pulley K38, K50, QSK38, and QSK50
Finishing Steps
Adjust the alternator adjusting link. Refer to
Section 13.
Start the engine and check for proper operation.
Alternator Pulley (013-006)
Preparatory Steps
WARNING
cable last.
13.
Remove alternator belt. Refer to Procedure 013-005
(Drive Belt, Alternator) in Section 13.
Remove
NOTE: A capscrew fitted to the end of the shaft will
prevent damage to the threads.
equivalent. Remove the pulley from the water pump drive
shaft.
K38, K50, QSK38, and QSK50 Alternator Pulley
Install
CAUTION
bearings in the water pump drive can be damaged and
the water pump drive can fail.
CAUTION
the seal can leak.
shaft and the inside diameter of the bore in the pulley.
CAUTION
running your finger around it 8 to 10 times, applying
gentle pressure. Be sure there is no oil on your hands.
Avoid touching the sealing lip (black lip). The dust lip
will remain bent approximately 1 minute, then return
slowly to the operating position.
Position the pulley on the shaft. Use the tool to push the
pulley on the shaft until the sleeve on the tool touches the
shaft. The pulley will then be even with the end of the
shaft.
Finishing Steps
WARNING
cable last.
Install alternator belt. Refer to Procedure 013-005
(Drive Belt, Alternator) in Section 13.
13.
Batteries K38, K50, QSK38, and QSK50
Batteries (013-007)
Inspect
Use an inductive charging and cranking system analyzer
to load-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 manufacturer's
instructions.
Replace the battery if it will not charge to the
manufacturer's specifications or the battery will not
maintain a charge.
WARNING
cable last.
WARNING
Acid is extremely dangerous and can damage the
machinery and can also cause serious burns. Always
provide a tank of strong soda water as a neutralizing
agent when servicing the batteries. Wear goggles and
protective clothing to reduce the possibility of serious
personal injury,
NOTE: Maintenance-free batteries are sealed and do
not require the addition of water.
If conventional batteries are used, remove the cell caps or
covers and check the electrolyte (water and sulfuric acid
solution) level.
Fill each battery cell with water. Refer to the
Do not attempt to check the specific gravity of a battery
immediately after adding water. If it is necessary to add
water to allow use of the hydrometer, charge the battery
several minutes at a high rate to mix the electrolyte.
Use a hydrometer to measure the specific gravity of each
cell.
Refer to the accompanying table to determine the battery
state of charge based on the specific-gravity readings.
Battery State of Charge Specific Gravity @ 27C
[80F]
100 percent 1.260 to 1.280
75 percent 1.230 to 1.250
50 percent 1.200 to 1.220
25 percent 1.170 to 1.190
Discharged 1.110 to 1.130
If the specific gravity of any cell is below 1.200, the battery
must be charged.
K38, K50, QSK38, and QSK50 Battery Cables and Connections
Battery Cables and Connections
(013-009)
Initial Check
There are two possible heavy-duty battery connections:
Battery terminal and clamp (1)
Threaded battery terminal and nut (2).
WARNING
cable last.
Remove and inspect the battery cables and connections
for cracks or corrosion.
Replace broken terminals, connectors, or cables.
If the connections are corroded, use a battery brush or
wire brush to clean the connections until shiny.
Make sure all debris is removed from the connecting
surfaces.
WARNING
cable last.
Install the cables and tighten the battery connections.
Coat the terminals with grease to prevent corrosion.
Starter Magnetic Switch K38, K50, QSK38, and QSK50
Starter Magnetic Switch (013-017)
Inspect for Reuse
Before inspecting specific starting system components
with the multimeter:
Inspect terminals for loose, broken, or corroded
connections.
Replace or repair wiring and components as
necessary.
WARNING
Be sure the starter switch is in the OFF position to
reduce the possibility of electrical shock and personal
injury.
Remove the cable connecting the magnetic switch to the
starter solenoid from the magnetic switch terminal.
Connect the leads of digital multimeter, Part Number
3377161, to the two large switch terminals.
Set the multimeter to measure resistance.
With the starter switch in the OFF position, the multimeter
must indicate resistance at infinity.
If the multimeter indicates zero or very little
resistance, replace the magnetic switch.
If the multimeter indicates resistance at infinity,
proceed with the following instructions.
Turn the starter switch to the START position.
The multimeter must indicate zero or very little resistance.
A click will be heard when the starting switch is turned to
the START position.
K38, K50, QSK38, and QSK50 Starter Magnetic Switch
If the multimeter indicates resistance at infinity with the
starter switch in the START position and a click is not
heard:
Turn the starter switch to the OFF position.
Set the multimeter scale to indicate DC voltage.
Connect the positive (+) lead of the multimeter to the
magnetic switch ground wire terminal and the other lead
to the small magnetic switch terminal.
The multimeter will indicate some voltage across the
magnetic switch terminals. If the multimeter indicates Full
System Voltage, the magnetic switch is malfunctioning
and must be replaced.
If the multimeter indicates no voltage, the magnetic switch
is not the cause of the complaint. Refer to Procedure
013-018.
Remove the multimeter leads and connect the magnetic
switch to the starter solenoid wire.
Starter Switch K38, K50, QSK38, and QSK50
Starter Switch (013-018)
Test
WARNING
Be sure the starter switch is in the OFF position to
reduce the possibility of electrical shock and personal
injury.
Remove the wire connecting the starter switch to the
magnetic switch from the starter switch terminal.
Connect the positive (+) lead of the digital multimeter,
Part Number 3377161, to the starter switch terminal and
the negative (-) lead to a chassis or engine ground
location.
With the starter switch in the OFF position, there must
not be voltage at the starter switch terminal. If the
multimeter indicates voltage, the starter switch is
malfunctioning and must be replaced.
The multimeter must indicate system voltage.
If there is no voltage:
Connect the multimeter positive (+) lead to the
starter switch terminal having a wire that connects
the starter switch to the starter solenoid.
K38, K50, QSK38, and QSK50 Starter Solenoid
If the multimeter indicates system voltage, the starter
switch is defective and must be replaced.
If the multimeter indicates no voltage, the switch is not the
cause of the complaint.
Inspect the wiring from the starter switch to the starter
solenoid and from the starter solenoid to the battery.
Replace any broken or damaged wires.
Starter Solenoid (013-019)
Voltage Check
Use the multimeter, Part Number 3377161, and set it to
measure VDC.
Connect the multimeter positive (+) lead to the starter
solenoid positive (+) cable terminal and the negative ( )
lead to the battery cable connection at the starting motor.
The multimeter must show system voltage.
Starter Solenoid K38, K50, QSK38, and QSK50
If the multimeter does not indicate system voltage, check
the battery to starting motor cable for broken, loose, or
corroded connections.
If the multimeter indicates system voltage, but the starting
motor will not operate, check the wire connecting the
starter solenoid to the starter switch for broken, loose, or
If the wire connecting the starter solenoid and starter
switch is not loose or damaged and the starter will not
operate:
Remove the cable connecting the starting motor and
starter solenoid from the solenoid terminal.
Connect the multimeter positive (+) lead to the
solenoid positive (+) terminal and the negative ( )
lead to a chassis or engine ground.
If the multimeter indicates system voltage, the starter
solenoid is malfunctioning and must be replaced.
K38, K50, QSK38, and QSK50 Starter Solenoid
If the multimeter does not indicate system voltage, check
the wire connecting the starter solenoid to the magnetic
switch for broken, loose, or corroded connections.
If the wire connecting the starter solenoid to the magnetic
switch is not loose or damaged and the starting motor will
not operate, check the cable connecting the starter
solenoid to the starting motor for broken, loose, or
Check the cable connecting the starter to the battery for
broken, loose, or corroded connections.
If the cables are not loose or damaged, the starting motor
is defective and must be replaced.
Starting Motor K38, K50, QSK38, and QSK50
Starting Motor (013-020)
Preparatory Steps
WARNING
cable last.
Disconnect the battery. Refer to Procedure 013-009
Remove
Remove the electrical connections from the starter motor.
Remove the starter motor capscrews, starter, spacers,
and gaskets.
WARNING
Use steam. Clean the exterior of the starter motor.
Check the gear, shaft, terminal posts, and bushing for
wear or damage.
Replace the starter motor if worn or damaged.
Use engine oil. Lubricate the bushing.
NOTE: A pipe plug must be removed to lubricate the
bushing on some starter motors.
K38, K50, QSK38, and QSK50 Starting Motor
Install
CAUTION
Make sure to use the same thickness of starter motor
spacer (1), (if used), as the one removed to install the
starter motor to prevent engine or starter motor
damage.
NOTE: Installation of the top electric starter motor first on
K38 and K50 series engines will simplify the installation of
both starter motors.
Install the starter motor and capscrews.
Torque Value:
Cast Iron
Flywheel Housing
215 Nm [ 160 ft-lb ]
Torque Value:
Aluminium
Flywheel Housing
195 Nm [ 145 ft-lb ]
Install the electrical connections to the starter motor.
Finishing Steps
WARNING
cable last.
Connect the battery. Refer to Procedure 013-009
Operate the starter and check for proper operation.
Alternator Adjusting Link K38, K50, QSK38, and QSK50
Alternator Adjusting Link (013-022)
WARNING
WARNING
WARNING
personal injury.
Check the adjusting link threads for damage.
Replace any parts that are damaged or worn.
Inspect for Reuse
Use the belt tension gauge. Check the belt tension.
Alternator belt tension
Gauge Part Number. Tension
ST-1293 (Burrough) 165 lb
ST-1274 (Kriket) 88 lb
K38, K50, QSK38, and QSK50 Alternator Adjusting Link
Adjust
Loosen the alternator and adjusting link mounting
capscrews.
Loosen the jam nuts on the adjusting screw.
Turn the adjusting screw clockwise to tighten the belt
tension.
Tighten the jam nuts on the adjusting screw to 55 Nm [40
ft-lb].
Tighten the adjusting link and alternator mounting
capscrews.
Torque Value:
Nut 1 95 Nm [ 70 ft-lb ]
Torque Value:
Nut 2 70 Nm [ 55 ft-lb ]
Torque Value:
Nut 3 95 Nm [ 70 ft-lb ]
Check the belt tension again to make sure it is correct.
Alternator Adjusting Link K38, K50, QSK38, and QSK50
Notes
Section 14 Engine Testing Group 14 Page 14-a
Section 14 Engine Testing Group 14
Section Contents
Page
Dynamometer Worksheet ................................................................................................................................14-4
Worksheet.......................................................................................................................................................14-4
Engine Compression .....................................................................................................................................14-52
Finishing Steps............................................................................................................................................. 14-56
Pressure Differential Test..............................................................................................................................14-54
Setup............................................................................................................................................................14-53
Engine Run-in (Engine Dynamometer) ..........................................................................................................14-25
Run-In Instructions........................................................................................................................................14-25
Engine Run-in (Without Dynamometer) ........................................................................................................14-11
Run-In Instructions........................................................................................................................................14-11
Engine Testing (Chassis Dynamometer) ........................................................................................................14-5
Test................................................................................................................................................................14-5
Engine Speed (rpm)......................................................................................................................................14-5
Fuel Pressure...............................................................................................................................................14-6
Fuel Rate.....................................................................................................................................................14-6
Fuel Inlet Restriction.....................................................................................................................................14-6
Fuel Drain Line Restriction...........................................................................................................................14-6
Intake Manifold Pressure..............................................................................................................................14-7
Intake Manifold Air Temperature Control - Chassis Dynamometer test..........................................................14-7
Intake Air Restriction....................................................................................................................................14-8
Intake Manifold Air Temperature Control - Chassis Dynamometer test..........................................................14-8
Engine Blowby.............................................................................................................................................14-8
Lubricating Oil Pressure.............................................................................................................................14-10
Air Compressor.......................................................................................................................................... 14-11
Starting Motor............................................................................................................................................ 14-11
Engine Testing (Engine Dynamometer) ........................................................................................................14-12
Install............................................................................................................................................................14-12
Coolant Plumbing.......................................................................................................................................14-12
Intake Air Temperature Control...................................................................................................................14-13
LTA............................................................................................................................................................14-13
Test............................................................................................................................................................14-13
Engine Throttle Control...............................................................................................................................14-15
Test...............................................................................................................................................................14-19
Engine Speed (rpm)....................................................................................................................................14-20
Fuel Drain Line Restriction......................................................................................................................... 14-20
Intake Air Restriction..................................................................................................................................14-20
Exhaust Air Restriction...............................................................................................................................14-21
Engine Blowby........................................................................................................................................... 14-21
Lubricating Oil Pressure.............................................................................................................................14-23
Engine Coolant Pressure............................................................................................................................14-23
Air Compressor.......................................................................................................................................... 14-24
Starting Motor............................................................................................................................................ 14-24
Service Tools ...................................................................................................................................................14-1
Engine Testing................................................................................................................................................14-1
Page 14-b Section 14 Engine Testing Group 14
Section 14 Engine Testing Group 14 Page 14-1
Service Tools
Engine Testing
Repair Location.
3164875
Manometer
Used with blowby orifice for measuring engine crankcase pressure.
3822567
Blowby Check Tool (0.354 inch Orifice)
Used with manometer Part Number ST-1111-3 to measure engine
crankcase pressure.
3822568
Blowby Check Tool (0.406 inch Orifice)
crankcase pressure. Cummins recommends this orifice be used on
the KTA38GC engine for blowby measure.
3375150
Bottle Stopper Blowby Tool (0.302 inch Orifice)
crankcase pressure.
3824223
Differential Pressure Tester
This tester with appropriate leak test adapter checks individual
cylinders to locate sources of leaks or excessive blowby. Use
adapter, Part number 4918177, with this tester for use on the 14 mm
spark plugs.
3400157
Filter Wench
Used to remove spin on filters.
Page 14-2 Section 14 Engine Testing Group 14
3400158
Filter Wrench Strap Type up to 152 mm [6 inch]
Used to remove spin on filters.
3163264
Engine Lift Fixture Kit
Used to lift the engine during installation or removal.
3375109
Used to lift the engine during installation or removal.
ST-1273
Pressure Gauge [0 to 75 in-Hg]
Used to measure intake manifold pressure turbo boost.
3375275
Pressure Gauge [0 to 100 psi]
Used to measure lubricating oil pressure.
3375932
Pressure Gauge [0 to 600 psi]
Used to measure fuel pressure. Includes necessary hoses and
hardware attached to a fuel pump.
3376375
Fuel Flow Measuring Instrument
Used to measure the fuel rate consumption of a Cummins diesel
engine.
3377462
Digital Optical Tachometer
Used to measure engine speed (rpm).
ST-434
Vacuum Gauge
Used to check fuel filter or intake air restriction.
3163890
Engine Control
Used to operator the engine out-of-chassis on the QSK50 engines.
Used with the Engine Control Harness, Part Number 4918643.
4918643
Engine Control Harness
Used to operate the engine out-of-chassis on the QSK50 with
electronically actuated injectors.
4918416
INLINE5 Adapter Kit
Used with the Engine Control, Part Number 3163890 and the Engine
Control harness, Part Number 4918643. Used with the SAE J1939
standard protocol. Used with INSITE electronic service tool 6.3 or
later versions.
Dynamometer Worksheet K38, K50, QSK38, and QSK50
Dynamometer Worksheet (014-001)
Worksheet
Date: Repair Order No: Operator:
ESN: CPL: Fuel Pump Code:
Complaint: SC Code:
PARAMETER CODE SPECIFICATIONS ACTUAL READING
Fuel Pressure (psi @ rpm) 150 to 180 psi at Idle
Fuel Pressure (psi @ rpm) 225 to 250 psi at 1800 rpm
Fuel Pressure (psi @ rpm) 250 to 300 psi at 2100 rpm
Fuel Rate (lb/hr)
Intake Mfd. Pressure (in.Hg) See Fuel Pump Code
Intake Mfd. Temperature
*Intake Air Restriction 25 in. H
2
O, Maximum
*Exhaust Air Restriction 3 in. Hg, Maximum
*Fuel Inlet Restriction 8 in. Hg (Dirty Filter), Maximum
*Fuel Drain Line Restriction 3 psi, Maximum
Engine Blowby See Tables
* Recorded at maximum horsepower speed and full load
Road Speed Limit Engine High Speed Limit
Check Oil Level Low High OK Fuel Quality OK Not OK
Engine
Speed
Fuel *Rate/Press Fuel
Temp
Turbo Inlet
Air Temp
Intake Manifold
Temp/Press
Coolant Temp/
Press
Engine
Blowby
Lube Oil
Press
HP or
Torque
* Be sure that the fuel rate is corrected for temperature.
Fuel Temperature Correction for Flow Rate
Less than 7C [45F] Flow meter not accurate
7 to 13C [45 to 55F] Subtract 2% from flow rate reading
13.0 to 20.0C [55 to 68F] Subtract 1% from flow rate reading
20.0 to 29C [68 to 85F] No Correction
29 to 42C [85 to 108F] Add 1% to flow rate reading
42 to 56C [108 to 132F] Add 2% to flow rate reading
56C above [132F] Flow meter not accurate.
Pressure Conversions
1 in. H
2
0 = 0.074 in. Hg = 0.036 psi
1 in. Hg = 13.514 in. H
2
0 = 0.491 psi
1 psi = 2.036 in. Hg = 27.7 in. H
2
0
This Page Can Be Copied For Your Convenience.
K38, K50, QSK38, and QSK50 Engine Testing (Chassis Dynamometer)
Engine Testing (Chassis
Dynamometer) (014-002)
Test
To monitor engine performance properly, record the
following parameters. To limit dynamometer operating
time, instrument the engine to perform as many checks as
possible. The INSITE tool will provide most if not all of
the following:
Engine speed rpm with a verified tachometer
Fuel pressure
Fuel rate
Fuel temperature (if needed to correct fuel rate)
Fuel inlet restriction
Fuel drain line restriction
Intake manifold pressure (per bank).
Intake air restriction (per bank)
Exhaust air restriction (per bank)
Coolant temperature
Engine blowby
Lubricating oil pressure
Coolant pressure
Inlet manifold air temperature
Turbocharger inlet air temperature.
Engine Speed (rpm)
Use digital optical tachometer, Part Number 3377462, to
check and verify engine speed.
Engine Testing (Chassis Dynamometer) K38, K50, QSK38, and QSK50
Fuel Pressure
This measurement can also be taken using INSITE
electronic service tool.
Fuel Rate
This measurement can also be taken using INSITE
electronic sService tool.
Use a fuel measuring device to measure the rate of fuel
consumption.
Fuel Inlet Restriction
Use the INSITE electronic service tool or pressure gauge
ST-434 to measure the fuel restriction between the fuel
filter and the gear pump inlet. Refer to Procedure 006-020.
Fuel Drain Line Restriction
Use pressure gauge, Part Number ST-1273, to measure
fuel drain line restriction. Refer to Procedure 006-012.
Intake Manifold Pressure
Measure the intake manifold pressure (turbocharger
boost). This test can be done using the INSITE electronic
service tool or manually, or the appropriate electronic
service tool manual.
Intake Manifold Air Temperature Control - Chassis
Dynamometer test
When operating an engine on a dynamometer, follow
these steps for best results and safe operation.
If the engine is equipped with an automatic fan, lock the
cooling fan in the ON mode. This can be done by installing
a jumper across the temperature switch, or by supplying
shop air to the control valve. Refer to the fan drive
manufacturer for the recommended procedure.
Monitor the intake manifold air temperature using
INSITE electronic service tool in the monitor mode, or
install Fluke digital thermometer, Part Number 3822666,
and thermocouple wire kit, Part Number 3822988, into the
intake manifold.
The intake manifold air temperature must not exceed 77
C [171F].
Maintain intake manifold air temperature to 66C [110F]
or below during chassis dynamometer operation.
If the intake manifold temperature exceeds 77C [171F],
shut off the engine. Allow the engine to cool.
Check the fan drive. Be sure the fan is locked in the ON
mode.
Remove any obstructions such as a winterfront or debris.
Manually lock the shutters in the OPEN position if
equipped.
Inspect the dynamometer room for adequate supply of
suitably cool or outside air. Make sure that dynamometer
room recirculation is not an issue.
Resume the test.
Intake Air Restriction
Measure the inlet air restriction. Install a manometer, Part
Number ST-1111-3, in the intake air piping.
The gauge adapter must be installed at a 90-degree angle
to the airflow in a straight section of pipe at a minimum of
one pipe diameter before the turbocharger.
Refer to Procedure 010-031..
Intake Manifold Air Temperature Control - Chassis
Dynamometer test
Measure the exhaust air restriction. Install the pressure
gauge, Part Number ST-1273, or a manometer Part
Number ST-1111-3, in the exhaust air piping.
The gauge adapter must be installed near the
turbocharger in a straight section of pipe at the turbine
outlet.
Engine Blowby
Excessive blowby indicates an air compressor, a
turbocharger, or an engine malfunction, allowing
combustion gases or air to enter the crankcase and build
a pressure higher than normal.
This procedure describes how to measure crankcase
pressure and how to determine the component that is
malfunctioning.
Use the blowby service tool, Part Number 3822568, and a
water manometer, Part Number ST-1111-3. Maximum
gauge capacity is 1270 mm H
2
O [50 in H
2
O].
Use a length of hose (1) to attach the blowby tool to one
of the crankcase breathers.
Attach a manometer to the location shown (2).
Operate the engine at rated rpm and full load (wide-open
throttle) until a steady reading is obtained.
Compare the blowby readings to previous readings on the
engine. If previous readings for the engine are not
available, compare the blowby reading to new engine
specifications.
Engine Blowby 10-mm [0.406-in] Orifice rpm = All
ratings
mm H
2
O in H
2
O
New/Rebuilt Engine 127 MAX 5
Used Engine 330 MAX 13
A sudden increase in blowby indicates a problem. A
gradual increase over a period of time is normal (due to
wear of internal engine components).
If the blowby is higher than normal, check the crankcase
breathers and breather tubes to see whether they are
plugged.
Check the engine oil level. If the level is too high, it can
cause a higher than normal crankcase pressure.
Operate the engine at rated speed. Record the blowby
value.
Isolate the air compressor to determine whether it is
malfunctioning and causing the high blowby pressure.
Relieve the air pressure on the first air tank in the system
after the air compressor (wet tank).
Disconnect the air inlet and outlet connections. Plug the
intake manifold or air piping where the inlet connection
was removed.
Operate the engine at rated speed and full load (wide-
open throttle) until a steady blowby reading is obtained.
Compare the blowby readings to the previous value. If the
blowby is now acceptable, replace the air compressor.
A sudden increase in blowby or a high reading that is
not steady indicates that there is internal damage in the
engine. To determine which cylinder is at fault, refer to the
Troubleshooting Trees, Section TS.
Lubricating Oil Pressure
Use pressure gauge, Part Number. 3375275, or the
INSITE tool to measure lubricating oil pressure. .
Install the pressure gauge to the main oil rifle (1) or oil filter
head (2).
kPa psi
Low Idle (Minimum
Allowable)
138 MAX 20
At 1200 rpm (Minimum
Allowable)
207 MAX 30
K38, K50, QSK38, and QSK50 Engine Run-in (Without Dynamometer)
Air Compressor
All air compressors manufactured by Cummins Inc. must
be operating during the engine run-in. During the
performance check, all air compressors must be in the
unload or nonoperating mode.
Connect a source of compressed air capable of providing
665 kPa [97 psi] to the air compressor unloader (1). This
air line must contain a valve between the source and the
unloader.
The compressed air load in the accompanying illustration
must be attached to the air compressor outlet (2).
Use an air tank (2). Install an air regulator (3) capable of
maintaining 345- to 517-kPa [50- to 75-psi] air pressure at
both minimum and maximum engine rpm.
Install a steel tube or high-temperature hose (1).
Hose Temperature (Minimum): 260 C [ 500 F ]
Connect the tube or hose (1) to the air compressor outlet.
Starting Motor
Inspect the voltage rating on the starting motor before
installing the electrical wiring.
Install the electrical wiring to the starting motor and
batteries, if used.
If another method of starting the engine is used, follow the
OEM instructions to make the necessary connections.
Engine Run-in (Without Dynamometer) (014-004)
Run-In Instructions
CAUTION
Do not operate the engine at rated speed for the initial 1 to 2 hours, or 100 to 150 kilometers [50 to 100 miles].
CAUTION
Do not allow the engine to "IDLE" for more than 5 minutes during the initial 2 hours, or 150 kilometers [100
miles].
Operate the engine as near as possible to the run-in-period schedule described in procedure 014-006, Engine Run-
in-Period with Engine Dynamometer.
Use the transmission or driven member to load the engine. Choose a load that will not allow the engine to operate at
the rated RPM when the throttle is in the "FULL OPEN" position.
NOTE: The best load is one that will allow the engine to operate as near to the torque peak RPM as possible.
Engine Testing (Engine Dynamometer) K38, K50, QSK38, and QSK50
Engine Testing (Engine Dynamometer)
(014-005)
General Information
This document provides procedures for the use of an
engine control, Part Number 3163890. The engine control
is a portable, handheld electronic control, used to start
and control engine speed on the Cummins electronic
engines. It replaces the throttle pedal, driver interface
panel, and fault code monitoring circuits. The engine
control has a datalink provision to connect to an electronic
service tool to monitor engine operation and fault codes.
The engine control harnesses required for the engines are
purchased separately. The engine control and engine
control harnesses are designed to be used with both (+)
12-VDC and (+) 24-VDC battery systems.
NOTE: The engine control can be used on engines with
frequency throttle calibrations by first downloading a
linear throttle calibration to the electronic control module
(ECM). After the testing/repair is complete, reload the
correct frequency throttle calibration.
Install
NOTE: Make certain that the dynamometer capacity is
sufficient to permit testing at 100 percent of the engine's
rated horsepower. If the capacity is not enough, the
testing procedure must be modified to the restrictions of
the dynamometer.
Use engine lifting fixture, Part Number 3163264, 3375109,
or equivalent, to install the engine to the test stand. Align
and connect the dynamometer. See the manufacturer's
instructions for aligning and testing the engine.
Coolant Plumbing
Connect the coolant supply to the water inlet connection.
Connect the coolant return to the water outlet connection.
Install the drain plugs, and close all of the water drain
cocks.
NOTE: Low temperature aftercooler engines require
connecting the low temperature aftercooler water lines to
a remote heat exchanger.
K38, K50, QSK38, and QSK50 Engine Testing (Engine Dynamometer)
Intake Air Temperature Control
The use of a remote heat exchanger is mandatory
whenever a Cummins low temperature aftercooler engine
is attached to an engine dynamometer for the purpose of
engine run-in, performance testing, and engine
diagnostics. Do not attempt to run a Cummins low
temperature aftercooler engine without any means of
controlling the intake manifold air temperature.
A. Aftercooler water out
B. Aftercooler water in
C. Cooling water out to drain
D. Cooling water in.
LTA
All industrial engines require low temperature aftercooler
and, therefore, have unique radiator requirements.
The heat exchanger must be sized to maintain 70C
[158F] maximum intake air temperature at full power.
A. Cooling water in
B. Thermostat housing
C. Low temperature aftercooler out
D. Cooling water out
E. Low temperature aftercooler return.
Test
CAUTION
The lubricating oil system must be primed before
operating the engine after rebuild to avoid internal
component damage. Do not prime the system from
the bypass filter as the filter will be damaged.
Industrial engines are equipped with an automatic prelube
system from the factory. If the engine is not equipped with
an automatic prelube system, follow the instructions to
prelube the engine manually.
For engines without an automatic prelube device, use a
pump capable of supplying 205-kPa [30-psi] continuous
pressure.
Remove the pipe plug at the front rear underside of the
one-piece lubricating oil filter head.
Install an extended elbow (1) into the rear port the pipe
plug was removed from. The final position of this elbow is
facing the rear of the engine and slightly inboard to make
certain that the check valve clears the front filter on the
one-piece lubricating filter head.
Tighten the elbow.
Apply a small amount of Loctite 641 to the tapered threads
of the male adapter (3) and install it into the flow end of
the check valve (2).
Apply a small amount of Loctite 641 to the tapered threads
of the extended elbow (1) and install the check valve with
the arrow pointing the elbow in the lubricating oil filter
head.
Tighten the check valve.
Connect the pump to the male adapter.
Use a supply of clean oil. Turn the pump to the ON
position. Check the engine oil pressure gauge. When the
gauge indicates oil pressure, begin monitoring the oil level
in the oil pan.
Remove the pump.
Remove the extended elbow (1), check valve (2), and
adapter (3) from the lubricating oil filter head.
Install the pipe plug.
Check the engine lubricating oil level to make sure it is
filled to the proper level.
Use a known source of good-quality number 2 diesel fuel.
Number 1 diesel fuels, along with most other alternate
fuels, are lighter (lower specific gravity, higher API gravity)
than number 2 diesel fuel. The lighter the fuel, the lower
the energy content per gallon (liter).
WARNING
CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50C [120F] before adding coolant.
Check the engine coolant level. Refer to Procedure
008-018.
Engine Throttle Control
Electrically Actuated Injectors
WARNING
(-) battery cable first, and attach the negative (-)
battery cable last.
Disconnect the battery cables before beginning the
following procedure.
Disconnect the OEM harness from the electronic control
module (ECM) (if applicable).
Disconnect the OEM harness 16-pin and 31-pin Deutsch
connectors from the engine wiring harness.
Connect the engine control harness, Part Number
4918643.
Connect the engine control harness 16-pin and 31-pin
Deutsch connectors to the engine wiring harness.
Remove the 3-pin Deutsch terminating resistor cap (cap
will have a blue insert) from the wiring harness.
Connect the engine control harness 3-pin Deutsch
connector to the J1939 connector of the engine wiring
harness.
The 3-pin Deutsch terminating resistor cap must be
installed after the engine control harness is removed. If
the cap is broken or has been misplaced, replace with
resistor cap, Part Number 3163051.
NOTE: If additional cable length is needed to connect the
engine control, use electrical cable, Part Number
3163895.
Connect the engine control harness (2) to the engine
control. An INSITE electronic service tool equipped
personal computer can be used to monitor circuits for
proper operation. Connect the INLINE5 datalink adapter
kit (3), Part Number 4918416, and a personal computer to
the datalink connector of the engine control.
Engines that are run on an engine dynamometer require
the engine harness be installed and connected to the
engine. Additionally, the engine control, Part Number
3163890, must be used to properly control the engine
during the dynamometer run.
Ground Connection
Connect the black-wire alligator clip of the engine control
harness to the engine block to achieve electrical ground.
CAUTION
Do not connect the alligator clip to the starter motor
solenoid S terminal. Doing so can cause equipment
damage.
Starter Connection
If not already equipped, install and wire a magnetic starter
switch.
Clip the alligator connector to the positive (+) coil terminal
of the magnetic starter switch.
Air Starter
If an air starter is being used, coil the red wire into a loop
and secure the loop to the engine control harness to
protect it from an electrical short.
WARNING
Batteries can emit explosive gases. To avoid personal
injury, always ventilate the compartment before
servicing the batteries. To avoid arcing, remove the
negative (-) battery cable first and attach the negative
(-) battery cable last.
Connect battery power to the starter.
Connect the dynamometer test OEM wiring harness
starter solenoid lead (yellow) to the starter solenoid.
Connect the ground lead (black) to the starter solenoid.
Connect the ground lead (black) to the starter or battery
negative (-) or ground side. Connect the (+) 12 VDC power
lead (red) to either the starter or battery positive (+) 12
VDC side.
Rotate the throttle knob fully counterclockwise. Push
down on the throttle knob to return the throttle to the idle
position.
Repeat this step three times.
Turn the keyswitch to the OFF position for 30 seconds.
CAUTION
Check coolant and lubricating oil levels before
starting and operating engine. If coolant and
lubricating oil are not at the proper level engine
damage can result.
Turn the keyswitch to the START position until the engine
starts and release the keyswitch.
CAUTION
Verify the red wire is connected to the positive (+)
battery terminal and the black wire is connected to the
negative (-) battery terminal. Equipment or engine
damage can result if not connected properly.
The power light will illuminate when power is supplied and
the keyswitch is turned to the accessory or ON position.
If the power light does not illuminate, return the keyswitch
to the OFF position. Verify the red wire is connected to the
positive (+) battery terminal and the black wire is
connected to the negative (-) battery terminal.
Turn the keyswitch to the ON position.
Light indicators on the engine control, STOP, WARN,
MAINT, WIF, and WAIT TO START, will illuminate, if
applicable. The light indicators will illuminate for
approximately 30 seconds. If no fault codes are found, the
light indicators will extinguish.
If the STOP light indicator (red) or WARN light indicator
(yellow) continues to illuminate, use INSITE electronic
service tool and the OEM service literature to diagnose the
engine fault code.
CAUTION
damage can result.
NOTE: The engine can be returned to idle at any time by
pushing in on the throttle knob.
Slowly rotate the throttle knob counterclockwise to
increase the engine rpm.
Slowly rotate the throttle knob clockwise to decrease the
engine rpm.
Turn the keyswitch to the OFF position to stop the engine.
Return parameters to their original values when the test
or run-in is complete.
Connect the keyswitch panel datalink cable to the
Cummins electronic service tool.
Use INSITE electronic service tool to set the engine up
for the dynamometer.
The setup is now complete, and the auto/manual throttle
can be used to control engine speed.
Engine operating specifications are available from
Cummins authorized repair locations.
Test
To properly monitor engine performance, record the
following parameters. To limit dynamometer operating
time, instrument the engine to make as many checks as
possible. The INSITE electronic service tool will provide
most, if not all, of the following:
Engine speed rpm with a verified tachometer
Fuel pressure
Fuel rate
Fuel temperature (if needed to correct fuel rate)
Fuel inlet restriction
Fuel drain line restriction
Intake manifold pressure (per bank).
Intake air restriction (per bank)
Exhaust air restriction (per bank)
Coolant temperature
Engine blowby
Lubricating oil pressure
Coolant pressure
Inlet manifold air temperature
Turbocharger inlet air temperature.
Engine Speed (rpm)
check the engine speed.
Fuel Drain Line Restriction
NOTE: Do not measure fuel drain line restriction with the
fuel measuring device installed. This will not measure the
drain line restriction of the vehicle's return plumbing.
Use pressure gauge, Part Number ST-1273, to measure
fuel drain line restriction.
Intake Air Restriction
Install the gauge adapter at a 90-degree angle to the
airflow in a straight section of pipe at a minimum of one
pipe diameter before the turbocharger.
Install the vacuum gauge, Part Number ST-434, or a
manometer, Part Number ST-1111-3, in the intake air
piping.
Measure the inlet air restriction.
Exhaust Air Restriction
Install the gauge adapter near the turbocharger, in a
straight section of pipe at the turbine outlet.
Install the pressure gauge, Part Number ST-1273, or a
manometer in the exhaust air piping.
Measure the exhaust air restriction.
Engine Blowby
Excessive blowby indicates an air compressor, a
turbocharger, or an engine malfunction, allowing
combustion gases or air to enter the crankcase and build
a pressure higher than normal.
This procedure describes how to measure crankcase
pressure and how to determine the component that is
malfunctioning.
Use the blowby service tool and a water manometer, Part
Number ST-1111-3. Maximum gauge capacity is 1270 mm
H
2
0 [50 in H
2
0].
Blowby Tool Part Number Orifice Size
3822570 9.00 mm [0.354 in]
3822571 10.30 mm [0.406 in]
Use a length of hose (1) to attach the blowby tool to one
of the crankcase breathers.
Attach a manometer to the location shown (2).
Operate the engine at rated rpm and full load (wide open
throttle) until a steady reading is obtained.
Compare the blowby readings to previous readings on the
engine. If previous readings for the engine are not
available, compare the blowby reading to new engine
specifications.
A sudden increase in blowby indicates a problem. A
gradual increase over time is normal (due to wear of
internal engine components).
If the blowby is higher than normal, check the crankcase
breathers and breather tubes to see whether they are
plugged.
Check the engine oil level. If the level is too high, it can
cause a higher than normal crankcase pressure.
Isolate the air compressor to determine whether it is
malfunctioning and causing the high blowby pressure.
Relieve the air pressure on the first air tank in the system
after the air compressor (wet tank).
Disconnect the air inlet and outlet connections. Plug the
intake manifold or air piping where the inlet connection
was removed.
Operate the engine at rated speed and full load (wide-
open throttle) until a steady blowby reading is obtained.
Compare the blowby readings to the previous value. If the
blowby is acceptable, replace the air compressor. Refer
A sudden increase in blowby or a high reading that is
not steady indicates that there is internal damage in the
engine.
Use pressure gauge, Part Number 3375275, to measure
lubricating oil pressure.
Install the pressure gauge to the main oil rifle (1) or air filter
head (2).
kPa psi
Low Idle 138 MIN 20
Rated rpm 413 MIN 60
Engine Coolant Pressure
Measure the coolant pressure at the water manifold (1).
Coolant Pressure
kPa psi
241 MAX 35
Air Compressor
All air compressors manufactured by Cummins Inc. must
be operating during the engine run-in. During the
performance check, all air compressors must be in the
unloaded or non-operating mode.
Connect a source of compressed air capable of producing
unloader.
Attach compressed air load to the air compressor outlet
(2).
Use an air tank (2). Install an air regulator (3) capable of
maintaining 345- to 517-kPa [50- to 75-psi] air pressure at
both minimum and maximum engine rpm.
Install a steel tube or high-temperature flexible hose (1)
capable of 260C [500F].
Connect the tube or hose (1) to the air compressor outlet.
Starting Motor
Inspect the voltage rating on the starting motor before
installing the electrical wiring.
Install the electrical wiring to the starting motor and
batteries, if used.
NOTE: If another method of starting the engine is used,
follow the manufacturer's instructions to make the
necessary connections.
K38, K50, QSK38, and QSK50 Engine Run-in (Engine Dynamometer)
Engine Run-in (Engine Dynamometer)
(014-006)
General Information
This document provides procedures for the use of an
engine control, Part Number 3163890. The engine control
is a portable, handheld electronic control, used to start
and control engine speed on the Cummins electronic
engine families. It replaces the throttle pedal, driver
interface panel, and fault code monitoring circuits. The
engine control has a datalink provision to connect to an
electronic service tool to monitor engine operation and
fault codes. The engine control harnesses required for the
engines are purchased separately. The engine control and
engine control harnesses are designed to be used with
both (+) 12-VDC and (+) 24-VDC battery systems.
NOTE: The engine control can be used on engines with
frequency throttle calibrations by first downloading a
linear throttle calibration to the electronic control module
(ECM). After the testing/repair is complete, reload the
correct frequency throttle calibration.
Run-In Instructions
The performance of an engine installed in a vehicle can
be tested on a chassis dynamometer.
Engine Speed (rpm) - Measure
At the tachometer drive
Measure the engine RPM at the tachometer drive location
(1). This RPM is the same as the crankshaft RPM.
Minimum Gauge Capacity: 2500 RPM
Engine Run-in (Engine Dynamometer) K38, K50, QSK38, and QSK50
With a verified tachometer
check and verify speed.
Oil Pressure - Measure
Measure the engine oil pressure at location (1).
Minimum Gauge Capacity: 1034 kPa [150 psi]
Oil Temperature - Measure
Measure the oil temperature at the oil pan sump.
Minimum Gauge Capacity: 149C [300F]
Coolant Temperature - Measure
Measure the coolant temperature at the thermostat
housing support. The measurement of the coolant outlet
temperature for both banks of the engine can aid during
troubleshooting.
Engine Blowby - Measure
Measure the engine blowby (crankcase pressure). Use
one of the two blowby service tool kits and a manometer.
Minimum Gauge Capacity: 1270 mm-H
2
0 [50 in-H
2
0]
CAUTION
The engine blowby tools are designed similar. The
difference between the tools is the size of the orifice.
Use a length of hose (1) to attach a blowby tool to each of
the two crankcase breathers.
Attach a manometer to the location shown (2). The other
tool must be plugged (3).
NOTE: Make certain that the blowby tool with the correct
orifice size is used.
Blow-By Tool Kit
Part Number
mm in
3822570 9.00 0.354
3822571 10.31 0.406
NOTE: Each tool kit contains two orifices.
Fuel Rail Pressure - Measure
Measure the fuel rail pressure at the fitting at the fuel
pump outlet.
Air Manifold Pressure - Measure
Measure the intake manifold pressure (boost) at the
location shown.
NOTE: Any of the plugs in the air crossover can be used.
Minimum Gauge Capacity: 2286 mm-Hg [90 in-Hg]
Measure the intake manifold pressure (boost) at the
location shown for KTA engines and KTTA engines with
outboard aftercoolers.
Use two manometers and measure the pressure for each
bank of the engine.
Fuel Vacuum and Temperature - Measure
Use a gauge. Do not use a manometer filled with liquid.
The liquid will mix with the fuel and the measurement will
not be accurate.
Use one of the adapters listed below. Install the adapter
as near to the fuel pump inlet as possible. Attach a
vacuum gauge to the adapter.
Hose
Size
Adapter Thread Fitting Angle
12 3375845 1-1/16 - 14 45 Degrees
12 3376719 1-1/16 - 12 37 Degrees
16 3376922 1-5/16 - 12 37 Degrees
NOTE: The hole in all of the adapters for the gauge hose
connection is [1/8-inch NPTF].
Measure the fuel temperature as near to the fuel pump
inlet as possible.
Minimum Gauge Capacity: 66 C [150 F]
NOTE: The engine horsepower will be less than specified
when the fuel temperature exceeds 43C [110F]. The
fuel temperature must not exceed 32C [90F] during the
performance check.
Exhaust Pipes - Connect
The I.D. of the exhaust pipe must be the correct size.
Minimum Exhaust Pipe Size
mm in
127 KT38 5.0
127 KTA38 5.0
152 KTTA38 6.0
152 KTA50, K1500E 6.0
203 KTTA50, K2000E, K1800E 8.0
* Note:An engine with outboard aftercoolers and two
center mount turbochargers.
Exhaust Back-Pressure and Temperature - Measure
CAUTION
The exhaust back-pressure sensor must be installed
a minimum of 254 mm [10 in] from the turbocharger
(2). The excessive heat will damage the sensor.
Measure the exhaust temperature and the exhaust back
pressure from the fittings in the exhaust pipe. Install the
temperature sensor as near to the turbocharger as
possible (1).
Air Inlet Pipes - Connect
NOTE: The inlet piping must contain a filter.
Connect an air inlet restriction sensor (1) between the air
filter and the turbocharger.
Minimum Gauge Capacity: 1270 mm-H
2
0 [50 in-H
2
0].
Fuel Return Line Pressure - Measure
Use a gauge. Do not use a manometer filled with liquid.
The liquid will mix with the fuel and the measurement will
not be accurate.
Use one of the adapters listed below. Install the adapter
between the check valve (1) and the fuel tank. Install a
pressure gauge to the adapter.
Minimum Gauge Capacity: 254 mm-Hg [10 in-Hg].
Hose
Size
Adapter Thread Fitting Angle
10 ST-434-2 7/8 - 14 37 Degrees
12 3376719 1-1/16 - 12 37 Degrees
12 3375845 1-1/16 - 14 45 Degrees
Oil Contamination - Monitor
Use a lubricating oil sampling filter, Part Number ST-1135
(1) or equivalent. Connect the filter oil inlet hose to the
location on the lubricating oil filter head as shown (2). The
oil is not filtered at this location.
Connect the sampling filter oil outlet hose to the sight-
glass hole in the oil pan adapter. See the filter
manufacturer's instructions to perform the test.
NOTE: If this tool is not available, inspect the full-flow oil
filters after the engine test.
If the port on the lubricating oil filter head is in use, the
sampling filter inlet can be connected at the pipe plug hole
on the oil jumper cover on the block.
Piston Cooling Pressure - Measure (outboard piston
cooling)
NOTE: Measure the piston cooling oil pressure on both
banks because there are two piston cooling pressure
regulators.
Measure the piston cooling oil rifle pressure in the location
shown (1).
NOTE: Some of the newer engines have rivet type plugs
(AVSEALS) instead of threaded pipe plugs in the piston
cooling nozzles. It will be necessary to fabricate test
nozzles if the piston cooling pressure is to be measured.
Remove the AVSEAL by drilling the center. Drill the nozzle
to the proper size for the threads to accommodate a pipe
fitting. Do not damage the nozzle spray nose or hole.
Piston Cooling Pressure - Measure (inboard piston
cooling)
NOTE: When the main oil rifle pressure exceeds 172 kPa
[25 psi], the oil will begin to flow to the piston cooling rifle.
When the main oil rifle pressure indicates 303 kPa [44 psi],
the oil pressure in the piston cooling rifle must be within
69 kPa [10 psi] of the main oil rifle pressure.
Fuel Flow - Measure
Because of excessive heat, do not connect the fuel flow
measuring instrument until the engine run-in-period
procedure is complete.
Use a fuel flow measuring instrument, Part Number
3376375, to measure the fuel flow. See the
manufacturer's instructions for installation and testing
procedures.
Coolant Pressure - Measure
On KT or KTA engines with the center mount aftercoolers,
measure the coolant pressure at the water manifold (1).
On KTA and KTTA engines with outboard aftercoolers,
measure the coolant pressure at the cylinder block (2).
Remove the draincock.
Cooling System - Connect
Install the coolant supply to the water pump (1).
Install the coolant return to both of the connections on the
thermostat housing (2).
Install four Diesel Coolant Additive (DCA)/Supplemental
Coolant Additive (SCA) water filters (3). Be sure the two
Diesel Coolant Additive/Supplemental Coolant Additive
(SCA) filter valves are in the "OUT" position.
Add the correct amount of Diesel Coolant Additive/
Supplemental Coolant Additive (SCA) powder or liquid to
charge the system properly.
NOTE: Connect deaeration hoses to both of the fittings on
top of the aftercooler water outlet connections (4), or open
the petcocks on the aftercooler water outlet connections
(4) during the coolant filling procedure. All air must be
eliminated to allow a complete fill of coolant.
Fill the engine with a coolant of 50 percent antifreeze and
50 percent water.
Check for leaks. Repair any leaks immediately.
Air Compressors - Unload
All air compressors manufactured by Cummins Inc.
must be operated during the engine run-in-period. During
the performance check, all air compressors must be in the
unloaded or non-operating mode.
Connect a source of compressed air capable of producing
unloader.
The load shown in the next illustration must be attached
to the air compressor outlet (2).
Use an air tank (2). Install a regulator (3) capable of
maintaining 345 kPa to 517 kPa [50 psi to 75 psi] at both
minimum and maximum engine RPM. Use a steel tube or
a high temperature flexible hose (1) capable of 260C
[500F].
Connect the air compressor outlet (1) to the air tank.
Lubricating System - Prime
Cummins Inc. recommends an external pressure pump to
prime the lubricating system. If an external pressure pump
is not available, see the Cranking Engine-Fuel "OFF"
Method.
External Pressure Pump Method
Use a pump capable of supplying 207 kPa [30 psi]
continuous pressure. Connect the pump to the port on the
oil filter head as shown.
Use a supply of clean oil. Turn the pump to the "ON"
in the oil pan.
NOTE: This method will fill the full-flow filters and lubricate
the turbochargers.
Use the engine oil dipstick. Monitor the oil level. Turn the
external pump to the "OFF" position when the oil touches
the "LOW" mark on the dipstick.
Disconnect the pump. Install the pipe plug in the filter
head.
Allow 10 minutes for the oil to drain into the oil pan. Use
the oil dipstick. Check the oil level.
Add oil until the oil touches the "HIGH" mark.
NOTE: The engine lubrication system is now primed. Omit
the next six illustrations. Proceed with Prime the Fuel
System.
Cranking Engine-Fuel "OFF" Method
Use the oil dipstick to measure the oil level. Add oil until
it touches the "HIGH" mark on the dipstick.
NOTE: All turbochargers on the KTTA engine must be
lubricated.
Use 60 to 90 milliliters [2 to 3 fluid ounces] of engine oil.
Disconnect the turbocharger oil inlet hose. Lubricate the
turbochargers. Connect the hose.
Use 3.5 liters [0.93 U.S. gallon] of oil for each full-flow
filter. Fill all of the filters with oil.
NOTE: The manual override screw must be turned
Counterclockwise until it stops.
CAUTION
Disconnect the two wires that supply power to the
solenoid.
CAUTION
When starting motors are used, do not crank the
starting motor for more than 30 seconds. Excessive
heat will damage the starting motor.
Use the starting motor. Crank the engine until the oil
pressure gauge indicates 207 kPa [30 psi].
If the oil pressure is less than specification after 30
seconds, allow 2 minutes for the starting motor to cool.
Allow 10 minutes for the oil to drain into the oil pan.
Use the oil dipstick. Measure the oil level. Add oil until the
oil touches the "HIGH" mark on the dipstick.
Connect the two wires to the fuel pump solenoid.
Fuel System - Prime
Use clean filtered fuel.
Fill the fuel filters with fuel. Install the fuel filters.
Connect the facility fuel supply to the inlet of the fuel filter
head (1).
Use clean, filtered fuel.
Fill the fuel pump suction hose or the fuel pump housing
with fuel.
Connect a throttle control device to the throttle arm on the
fuel pump.
NOTE: The solenoid power requirement is cast-molded in
the housing near the terminals.
Use a power supply that has an in-line switch. Connect the
electrical power to the solenoid terminal (1).
NOTE: The manual override screw must be turned
counterclockwise until it stops. This will allow the
solenoid to "OPEN" and "CLOSE" when the electrical
supply is turned to the "ON" and "OFF" positions.
See the appropriate fuel pump calibration manual to
determine the test values.
Test Horsepower: Line 3.
Rated RPM: Line 3.
Torque Rise: Line 5.
Torque Peak RPM: Line 18.
CPL: Line 2.
Engine Fuel Rail Pressure: Line 4.
Fuel Rate: Line 7.
Intake Manifold Pressure (Boost): Line 15.
NOTE: If the dynamometer is equipped to measure in
metric units, the values from the fuel pump manual must
be converted. Use these conversion factors:
English Symbol Multiply by, to
Obtain
Metric Symbol
ft-lb 1.356 Nm
hp 0.746 kw
Use this tabulation to determine the test load.
The run-in-period test must be performed with the engine operating at torque peak RPM. Operate a generator set
engine at rated RPM.
Example: The test load for a 2000 hp engine rated at 2000 RPM with a 15 percent torque rise is 1661 Nm [1225 ft-
lb].
NOTE: This tabulation assumes the dynamometer constant is 5252. If the dynamometer constant is not 5252, use
the following formula to determine the correct test load:
Correct Test Load = (Dynamometer Constant) x (Test Load) divided by 5252
Example: The dynamometer constant for testing the engine in the above example is 4000.
Correct Test Load = (4000 x 1225) divided by 5252 = 933 ft-lb
Rated RPM Rated Horsepower Torque Rise Test Load
1500 All All 1015 Nm [750 ft-lb]
1800 0 to 999 All 745 Nm [550 ft-lb]
1800 1000 to 1050 All 1015 Nm [750 ft-lb]
1800 1051 to 1100 All 1120 Nm [825 ft-lb]
1800 Above 1100 All 1390 Nm [1025 ft-lb]
1900 0 to 999 All 880 Nm [650 ft-lb]
1900 1000 to 1050 All 1015 Nm [750 ft-lb]
1900 1051 to 1200 All 1120 Nm [825 ft-lb]
1900 1201 to 1600 All 1490 Nm [1100 ft-lb]
1900 Above 1600 All 1695 Nm [1250 ft-lb]
1950 0 to 800 All 745 Nm [550 ft-lb]
2000 0 to 999 All 1015 Nm [750 ft-lb]
2000 1600 All 1490 Nm [1100 ft-lb]
2000 1800 All 1660 Nm [1225 ft-lb]
2100 0 to 999 All 880 Nm [650 ft-lb]
2100 1000 to 1100 All 1015 Nm [750 ft-lb]
2100 1200 All 1120 Nm [825 ft-lb]
2100 1350 All 1290 Nm [950 ft-lb]
2100 1600 All 1490 Nm [1100 ft-lb]
2100 1800 All 1625 Nm [1200 ft-lb]
Engine - "START"
CAUTION
Do not crank the electric starting motor for more than
30 seconds. Excessive heat will damage the starting
motor.
"START" the engine. If the engine does not begin
operating after 30 seconds, allow 2 minutes for the electric
starting motor to cool.
CAUTION
If the oil pressure is not within specifications, turn the
engine "OFF" immediately. Both low and high oil
pressure will cause engine damage.
Main Oil Rifle Pressure (at Idle)
kPa psi
138 MIN 20
Operate the engine at the "IDLE" position. Check for leaks
and unusual noises.
If the engine appears acceptable, proceed with the break
in procedure.
If the engine appears unacceptable, (i.e. major oil coolant
leak or engine noise) stop the engine.
CAUTION
Do not operate the engine at "IDLE" longer than
specified. Excessive carbon formation will cause
engine damage.
Adjust the engine RPM to 1200 RPM. Adjust the
dynamometer load to the test load as determined
previously. Operate the engine at this setting until the
coolant temperature indicates 71C [160F].
Check for leaks. Fix any leaks.
Check all gauges and record the readings.
NOTE: Do not proceed to the next step until the blowby
becomes stable within specifications.
Adjust the engine RPM to the torque peak RPM. Adjust
the dynamometer load to equal the test load multiplied by
2. Operate the engine for 2 minutes.
Check all the gauges and record the readings.
Maintain the engine RPM at torque peak RPM. Increase
3. Operate the engine at this load for 2 minutes.
Move the throttle lever to the "FULL OPEN" position.
Increase the load until the engine RPM is at torque peak
RPM.
Operate the engine at this setting for 10 minutes or until
the blowby becomes stable within specifications.
Decrease the dynamometer load until the engine RPM
increases to the rated RPM.
Operate the engine at this load for 5 minutes.
Decrease the dynamometer load completely.
Do not turn the engine "OFF" immediately. The engine
must be allowed to cool.
Move the throttle lever to the "LOW IDLE" position.
Operate the engine at this setting for 3 to 5 minutes. This
will allow the turbocharger and the other engine
components to cool.
CAUTION
specified. Excessive carbon formation can cause
engine damage.
Turn the engine "OFF".
Engine Performance - Check
Connect the fuel flow measuring instrument, Part Number
3376375, or equivalent. Measure the fuel consumption
during the performance check.
Follow the manufacturer's instructions that accompany
this instrument.
All air compressors must be unloaded during the
performance check.
Apply 655 kPa [95 psi] air pressure to the air compressor
unloader valve (1).
CAUTION
motor.
"START" the engine.
CAUTION
kPa psi
138 MIN 20
Adjust the dynamometer load until the engine maintains
the rated RPM.
Allow the readings to stabilize. Read the horsepower.
The oil temperature must be a minimum of 88C [190F].
The fuel temperature must not exceed 32C [90F]. The
horsepower reading will not be accurate if the oil or fuel
temperature is not within specification.
components to cool.
CAUTION
engine damage.
If the engine has, or will have throttle air cylinders, adjust
them now.
Disconnect all the connections and instruments.
Remove the engine from the dynamometer. Prepare the
engine for Painting, refer to procedure 000-009. For Long
Term Storage information, refer to procedure 000-005.
For engines without automatic prelube, use a pump, Part
Number 07600483, capable of supplying 205-kPa [30-psi]
continuous pressure. Connect the pump to the front of the
engine oil cooler as shown.
Use a supply of clean oil. Turn the pump to the ON
in the oil pan.
Check the engine lubricating oil level to be sure it is filled
to the proper level.
WARNING
CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50C [120F] before adding coolant.
Check the engine coolant level. Refer to Procedure
008-018.
Use a known source of good-quality number 2 diesel fuel.
Number 1 diesel fuels, along with most other alternate
fuels, are lighter (lower specific gravity, higher API gravity)
than number 2 diesel fuel. The lighter the fuel, the lower
the energy content (BTU) per gallon (liter, etc.).
Engine Throttle Control
WARNING
battery cable last.
Disconnect the battery cables before beginning the
following procedure.
Disconnect the OEM harness from the electronic control
module (ECM) (if applicable).
Disconnect the OEM harness 16-pin and 31-pin Deutsch
connectors from the engine wiring harness.
Connect the engine control harness, Part Number
4918643.
Connect the engine control harness 16-pin and 31-pin
Deutsch connectors to the engine wiring harness.
Remove the 3-pin Deutsch terminating resistor cap (cap
will have a blue insert) from the wiring harness.
Connect the engine control harness 3-pin Deutsch
connector to the J1939 connector of the engine wiring
harness.
The 3-pin Deutsch terminating resistor cap must be
installed after the engine control harness is removed. If
the cap is broken or has been misplaced, replace with
resistor cap, Part Number 3163051.
NOTE: If additional cable length is needed to connect the
engine control, use electrical cable, Part Number
3163895.
Connect the engine control harness (2) to the engine
control. An INSITE electronic service tool equipped
personal computer can be used to monitor circuits for
proper operation. Connect the INLINE5 datalink adapter
kit (3), Part Number 4918416, and a personal computer to
the datalink connector of the engine control.
Engines that are run on an engine dynamometer require
the engine harness be installed and connected to the
engine. Additionally, the engine control, Part Number
3163890, must be used to properly control the engine
during the dynamometer run.
Ground Connection
Connect the black-wire alligator clip of the engine control
harness to the engine block to achieve electrical ground.
CAUTION
Do not connect the alligator clip to the starter motor
solenoid S terminal. Doing so can cause equipment
damage.
Starter Connection
If not already equipped, install and wire a magnetic starter
switch.
Clip the alligator connector to the positive (+) coil terminal
of the magnetic starter switch.
Air Starter
If an air starter is being used, coil the red wire into a loop
and secure the loop to the engine control harness to
protect it from an electrical short.
WARNING
Batteries can emit explosive gases. To avoid personal
injury, always ventilate the compartment before
servicing the batteries. To avoid arcing, remove the
negative (-) battery cable first and attach the negative
(-) battery cable last.
Connect battery power to the starter.
Connect the dynamometer test OEM wiring harness
starter solenoid lead (yellow) to the starter solenoid.
Connect the ground lead (black) to the starter solenoid.
Connect the ground lead (black) to the starter or battery
negative (-) or ground side. Connect the (+) 12 VDC power
lead (red) to either the starter or battery positive (+) 12
VDC side.
Rotate the throttle knob fully counterclockwise. Push
down on the throttle knob to return the throttle to the idle
position.
Repeat this step three times.
Turn the keyswitch to the OFF position for 30 seconds.
CAUTION
damage can result.
CAUTION
Verify the red wire is connected to the positive (+)
battery terminal and the black wire is connected to the
negative (-) battery terminal. Equipment or engine
damage can result if not connected properly.
The power light will illuminate when power is supplied and
the keyswitch is turned to the accessory or ON position.
If the power light does not illuminate, return the keyswitch
to the OFF position. Verify the red wire is connected to the
positive (+) battery terminal and the black wire is
connected to the negative (-) battery terminal.
Turn the keyswitch to the ON position.
Light indicators on the engine control, STOP, WARN,
MAINT, WIF, and WAIT TO START, will illuminate if
applicable. The light indicators will illuminate for
approximately 30 seconds. If no fault codes are found, the
light indicators will extinguish.
If the STOP light indicator (red) or WARN light indicator
(yellow) continues to illuminate, use INSITE electronic
service tool and the OEM service literature to diagnose the
engine fault code.
CAUTION
damage can result.
NOTE: The engine can be returned to idle at any time by
pushing in on the throttle knob.
Slowly rotate the throttle knob counterclockwise to
increase the engine rpm.
Slowly rotate the throttle knob clockwise to decrease the
engine rpm.
Turn the keyswitch to the OFF position to stop the engine.
Return parameters to their original value when the test or
run-in is complete.
Connect the keyswitch panel datalink cable to the
Cummins electronic service tool.
Use INSITE electronic service tool to set the engine up
for the dynamometer.
The setup is now complete, and the auto/manual throttle
can be used to control engine speed.
Engine operating specifications are available from
Cummins authorized repair locations.
Refer to Engine Testing - Engine Dynamometer,
Procedure 014-005, for the engine operating procedures
and safety precautions.
The run-in test must be preformed with the engine
operating at torque peak rpm. Operate a generator set at
the rated rpm. See the performance charts available
through Cummins Inc.
Rated RPM Torque Peak
1800 1500
1900 1500
Engine - "START"
CAUTION
motor.
CAUTION
"START" the engine. If the engine does not begin
operating after 30 seconds, allow 2 minutes for the electric
starting motor to cool.
kPa psi
138 MIN 20
483 MAX 70
If the oil pressure is not within specifications, the engine
must be shut down.
Operate the engine at the "IDLE" position. Check for leaks
and unusual noises.
If the engine appears acceptable, proceed with the break
in procedure.
If the engine appears unacceptable, (i.e. major oil coolant
leak or engine noise) stop the engine.
CAUTION
specified. Excessive carbon formation will cause
engine damage.
Adjust the engine RPM to 1200 RPM. Adjust the
dynamometer load to the test load as determined
previously. Operate the engine at this setting until the
coolant temperature indicates 71C [160F].
Check for leaks. Fix any leaks.
Check all gauges and record the readings.
Adjust the engine RPM to the torque peak RPM. Adjust
2. Operate the engine for 2 minutes.
Maintain the engine RPM at torque peak RPM. Increase
3. Operate the engine at this load for 2 minutes.
Increase the load until the engine RPM is at torque peak
RPM.
Operate the engine at this setting for 10 minutes or until
the blowby becomes stable within specifications.
Decrease the dynamometer load until the engine RPM
increases to the rated RPM.
Operate the engine at this load for 5 minutes.
components to cool.
CAUTION
engine damage.
Engine Compression K38, K50, QSK38, and QSK50
Engine Compression (014-012)
Preparatory Steps
Remove the rocker lever cover. Refer to Procedure
07-04 in the Troubleshooting and Repair Manual
K19, Bulletin 3810307. Refer to Procedure 003-011
in the Troubleshooting and Repair Manual QSK19
Series Engines, Bulletin 3666098. Refer to
Procedure 07-04 in the K38 and K50
Troubleshooting and Repair Manual, Bulletin
3810432. Refer to Procedure 003-011 in the QSK45
and QSK60 Base Engine Troubleshooting and
Repair Manual, Bulletin 3666261. Refer to
Procedure 003-011 in the Troubleshooting and
Repair Manual QSK78 Series Engines Bulletin
3666727. Refer to Procedure 003-011 in the
Troubleshooting and Repair Manual QSK23 Series
Engines, Bulletin 4021375.
Remove the rocker lever assembly. Refer to
Procedure 07-09 Troubleshooting and Repair
Manual K19, Bulletin 3810307. Refer to Procedure
003-009 Troubleshooting and Repair Manual QSK19
Remove the injector. Refer to Procedure 05-09 in the
Troubleshooting and Repair Manual K19, Bulletin
Engines, Bulletin 3666098. Refer to Procedure 05-09
in the K38 and K50 Troubleshooting and Repair
Manual, Bulletin 3810432. Refer to Procedure
006-026 QSK45 and QSK60 Base Engine
Engines Bulletin 3666727. Refer to Procedure
QSK23 Series Engines, Bulletin 4021375.
K38, K50, QSK38, and QSK50 Engine Compression
Establish top dead center (TDC) on the compression
stroke. Refer to Procedure 07-20 in the
Engines , Bulletin 3666098. Refer to Procedure
07-18 in the K38 and K50 Troubleshooting and
Procedure 006-025 in the QSK45 and QSK60 Base
Engine Troubleshooting and Repair Manual ,
Bulletin 3666261. Refer to Procedure 006-025 in the
Engines , Bulletin 3666727. Refer to Procedure
QSK23 Series Engines , Bulletin 4021375.
Continue to rotate the crankshaft until the piston passes
TDC and is 12.7 mm [0.50 inch] after top dead center
(ATDC).
Rotate the crankshaft in the opposite direction to raise the
piston 6.35 mm [0.250 inch] below TDC.
Setup
Install the appropriate air fitting (supplied with the
differential pressure tester, Part Number 3824223) into the
top of the leak test adapter with thread sealing tape.
Check all o-rings for cracks or damage prior to each
cylinder test and replace if necessary.
Lubricate the o-rings and leak test adapter with 15W-40
lubricating oil.
NOTE: If the injector installation tool, Part Number
3824830, is not available, use a 40 mm [1 9/16-inch]
socket with an extension and a rubber mallet to install the
leak test adapter.
Install the leak test adapter and hold-down clamp into the
cylinder head.
Use injector installation tool, Part Number 3824830, to
seat the leak test adapter in the bore.
The slide hammer will make a dull sound when the leak
test adapter is seated properly.
Install the injector hold-down clamp and capscrew.
NOTE: The crankshaft breather is not to be obstructed
during this test, do not install plugs or orifices as used in
traditional blowby tests.
Close the ball valve on the differential cylinder pressure
tester, Part Number 3824223. Connect the differential
cylinder pressure tester outlet hose to the fitting on the
leak test adapter.
Pressure Differential Test
WARNING
personal injury.
Connect the differential cylinder pressure tester inlet hose
to shop air.
Open the differential pressure tester ball valve slowly,
taking careful note of any crankshaft rotation. If any
rotation is apparent, the piston will not be correctly
positioned in the cylinder. If the piston is correctly
positioned in the cylinder and the engine crankshaft still
rotates, the engine barring mechanism must be locked to
prevent engine rotation.
Make certain that there are no leaks at any connection
joint.
K38, K50, QSK38, and QSK50 Engine Compression
Pressurize the cylinder and adjust the regulator on the
differential pressure tester until gauge (1) indicates 100
psi [689 kPa]. When the reading on gauge (2) has
stabilized, record the pressure reading of both gauges and
record the cylinder number and bank.
If at any time during the test the reading on gauge (2) is
not stable, lightly tap the tops of the engine valves with a
rubber mallet to make certain that they are closed. If the
reading on gauge (2) remains unstable, repeat positioning
procedure described earlier.
Position each remaining cylinder and test.
The leakdown test can be used to determine the relative
condition of a cylinder when compared to other cylinders
in the engine. The leakdown test can also help diagnose
the source of the leak or blowby. This includes, but is
not limited to, air flow from the breather (worn cylinder),
air flow in the intake or exhaust manifold (leaking valves)
or air bubbles in the coolant (leaking cylinder head gasket,
cylinder head crack or cylinder block crack).
Before taking any action based on leakdown test results,
repeat the leakdown test for the suspect cylinder and
compare to the original results. Factory leakdown limits
will not be established, cautious judgment must be used
before replacing parts or taking any action due to results
from the leakdown test.
Additionally, the test results subject to comparison need
to be obtained within a relatively short time frame.
Leakdown test results are expected to vary depending on
engine temperature. Because of this, comparing
leakdown results from different engines is not
recommended.
Remove the differential pressure tester and leak test
adapter.
Finishing Steps
Install the injector. Refer to Procedure 05-09 in the
006-026 QSK45 and QSK60 Base Engine
Install the rocker lever assembly. Refer to Procedure
07-09 Troubleshooting and Repair Manual K19,
Bulletin 3810307. Refer to Procedure 003-009
003-009 in the QSK45 and QSK60 Base Engine
Install the rocker lever cover. Refer to Procedure
K19, Bulletin 3810307. Refer to Procedure 003-011
in the Troubleshooting and Repair Manual QSK19
Section 16 Mounting Adaptations Group 16 Page 16-a
Section 16 Mounting Adaptations Group 16
Section Contents
Page
Engine Lifting Brackets ...................................................................................................................................16-3
Install..............................................................................................................................................................16-3
Remove..........................................................................................................................................................16-3
Engine Mounts ...............................................................................................................................................16-33
Engine Support Bracket, Front .......................................................................................................................16-5
Finishing Steps...............................................................................................................................................16-9
Install..............................................................................................................................................................16-8
Remove..........................................................................................................................................................16-5
Flexplate ........................................................................................................................................................16-10
Finishing Steps............................................................................................................................................. 16-13
Install............................................................................................................................................................16-12
Measure........................................................................................................................................................16-12
Face Runout...............................................................................................................................................16-12
Remove.........................................................................................................................................................16-10
Flywheel .........................................................................................................................................................16-14
Finishing Steps............................................................................................................................................. 16-18
Install............................................................................................................................................................16-16
Remove.........................................................................................................................................................16-14
Flywheel Housing ..........................................................................................................................................16-19
Finishing Steps............................................................................................................................................. 16-31
Install............................................................................................................................................................16-27
Measure........................................................................................................................................................16-28
Alignment...................................................................................................................................................16-28
Redowel........................................................................................................................................................16-21
Remove.........................................................................................................................................................16-20
Flywheel Ring Gear .......................................................................................................................................16-32
Assemble......................................................................................................................................................16-32
Service Tools ...................................................................................................................................................16-1
Mounting Adaptations......................................................................................................................................16-1
Page 16-b Section 16 Mounting Adaptations Group 16
Section 16 Mounting Adaptations Group 16 Page 16-1
Service Tools
Mounting Adaptations
Repair Location.
3163720
Dowel Pin Puller
Kit contains various size collets used to remove dowel pins
throughout the engine.
ST-1232
Drill/Ream Fixture
Used to drill and ream dowel holes. Bushings are not included and
must be ordered separately.
3375109
Engine Lifting Fixture
Used with a hoist to lift the engine.
3163264
Used to lift the engine during installation of removal.
4918623
Engine Speed Sensor Socket
Used to remove the engine speed sensor on QSK50 engines.
3164794
Torque Wrench
Page 16-2 Section 16 Mounting Adaptations Group 16
3164798
Torque Wrench
3375957
3375958
K38, K50, QSK38, and QSK50 Engine Lifting Brackets
Engine Lifting Brackets (016-001)
Remove
NOTE: The K38 and K50 engines have four lifting
brackets, two on each bank. The lifting brackets for the
K38 are installed between cylinder numbers 1 and 2, and
5 and 6. The lifting brackets for the K50 are installed
between cylinder numbers 2 and 3, and 6 and 7.
Remove the capscrews, flat washer, and lifting bracket.
WARNING
WARNING
personal injury.
WARNING
Use solvent. Clean the bracket, washer, and capscrew.
Check the bracket for cracks. Check the capscrew for rust
and corrosion. Refer to Procedure 017-001 (Capscrew) in
Section 17.
NOTE: If the bracket does not contain a spot-face around
the hole for the capscrew, it is recommended that the
bracket be spot-faced before it is used again.
The spot-face must be 31.8 mm [1.25 inch] in diameter
(B), and have the same center as the capscrew hole. The
radius (C) of the spot-face must be 0.38 mm [0.015 inch].
The depth of the spot-face (A) must provide a flat surface
for the washer that is approximately 0.25 mm [0.010 inch]
deep. Use a spot-face tool that has a 21 mm [53/64-inch]
pilot.
Install
CAUTION
The sealant must be applied on the lifting brackets to
prevent corrosion of the capscrews caused by
moisture. The capscrews will break when the engine
is lifted if they are corroded.
Use RTV Sealant, Part Number 3164067, or equivalent.
Apply a bead of sealant to the block around the threaded
hole for the lifting bracket, as shown.
Engine Lifting Brackets K38, K50, QSK38, and QSK50
Add a bead of sealant to the bottom of the capscrew head.
Install the flat washer.
Apply a bead of sealant to the flat washer.
Install the lifting bracket, flat washer, and capscrew.
K38, K50, QSK38, and QSK50 Engine Support Bracket, Front
Engine Support Bracket, Front
(016-002)
Preparatory Steps
WARNING
WARNING
WARNING
WARNING
013-009.
Drain the coolant and remove the radiator. Refer to
Procedure 008-018.
Remove the fan drive belt, if applicable. Refer to
Procedure 008-002.
Remove the vibration damper. Refer to Procedure
001-052.
Remove the crankshaft adapter. Refer to Procedure
001-017
Remove
WARNING
WARNING
Before lifting the engine, check the four engine lifting
brackets. Be sure bracket contains a spot face under
the hardened steel washer. If the bracket is not spot
faced, remove the capscrew.
Check for rust (corrosion). If the capscrew has rust
(corrosion), replace the capscrew before lifting the engine.
Engine Support Bracket, Front K38, K50, QSK38, and QSK50
Support the engine in strict accordance with correct safety
considerations and precautions. Refer to Procedure
000-001.
If the front of the engine must be supported from
underneath while work is performed on the front end, drain
the oil and remove the oil pan adapter assembly first.
The engine can then be supported by a heavy wooden
timber placed under the block pan rails.
Use suitable means to take the weight off the front
support.
K38 and K50 engines have four lifting brackets that are
bolted to the cylinder block. Lifting brackets are designed
to lift the engine only.
Remove the capscrews that mount the front support to the
chassis or frame. Remove the front support from the gear
housing cover trunnion.
Inspect for Reuse
WARNING
CAUTION
Damaged engine mounts and brackets can cause the
engine to move out of alignment, damage the
driveline components in the equipment, and result in
vibration complaints.
Two different front support assemblies have been
supplied on K38 and K50 engines. Earlier engines have a
two piece support. Later engines use a one piece support.
Inspect the front engine mount for cracks or other
damage.
Inspect all mounting brackets for cracks or damaged bolt
holes.
Replace the bracket if cracked or otherwise damaged.
Measure the front support bore.
Front Support Bore Diameter
mm in
210.03 MIN 8.269
210.08 MAX 8.271
If the front support bore is not within specifications, the
front engine support bracket must be replaced.
Engine Support Bracket, Front K38, K50, QSK38, and QSK50
Check the trunnion sleeve for damage. The sleeve must
be replaced if it is worn or cracked.
Install
WARNING
Use grease and lubricate the bore of the mount and
trunnion sleeve on the front gear cover.
Install the front engine support by slipping it over the
trunnion bushing.
If the two-piece front support is used, tighten the
capscrews to the specified torque.
Raise the engine to take the weight off the supports used
under the engine block. Remove the supports and install
the oil pan. Refer to Procedure 007-027.
Lower the engine until the front engine support is in
position.
Remove the engine lifting fixture.
Finishing Steps
WARNING
WARNING
WARNING
Install the crankshaft adapter. Refer to Procedure
001-017.
Install the vibration dampers. Refer to Procedure
001-052.
Install fan drive belt, if applicable. Refer to Procedure
008-002.
Replace items removed and fill with coolant. Refer to
Procedure 008-018.
Flexplate K38, K50, QSK38, and QSK50
Flexplate (016-004)
Preparatory Steps
WARNING
cable last.
013-009.
Disconnect the starter air to prevent accidental
engine starting. Refer to Procedure 012-022.
components. Refer to the OEM manual.
Remove
WARNING
NOTE: The use of a guide pin will aid the disassembly
procedure.
Remove the SAE Grade 8 capscrews and the hardened
washers. Remove the flexplate.
WARNING
WARNING
personal injury.
Do not disassemble the flexplate assembly. Refer to
Procedure 016-999.
Use solvent. Clean the flexplate. Dry with compressed air.
Check the ring gear for damaged or worn teeth. If the ring
gear is damaged or worn, it must be replaced. Refer to
Procedure 016-008.
K38, K50, QSK38, and QSK50 Flexplate
WARNING
Cummins Inc, does not recommend resurfacing of the
flexplate. Resurfacing of the flexplate can cause
possible personal injury, property damage, or cause it
to be too thin and result in breakage.
Use the dye penetrant method to check the area of the
mounting holes for cracks. There must not be any cracks
in the flexplate mounting area.
Check the mounting pilot for damage. If the pilot is
damaged, the flexplate must be replaced.
Check the tightness of the twenty five capscrews.
Use SAE Grade 8 capscrews if replacement is required.
The flexplate can consist of as many as nine separate
steel plates.
Check closely for cracks.
If any of the steel plates are cracked or damaged, the
engine flexplate must be replaced.
Check the two tapered dowels for damage. If the dowels
are bent or broken, they must be replaced.
Flexplate K38, K50, QSK38, and QSK50
Measure
NOTE: The crankshaft must be pushed or pulled in the
same direction each time a measurement is made, in
order to obtain an accurate reading.
Bar the engine from the front of the crankshaft for both
radial and face measurements. The barring device will
cause the flexplate to distort if barred from the rear, and
also cause the crankshaft to walk up the main bearing
sidewall.
Radial Runout
Attach an indicator to the flywheel housing with the
indicator tip on the flexplate as shown. Check the indicator
while rotating the engine.
Maximum Radial Runout: 0.08 mm [0.003 in]
If the runout is not within specification, the pilot on the
flexplate is not seated correctly on the crankshaft. If the
pilot is damaged, the entire flexplate assembly must be
replaced.
Face Runout
Attach an indicator to the flywheel housing with the
indicator tip on the face of the face of the flexplate. Check
the indicator while rotating the engine.
Maximum Face Runout: 0.89 mm [0.035 in].
If the alignment is not within specification, check for
foreign material between the flexplate and the crankshaft.
Two 3/8 x 16 inch threaded holes were added to the
adapter to aid in the removal of the assembly.
Install
Install the roll pin (1) in the crankshaft.
The pin is required to align the timing marks that are on
the flexplate.
NOTE: The flexplate is not the same for the K38 and K50
engines. The valve and injector adjustment marks that are
stamped on the parts are different.
K38, K50, QSK38, and QSK50 Flexplate
WARNING
The flexplate mounting capscrews must be SAE Grade
8 minimum with rolled threads. The flexplate
mounting plain washers are special hardened . Do not
substitute the parts or a failure can result that can
cause personal injury.
The use of a guide bolt will aid the assembly procedure.
Do not lubricate the threads of the crankshaft.
Use engine oil. Lubricate the capscrews and the washers.
Allow the excess oil to drip from the parts.
Check to be sure the mating surfaces of the crankshaft
and flexplate are clean, dry, and free of nicks or burrs.
Align the hole in the flexplate for the roll pin with the roll
pin in the crankshaft.
Install the flexplate, washers, and the capscrews. The
flexplate must fit firmly against the crankshaft.
Use the following steps to tighten the capscrews in the
sequence shown.
Step2 285 Nm [ 210 ft-lb ]
Step3 515 Nm [ 380 ft-lb ]
Finishing Steps
WARNING
cable last.
Connect the starter air. Refer to Procedure 012-022.
Start the engine. Check equipment operation.
Flywheel K38, K50, QSK38, and QSK50
Flywheel (016-005)
Preparatory Steps
WARNING
battery cable last.
WARNING
13.
Disconnect the air starter to prevent accidental
engine starting. Refer to Procedure 012-022 (Air
Starting Motor) in Section 12.
Remove
WARNING
Remove two capscrews and install two guide studs.
Install the tee-handles.
Install the lifting straps.
Remove the remaining capscrews.
A mallet can be used to tap the flywheel if necessary.
Remove the flywheel.
K38, K50, QSK38, and QSK50 Flywheel
WARNING
can cause personal injury.
WARNING
WARNING
personal injury.
Use solvent or steam to clean the flywheel.
Use a wire brush to clean the crankshaft pilot bore.
Inspect the teeth of the ring gear for wear or damage.
If the teeth of the ring gear are worn or damaged, the ring
gear must be replaced.
Use the dye penetrant, Part Number 3375452, to check
the area of the mounting capscrew holes for cracks. There
must not be any cracks in the flywheel mounting area.
Inspect the mounting pilot hole for damage. If the pilot hole
is damaged, the flywheel must be replaced.
WARNING
Cummins Inc., does not recommend resurfacing the
flywheel. Resurfacing the flywheel can cause it to be
too thin and cause personal injury, property damage,
or result in breakage.
Inspect the face of the flywheel for cracks or other
damage.
The flywheel must be replaced if cracked or otherwise
damaged.
Install
Install the roll pin (1) in the crankshaft.
The pin is required to align the timing marks that are on
the flywheel.
NOTE: The flywheel and flexplate are not the same for
K38 and K50 engines. The valve and injector adjustment
marks that are stamped on the parts are different.
Lubricate the flywheel mounting capscrew threads and
flange head surfaces with clean engine oil.
Install the washer onto the capscrew and lubricate the
washer (1).
WARNING
Install two guide studs to prevent the flywheel from
rotating.
Install the flywheel.
Install the flywheel mounting capscrews.
Remove the two guide studs and install the last two
flywheel mounting capscrews.
K38, K50, QSK38, and QSK50 Flywheel
Tighten the flywheel mounting capscrews in the sequence
shown.
Step2 285 Nm [ 210 ft-lb ]
Step3 515 Nm [ 380 ft-lb ]
Measure the flywheel total indicator runout.
NOTE: The crankshaft end clearance must be pushed or
pulled in the same direction each time a point is
measured.
Attach an indicator as shown. Continue to look at the
indicator while rotating the engine.
Maximum radial runout is 0.13 mm [0.005 inch]. If the
runout is not within specification, the pilot on the flywheel
is not positioned correctly on the crankshaft.
If the pilot is damaged, the flywheel must be replaced.
Attach an indicator as shown. Measure the flywheel
alignment at four equally spaced points by rotating the
flywheel.
Measure the distance from the center of the crankshaft to
the indicator tip. Multiply (x) the distance by 0.025 mm
[0.001 inch] to obtain the maximum run out.
If the flywheel alignment is not within specifications,
check for interference between the flywheel and the
crankshaft.
Finishing Steps
WARNING
WARNING
battery cable last.
Install the drive unit and related components. Refer
to the OEM manual.
Connect the air starter. Refer to Procedure 012-022
(Air Starting Motor) in Section 12.
K38, K50, QSK38, and QSK50 Flywheel Housing
Flywheel Housing (016-006)
Preparatory Steps
WARNING
WARNING
WARNING
WARNING
13.
Disconnect the air starter to prevent accidental
engine starting. Refer to Procedure 012-022 (Air
Starting Motor) in Section 12.
instructions.
Remove the engine speed sensor, use the special
socket tool, Part Number 4918623 or equivalent.
Refer to Procedure 019-042 (Engine Speed Sensor
(ESS)) in the Troubleshooting and Repair Manual
Electronic Control System, KTA38GC CM558,
Bulletin 4021665.
Drain the engine oil. Refer to Procedure 007-025
(Lubricating Oil Pan) in Section 7.
Remove the starter motor. Refer to Procedure
013-020 (Starting Motor) in Section 13.
Remove the oil pan adapter assembly. Refer to
Procedure 007-027 (Lubricating Oil Pan Adapter) in
Section 7.
Flywheel Housing K38, K50, QSK38, and QSK50
Remove
WARNING
NOTE: Newer engines have a flywheel housing that also
contains a rear crankshaft seal. When this housing is
used, the rear seal housing or the rear gear drive housing
is not used. The newer housing is referred to as Housing
with Rear Seal in the procedure. Older housings are
referred to as Housing without Rear Seal.
On engines equipped with flywheel housings without a
rear seal, remove the SAE Grade 8 capscrews (4) and (5).
There are twelve capscrews.
After removing the first few capscrews, install guide bolts
to aid in the disassembly procedure.
are damaged.
WARNING
On housings with rear seals, remove the SAE Grade 8
capscrews (5) and (6). There are twelve capscrews.
After removing the first few capscrews, install guide bolts
to aid in the disassembly procedure.
are damaged.
Remove the rear seal.
Discard the gasket.
WARNING
WARNING
WARNING
personal injury.
Use solvent or steam to clean the flywheel housing.
Inspect all surfaces for nicks, burrs, or cracks.
Use a fine crocus cloth to remove small nicks and burrs.
Install the covers.
NOTE: Gaskets are only required on wet type flywheel
housings.
Inspect all threaded capscrew holes for damage.
Inspect the engine speed sensor threaded hole for
damage.
Repair or replace the housing if the threaded holes are
damaged.
Redowel
The tools needed to perform this procedure are:
Part Number ST-1232, Drill Ream Fixture that contains:
1. Plate, Part Number ST-1232-1
2. Locator pin, Part Number 3375052
3. Drill/Ream actual sizes. Bushing set depends on the
dowel size
4. Drill adapter locally obtained; use to adapt open-
shank reamers to drill-chuck
5. Reamer locally obtained
6. Drill bit locally obtained.
WARNING
NOTE: The procedure remains the same, even though the
following illustrations show a K19 flywheel housing.
Use a dowel pin extractor, Part Number 3163720, or
equivalent. Remove the two dowels (9) from the block.
Measure a dowel pin that is removed so that an oversize
dowel pin size can be determined.
WARNING
Install the flywheel housing.
Do not tighten the capscrews. The flywheel housing will
need to be aligned.
Align the flywheel housing to the crankshaft.
Move the housing with a mallet until the bore is within
specifications. Make sure that the bore and face of the
housing are in alignment.
Flywheel Housing - Radial Run Out
Inside Diameter SAE
Number
Maximum Runout
mm in mm in
787 31.0 00 0.30 0.012
648 25.5 0 0.25 0.010
Flywheel Housing - Face Run Out
Inside Diameter SAE
Number
Maximum Runout
mm in mm in
787 31.0 00 0.30 0.012
648 25.5 0 0.25 0.010
When the housing is in alignment, tighten the capscrews
in the sequence shown.
Flywheel Housing - Torque Sequence
Step2 203 Nm [ 150 ft-lb ]
Step3 366 Nm [ 270 ft-lb ]
After the capscrews are tightened, check the alignment
again.
This illustration shows the location of the dowel holes on
the flywheel housing.
Use appropriate size capscrews. Attach Part Number
ST-1232-1, Plate, that is contained in Part Number
ST-1232 Drill Ream Fixture, to the crankshaft.
Do not tighten the capscrews so much that the plate does
not move.
CAUTION
The crankshaft must be "locked" in position. It can
turn during reaming.
Use the locator pin to align the plate with the hole for the
dowel pin. Tighten the capscrews. The taper on the pin
must engage the dowel pin hole.
The locator pin must rotate easily after the capscrews are
tightened.
"Lock" the crankshaft in position. Be sure the locator pin
is still in alignment and that the locator pin can be rotated
easily.
Measure the dowel pins to be installed.
Obtain a reamer (5) that is 0.013 mm to 0.025 mm [0.0005
inch to 0.001 inch] smaller than the dowel.
The dowel length must protrude from the block one-half
of the flywheel housing wall thickness.
There are three oversize dowel pins available from
Cummins Inc.
Oversize Dowel Pin Outside Diameter
mm in Oversize
13.08 0.515 [0.015 in]
13.46 0.530 [0.030 in]
13.84 0.545 [0.045 in]
Install the appropriate drill bushings (4). The following
bushings are available from Cummins Inc.
Drill/Ream Bushing Sets - 25.4 mm [1.0 inch]
Oversize
mm
Oversize
[Inch]
Bushing
Size mm
Bushing
Size
[Inch]
3376495 Special 12.304 [0.4844]
Standard 12.700 [0.5000]
0.38 [0.015] 13.096 [0.5156]
0.76 [0.030] 13.492 [0.5312]
1.14 [0.045] 13.879 [0.5464]
ST-1234 Standard 14.288 [0.5625]
0.38 [0.015] 14.684 [0.5781]
0.76 [0.030] 15.080 [0.5937]
1.14 [0.045] 15.479 [0.6094]
ST-1235 Standard 15.875 [0.6250]
0.38 [0.015] 16.271 [0.6406]
0.76 [0.030] 16.667 [0.6562]
1.14 [0.045] 17.066 [0.6719]
ST-1236 Standard 17.463 [0.6875]
0.38 [0.015] 17.859 [0.7031]
0.76 [0.030] 18.255 [0.7187]
1.14 [0.045] 18.654 [0.7344]
ST-1237 Standard 19.050 [0.7500]
0.38 [0.015] 19.446 [0.7656]
0.76 [0.030] 19.842 [0.7812]
ST-1238 22.621 [0.8906]
23.813 [0.9375]
The drill bushing that is used must be the same size as
the reamer (or the drill) that is used.
WARNING
WARNING
personal injury.
CAUTION
Do not allow metal chips to enter the engine. Damage
to the engine will result.
When the new dowel pins are more than 0.38 mm [0.015
inch] larger than the old dowels, drill the hole to a size that
is slightly smaller than the reamer. Then the reamer will
not have to remove an excessive amount of material.
Ream the hole until the reamer touches the bottom of the
hole in the block.
Remove the reamer. Clean the hole. Use solvent. Dry with
compressed air. Push the reamer through the hole again.
The reamer must touch the bottom of the hole in the block.
After reaming one hole, turn the plate and align it with the
next dowel hole. Repeat the procedure in the next hole.
CAUTION
The dowel hole must not contain any metal chips.
Damage will result.
Remove the plate from the crankshaft.
Use a square nose drift. Install each dowel until it touches
the bottom of the hole in the block.
After the dowels are installed, measure the bore and the
face alignment again.
Install
WARNING
NOTE: Newer engines have a flywheel housing that also
contains a rear crankshaft seal. When this housing is
used, the rear seal housing or the rear gear drive housing
is not used. The newer housing is referred to as Housing
with Rear Seal in the procedure. Older housings are
referred to as Housing without Rear Seal.
NOTE: Guide bolts with 3/4-10 inch threads that are a
minimum of 203 mm [8 in] in length will aid the assembly
procedure.
On flywheel housings without the rear seal, make sure the
two dowel pins (7) are installed in the cylinder block.
Check to make sure the mating surfaces of the block and
the housing are clean, dry, and free from nicks and burrs.
Install the flywheel housing (2). Push the housing over the
dowel pins and to the cylinder block.
The capscrews (4) and (5) must be SAE Grade 8.
Install the twelve lock washers (3) on the ten capscrews
(4) and the two capscrews (5). Remove any guide bolts.
Follow the sequence shown to tighten the capscrews.
WARNING
On flywheel housings with the rear seal, make sure the
two dowel pins are installed in the cylinder block.
Check to make sure the mating surfaces of the block and
the housing are clean, dry, and free from nicks and burrs.
Install the gasket (1).
Install the flywheel housing (2). Push the housing over the
dowel pins and to the cylinder block.
The capscrews (5) and (6) must be SAE Grade 8.
The two capscrews (5) have 7/16-14 inch threads. The
other capscrews (6) have 3/4-10 in threads.
Install the two lock washers (3) and twelve lock washers
(4).
Install the two capscrews (5) and twelve capscrews (6).
Follow the sequence shown to tighten the capscrews.
Torque Value:
7/16-14 in
Capscrews
90 Nm [ 66 ft-lb ]
3/4-10 in
Capscrews
366 Nm [ 270 ft-lb ]
Measure
Alignment
The bore and the face of the housing must be in alignment
with the crankshaft.
The indicator arm must be rigid for an accurate reading.
It must not sag.
Attach an indicator to the crankshaft as shown to check
the radial run out.
Position the indicator at the 12 o'clock position. Adjust the
dial until the needle points to 0.
Rotate the crankshaft 1 complete revolution (360
degrees).
Record the total indicator runout.
The maximum allowable total indicator runout depends on
the diameter of the bore.
Bore Diameter Maximum
MIN/MAX MIN/MAX SAE
Number
Total Indicator
Runout
mm in mm in
787.4/810.5 [31.00/31.91] 00 0.30 0.012
647.7/648.0 [25.50/25.51] 0 0.25 0.010
If the alignment is not within specifications and the bore
is round, the housing can be shifted. If the alignment is
not within specifications and the bore is not round, the
housing must be replaced.
CAUTION
The crankshaft must be pushed or pulled in the same
direction each time it is measured.
Face Runout
Attach an indicator at the 12 o'clock position. Adjust the
dial until the needle points at 0.
Record the indicator reading at 3 different points: 3
o'clock, 6 o'clock, and 9 o'clock.
Turn to the original 12 o'clock position. Make sure the
needle still points to 0.
Determine the total indicator runout.
Total Indicator Runout
Example mm in
12 o'clock 0.00 [0.00]
3 o'clock +0.08 [+0.003]
6 o'clock -0.05 [-0.002]
9 o'clock +0.08 [+0.003]
Equal Total Indicator Runout 0.13 [0.005]
The maximum allowable total indicator runout depends on
the diameter of the bore.
Bore Diameter Maximum
MIN/MAX MIN/MAX SAE
Number
Total Indicator
Runout
mm in mm in
787.4/810.5 [31.00/31.91] 00 0.30 0.012
647.7/648.0 [25.50/25.51] 0 0.25 0.010
If the alignment is not within specifications, remove the
housing. Check for nicks, burrs, or foreign material
between the block and the housing.
Check the alignment again. If the alignment is not within
specifications, the block or the housing is not machined
correctly.
Finishing Steps
WARNING
WARNING
WARNING
Install the oil pan adapter assembly. Refer to
Procedure 007-027 (Lubricating Oil Pan Adapter) in
Section 7.
Install the starter motor. Refer to Procedure 013-020
(Starting Motor) in Section 13.
instructions.
On QSK50 engines, equipped with electronically
actuated injectors, install the engine speed sensor,
use the special socket tool, Part Number 4918623 or
equivalent. Refer to Procedure 019-042 in the
Control System, QSK50 and QSK60 Modular
Install new full flow oil filters. Refer to Procedure
007-013 (Lubricating Oil Filter (Spin-On)) in Section
7.
Fill the engine with oil. Refer to Procedure 007-025
(Lubricating Oil Pan) in Section 7.
Connect the air supply to the air starter. Refer to
Procedure 012-022 (Air Starting Motor) in Section 12.
Operate the engine to operating temperature. Check
for leaks. Check equipment operation.
Flywheel Ring Gear K38, K50, QSK38, and QSK50
Flywheel Ring Gear (016-008)
Assemble
WARNING
CAUTION
Damage to the ring gear and the ring gear teeth can
result.
CAUTION
Do not attempt to install the ring gear without heating
it, the ring gear will be damaged or broken.
Adjust the oven temperature to 232C [450F]. Heat the
ring gear in the oven for a minimum of one hour, and a
maximum of six hours. The inner diameter of the ring gear
will become larger and simplify the installation of the ring
gear on the flywheel.
WARNING
CAUTION
Do not exceed 316C [600F]. Damage to the ring gear
will result from the hardness of the metal being
reduced.
Use a heating flame to heat the ring gear if an oven is
not available.
Use a Tempilstik crayon or equivalent, to check the
temperature of the ring gear. Heat the ring gear to 232C
[450F].
WARNING
CAUTION
Allow the ring gear to air cool. Do not use water or oil
to reduce the cooling time. Damage to the ring gear
can result.
Remove the ring gear from the oven.
The part number is on the same side as the bevel.
Position the ring gear so that the bevel is positioned
toward the crankshaft edge of the flywheel as shown.
Install the ring gear.
K38, K50, QSK38, and QSK50 Engine Mounts
Engine Mounts (016-010)
WARNING
WARNING
personal injury.
Two different front support assemblies have been
supplied on K38 and K50 engines. Previous engines were
supplied with a support comprised of two pieces. Present
engines are supplied with a support that is one piece.
Use solvent to clean the support. Dry with compressed air
Check the part for cracks or other damage. If the support
is cracked or damaged, it must be replaced.
Follow the procedure below to check for wear. If wear is
apparent the mounts must be replaced
When applicable, assemble the front support.
Torque Value:
Front Support
Capscrews
298 Nm [ 220 ft-lb ]
NOTE: The bore specification is identical for both
supports.
Front Support Bore
mm in
210.03 MIN 8.269
210.08 MAX 8.271
NOTE: Modify the older support that has two pieces for
the installation of a grease fitting during engine rebuild.
Drill and tap the cap of the support for a grease fitting.
Engine Mounts K38, K50, QSK38, and QSK50
Notes
Section 17 Miscellaneous Group 17 Page 17-a
Section 17 Miscellaneous Group 17
Section Contents
Page
Capscrew .........................................................................................................................................................17-1
Magnetic Crack Inspect...................................................................................................................................17-1
Cup Plug ..........................................................................................................................................................17-2
Install..............................................................................................................................................................17-3
Remove..........................................................................................................................................................17-2
Flexible Hose ...................................................................................................................................................17-3
Pipe Plug .........................................................................................................................................................17-4
Install..............................................................................................................................................................17-4
Remove..........................................................................................................................................................17-4
Straight Thread Plug .......................................................................................................................................17-5
Install..............................................................................................................................................................17-6
Remove..........................................................................................................................................................17-5
Page 17-b Section 17 Miscellaneous Group 17
K38, K50, QSK38, and QSK50 Capscrew
Section 17 Miscellaneous Group 17 Page 17-1
Capscrew (017-001)
Magnetic Crack Inspect
This procedure describes the visual and magnetic particle inspection of special and high strength capscrews for the:
1. Cylinder head
2. Main bearing cap
3. Flywheel
4. Connecting rod
5. Crankshaft pulley or adapter
6. Lifting bracket
7. Crankshaft counterweights
1. the threads are damaged.
2. rust or corrosion has caused pitting in the body.
3. the body is nicked, galled, bent, or stretched.
NOTE: Refer to Procedure 001-014 (Connecting Rod) in Section 1 contains additional information about the
connecting rod capscrews.
CAUTION
Prevent damage to the capscrews. Nicks in the body of the capscrew can cause an area of stress that can
fail during engine operation. Damage to the threads will cause torque values to be wrong and will damage
the mating parts.
If necessary, use a wire wheel to remove all rust, corrosion, and dirt from the capscrews.
WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
WARNING
Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause
personal injury.
Use solvent. Clean the part. Dry with compressed air.
Check the capscrew. The capscrew must be replaced if:
NOTE: Some capscrews (cylinder head, main bearing cap, connecting rods) have threads that have been formed by
a rolling operation during manufacture. Repair of rolled threads by the use of a thread die is not recommended. The
thread die can create a sharp corner on the minor diameter (root) of the threads. This sharp corner can cause an area
of increased stress.
Use a magnetic particle testing machine such as Magnaflux.
Use the residual method. Apply a head shot of 300 to 400 ampere-turns direct current or rectified alternating current.
Use an ultraviolet light. Check for indications of cracks.
NOTE: The magnetic particles tend to accumulate on sharp corners and edges. Do not mistake these accumulations
for cracks.
No indications are acceptable (OK).
Prepare the machine for a coil shot.
Be sure the capscrew is near one side of the coil and not in the center.
Apply 1000 to 1250 ampere-turns.
Use an ultraviolet light. Check for indications of cracks.
No indications are acceptable (OK).
Demagnetize the capscrew thoroughly.
WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
WARNING
Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause
personal injury.
Cup Plug K38, K50, QSK38, and QSK50
Page 17-2 Section 17 Miscellaneous Group 17
Use solvent. Clean the part. Dry with compressed air.
Cup Plug (017-002)
Remove
CAUTION
Do not allow metal shavings to fall inside the engine
when drilling a hole in the cup plug. Damage to engine
components can occur.
Use a center punch to mark the cup plugs for drilling.
Drill a 3.20 mm [0.125 in] hole in the cup plug.
Use a dent puller to remove the cup plug.
Discard all used cup plugs.
Thoroughly clean the cup plug bore using Scotch-Brite,
or equivalent.
Use spray cleaner, Part Number 3375433 or equivalent,
to clean the bore.
Inspect the cup plug bores for damage.
Repair any damaged cup plug bores.
K38, K50, QSK38, and QSK50 Flexible Hose
Install
CAUTION
Excessive sealant can run back into the engine and
cause damage to other components. Allow the sealant
to dry for a minimum of two hours before operating
the engine. The plug can come out of the bore if the
sealant is not dry.
Apply a 2 mm [1/6 in] bead of cup plug sealant, Part
Number 3375068 or equivalent, to the outside
circumference of the cup plug and the inside
circumference of the cup plug bore.
Do not install a used cup plug.
Install the cup plug with the appropriate cup plug driver.
CAUTION
Do not install the cup plug too deeply. If the cup plug
is not installed straight and flat, it must be replaced
with a new cup plug.
The cup plug must be installed with the edge of the cup
plug 0.5 to 1.0 mm [0.020 to 0.040 in] deeper than the
leading chamfer of the bore.
Flexible Hose (017-005)
Inspect for Reuse
Inspect all flexible hoses and their connections for leaks
or deterioration.
Repair or replace the hose if damaged.
Pipe Plug K38, K50, QSK38, and QSK50
Pipe Plug (017-007)
Remove
Remove the pipe plug.
to clean the threads of the pipe plugs and threaded bores.
Inspect the threads of the pipe plug for damage.
Replace the pipe plug if damaged.
Inspect the threaded bore for damage.
Repair the threaded bore if damaged.
Install
Apply a film of pipe plug sealant, Part Number 3375066 or
equivalent, to the pipe plug threads.
Install the pipe plug.
K38, K50, QSK38, and QSK50 Straight Thread Plug
Tighten the pipe plug. Refer to Procedure 018-005 for pipe
plug torque specifications.
Straight Thread Plug (017-011)
Remove
Select the appropriate size allen wrench or socket and
remove the straight thread plug.
to clean the threads of the straight thread plug and
threaded bore.
Inspect the threads of the straight thread plug for damage.
Replace the straight thread plug if damaged.
Inspect the threaded bore for damage.
Repair the bore if damaged.
Straight Thread Plug K38, K50, QSK38, and QSK50
Install
Install a new o-ring on the straight thread plug.
Lubricate the o-ring with clean 15W-40 oil.
Install the straight thread plug.
K38, K50, QSK38, and QSK50 Straight Thread Plug
Tighten the straight thread plug.
Refer to the chart in the graphic for torque values.
Straight Thread O-Ring Plugs
Thread Size in inches Nm in-lb Nm ft-lb
1/4 4 35
3/8 6 50
1/2 8 70
9/16 12 105
5/8 16 145
3/4 20 180
7/8 35 26
1 40 30
1-1/16 45 33
1-3/16 55 41
Straight Thread Plug K38, K50, QSK38, and QSK50
Notes
Section 21 Main Power Generator Group 21 Page 21-a
Section 21 Main Power Generator Group 21
Section Contents
Page
Bearing, Generator ..........................................................................................................................................21-8
Clean............................................................................................................................................................21-18
Internal.......................................................................................................................................................21-18
External......................................................................................................................................................21-18
Finishing Steps............................................................................................................................................. 21-16
Install............................................................................................................................................................21-13
Lubrication for the Power Components..........................................................................................................21-17
Remove..........................................................................................................................................................21-9
Generator (Alternator) Exciter Rotating Diodes ...........................................................................................21-18
Finishing Steps............................................................................................................................................. 21-22
Install............................................................................................................................................................21-21
Remove.........................................................................................................................................................21-19
Generator (Alternator) Windings ...................................................................................................................21-23
Clean............................................................................................................................................................21-23
Finishing Steps............................................................................................................................................. 21-24
Generator Fuse Holder ....................................................................................................................................21-1
Generator Rotor .............................................................................................................................................21-30
Finishing Steps............................................................................................................................................. 21-36
Install............................................................................................................................................................21-33
Remove.........................................................................................................................................................21-30
Generator, Main ...............................................................................................................................................21-1
Instrument Panel..........................................................................................................................................21-2
Permanent Magnet Generator .......................................................................................................................21-25
Finishing Steps............................................................................................................................................. 21-29
Install............................................................................................................................................................21-27
Remove.........................................................................................................................................................21-25
Page 21-b Section 21 Main Power Generator Group 21
K38, K50, QSK38, and QSK50 Generator, Main
Section 21 Main Power Generator Group 21 Page 21-1
Generator Fuse Holder (021-005)
Inspect
NOTE: The Generator Fuse Holder is located in the DC or
Generator Interface Box (GIB) box.
Check that the fuse is installed in the fuse holder correctly.
Refer to the engine wiring diagram to make sure the fuse
is the correct amperage.
If the fuse is installed correctly, check for a blown fuse.
Remove the fuse(s) to be checked.
Touch each one of the multimeter leads to each fuse
terminal. Measure the resistance.
The multimeter must show less than 10 ohms, which is a
closed circuit. If the circuit is closed, then put the fuse
back into the holder and install the fuse cover.
NOTE: Whenever a fuse is replaced, it must always be
replaced with the correct amperage fuse. Installing a
higher amperage fuse can cause damage to the engine or
generator set.
Generator, Main (021-009)
General Information
Alternator
Newage Stamford, four pole, three phase, 60 Hz design
brushless rotating field design and is built to meet BS5000 Part 3 and international standards
self-excited with excitation power from a permanent magnet generator (PMG) powered excitation system.
The manufacturer's installation service and maintenance manual is available on the manufacturer's website at:
http://www.newage-avkseg.com/engish/content/download/newage/manuals/p7/p7_gb_10_04_02.pdf
To access this document, copy the URL above and paste it into your web browser address bar.
Service assembly drawings can be viewed on page 37 of the installation service and maintenance manual listed above.
For service parts and contacts, information can be viewed at the following address:
http://www.newage-avkseg.com/select_language.html
Generator Control Panels
GP 6001
GP 6002
GP 6003
GP 6004
GP 6005
GP 6006
GP 6007
The following is a breakdown of the generator control panel options.
K38 C Power
Generator, Main K38, K50, QSK38, and QSK50
Page 21-2 Section 21 Main Power Generator Group 21
Control Panel Options
Option Number Panels Used Quantity Description
GP 6004 None 0 No controls
GP 6005 4930117 1 Base panel
GP 6006
4930117 1 Base panel
3972970 1 Remote panel
GP 6007
K50 C Power
Control Panel Options
Option Number Panels Used Quantity Description
GP 6004 None 0 No controls
GP 6001 4930117 1 Base panel
GP 6002
GP 6003
User's manuals for the panels are available for download at the Cummins Marine website.
http://marine.cummins.com/public_cummins/content.jhtml?tlaId
+5&anchorId=contentId=43&marketId=13&menuId=1
Instrument Panel
Base Panel Cabinet (into which the base panel mounts)
Panel Description
1. Control panel
2. Block heater indicator button
3. Cable connection
4. Emergency stop button
Base Control Panel
Panel Description
1. Digital display
2. LED indicator lights
3. Button A: toggles between instrument view and alarm list view
4. Button B: toggles between two instrument views
5. Alarm silence
6. Backlight on/off
7. Alarm acknowledge
8. Start button
9. Stop button.
The base panel is an electronic control unit for controlling and monitoring diesel engines used as propulsion engines
or generator sets. The base panel monitors the following data:
Oil pressure
Oil temperature
Turbocharger pressure
Coolant temperature
Battery voltage
Engine speed
Exhaust temperature
Total engine hours
Trip engine hours
Number of starts.
The panel is also equipped with an event log which records a history of the last 500 events such as alarms, start ups,
and shut downs.
The base panel has several built in alarms, as shown in the table below.
Base Panel Built-in Alarms
Alarm Description
Low battery voltage Low voltage at the start battery
Secondary battery low voltage Low voltage at the secondary battery source
Overspeed Engine running faster than the overspeed setpoint
Engine stopped Engine stopped for unknown reason
Engine failed to stop 60 seconds after issuing the stop command, the engine
has still not stopped
Base Panel Built-in Alarms
Alarm Description
Start failure Engine failed to start after the last start attempt
Pickup failure Unable to read the pickup signal while engine is running
Output circuit overload Short circuit in one of the (+)24-VDC terminals
Analog sensor failure Detailed information on which analog channel has failed
Broken wire Detailed information on which terminal experiences the
broken wire
Operation of the Base Panel - The base panel has several different screens or views. These views include:
Two instrument views
Alarm list view
Information view
Event log view
To toggle between instrument view and alarm list view press button A. (See Figure 2)
To toggle between the two instrument views press button B. (See Figure 2)
To go to information view press and hold button A for approximately 1 second.
To go to event log view press and hold button B for approximately 1 second.
When connected to the remote panel, both the remote panel and the base panel can control the engine. However it
is possible to lock out the remote panel and allow control only from the base panel.
To lock out the remote panel:
1. Go to INFO view
2. Press and hold BUZZER OFF for 2 seconds until a beep is heard. The screen will change to toggle Local Mode
ON/OFF. When ON, this disables the remote panel commands.
Stop Button - To stop the unit, press and hold the red button labeled STOP until the unit has stopped. If the STOP
button is held for less than one half a second the engine will not stop. The control unit stops the generator set by
pulling the stop solenoid. When the red LED in the stop button is lit, this indicates that the control unit is pulling the
stop solenoid.
Start Button - Manual start is done with the green button labeled Start. Press and hold the button until the engine has
started.
A running engine indicated by the green LED in the Start button and the text Running in the left most status field on
the digital display. The rpm meter will indicate the engine speed.
Standby and Manual Mode Button - The standby button is a toggle button, meaning that for every other keypress, the
unit is set to Standby or Manual. A green LED in the Standby button indicates that the unit is set to Standby. The right
most status field also indicates the chosen mode by displaying either Standby or Manual.
Acknowledge (Reset) Button - In case of alarms, a press on the acknowledge button, labeled ACKN, will reset the
alarm(s). At the same time, the buzzer will be silenced. In the Alarm List view ACKN will reset all alarms, whereas, in
the instrument view, ACKN will reset the alarm in the top of the screen only.
Buzzer Off Button - Press the buzzer OFF button to silence the built in buzzer signal that is activated when an alarm
occurs. The alarm that activated the buzzer remains active until acknowledged.
Instrument Panel
Remote Panel Digital Display
Remote Panel Digital Display
The remote panel is a touch screen display that shows most of the data available from the base control panel. It can
also execute many of the same commands as the base panel. It connects to the supplied terminals on the engine
cabinet with six wires. Four wires are for communication and two are for power supply
1. Oil pressure gauge
2. Oil temperature gauge
3. Indicator light
Grey - ready to start
Green - starting/running
Red - stopping/stopped
4. Button to access the alarm list
5. Engine rpm
6. Navigate between pages
7. Battery voltage gauge
8. Start button
9. Stop button
10. Reset button
11. Coolant temperature gauge.
Analog Values Available From the Remote Panel
Value Description Range and Units
Oil pressure 0.0 to 6.0 bar [0 to 87 psi]
Oil temperature 0 to 150C [32 to 302F]
Coolant temperature 0 to 130C [32 to 266F]
Battery voltage 20 to 30 VDC
Engine speed 0 to 2000 rpm
Exhaust stack temperature 0 to 600C [32 to 1112F]
Total engine hours 0 to 99999 hours
Trip engine hours 0 to 999 hours
Start counter 0 to 99999 starts
Instrument Panel
Screen Overviews
NOTE: The alarm list is not displayed. It can be accessed from all the pages.
Start up screen and the applications main view.
Main View
This is the Start-up screen and the applications main view.
1. Oil pressure
2. Oil temperature
3. Indicator light
Grey - ready to start
Green - starting/running
Red - stopping/stopped
4. Button to access the alarms list
5. Engine rpm
6. Navigate between pages
7. Battery voltage
8. Start button
9. Stop button
10. Reset button
11. Coolant temperature.
Each press on this button (1) toggles between Standby and Manual setting
Exhaust Temperatures
This screen displays the exhaust temperatures and the counters. The Standby/Manual setting is changed through
this screen as well.
The following table lists the commands that can be executed with the remote panel.
Remote Panel Commands
Command Description
Engine Start Brings up a dialog to confirm engine start
Engine Stop Brings up a dialog to confirm engine stop. An ongoing start attempt can
be cancelled by pressing stop.
Acknowledge Alarms Will acknowledge all pending alarms in the Base Panel
Set to Standby The base panel will do automatic start attempts.
Set to Manual The base panel will not do automatic start attempts.
Remote Panel Alarm Descriptions
Alarm Description Comment
Low oil pressure 1.7 bar [25 psi]
High coolant temperature 106C [223F]
Emergency stop/start disabled Manual emergency stop is operated. Start is disabled.
Low coolant pressure 0.7 bar [10 psi]
Power failure Either the primary or the secondary (backup) voltage supply to the DCU
305 R2 is too low.
Overspeed
50 Hz overspeed = 1725 rpm
60 Hz overspeed = 2070 rpm
Oil pressure 2.4 bar [35 psi]
Oil temperature 120C [248F]
Coolant temperature 104C [219F]
Start failure When set to standby only.
Bearing, Generator K38, K50, QSK38, and QSK50
Subbase
Because the engine and alternator are being offered as a complete set, another new option is the subbase. The
subbase option includes all the vibration damping and fastening hardware necessary to mount the engine and
alternator onto the base rail.
Bearing, Generator (021-027)
Preparatory Steps
WARNING
To reduce the possibility of property damage and
personal injury from electrical shock, make certain the
unit is isolated from all voltage sources.
WARNING
cable last.
Disconnect the batteries or air supply line to the air starter
to prevent accidental engine starting.
K38, K50, QSK38, and QSK50 Bearing, Generator
Remove
The non-drive end bracket must be removed in order to
replace the bearing on all frame sizes.
Remove the non-drive end access cover, the terminal box
sides, lid, and support brackets.
Remove the permanent magnet exciter stator and rotor.
Do not pry on the generator fan to rotate the engine. The
fan blades can be easily bent and broken. The entire
generator rotor must be disassembled to replace the
generator fan, if damaged.
WARNING
Disconnect exciter leads X and XX as well as P2, P3, and
P4 at the auxiliary terminal block.
Bring the leads back into the non-drive end bracket.
Loosen the four inner capscrews that hold the bearing
housing cap to the bearing cartridge first. It is difficult to
keep the bearing cartridge from rotating if the four outer
capscrews have been removed.
Remove the four outer capscrews that hold the bearing
cartridge or inner bearing cap to the end bracket.
WARNING
Remove all the capscrews that hold the non-drive end
bracket to the frame.
Thread two of the capscrews into the jacking holes in the
end bracket horizontal center line. Screw these capscrews
in to pull the end bracket pilot from the locating recess in
the main generator frame.
Tap the end bracket lightly while turning the jacking
screws in. Check to make sure the bearing cartridge is
not stuck in the end bracket.
CAUTION
The main exciter stator is attached to the end bracket
and comes out when the end bracket is removed. Use
extreme care not to damage the main exciter stator as
the end bracket is removed.
WARNING
The end bracket must be supported as it is removed from
the bearing cartridge.
Remove the capscrews that hold the bearing cap to the
bearing cartridge.
Remove the bearing cap.
Remove the large snap ring from the generator shaft.
CAUTION
Use two or more flat washers or a spacer between the
puller and the end of the shaft to avoid damaging the
threads in the end of the shaft.
Use a puller to remove the bearing.
Press the old bearing from the bearing cartridge.
The outer race of the bearing is lightly pressed into the
bearing cartridge. Remove the bearing outer race.
WARNING
WARNING
personal injury.
Clean the bearing cap and bearing cartridge using
solvent.
Dry the components with compressed air.
Inspect the bearing cartridge and bearing caps for cracks,
fretting, or other signs of damage.
If damage is present, replace the bearing cartridge caps.
Install
Pack 27 ml [1 fluid oz] of the recommended lubricant into
the bearing and put the same amount of lubricant into the
bearing cartridge and end cap.
Sealed bearings are also an option.
CAUTION
When installing the bearing in the cartridge, press on
the outer race of the bearing to avoid damaging the
bearing.
WARNING
To reduce the possibility of personal injury, use
insulated gloves to handle the hot bearing cartridge.
Heat the bearing cartridge in an oven to 100C [212F] for
1 hour.
Press the bearing into the bearing cartridge.
NOTE: The maximum oven temperature should not
exceed 120C [248F]
Heat the bearing cartridge, with bearings installed, in an
oven to 100C [212F] for 2 hours.
Apply a thin coating of clean engine oil to the generator
shaft.
WARNING
To reduce the possibility of personal injury, use
insulated gloves to handle the hot bearing cartridge.
Use insulated gloves to install the bearing onto the shaft.
Quickly push the bearing onto the shaft until it seats
against the shaft shoulder. The bearing must slide on the
shaft and be seated without excessive force.
CAUTION
Apply pressure to only the inside race of the bearing.
Applying pressure to the outer bearing race will
damage the bearing.
If the bearing binds on the shaft before being fully seated,
use a length of pipe with an inside diameter slightly larger
that the shaft diameter to drive the bearing against the
shaft seat. Apply pressure to the inner race of the bearing
only.
Install the snap ring onto the shaft next to the inner bearing
race.
Make sure the snap ring is seated in the groove.
Install the bearing cap.
NOTE: Make sure that the end plug of the three wire
harness which is attached to the permanent magnet
exciter stator, and is through the end bracket and the
harness is retained by the internal wire clamp. The
harness is difficult to install when the end bracket is on the
generator.
Install the end bracket onto the bearing cartridge.
WARNING
Place a sling around the exciter mounting surface and lift
the end bracket and rotor to pilot the end bracket into the
generator frame recess.
Install the end bracket capscrews.
Tap the end bracket with a dead-blow hammer as the
capscrews are tightened
Align the bearing cartridge threaded capscrew holes with
the holes in the end bracket by turning the bearing cap.
The bearing cartridge will rotate in the end bracket.
Install and tighten the bearing cartridge capscrews.
Pull the main exciter leads (X and XX) and the permanent
magnetic exciter stator leads (P2, P3, and P4) through the
hole in the frame terminal box.
Connect the leads to the corresponding terminals on the
auxiliary terminal block.
Install the permanent magnetic exciter.
Install the non-drive end access cover, the terminal box
sides, lid, and support brackets.
Finishing Steps
WARNING
cable last.
Connect the batteries or air supply line to the air
starter.
Lubrication for the Power Components
CAUTION
Greasing of the alternator bearings must only take
place when the generator set is in operation. Greasing
the bearings on a static (non-running) alternator can
damage the bearing cartridge seals.
The bearing grease type and supplier must always be
confirmed by checking the alternator dataplate, before the
bearings are serviced.
CAUTION
Check that the grease gun nozzle and bearing
lubrication fittings are free from contaminants before
beginning the lubrication process. Failure to do so
can allow contaminants to be injected into the
bearing, which can cause premature bearing failure.
With the generator set operating, pump the specified
amount of grease into the bearings.
NOTE: The average grease gun expels approximately 1
gram per stroke.
Grease Volume Specifications Maintenance
Alternator Model Drive End Non-Drive End
Frame 7 - All 89 grams 75 grams
Frame 8 - All 140 grams 100 grams
DIG130 - All 80 grams 80 grams
P-80 - 6232 Bearing 121 grams 121 grams
NOTE: An increase in alternator bearing operating
temperature can be observed following the lubrication
process. Bearing temperature will return to normal after
approximately 10 hours of operation.
Generator (Alternator) Exciter Rotating Diodes K38, K50, QSK38, and QSK50
Clean
Internal
CAUTION
To reduce the possibility of personal injury, the
generator set must be shut down and the alternator
isolated from any voltage source before opening any
alternator access doors.
NOTE: Greasing the bearings with the generator set
operating allows the old grease and excess grease to
purge from the bearing cartridge through internal vents.
The termination of the internal vents can differ by
alternator manufacturer and model.
The non-drive end bearing internal vent location is shown
in the illustration. The drive-end internal vent is similar.
Remove any old or excess grease purged from the bearing
during the lubrication process by opening the alternator
side panels and wiping the collected grease from the
affected internal vent areas.
Additional grease can purge after cleaning the internal
vent areas, if the alternator had not achieved normal
operating temperature during the lubrication process.
External
NOTE: Greasing the bearings with the generator set
operating allows the old grease and excess grease to
purge from the bearing cartridge through external vents.
The termination of the external vents can differ by
alternator manufacturer and model.
Alternators with external bearing vents do not need to
have the generator set shut down for the removal of
purged grease.
Remove any old or excess grease purged from the bearing
during the lubrication process from the affected external
vent areas.
Additional grease can purge after cleaning the external
vent areas, if the alternator had not achieved normal
operating temperature during the lubrication process.
Generator (Alternator) Exciter
Rotating Diodes (021-028)
Preparatory Steps
WARNING
Remove the non-drive end access cover and the two side
covers from the terminal box.
K38, K50, QSK38, and QSK50 Generator (Alternator) Exciter Rotating Diodes
Remove
There are three diodes on each of the two plates attached
to the hub. These plates are on the drive end side of the
main exciter rotor. The diodes are easier to check if the
crankshaft is rotated.
NOTE: During assembly, the diode lead (3) is installed at
the bottom of the connection stud (2). To make later
service easier, put the diode lead (3) on the connection
stud (2) last (under the nut).
A lead from a diode (3) and a lead from the main exciter
rotor (1) are both attached to the adjacent connector stud
(2).
Remove the diode lead (3) from the connection stud (2).
Use a multimeter, Part Number 3376898, set to ohms.
Connect one lead of the meter to the diode lead and the
other meter lead to the diode plate. record the reading.
Reverse the meter leads and record the readings again.
A good diode will give a high resistance reading in one
direction and a lower resistance reading in the opposite
direction. The high reading must be at least ten times the
low reading.
A faulty diode will give a high resistance reading (open) in
both directions or a low resistance reading (shorted) in
both directions.
Before installing a new diode, check the appearance of
the varistor (surge suppressor). The varistor is located on
the opposite side of the shaft from the main generator
rotor leads.
A faulty generator varistor will be burned or have a lead
wire burned off.
The diodes (1) are held in place by captive inserts (2)
within the molded base (3).
Remove the diode (1) by turning it counterclockwise.
To replace the varistor:
1. Disconnect the main generator rotor leads.
2. Remove all six diodes.
3. Move the ends of the two plates away from the main
exciter rotor.
4. Remove the nut from the varistor stud.
5. Remove the varistor wire lead from the stud.
6. Replace the varistor assembly.
K38, K50, QSK38, and QSK50 Generator (Alternator) Exciter Rotating Diodes
Install
NOTE: When replacing a diode, the replacement must be
from the same manufacturer and have the same model
number. Diodes with black leads are reverse polarity and
have a letterR in the model designation. The arrow on
the diode will point toward the terminal. Always check the
diode with a meter to be sure of its polarity.
An example is Part Number I R 85 49HFR 100, which
identifies a diode by International Rectifier Company.
The 85 49 is the date code. The 40 indicates a 40 ampere
continuous rating. The HF is a designation for the size and
shape. The R indicates reverse polarity. The 100 indicates
that the diode is rated to withstand 1000 volts in the
reverse direction.
International Diodes
International
Rectifier
Marconi
Red Lead 40HF100 M41-1000
Black Lead 40HFR100 M41R1000
A diode obtained from an electrical supply company will
not have a lead soldered to the terminal.
If a lead must be soldered to the terminal, use 60-40 rosin
core solder.
Hold the diode terminal with a long nose pliers during the
soldering to prevent excessive heat transfer though the
terminal to the diode junction.
CAUTION
This compound must not be applied to the diode stud
threads. It will act as a lubricant and allow the diode
to loosen.
The area if the diode that will be in contact with the plate
must be coated with Midland Silicone Heat Sink
Compound, Type MS 2623, or equivalent.
NOTE: All of the diode (1) installed on one plate must have
the same polarity, and all the diodes (2) on the other plate
must have the opposite polarity. Do not mix the polarity
of the diodes on the plate.
NOTE: On generators with permanent magnet exciter, it
makes no difference which plate has the R polarity
diodes.
Install the diodes on the plates.
Finishing Steps
Install the access panels to the terminal box.
K38, K50, QSK38, and QSK50 Generator (Alternator) Windings
Generator (Alternator) Windings
(021-029)
Preparatory Steps
WARNING
WARNING
Medium voltage, 601 to 15,000 volts, present special
hazards of severe personal injury or death. An
electrical shock hazard may exist after generator set
shutdown due to induced voltage within the generator
or cables.
WARNING
cable last.
Isolate the generator set from all energy sources
(Lock-out/Tag-out).
Disconnect the batteries or starting air (if installed).
Refer to Procedure 013-009 or 012-022.
Remove the generator from the engine. Refer to
Procedure 021-009.
Remove the permanent magnetic exciter stator.
Remove the rotor from the main generator. Refer to
Procedure 021-031.
Clean
WARNING
The windings of medium voltage, 601 to 15,000 volts,
generator sets must be dry before the generator is
operated. Failure to make sure of dry windings prior
to start-up can result in catastrophic equipment
failure, severe personal injury, or death.
CAUTION
Water based alkaline detergents must not be used.
These cleaners contain wetting agents that leave
hygroscopic contaminants that readily absorb
moisture, reduce insulation resistance, and promote
surface tracking.
NOTE: If steam is not available, a pressure wash with
clean hot water can be used.
NOTE: Extremely oily contaminants can be removed with
the hot pressure wash and a solvent based biodegradable
cleaner with a neutral pH.
Use steam to clean the generator windings.
Generator (Alternator) Windings K38, K50, QSK38, and QSK50
Thoroughly wash the windings with clean water to remove
all traces of detergents.
Dry the generator stator windings. Refer to the Blown Air
Dehumidify step in Procedure 021-009.
NOTE: The anti-tracking resin or varnish must be:
of the same insulation thermal rating as the
generators working duty cycle
checked to make sure the resin or varnish will adhere
to the original insulation material.
Overcoat the stator windings with an appropriate electrical
anti-tracking resin or varnish.
Overcoating protects the windings from immediate
contamination of the winding surface.
Finishing Steps
WARNING
WARNING
cable last.
Install the rotor into the main generator. Refer to
Procedure 021-031.
Install the permanent magnetic exciter stator and
rotor. Refer to Procedure 021-030.
Install the generator to the engine. Refer to
Procedure 021-009.
Connect the batteries or starting air (if installed).
Dehumidify the generator prior to placing in service.
K38, K50, QSK38, and QSK50 Permanent Magnet Generator
Permanent Magnet Generator
(021-030)
Preparatory Steps
WARNING
cable last.
CAUTION
To reduce the possibility of shock loading of
components downstream of the supply valve, opening
and closing of the fuel supply valve must be done
slowly.
Slowly close the fuel supply valve to the engine.
Remove
WARNING
Remove the three capscrews and the access cover.
Mark the permanent magnet exciter stator housing on the
non-drive end bracket so it can be returned to the same
location during assembly.
Permanent Magnet Generator K38, K50, QSK38, and QSK50
Disconnect the plug inside the permanent magnet exciter
access cover. This plug connects the stator to the leads
going into the generator rear end bracket.
Remove the four capscrews and clamps that hold the
permanent magnet exciter stator to the end bracket.
CAUTION
The rotor is highly magnetic and attracts the stator
housing. Use care not to damage the stator windings
as the stator is removed.
Pull the permanent magnet exciter stator housing out of
the recess in the end bracket. Lightly tap on the housing
to loosen it.
Light pulling force will be required.
Remove the shaft centerline capscrew from the end of the
rotor shaft.
CAUTION
Do not attempt to take the permanent magnet rotor
apart. The magnetic proprieties of the rotor will be
destroyed.
Pull the complete permanent magnet exciter rotor
assembly from the shaft. The shaft is located with a dowel
pin. A firm pull will be required to remove the rotor.
Wrap the permanent magnet exciter rotor in a protective
cover to keep it clean and to prevent metallic particles
from collecting on the magnets.
Install
Place the permanent magnet exciter rotor on the
generator shaft aligning the dowel pin in the shaft with the
locating hole in the rotor.
Push the rotor into position.
Permanent Magnet Generator K38, K50, QSK38, and QSK50
Install the center rotor retaining capscrew and tighten.
CAUTION
The rotor is highly magnetic and attracts the stator
housing. Use care not to damage the stator windings
during installation. Use care not to get your fingers
pinched in the installation process.
Install the permanent magnet exciter stator housing in the
end bracket recess with the stator leads at the top. Lightly
tap the housing to seat it into the recess.
Align the location mark on the permanent magnet exciter
stator housing with the location mark on the end bracket
made during removal.
Install the four capscrews and clamps that hold the
permanent magnet exciter stator housing to the end
bracket.
Pull the plug attached to the leads extending from the
generator rear end bracket through the stator opening.
Connect the lead to the connector on the stator windings.
Install the access cover.
Finishing Steps
WARNING
cable last.
CAUTION
slowly.
Slowly open the fuel supply valve to the engine.
Generator Rotor K38, K50, QSK38, and QSK50
Generator Rotor (021-031)
Preparatory Steps
WARNING
WARNING
This assembly weighs 23 kg [50 lb] or more. To reduce
the possibility of personal injury, use a hoist or get
assistance to lift this assembly.
WARNING
cable last.
CAUTION
slowly.
NOTE: The main rotor assembly is removed from the drive
end of the generator. A minimum free area, the length of
the generator is required to remove the rotor.
Slowly close the fuel supply valve to the engine.
In some applications it will be necessary to remove
the generator from the engine. Refer to Procedure
021-009.
Remove the permanent magnetic exciter stator and
Remove
Disconnect exciter leads X and XX as well as P2, P3, and
P4 from the auxiliary terminal block.
Pull the leads back into the non-drive end bracket.
K38, K50, QSK38, and QSK50 Generator Rotor
Remove the four outer capscrews that hold the non-drive
end bearing cartridge to the end bracket.
NOTE: Do not loosen the four inner capscrews unless the
bearing is to be replaced.
Remove all the capscrews that hold the non-drive end
Thread two of the capscrews into the jacking holes on the
end bracket horizontal center line. Screw these capscrews
in to pull the end bracket pilot from the locating recess in
the main generator frame.
Lightly tap the end bracket while turning the jacking
screws in. Check to make certain the bearing cartridge is
not stuck in the end bracket.
WARNING
CAUTION
The main exciter stator is attached to the end bracket
and comes out when the end bracket is removed. Use
extreme care not to damage the main exciter as the
end bracket is removed.
The end bracket must be supported as it is removed from
the bearing cartridge.
Remove the eight capscrews holding the drive end
WARNING
There are two capscrews under the generator between the
generator feet. The generator will need to be lifted to
access these two capscrews.
Support the drive end bracket while tapping the end
bracket to release it from the recess in the generator
frame.
CAUTION
Do not pry on the fan ring between the fan blades. The
fan blades can be easily bent or broken. The entire
generator rotor must be disassembled (normally at the
factory) to replace the generator fan.
Move the rotor out from the stator by prying on the fan ring
at the fan blade.
WARNING
NOTE: This procedure requires two people. With one
person doing the lifting while the other supports and
guides the non-drive end of the shaft.
Support the rotor drive end with a sling around the main
generator rotor poles.
Continue to pull and rotate the rotor assembly as it is
removed from the stator.
Move the sling closer to the center balance point of the
rotor as it is removed
Position the sling around the main generator rotor where
only a slight down force on the fan is required to balance
the assembly.
Set the rotor in a formed support as shown to reduce the
possibility of damage to the main exciter rotor windings.
Install
WARNING
NOTE: This procedure requires two people. With one
person doing the lifting while the other supports and
guides the non-drive end of the shaft.
Position the sling around the main generator rotor where
only a slight down force on the fan is required to balance
the assembly.
Position the rotor into the stator as far as it will allow. Use
care to avoid bumping the main exciter rotor into the main
generator stator.
CAUTION
Do not wrap the sling around the rotor winding end
turns. A sling can damage the rotor winding end turn
insulation.
Lower the rotor and reposition the sling closer to the fan.
Lift the rotor and continue installation until the sling can
no longer be used.
WARNING
Install the drive end bearing cartridge if the bearing has
been removed. Refer to Procedure 021-027.
Install the drive end bracket on the generator frame. A
hoist must be used to lift the drive end bracket, while
tapping the end bracket as the capscrews are being
tightened, to make sure that the end bracket is seated in
the main generator recess.
WARNING
Lift the generator and install the two capscrews under the
generator between the generator feet.
NOTE: Check that the permanent magnet exciter harness
attached to the stator is through the end bracket and the
harness is retained by the internal wire clamp. The
harness is difficult to install when the end bracket is on the
generator. The main exciter stator leads must be on the
top of the generator.
Install the end bracket on the bearing cartridge.
WARNING
Place a sling around the exciter mounting surface and lift
the end bracket and rotor to pilot the end bracket into the
generator frame recess.
Install the end bracket capscrews.
Tap the end bracket with a dead-blow hammer as the
capscrews are tightened
Pull the main exciter leads (X and XX) and the permanent
magnetic exciter stator leads (P2, P3, and P4) through the
hole in the frame terminal box.
Connect the leads to the corresponding terminals on the
auxiliary terminal block.
Align the bearing cartridge threaded capscrew holes with
the holes in the end bracket by turning the bearing cap.
The bearing cartridge will rotate in the end bracket.
Install the bearing cartridge capscrews.
Finishing Steps
WARNING
WARNING
WARNING
cable last.
CAUTION
slowly.
Install the permanent magnetic exciter stator and
If removed, install the generator to the engine. Refer
Slowly open the fuel supply valve to the engine.
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How to Use the Cummins Service Publications Electronic Book on CD-ROM:
To use the CD-ROM, simply insert the CD-ROM into your computer and it should automatically run, open Adobe Acrobat
and open the Electronic Book. (This happens with Microsoft Windows Auto-Play functionality, and Adobe Acrobat pre-
loaded by you on your computer).
(continued)

Helpful Support Tips:
If Windows Auto-Play is not enabled, try re-enabling it, or navigate with Windows Explorer to your CD-ROM drive and
double click on the CD-ROM drive letter to open it. Then double-click on the program named clickhere. (Do not
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In rare occasions, after inserting the CD-ROM you may receive a notice from Adobe Acrobat that it could not open
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Special Instructions for Cummins PowerSweep PC Users:
(This only applies to Cummins Inc. & Distributor Employees):
Cummins PowerSweep PC users that DO NOT have Local Administrative rights to their PC will require a HexaLock patch
software installation. If you are a Cummins Inc. or Distributor Employee who wants to use these CD-ROMs, and you have
a PowerSweep PC please order the HexaLock software from the Cummins Software Shelf. The Software Shelf
personnel will contact you to arrange installation. Software will be installed remotely by Software Shelf personnel. Once
software is installed, first reboot your PC, then attempt to read your encrypted CD-ROM manual while Cummins Software
Shelf personnel are still on the telephone.

Electronic Book Technical Support:
Support for this product is available from Monday through Friday weekly, excluding Holidays, from 8 a.m. to 5 p.m.
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CD-ROM Media Replacement Options:
Up to 90 days from date of purchase:
Within the first 90 days from your date of purchase, if your copy of an Electronic Book on CD-ROM does not function, and
after a Cummins Electronic Book Technical Support Technician has confirmed the situation and authorized its
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request.

Media Replacement Ship to Address:
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Cummins Service Publications Electronic Books on CD-ROM are Copyright Cummins Inc.
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All other names and products used herein are trademarks for their respective owner.
Section L Service Literature Page L-a
Section L Service Literature
Section Contents
Page
Additional Service Literature ............................................................................................................................L-1
General Information..........................................................................................................................................L-1
Cummins Customized Parts Catalog ................................................................................................................L-3
General Information..........................................................................................................................................L-3
Ordering the Customized Parts Catalog.............................................................................................................L-3
Ordering by Telephone...................................................................................................................................L-3
Ordering On-Line...........................................................................................................................................L-3
Service Literature Ordering Location ...............................................................................................................L-2
Contact Information...........................................................................................................................................L-2
Page L-b Section L Service Literature
K38, K50, QSK38, and QSK50 Additional Service Literature
Section L Service Literature Page L-1
Additional Service Literature
General Information
The following publications are available on QuickServe or can be purchased by contacting a Cummins Distributor.
Bulletin Title of Publication
3810313 PT (Type D) STC Injector Shop Manual
3810344 PT (Type D) Top Stop Injector Shop Manual
3810243 Holset HC-5 or HC-5A Turbocharger Shop Manual
3666040 Shop and Installation Manual Rear Engine Power Take-Off (REPTO)
3810257 Cummins ST 677 Two Cylinder Air Compressor Shop Manual
3379035 Alternative Repair Manual
4021520 QSK50 CM850 Industrial Modular Common Rail Wiring Diagram
4021537 QSK50 CM850 Power Generation Modular Common Rail Wiring Diagram
3379052 Construction/Industrial Diesel Engines Operation and Maintenance Manual
3666069 CENTRY System (PT) Operation and Maintenance Manual
3810497 Operation and Maintenance Manual K38, K50, QSK38 and QSK50
3667180 K38 and K50 Owners Manual
3666231 Centinel Master Repair Manual
3666085 CENTRY Fault Code Manual
3377710 Service Products Catalog
3379000 Air for Your Engines
3379001 Fuels for Cummins Engines
3379068 Fuel Pump PT (Type G) Calibration Values (1970-1975)
3379071 Injectors PT Rebuild Manual
3379084 Fuel Pump PT (Type G) Rebuild and Calibration Instructions
3379091 Turbochargers Rebuild Manual
3379177 American Bosch Governors
3379179 Woodward Governors
3379182 Fuel Pump PT (Type G) Calibration Values (1976-1980)
3379231 Electric Fuel Control Governor (EFC)
3379352 Fuel Pump PT (Type G) Calibration Values (1981-Present)
3387622 Cold Weather Operations
3379664 Injector Parts Flow and Cross Reference
3666085 CENTRY Fault Code Manual
3666106 Hydro-mechanical Step Timing Control Valve
3666132 Coolant Requirements and Maintenance
3666191 Cummins Branded Starters and Alternators
3810235 Brown Boveri Exhaust-Gas Turbocharger, RR 153
3810251 Rockford Clutch Overhaul Procedure
3810340 Cummins Engine Oil Recommendations
3810334 K38 Standard Repair Times
3810335 K50 Standard Repair Times
3379133 Control Parts List (CPL)
3810250 Rockford Fan Clutch Service Manual and Parts List
Service Literature Ordering Location K38, K50, QSK38, and QSK50
Page L-2 Section L Service Literature
Service Literature Ordering Location
Contact Information

Region Ordering Location
United States and Canada Cummins Distributors
or
Credit Cards at 1-800-646-5609
or
Order online at www.powerstore.cummins.com
All Other Countries Cummins Distributors or Dealers
K38, K50, QSK38, and QSK50 Cummins Customized Parts Catalog
Section L Service Literature Page L-3
Cummins Customized Parts Catalog
General Information
Cummins is pleased to announce the availability of a parts catalog compiled specifically for you. Unlike the generic
versions of parts catalogs that support general high volume parts content; Cummins Customized catalogs contains
only the new factory parts that were used to build your engine.
The catalog cover, as well as the content, is customized with you in mind. You can use it in your shop, at your worksite,
or as a coffee table book in your RV or boat. The cover contains your name, company name, address, and telephone
number. Your name and engine model identification even appears on the catalog spine. Everybody will know that
Cummins created a catalog specifically for you.
This new catalog was designed to provide you with the exact information you need to order parts for your engine. This
will be valuable for customers that do not have easy access to the Cummins Electronic Parts Catalog or the Cummins
Parts Microfilm System.
Additional Features of the Customized Catalog include:
Engine Configuration Data
Table of Contents
Separate Option and Parts Indexes
Service Kits (when applicable)
ReCon Part Numbers (when applicable)
Ordering the Customized Parts Catalog
Ordering by Telephone
North American customers can contact their Cummins Distributor or call Gannett Direct Marketing Services at
1-800-646-5609 and order by credit card. Outside North America order on-line or make an International call to Gannett
at (++)502-454-6660.
Ordering On-Line
The Customized Parts Catalog can be ordered On-Line from the Cummins Powerstore by credit card. Contact the
Powerstore at WWW.POWERSTORE.CUMMINS.COM
Contact GDMS or the CUMMINS POWERSTORE for the current price; Freight may be an additional expense.
Information we need to take your Customized Parts Catalog Order. This information drives the cover content of the
CPC.
Customer Name
Street Address
Company Name (optional)
Telephone no.
Credit Card No.
Cummins Engine Serial Number (located on the engine data plate)
Please identify the required media: Printed Catalog, CD-ROM, or PDF File
Unfortunately not all Cummins Engines can be supported by this parts catalog. Engines older than 1984 or newer
than 3 months may not have the necessary parts information to compile a catalog. We will contact you if this occurs
and explain why we are unable to fill your order.
Customized Parts Catalogs are produced specifically for a single customer. This means they are not returnable for a
refund. If we make an error and your catalog is not useable, we will correct that error by sending you a new catalog.
Cummins Customized Parts Catalog K38, K50, QSK38, and QSK50
Page L-4 Section L Service Literature
Notes
Section M Component Manufacturers Page M-a
Section M Component Manufacturers
Section Contents
Page
Component Manufacturers' Addresses ...........................................................................................................M-1
Air Compressors..............................................................................................................................................M-1
Air Cylinders....................................................................................................................................................M-1
Air Heaters.......................................................................................................................................................M-1
Air Starting Motors...........................................................................................................................................M-1
Alternators.......................................................................................................................................................M-1
Auxiliary Brakes...............................................................................................................................................M-1
Belts................................................................................................................................................................M-1
Catalytic Converters.........................................................................................................................................M-1
Coolant Level Switches....................................................................................................................................M-1
Clutches..........................................................................................................................................................M-1
Coolant Heaters...............................................................................................................................................M-2
Drive Plates.....................................................................................................................................................M-2
Electric Starting Motors....................................................................................................................................M-2
Electronic Switches..........................................................................................................................................M-2
Engine Protection Controls...............................................................................................................................M-2
Fan Clutches....................................................................................................................................................M-2
Fans................................................................................................................................................................M-2
Fault Lamps.....................................................................................................................................................M-2
Filters...............................................................................................................................................................M-2
Flexplates........................................................................................................................................................M-2
Fuel Coolers....................................................................................................................................................M-2
Fuel Pumps......................................................................................................................................................M-2
Fuel Warmers..................................................................................................................................................M-2
Gauges............................................................................................................................................................M-3
Governors........................................................................................................................................................M-3
Heat Sleeves....................................................................................................................................................M-3
Hydraulic and Power Steering Pumps..............................................................................................................M-3
In-Line Connectors...........................................................................................................................................M-3
Oil Heaters.......................................................................................................................................................M-3
Prelubrication Systems.....................................................................................................................................M-3
Radiators.........................................................................................................................................................M-3
Throttle Assemblies..........................................................................................................................................M-3
Torque Converters...........................................................................................................................................M-3
Page M-b Section M Component Manufacturers
Component Manufacturers' Addresses (203-001)
NOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins
engines. Suppliers can be contacted directly for any specifications not covered in this manual.
Air Compressors
Bendix Heavy Vehicles Systems
Div. of Allied Automotive
901 Cleveland Street
Elyria, OH 44036
Telephone: (216) 329-9000
Holset Engineering Co., Inc.
1320 Kemper Meadow Drive
Suite 500
Cincinnati, OH 45240
Telephone: (513) 825-9600
Midland-Grau
Heavy Duty Systems
Heavy Duty Group Headquarters
10930 N. Pamona Avenue
Kansas City, MO 64153
Telephone: (816) 891-2470
Air Cylinders
Bendix Ltd.
Douglas Road
Kingswood
Bristol
England
Telephone: 0117-671881
Catching Engineering
1733 North 25th Avenue
Melrose Park, IL 60160
Telephone: (708) 344-2334
TEC - Hackett Inc.
8909 Rawles Avenue
Indianapolis, IN 46219
Telephone: (317) 895-3670
Air Heaters
Fleetguard, Inc.
1200 Fleetguard Road
Cookeville, TN 38502
Telephone: (615) 526-9551
Kim Hotstart Co.
P.O. Box 11245
Spokane, WA 99211-0245
Telephone: (509) 534-6171
Air Starting Motors
Ingersoll Rand
Chorley New Road
Horwich
Bolton
Lancashire
England
BL6 6JN
Ingersoll-Rand Engine
Starting Systems
888 Industrial Drive
Elmhurst, IL 60126
Telephone: (708) 530-3875
StartMaster
Air Starting Systems
A Division of Sycon Corporation
9595 Cheney Avenue
P. O. Box 491
Marion, OH 43302
Telephone: (614) 382-5771
Alternators
Robert Bosch Ltd.
P.O. Box 98
Broadwater Park
North Orbital Road
Denham
Uxbridge
Middlesex UD9 5HG
England
Telephone: (0)1895-838383
Prestolite Electrics
Cleveland Road
Leyland
PR5 1XB
England
Telephone: (0)1772-421663
C. E. Niehoff & Co.
2021 Lee Street
Evanston, IL 60202
Telephone: (708) 866-6030
Delco-Remy America
2401 Columbus Avenue
P.O. Box 2439
Anderson, IN 46018
Telephone: (317) 646-3528
Leece-Neville Corp.
400 Main Street
Arcade, NY 14009
Telephone: (716) 492-1700
Auxiliary Brakes
The Jacobs Manufacturing Company
Vehicle Equipment Division
22 East Dudley Town Road
Bloomfield, CT 06002
Telephone: (203) 243-1441
Belts
T.B.A. Belting Ltd.
P.O. Box 77
Wigan
Lancashire
WN2 4XQ
England
Telephone: (0)1942-259221
Dayco Mfg.
Belt Technical Center
1955 Enterprize
Rochester Hills, MI 48309
Telephone: (810) 853-8300
Gates Rubber Company
900 S. Broadway
Denver, CO 80217
Goodyear Tire and
Rubber Company
Industrial Products Div.
2601 Fortune Circle East
Telephone: (317) 898-4170
Catalytic Converters
Donaldson Company, Inc.
1400 West 94th Street
P.O. Box 1299
Minneapolis, MN 55440
Telephone: (612) 887-3835
Nelson Division
Exhaust and Filtration Systems
1801 U.S. Highway 51 P.O. Box 428
Stoughton, WI 53589
Telephone: (608) 873-4200
Walker Manufacturing
3901 Willis Road
P.O. Box 157
Grass Lake, MI 49240
Telephone: (517) 522-5500
Coolant Level Switches
Robertshaw Controls Company
P.O. Box 400
Knoxville, TN 37901
Telephone: (216) 885-1773
Clutches
Twin Disc International S.A.
Chaussee de Namur
Nivelles
Belguim
Twin Disc Incorporated
1328 Racine Street
Racine, WI 53403
Telephone: (414) 634-1981
K38, K50, QSK38, and QSK50 Component Manufacturers' Addresses
Section M Component Manufacturers Page M-1
Coolant Heaters
Fleetguard, Inc.
Telephone: (615) 526-9551
Drive Plates
Detroit Diesel Allison
Division of General Motors
Corporation
P.O. Box 894
Indianapolis, IN 46206-0894
Telephone: (317) 242-5000
Electric Starting Motors
Prestolite Electrics
Cleveland Road
Leyland
PR5 1XB
England
Telephone: 01772-421663
Delco-Remy America
2401 Columbus Avenue
P.O. Box 2439
Anderson, IN 46018
Telephone: (317) 646-3528
Leece-Neville Corp.
400 Main Street
Arcade, NY 14009
Telephone: (716) 492-1700
Nippondenso Inc.
2477 Denso Drive
P.O. Box 5133
Southfield, MI 48086
Telephone: (313) 350-7500
Electronic Switches
Cutler-Hammer Products
Eaton Corporation
4201 N. 27th Street
Milwaukee, WI 53216
Telephone: (414) 449-6600
Engine Protection Controls
Flight Systems Headquarters
Hempt Road
P.O. Box 25
Mechanicsburg, PA 17055
Telephone: (717) 697-0333
The Nason Company
2810 Blue Ridge Blvd.
West Union, SC 29696
Telephone: (803) 638-9521
Teddington Industrial
Equipment
Windmill Road
Sunbury on Thames
Middlesex
TW16 7HF
England
Telephone: (0)9327-85500
Fan Clutches
Kysor Cooling Systems N.A.
6040 West 62nd Street
Telephone: (317) 328-3330
Holset Engineering Co. Ltd.
ST Andrews Road
Huddersfield, West Yorkshire
England HD1 6RA
Telephone: (0)1484-22244
Horton Industries, Inc.
P.O. Box 9455
Minneapolis, MN 55440
Telephone: (612) 378-6410
Rockford Clutch Company
1200 Windsor Road
P.O. Box 2908
Rockford, IL 61132-2908
Telephone: (815) 633-7460
Fans
Truflo Ltd.
Westwood Road
Birmingham
B6 7JF
England
Telephone: (0)121-3283041
Hayes-Albion Corporation
Jackson Manufacturing Plant
1999 Wildwood Avenue
Jackson, MI 49202
Telephone: (517) 782-9421
Engineered Cooling Systems, Inc.
201 W. Carmel Drive
Carmel, IN 46032
Telephone: (317) 846-3438
Brookside Corporation
P.O. Box 30
McCordsville, IN 46055
Telephone: (317) 335-2014
TCF Aerovent Company
9100 Purdue Rd., Suite 101
Telephone: (317) 872-0030
Kysor-Cadillac
1100 Wright Street
Cadillac, MI 49601
Telephone: (616) 775-4681
Schwitzer
6040 West 62nd Street
P.O. Box 80-B
Telephone: (317) 328-3010
Fault Lamps
Cutler-Hammer Products
Eaton Corporation
4201 N. 27th Street
Milwaukee, WI 53216
Telephone: (414) 449-6600
Filters
Fleetguard International Corp.
Cavalry Hill Industrial Park
Weedon
Northampton NN7 4TD
England
Telephone: 01327-341313
Fleetguard, Inc.
Telephone: 1-800-22-Filters
(1-800-223-4583)
Flexplates
Corrugated Packing and
Sheet Metal
Hamsterley
Newcastle Upon Tyne
England
Telephone: (0)1207-560-505
Allison Transmission
Division of General Motors
Corporation
P.O. Box 894
Telephone: (317) 242-5000
Midwest Mfg. Co.
29500 Southfield Road, Suite 122
Southfield, MI 48076
Telephone: (313) 642-5355
Wohlert Corporation
708 East Grand River Avenue
P.O. Box 20217
Lansing, MI 48901
Telephone: (517) 485-3750
Fuel Coolers
Hayden, Inc.
1531 Pomona Road
P.O. Box 848
Corona, CA 91718-0848
Telephone: (909) 736-2665
Fuel Pumps
Robert Bosch Corp.
Automotive Group
2800 South 25th Ave.
Broadview, IL 60153
Fuel Warmers
Fleetguard, Inc.
Telephone: (615) 526-9551
Component Manufacturers' Addresses K38, K50, QSK38, and QSK50
Page M-2 Section M Component Manufacturers
Gauges
Grasslin U.K. Ltd.
Vale Rise
Tonbridge
Kent
TN9 1TB
England
Telephone: (0)1732-359888
Datcon Instruments
P.O. Box 128
East Petersburg, PA 17520
Telephone: (717) 569-5713
Rochester Gauges, Inc.
11616 Harry Hines Blvd.
P.O. Box 29242
Dallas, TX 75229
Telephone: (214) 241-2161
Governors
Woodward Governor Co.
P.O. Box 1519
Fort Collins, CO 80522
Telephone: (303) 482-5811
(800) 523-2831
Barber Colman Co.
1354 Clifford Avenue
Loves Park, IL 61132
Telephone: (815) 637-3000
United Technologies
Diesel Systems
1000 Jorie Blvd.
Suite 111
Oak Brook, IL 69521
Telephone: (312) 325-2020
Heat Sleeves
Bentley Harris Manufacturing Co.
100 Bentley Harris Way
Gordonville, TN 38563
Telephone: (313) 348-5779
Hydraulic and Power Steering
Pumps
Honeywell Control Systems Ltd.
Honeywell House
Arlington Business Place
Bracknell
Berks RG12 1EB
Telephone: (0)1344-656000
Sperry Vickers
P.O. Box 302
Troy, MI 48084
Telephone: (313) 280-3000
Z.F.
P.O. Box 1340
Grafvonsoden Strasse
5-9 D7070
Schwaebisch Gmuend
Germany
Telephone: 7070-7171-31510
In-Line Connectors
Pioneer-Standard Electronics, Inc.
5440 Neiman Parkway
Solon, OH 44139
Telephone: (216) 349-1300
Deutsch
Industrial Products Division
37140 Industrial Avenue
Hemet, CA 92343
Telephone: (714) 929-1200
Oil Heaters
Fleetguard, Inc.
Telephone: (615) 526-9551
Kim Hotstart Co.
P.O. Box 11245
Spokane, WA 99211-0245
Telephone: (509) 534-6171
Prelubrication Systems
RPM Industries, Inc.
Suite 109
55 Hickory Street
Washington, PA 15301
Telephone: (412) 228-5130
Radiators
JB Radiator Specialties, Inc.
P.O. Box 292087
Sacramento, CA 95829-2087
Telephone: (916) 381-4791
The G&O Manufacturing Company
100 Gando Drive
P.O. Box 1204
New Haven, CT 06505-1204
Telephone: (203) 562-5121
Young Radiator Company
2825 Four Mile Road
Racine, WI 53404
Telephone: (910) 271-2397
L and M Radiator, Inc.
1414 East 37th Street
Hibbing, MN 55746
Telephone: (218) 263-8993
Throttle Assemblies
Williams Controls, Inc.
14100 SW 72nd Avenue
Portland, OR 97224
Telephone: (503) 684-8600
Torque Converters
Twin Disc International S.A.
Chaussee de Namur
Nivelles
Belgium
Twin Disc Incorporated
1328 Racine Street
Racine, WI 53403-1758
Telephone: (414) 634-1981
Rockford Powertrain, Inc.
Off-Highway Systems
1200 Windsor Road
P.O. Box 2908
Rockford, IL 61132-2908
Telephone: (815) 633-7460
Modine Mfg. Co.
1500 DeKoven Avenue
Racine, WI 53401
Telephone: (414) 636-1640
K38, K50, QSK38, and QSK50 Component Manufacturers' Addresses
Section M Component Manufacturers Page M-3
Component Manufacturers' Addresses K38, K50, QSK38, and QSK50
Page M-4 Section M Component Manufacturers
Notes
Section V Specifications Page V-a
Section V Specifications
Section Contents
Page
Air Intake System ..........................................................................................................................................V-129
Specifications...............................................................................................................................................V-129
Air Intake System Group 10 - Specifications ............................................................................................ V-89
Air Intake Restriction................................................................................................................................................V-89
Turbocharger............................................................................................................................................................V-89
Turbocharger Axial Clearance..................................................................................................................................V-89
Turbocharger Radial Bearing Clearance..................................................................................................................V-90
Air Intake System Group 10 - Torque Values ............................................................................................V-91
Aftercooler Assembly............................................................................................................................................... V-91
Aftercooler Assembly (Center-Mount)......................................................................................................................V-95
Aftercooler Assembly (Outboard).............................................................................................................................V-97
Aftercooler Element..................................................................................................................................................V-97
Aftercooler Housing (Center Mount).......................................................................................................................V-110
Air Cleaner Assembly (Engine-Mounted).................................................................................................................V-97
Air Leaks, Air Intake and Exhaust Systems............................................................................................................. V-98
Turbocharger............................................................................................................................................................V-98
Turbocharger Coolant Hoses.................................................................................................................................V-107
Turbocharger Oil Drain Line...................................................................................................................................V-108
Turbocharger Oil Supply Line.................................................................................................................................V-108
Turbocharger, Water-Cooled..................................................................................................................................V-105
Cam Followers/Tappets Group 04 - Specifications ...................................................................................V-28
Cam Follower Assembly...........................................................................................................................................V-28
Cam Follower Roller and Pin....................................................................................................................................V-29
Cam Followers/Tappets Group 04 - Torque Values ..................................................................................V-30
Cam Follower Assembly...........................................................................................................................................V-30
Cam Follower Cover.................................................................................................................................................V-30
Capscrew Markings and Torque Values .......................................................................................................V-141
Capscrew Markings and Torque Values - Metric............................................................................................V-141
Capscrew Markings and Torque Values - U.S. Customary.............................................................................V-141
General Information......................................................................................................................................V-141
Compressed Air System ...............................................................................................................................V-132
Compressed Air System Group 12 - Specifications ................................................................................V-114
Air Compressor......................................................................................................................................................V-114
Compressed Air System Group 12 - Torque Values ...............................................................................V-115
Air Compressor......................................................................................................................................................V-115
Air Compressor Unloader and Valve Assembly.....................................................................................................V-115
Coolant Recommendations and Specifications ...........................................................................................V-137
Cooling System Sealing Additives.................................................................................................................V-139
Cooling System Soluble Oils.........................................................................................................................V-139
Fully Formulated Coolant/Antifreeze..............................................................................................................V-137
Cooling System .............................................................................................................................................V-127
with Mechanically Actuated Injector............................................................................................................V-127
with Electronically Actuated Injector...........................................................................................................V-127
Cooling System Group 08 - Specifications ................................................................................................V-57
Coolant Thermostat..................................................................................................................................................V-57
Fan Drive Idler Arm Assembly..................................................................................................................................V-57
Fan Hub, Belt Driven................................................................................................................................................V-57
Sea Water Pump......................................................................................................................................................V-57
Water Pump............................................................................................................................................................. V-57
Cooling System Group 08 - Torque Values ...............................................................................................V-59
Belt Guard................................................................................................................................................................V-59
Coolant Bypass Tube...............................................................................................................................................V-60
Coolant Thermostat..................................................................................................................................................V-60
Coolant Thermostat Housing Support......................................................................................................................V-61
Drive Belt, Cooling Fan............................................................................................................................................ V-59
Page V-b Section V Specifications
ECM Cooling Plate...................................................................................................................................................V-74
ECM Cooling Plate Lines......................................................................................................................................... V-74
Expansion Tank........................................................................................................................................................V-64
Fan Drive Idler Arm Assembly..................................................................................................................................V-63
Fan Hub Bracket...................................................................................................................................................... V-63
Fan Hub, Belt Driven................................................................................................................................................V-63
Fan, Cooling.............................................................................................................................................................V-64
Heat Exchanger........................................................................................................................................................V-64
Sea Water Pump......................................................................................................................................................V-70
Sea Water Pump Support........................................................................................................................................ V-71
Water Manifold.........................................................................................................................................................V-72
Water Pump............................................................................................................................................................. V-72
Cummins/Fleetguard Filter Specifications .................................................................................................V-133
Cylinder Block Group 01 - Specifications ....................................................................................................V-1
Bearings, Connecting Rod.........................................................................................................................................V-1
Bearings, Main...........................................................................................................................................................V-1
Bearings, Thrust.........................................................................................................................................................V-2
Camshaft....................................................................................................................................................................V-2
Camshaft Bushings....................................................................................................................................................V-3
Camshaft Gear (Camshaft Installed)..........................................................................................................................V-3
Camshaft Gear (Camshaft Removed)........................................................................................................................V-3
Camshaft Thrust Bearing......................................................................................................................................... V-11
Connecting Rod..........................................................................................................................................................V-4
Crankshaft..................................................................................................................................................................V-5
Crankshaft Gear, Front (Crankshaft Removed).........................................................................................................V-5
Cylinder Block............................................................................................................................................................V-6
Cylinder Block and Liner Seats..................................................................................................................................V-7
Cylinder Block Counterbore..................................................................................................................................... V-11
Cylinder Liner.............................................................................................................................................................V-7
Cylinder Liner Protrusion..........................................................................................................................................V-12
Gear Cover Accessory Drive Bushing......................................................................................................................V-13
Gear Cover, Front......................................................................................................................................................V-8
Gear Train Backlash, Front......................................................................................................................................V-11
Idler Gear, Camshaft..................................................................................................................................................V-8
Idler Shaft, Camshaft Idler Gear...............................................................................................................................V-11
Idler Shaft, Water Pump Idler Gear..........................................................................................................................V-12
Piston....................................................................................................................................................................... V-10
Piston and Connecting Rod Assembly.....................................................................................................................V-11
Piston Rings.............................................................................................................................................................V-10
Vibration Damper, Viscous.......................................................................................................................................V-10
Cylinder Block Group 01 - Torque Values .................................................................................................V-14
Bearings, Connecting Rod....................................................................................................................................... V-14
Bearings, Main......................................................................................................................................................... V-14
Bearings, Thrust.......................................................................................................................................................V-15
Camshaft..................................................................................................................................................................V-15
Camshaft Cover Plate..............................................................................................................................................V-15
Camshaft Gear (Camshaft Installed)........................................................................................................................V-15
Crankshaft................................................................................................................................................................V-15
Crankshaft Adapter.................................................................................................................................................. V-16
Crankshaft Pulley.....................................................................................................................................................V-16
Crankshaft Seal, Rear..............................................................................................................................................V-16
Cylinder Block.......................................................................................................................................................... V-16
Cylinder Block Counterbore..................................................................................................................................... V-18
Cylinder Liner...........................................................................................................................................................V-16
Cylinder Liner Protrusion..........................................................................................................................................V-19
Gear Cover, Front.................................................................................................................................................... V-16
Gear Housing, Front.................................................................................................................................................V-17
Hand Hole Cover......................................................................................................................................................V-17
Idler Gear, Camshaft................................................................................................................................................V-17
Piston Cooling Nozzle..............................................................................................................................................V-17
Vibration Damper, Double........................................................................................................................................V-18
Vibration Damper, Viscous.......................................................................................................................................V-18
Section V Specifications Page V-c
Water Header Plate, Cylinder Block.........................................................................................................................V-18
Cylinder Head Group 02 - Specifications ..................................................................................................V-20
Crosshead................................................................................................................................................................V-20
Cylinder Head...........................................................................................................................................................V-20
Cylinder Head Group 02 - Torque Values ..................................................................................................V-23
Crosshead................................................................................................................................................................V-23
Cylinder Head...........................................................................................................................................................V-23
Drive Belt Tension ........................................................................................................................................V-140
Tension Chart...............................................................................................................................................V-140
Drive Units Group 09 - Specifications ...........................................................................................................V-76
Accessory Drive.......................................................................................................................................................V-76
Accessory Drive Bushing.........................................................................................................................................V-77
Accessory Drive Gear and Shaft..............................................................................................................................V-77
Accessory Drive Pulley.............................................................................................................................................V-78
Fuel Pump Drive.......................................................................................................................................................V-78
Hydraulic Pump Drive...............................................................................................................................................V-80
Hydraulic Pump Drive Gear and Shaft.....................................................................................................................V-81
Rear Gear Drive (Lower Assembly).........................................................................................................................V-81
Rear Gear Drive (Upper Assembly).........................................................................................................................V-82
Rear Gear Drive Gear and Shaft (Upper Assembly)................................................................................................V-83
Water Pump Drive Bushing......................................................................................................................................V-84
Water Pump Drive Gear and Shaft...........................................................................................................................V-84
Woodward Governor Drive.......................................................................................................................................V-84
Drive Units Group 09 - Torque Values .......................................................................................................V-86
Accessory Drive.......................................................................................................................................................V-86
Fuel Pump Drive.......................................................................................................................................................V-86
Hydraulic Pump Drive...............................................................................................................................................V-87
Rear Gear Drive (Lower Assembly).........................................................................................................................V-87
Rear Gear Drive (Upper Assembly).........................................................................................................................V-87
Woodward Governor Drive.......................................................................................................................................V-88
Electrical Equipment Group 13 - Torque Values .....................................................................................V-116
Alternator................................................................................................................................................................V-116
Alternator Adjusting Link........................................................................................................................................V-116
Alternator Bracket...................................................................................................................................................V-116
Starting Motor.........................................................................................................................................................V-116
Electrical System ..........................................................................................................................................V-131
Batteries (Specific Gravity)............................................................................................................................V-131
Engine Testing Group 14 - Specifications ...............................................................................................V-117
Engine Run-in (Engine Dynamometer)..................................................................................................................V-117
Engine Testing (Chassis Dynamometer)................................................................................................................V-117
Engine Testing (Engine Dynamometer).................................................................................................................V-117
Engine Testing Group 14 - Torque Values ..............................................................................................V-118
Engine Compression..............................................................................................................................................V-118
Engine Run-in (Engine Dynamometer)..................................................................................................................V-118
Engine Testing (Engine Dynamometer).................................................................................................................V-118
Exhaust System ............................................................................................................................................V-130
Exhaust System Group 11 - Torque Values .............................................................................................V-111
Bellows...................................................................................................................................................................V-113
Exhaust Connection Pipe.......................................................................................................................................V-111
Exhaust Manifold (Wet) Water Connections..........................................................................................................V-112
Exhaust Manifold, Dry............................................................................................................................................V-111
Exhaust Manifold, Wet...........................................................................................................................................V-112
Fraction, Decimal, Millimeter Conversions ..................................................................................................V-143
Conversion Chart..........................................................................................................................................V-143
Fuel Recommendations and Specifications .................................................................................................V-135
Fuel System ..................................................................................................................................................V-125
with Electronically Actuated Injector...........................................................................................................V-125
with Mechanically Actuated Injector............................................................................................................V-125
Fuel System Group 05 - Specifications .....................................................................................................V-31
Page V-d Section V Specifications
Fuel Lift Pump..........................................................................................................................................................V-31
Fuel System Group 05 - Torque Values .....................................................................................................V-32
.................................................................................................................................................................................V-34
Fuel Lift Pump..........................................................................................................................................................V-33
Fuel Pump................................................................................................................................................................V-32
Fuel Pump Gear Pump Check Valve.......................................................................................................................V-33
General Engine ..............................................................................................................................................V-123
General Specifications..................................................................................................................................V-123
Injectors and Fuel Lines Group 06 - Specifications ..................................................................................V-35
Fuel Drain Line Restriction.......................................................................................................................................V-35
Fuel Inlet Restriction.................................................................................................................................................V-35
Static Injection Timing..............................................................................................................................................V-35
Injectors and Fuel Lines Group 06 - Torque Values .................................................................................V-36
Air in Fuel.................................................................................................................................................................V-36
Fuel Block.................................................................................................................................................................V-36
Fuel Connection Block (Manifold-Mounted).............................................................................................................V-36
Fuel Drain Lines.......................................................................................................................................................V-37
Fuel Filter Head........................................................................................................................................................V-38
Fuel Filter Head Bracket...........................................................................................................................................V-39
Fuel Inlet Restriction.................................................................................................................................................V-39
Fuel Manifold (Combined)........................................................................................................................................V-39
Fuel Manifold (Drain)................................................................................................................................................V-40
Fuel Manifold (Supply).............................................................................................................................................V-41
Fuel Pressure Relief Valve.......................................................................................................................................V-46
Fuel Supply Lines.....................................................................................................................................................V-41
Injector......................................................................................................................................................................V-44
Injector Supply Lines (High Pressure)......................................................................................................................V-46
Single Bank Idle Valve.............................................................................................................................................V-44
Static Injection Timing..............................................................................................................................................V-44
STC Oil Control Valve (Electrical)............................................................................................................................V-45
STC Oil Control Valve (Mechanical).........................................................................................................................V-45
STC Oil Manifold......................................................................................................................................................V-45
STC Wiring Harness.................................................................................................................................................V-46
Timing Mark Pointer.................................................................................................................................................V-46
Lubricating Oil Recommendations and Specifications ................................................................................V-136
Lubricating Oil System .................................................................................................................................V-126
Lubricating Oil System Group 07 - Specifications ....................................................................................V-47
Lubricating Oil Filter Head........................................................................................................................................V-47
Lubricating Oil Filter Head, Aluminum......................................................................................................................V-47
Lubricating Oil High Pressure Relief Valve..............................................................................................................V-47
Lubricating Oil Pump................................................................................................................................................V-48
Lubricating Oil System Group 07 - Torque Values ...................................................................................V-50
Eliminator Filter........................................................................................................................................................V-55
Lubricating Oil Cooler Cover....................................................................................................................................V-54
Lubricating Oil Filter Head........................................................................................................................................V-50
Lubricating Oil Filter Head (Remote-Mounted).........................................................................................................V-51
Lubricating Oil Filter Head, Aluminum......................................................................................................................V-51
Lubricating Oil Pan...................................................................................................................................................V-52
Lubricating Oil Pan Adapter.....................................................................................................................................V-52
Lubricating Oil Pressure Regulator (Main Rifle).......................................................................................................V-52
Lubricating Oil Pump................................................................................................................................................V-52
Lubricating Oil Suction Tube (Block-Mounted).........................................................................................................V-53
Lubricating Oil Temperature Gauge.........................................................................................................................V-54
Pre-Lubricating Oil Pump.........................................................................................................................................V-54
Main Power Generator Group 21 - Torque Values ..................................................................................V-122
Bearing, Generator.................................................................................................................................................V-122
Generator Rotor.....................................................................................................................................................V-122
Permanent Magnet Generator................................................................................................................................V-122
Mounting Adaptations Group 16 - Specifications ....................................................................................V-119
Engine Mounts.......................................................................................................................................................V-119
Engine Support Bracket, Front...............................................................................................................................V-119
Section V Specifications Page V-e
Mounting Adaptations Group 16 - Torque Values ...................................................................................V-120
Engine Lifting Brackets...........................................................................................................................................V-120
Engine Mounts.......................................................................................................................................................V-121
Engine Support Bracket, Front...............................................................................................................................V-120
Flexplate.................................................................................................................................................................V-120
Flywheel.................................................................................................................................................................V-120
Flywheel Housing...................................................................................................................................................V-120
Newton-Meter to Foot-Pound Conversions ..................................................................................................V-144
Pipe Plug Torque Values ..............................................................................................................................V-145
Torque Table................................................................................................................................................V-145
Rocker Levers Group 03 - Specifications ..................................................................................................V-24
Overhead Set (OBC)................................................................................................................................................V-24
Overhead Set (Travel Method).................................................................................................................................V-24
Rocker Lever Assembly........................................................................................................................................... V-24
Rocker Levers Group 03 - Torque Values ................................................................................................. V-25
Crankcase Breather (External).................................................................................................................................V-25
Overhead Set (OBC)................................................................................................................................................V-25
Overhead Set (Travel Method).................................................................................................................................V-26
Rocker Lever Assembly........................................................................................................................................... V-26
Rocker Lever Cover................................................................................................................................................. V-27
Rocker Lever Housing..............................................................................................................................................V-27
Tap-Drill Chart - U.S. Customary and Metric ................................................................................................V-146
Weights and Measures - Conversion Factors ..............................................................................................V-147
Page V-f Section V Specifications
K38, K50, QSK38, and QSK50 Cylinder Block Group 01 - Specifications
Section V Specifications Page V-1
Component or Assembly (Procedure)
Ref.No./
Steps
Metric U.S.
.
Cylinder Block Group 01 - Specifications
Bearings, Connecting Rod (001-005)
Connecting Rod Bearing Thickness
Standard or Oversize (OS)
Standard 3.106 MIN 0.1223
3.157 MAX 0.1243
0.010 (OS) 3.233 MIN 0.1273
3.284 MAX 0.1293
0.020 (OS) 3.360 MIN 0.1323
3.411 MAX 0.1343
0.030 (OS) 3.487 MIN 0.1373
3.538 MAX 0.1393
0.040 (OS) 3.614 MIN 0.1423
3.665 MAX 0.1443
Rod Capscrew Stretch Specification
0.343 mm MIN 0.0135 in
0.470 mm MAX 0.0185 in
Rod to Crankshaft Side Clearance 0.30 mm MIN 0.012 in
0.51 mm MAX 0.020 in
Bearings, Main (001-006)
Main Bearing Thickness Standard or
Oversize (OS)
4.336 MAX 0.1707
0.010 (OS) 4.407 MIN 0.1735
4.463 MAX 0.1757
0.020 (OS) 4.534 MIN 0.1785
4.590 MAX 0.1807
0.030 (OS) 4.661 MIN 0.1835
4.717 MAX 0.1857
0.040 (OS) 4.788 MIN 0.1885
4.844 MAX 0.1907
Crankshaft End Clearance 0.13 mm MIN 0.005 in
0.51 mm MAX 0.020 in
Cylinder Block Group 01 K38, K50, QSK38, and QSK50
Page V-2 Section V Specifications
Ref.No./
Steps
Metric U.S.
.
Bearings, Thrust (001-007)
Thrust Bearing Thickness Standard or
Oversize
4.940 MAX 0.1945
0.010 (OS) 5.080 MIN 0.2000
5.194 MAX 0.2045
0.020 (OS) 5.334 MIN 0.2100
5.448 MAX 0.2145
0.030 (OS) 5.588 MIN 0.2200
5.702 MAX 0.2245
0.040 (OS) 5.842 MIN 0.2300
5.956 MAX 0.2345
Crankshaft End Clearance
0.13 mm MIN 0.005 in
0.51 mm MAX 0.020 in
Camshaft (001-008)
Camshaft Thrust End Clearance
0.15 mm MIN 0.006 in
0.33 mm MAX 0.013 in
Camshaft Bushing Journal Diameter 76.07 mm MIN 2.995 in
76.12 mm MAX 2.997 in
Camshaft End Clearance 0.15 mm MIN 0.006 in
0.33 mm MAX 0.013 in
Front Gear Train Gear Backlash
0.07 mm MIN 0.003 in
0.51 mm MAX 0.020 in
Cam Follower Capscrew Torque Value 39 Nm MIN 29 ft-lb
42 Nm MAX 31 ft-lb
K38, K50, QSK38, and QSK50 Cylinder Block Group 01
Ref.No./
Steps
Metric U.S.
.
Camshaft Bushings (001-010)
Camshaft Bushing Bore in the Block
80.963 mm MIN 3.1875 in
80.988 mm MAX 3.1885 in
Camshaft Gear (Camshaft Installed) (001-012)
Camshaft Gear Inside Diameter
57.125 mm MIN 2.2490 in
57.150 mm MAX 2.2500 in
Camshaft Gear Mounting Surface (Outside
Diameter)
57.201 mm MIN 2.2520 in
57.211 mm MAX 2.2524 in
Camshaft Thrust Bearing Thickness 9.14 mm MIN 0.360 in
9.45 mm MAX 0.372 in
Camshaft end clearance 0.15 mm MIN 0.006 in
0.33 mm MAX 0.013 in
Camshaft Gear (Camshaft Removed) (001-013)
Camshaft Outside Diameter (Gear Location)
57.201 mm MIN 2.2520 in
57.211 mm MAX 2.2524 in
Camshaft Gear Inside Diameter
57.125 mm MIN 2.2490 in
57.150 mm MAX 2.2500 in
Ref.No./
Steps
Metric U.S.
.
Camshaft Thrust Bearing Thickness 9.14 mm MIN 0.360 in
9.45 mm MAX 0.372 in
Connecting Rod (001-014)
Capscrew Length (1)
136.14 mm MIN 5.360 in
136.91 mm MAX 5.390 in
Capscrew outside diameter (2) 15.27 mm MIN 0.601 in
15.37 mm MAX 0.605 in
Capscrew outside diameter (3) 17.35 mm MIN 0.683 in
17.45 mm MAX 0.687 in
Connecting Rod Bushing inside diameter 60.985 mm MIN 2.4010 in
61.024 mm MAX 2.4025 in
Connecting Rod Bearing Bore inside
diameter
114.330
mm
MIN 4.5012 in
114.382
mm
MAX 4.5032 in
Connecting Rod Length
289.69 mm MIN 11.405 in
289.74 mm MAX 11.407 in
Maximum Connecting Rod Bend
Bushing Installed 0.10 MAX 0.004
Bushing Removed 0.20 MAX 0.008
Maximum Connecting Rod Twist
Bushing Installed 0.25 MAX 0.010
Bushing Removed 0.51 MAX 0.020
Ref.No./
Steps
Metric U.S.
.
Crankshaft (001-016)
Crankshaft Outside Diameter
Location (1) 110.74 MIN 4.360
110.77 MAX 4.361
Location (2) 111.07 MIN 4.373
111.13 MAX 4.375
Location (3) 184.10 MIN 7.248
184.15 MAX 7.250
Rod Bearing Journal Outside Diameter (5) 107.87 mm MIN 4.247 in
107.95 mm MAX 4.250 in
Main Bearing Outside Diameter (6)
165.05 mm MIN 6.498 in
165.10 mm MAX 6.500 in
Thrust Flange (7) 12.52 mm MIN 0.493 in
12.75 mm MAX 0.502 in
Crankshaft Bow at Top Indicator Reading
K38 Engine 0.267 MAX 0.0105
K50 Engine 0.356 MAX 0.0140
Adjacent Journal Run Out
Fully Fillet Hardened 0.089 MAX 0.0035
Non-Fully Fillet Hardened 0.089 MAX 0.0035
Crankshaft Gear, Front (Crankshaft Removed) (001-019)
Crankshaft Outside Diameter (Gear
Location)
111.25 mm MIN 4.380 in
111.28 mm MAX 4.381 in
Front Crankshaft Gear Inside Diameter 111.71 mm MIN 4.3768 in
111.89 mm MAX 4.3775 in
Ref.No./
Steps
Metric U.S.
.
Cylinder Block (001-026)
Correct Press 181.80 mm MIN 7.157 in
181.81 mm MAX 7.158 in
181.79 mm MAX 7.157 in
Oversized [Inch]
190.335 MAX 7.4935
0.010 190.538 MIN 7.5015
190.589 MAX 7.5035
0.020 190.792 MIN 7.5115
190.843 MAX 7.5135
0.030 191.046 MIN 7.5215
191.097 MAX 7.5235
0.040 191.300 MIN 7.5315
191.351 MAX 7.5335
190.335 MAX 7.4935
181.81 mm MAX 7.158 in
(4) Packing Ring Bore 177.34 mm MIN 6.982 in
177.39 mm MAX 6.984 in
Camshaft Idler Shaft Bore Inside Diameter 25.37 mm MIN 0.999 in
25.40 mm MAX 1.000 in
Ref.No./
Steps
Metric U.S.
.
Water Pump Idler Shaft Counter Bore - New
(13)
43.18 mm MIN 1.700 in
43.21 mm MAX 1.701 in
Water Pump Idler Shaft Counter Bore Depth
- New (14)
4.57 mm MIN 0.180 in
5.08 mm MAX 0.200 in
Water Pump Idler Shaft Bore - New (15) 21.97 mm MIN 0.865 in
22.23 mm MAX 0.875 in
Water Pump Idler Shaft Bore - Old (16)
25.37 mm MIN 0.999 in
25.40 mm MAX 1.000 in
(18) Cylinder Block Height 481.94 mm MIN 18.974* in
482.78 mm MAX 19.007 in
(19) Cylinder Block Height - Main Bearing
Saddle
395.00 mm MIN 15.551* in
395.81 mm MAX 15.583 in
Camshaft Bushing Inside Diameter 76.200 mm MIN 3.0000 in
76.289 mm MAX 3.0035 in
Main Bearing Bore Inside Diameter
(Capscrews Torqued to Specification)
173.86 mm MIN 6.845 in
173.89 mm MAX 6.846 in
Cylinder Block and Liner Seats (001-027)
Packing Ring Bore diameter
177.34 mm MIN 6.982 in
177.39 mm MAX 6.984 in
Cylinder Liner (001-028)
Cylinder Liner Inside Diameter
158.737
mm
MIN 6.2495 in
158.877
mm
MAX 6.2550 in
Ref.No./
Steps
Metric U.S.
.
Cylinder Liner Flange Thickness
13.39 MAX 0.527
0.25 mm [0.010 inch] 13.61 MIN 0.536
13.64 MAX 0.537
0.51 mm [0.020 inch] 13.87 MIN 0.546
13.89 MAX 0.547
0.76 mm [0.030 inch] 14.12 MIN 0.556
14.15 MAX 0.557
1.02 mm [0.040 inch] 14.38 MIN 0.566
14.40 MAX 0.567
Counterbore Ring Thickness
5.067 MAX 0.1995
0.05 mm [0.002 inch] 5.105 MIN 0.2010
5.118 MAX 0.2015
0.10 mm [0.004 inch] 5.156 MIN 0.2030
5.169 MAX 0.2035
Cylinder Liner Outside Diameter (2)
181.81 mm MIN 7.158 in
181.86 mm MAX 7.160 in
RTV Sealant Bead Size
1.1 mm MIN 0.0468 in
1.6 mm MAX 0.0625 in
Gear Cover, Front (001-031)
(15) Accessory Drive and Water Pump Drive: 39.75 MIN 1.565
39.790 MAX 1.571
(16) Hydraulic Pump Drive: 38.13 MIN 1.501
38.25 MAX 1.506
Idler Gear, Camshaft (001-036)
Idler Gear Bushing Inside Diameter 47.638 mm MIN 1.8755 in
47.714 mm MAX 1.8785 in
Camshaft Idler Shaft Outside Diameter - (1)
25.397 mm MIN 0.9995 in
25.400 mm MAX 1.0000 in
Camshaft Idler Shaft Outside Diameter - (2) 47.549 mm MIN 1.8720 in
47.600 mm MAX 1.8740 in
Ref.No./
Steps
Metric U.S.
.
(1) - Engine Serial Number Higher than
33110701
43.167 mm MIN 1.6995 in
43.180 mm MAX 1. 7000 in
(2) - Engine Serial Number Higher than
33110701
47.549 mm MIN 1.8720 in
47.600 mm MAX 1.8740 in
(1) - Engine Serial Number Lower than
33110701
25.397 mm MIN 0.9995 in
25.400 mm MAX 1.0000 in
(2) - Engine Serial Number Lower than
33110701
47.549 mm MIN 1.8720 in
47.600 mm MAX 1.8740 in
Thrust Bearing thickness
2.34 mm MIN 0.092 in
2.39 mm MAX 0.094 in
Camshaft Idler Shaft Bore Inside Diameter
25.38 mm MIN 0.999 in
25.40 mm MAX 1.000 in
Camshaft Idler Shaft Bore Inside Diameter -
(13)
43.18 mm MIN 1.700 in
43.22 mm MAX 1.701 in
(14)
4.57 mm MIN 0.180 in
5.08 mm MAX 0.200 in
(15)
21.97 mm MIN 0.865 in
22.23 mm MAX 0.875 in
Diameter (16)
25.38 mm MIN 0.999 in
25.4 mm MAX 1.000 in
Idler Gear End Clearance
0.13 mm MIN 0.005 in
0.46 mm MAX 0.018 in
Ref.No./
Steps
Metric U.S.
.
Front Gear Train Gear Backlash 0.07 mm MIN 0.003 in
0.51 mm MAX 0.020 in
Piston (001-043)
Piston Oil Ring Groove Width
4.788 mm MIN 0.1885 in
4.851 mm MAX 0.1910 in
Piston Pin Bore Inside Diameter 60.942 mm MIN 2.3993 in
60.952 mm MAX 2.3997 in
Piston Skirt Outside Diameter
(1) 158.445 MIN 6.2380
158.471 MAX 6.2390
(2a) 158.466 MIN 6.2388
158.542 MAX 6.2418
(2b) 158.440 MIN 6.2378
158.501 MAX 6.2402
Piston Rings (001-047)
Piston Ring Gap
Top 0.64 MIN 0.025
1.02 MAX 0.040
Intermediate 0.64 MIN 0.025
1.02 MAX 0.040
Oil 0.30 MIN 0.015
0.76 MAX 0.030
Vibration Damper, Viscous (001-052)
Houdaille
65.38 mm MAX 2.574 in
Made in England F-82 and After 65.51 mm MAX 2.579 in
Made in England Before F-82 65.66 mm MAX 2.585 in
Vibration Damper Eccentricity (Total Indictor
Reading)
0.51 mm MAX 0.020 in
Ref.No./
Steps
Metric U.S.
.
Vibration Damper Face Runout (Total
Indicator Reading)
0.58 mm MAX 0.023 in
Piston and Connecting Rod Assembly (001-054)
Connecting Rod and Crankshaft Side
Clearance
0.30 mm MIN 0.012 in
0.52 mm MAX 0.020 in
Gear Train Backlash, Front (001-055)
Front Gear Train Gear backlash 0.07 mm MIN 0.003 in
0.51 mm MAX 0.020 in
Camshaft Thrust Bearing (001-056)
Camshaft thrust bearing thickness 9.14 mm MIN 0.360 in
9.45 mm MAX 0.372 in
Cylinder Block Counterbore (001-058)
WITH Double Undercut Radius
189.79 mm MIN 7.472 in
190.04 mm MAX 7.482 in
WITHOUT Double Undercut Radius 187.20 mm MIN 7.370 in
187.45 mm MAX 7.380 in
Cylinder Liner Protrusion (A) 0.15 mm MIN 0.006 in
0.20 mm MAX 0.008 in
Idler Shaft, Camshaft Idler Gear (001-061)
47.714 mm MAX 1.8785 in
Ref.No./
Steps
Metric U.S.
.
Camshaft Idler Shaft Outside Diameter (1) 25.387 mm MIN 0.9995 in
25.400 mm MAX 1.0000 in
Camshaft Idler Shaft Outside Diameter (2)
47.549 mm MIN 1.8720 in
47.600 mm MAX 1.8740 in
Thrust Bearing Thickness 0.235 mm MIN 0.092 in
0.245 mm MAX 0.096 in
Idler Shaft, Water Pump Idler Gear (001-063)
47.714 mm MAX 1.8785 in
Water Pump Idler Shaft Outside Diameter
Engine Serial Number Higher than 33110701
(1)
43.167 mm MIN 1.6995 in
43.180 mm MAX 1.7000 in
Engine Serial Number Higher than 33110701
(2)
47.549 mm MIN 1.8720 in
47.600 mm MAX 1.8740 in
Engine Serial Number Lower than 33110701
(1)
23.397 mm MIN 0.9995 in
25.400 mm MAX 1.0000 in
Engine Serial Number Lower than 33110701
(2)
47.549 mm MIN 1.8720 in
47.600 mm MAX 1.8740 in
2.39 mm MAX 0.094 in
Cylinder Liner Protrusion (001-064)
K38 and K50 Cylinder Liner Protrusion 0.15 mm MIN 0.006 in
0.20 mm MAX 0.008 in
Ref.No./
Steps
Metric U.S.
.
Gear Cover Accessory Drive Bushing (001-066)
Front Cover Bushing Bore inside diameter
(15) Accessory Drive and Water Pump Drive: 43.08 MIN 1.696
43.10 MAX 1.697
(16) Hydraulic Pump Drive: 41.28 MIN 1.625
41.30 MAX 1.626
Cylinder Block Group 01 - Torque Values K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Cylinder Block Group 01 - Torque Values
Bearings, Connecting Rod (001-005)
Connecting Rod Capscews 1 102 Nm [ 75 ft-lb ]
2 Rotate 90 degrees.
3 Loosen both capscrews.
4 102 Nm [ 75 ft-lb ]
5 Rotate 90 degrees.
1 108 Nm [ 80 ft-lb ]
2 217 Nm [ 160 ft-lb ]
3 325 Nm [ 240 ft-lb ]
4 Loosen both capscrews.
5 108 Nm [ 80 ft-lb ]
6 217 Nm [ 160 ft-lb ]
7 325 Nm [ 240 ft-lb ]
365 Nm [ 270 ft-lb ]
Bearings, Main (001-006)
K38 And Qsk38 Main Bearing Cap
Capscrew
1 176 Nm [ 130 ft-lb ]
2 285 Nm [ 210 ft-lb ]
3 610 Nm [ 450 ft-lb ]
4 Loosen
5 176 Nm [ 130 ft-lb ]
6 285 Nm [ 210 ft-lb ]
7 610 Nm [ 450 ft-lb ]
Capscrew
1 176 Nm [ 130 ft-lb ]
2 285 Nm [ 210 ft-lb ]
3 610 Nm [ 450 ft-lb ]
4 Loosen
5 176 Nm [ 130 ft-lb ]
6 285 Nm [ 210 ft-lb ]
7 610 Nm [ 450 ft-lb ]
Mounting Capscrews
1 176 Nm [ 130 ft-lb ]
2 339 Nm [ 250 ft-lb ]
3 Loosen
4 339 Nm [ 250 ft-lb ]
5 +90 degrees
Mounting Capscrews
1 176 Nm [ 130 ft-lb ]
2 339 Nm [ 250 ft-lb ]
3 Loosen
4 339 Nm [ 250 ft-lb ]
5 +90 degrees
Ref.No./
Steps
Metric U.S.
.
K38 And Qsk38 Main Bearing Capscrews
Side Bolt
1 68 Nm [ 50 ft-lb ]
2 217 Nm [ 160 ft-lb ]
3 454 Nm [ 335 ft-lb ]
Bearings, Thrust (001-007)
40 Nm [ 30 ft-lb ]
Camshaft (001-008)
45 Nm [ 35 ft-lb ]
Camshaft Cover Plate (001-011)
40 Nm [ 30 ft-lb ]
Camshaft Gear (Camshaft Installed) (001-012)
45 Nm [ 35 ft-lb ]
Crankshaft (001-016)
Crankshaft Counterweight Capscrews 285 Nm [ 210 ft-lb ]
Connecting Rod Capscrews 285 Nm [ 210 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Crankshaft Adapter (001-017)
Crankshaft Adapter Capscrews 1 220 Nm [ 160 ft-lb ]
2 395 Nm [ 290 ft-lb ]
3 555 Nm [ 410 ft-lb ]
Crankshaft Pulley (001-022)
Crankshaft Pulley Capscrews 1 220 Nm [ 160 ft-lb ]
2 395 Nm [ 290 ft-lb ]
3 555 Nm [ 410 ft-lb ]
Crankshaft Seal, Rear (001-024)
35 Nm [ 25 ft-lb ]
35 Nm [ 25 ft-lb ]
Cylinder Block (001-026)
Main Bearing Capscrews
Side Bolts
Main Bearing Capscrews (Performing Two
Steps)
Side Bolts (Performing Two Steps)
176 Nm [ 130 ft-lb ] 14 Nm [ 10
ft-
lb ]
Main Bearing Capscrews
Side Bolts
Main Bearing Capscrews (Performing Two
Steps)
Side Bolts (Performing Two Steps)
176 Nm [ 130 ft-lb ] 14 Nm [ 10
ft-
lb ]
Cylinder Liner (001-028)
47 Nm [ 35 ft-lb ]
Gear Cover, Front (001-031)
[0.125 Inch]
[0.250 Inch]
[0.375 Inch]
20 Nm [ 15 ft-lb ]
27 Nm [ 20 ft-lb ]
34 Nm [ 25 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
61 Nm [ 45 ft-lb ]
60 Nm [ 45 ft-lb ]
Gear Housing, Front (001-033)
60 Nm [ 45 ft-lb ]
Hand Hole Cover (001-035)
40 Nm [ 30 ft-lb ]
Idler Gear, Camshaft (001-036)
Capscrews With Flange Head:
Capscrew Without Flange Head:
1 205 Nm [ 150 ft-lb ]
2 Loosen
3 290 Nm [ 215 ft-lb ]
250 Nm [ 185 ft-lb ]
Capscrews With Flanged Head:
Capscrew Without Flange Head:
1 205 Nm [ 150 ft-lb ]
2 Loosen
3 88 Nm [ 65 ft-lb ]
4 Rotate 90 degrees
250 Nm [ 185 ft-lb ]
Piston Cooling Nozzle (001-046)
10 Nm [ 96 in-lb ]
15 Nm [ 120 in-lb ]
Ref.No./
Steps
Metric U.S.
.
Gallery Cooled Piston Cooling Nozzle 23 Nm [ 17 ft-lb ]
23 Nm [ 17 ft-lb ]
Vibration Damper, Double (001-050)
190 Nm [ 140 ft-lb ]
Vibration Damper, Viscous (001-052)
Damper Washers And Capscrews 190 Nm [ 140 ft-lb ]
Water Header Plate, Cylinder Block (001-053)
Steel Lock Washers:
Copper Flat Washers:
41 Nm [ 30 ft-lb ]
34 Nm [ 25 ft-lb ]
95 Nm [ 70 ft-lb ]
41 Nm [ 30 ft-lb ]
41 Nm [ 30 ft-lb ]
Cylinder Block Counterbore (001-058)
41 Nm [ 30 ft-lb ]
41 Nm [ 30 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
68 Nm [ 50 ft-lb ]
41 Nm [ 30 ft-lb ]
41 Nm [ 30 ft-lb ]
47 Nm [ 35 ft-lb ]
Cylinder Liner Protrusion (001-064)
Liner Clamp Capscrews 68 Nm [ 50 ft-lb ]
Cylinder Head Group 02 - Specifications K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Cylinder Head Group 02 - Specifications
Crosshead (002-001)
Crosshead Guide Bore Inside Diameter
11.02 mm MIN 0.434 in
11.18 mm MAX 0.440 in
Crosshead Guide Bore Inside Diameter
11.02 mm MIN 0.434 in
11.18 mm MAX 0.440 in
Cylinder Head (002-004)
Maximum Allowable Crack Length 6 mm MAX 0.25 in
Maximum Allowable Valve Depth from the
Combustion Face
0.51 mm MAX 0.020 in
Maximum Allowable Crack Length 6 mm MAX 0.25 in
Maximum Allowable Valve Depth from the
Combustion Face
0.00 mm MIN 0.000 in
0.51 mm MAX 0.020 in
Cylinder Head Thickness
Used Cylinder Head Minimum Thickness (1) 119.76 MIN 4.715
New Cylinder Head Thickness (1) 120.52 MIN 4.745
120.78 MAX 4.755
K38, K50, QSK38, and QSK50 Cylinder Head Group 02
Ref.No./
Steps
Metric U.S.
.
Air Pressure 552 kPa MAX 80 psi
Valve Guide Inside Diameter (Installed) 12.600 mm MIN 0.496 in
12.667 mm MAX 0.499 in
Valve Guide Bore Inside Diameter
21.425 mm MIN 0.844 in
21.450 mm MAX 0.845 in
Valve Seat Insert Bore Inside Diameter (6)
Exhaust and Intake 60.37 MIN 2.377
60.40 MAX 2.378
Valve Seat Insert Bore Depth (7) and (8)
Exhaust and Intake 12.50 MIN 0.492
12.62 MAX 0.497
Minimum Valve Head Thickness (at the
outside diameter)
Exhaust 3.00 MIN 0.120
Intake 2.16 MIN 0.085
Valve Stem Outside Diameter
12.535 mm MIN 0.494 in
12.576 mm MAX 0.495 in
Valve Spring Force
Long Spring (Without Rotator) 1053 MIN 237
1237 MAX 278
Short Spring (With Rotator) 1134 MIN 255
1318 MAX 296
Valve Seat Insert Width
Intake 3.05 MIN 0.120
3.55 MAX 0.140
Exhaust 1.52 MIN 0.060
2.54 MAX 0.100
Cylinder Head Group 02 K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Valve Guide Height (Installed)
Taper-Top (3) 33.665 MIN 1.325
34.163 MAX 1.345
Flat-Top (5) 29.210 MIN 1.150
29.178 MAX 1.170
Injector Protrusion 2.29 mm MIN 0.090 in
2.79 mm MAX 0.110 in
Valve Guide Height (Installed)
27.737 mm MIN 1.092 in
28.245 mm MAX 1.112 in
K38, K50, QSK38, and QSK50 Cylinder Head Group 02 - Torque Values
Ref.No./
Steps
Metric U.S.
.
Cylinder Head Group 02 - Torque Values
Crosshead (002-001)
With Adapter
Without Adapter
35 Nm [ 25 ft-lb ]
40 Nm [ 30 ft-lb ]
Cylinder Head (002-004)
Cylinder Head Pressure Test Clamp 20 Nm [ 177 in-lb ]
Cylinder Head Test Adapter Clamp 54 Nm [ 40 ft-lb ]
1 270 Nm [ 200 ft-lb ]
2 407 Nm [ 300 ft-lb ]
3 555 Nm [ 410 ft-lb ]
Rocker Levers Group 03 - Specifications K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Rocker Levers Group 03 - Specifications
Overhead Set (OBC) (003-006)
Valve Clearances - Initial Set
Exhaust Valves (A) 0.69 MAX 0.027
Intake Valves (B) 0.36 MAX 0.014
Valve Clearances - Second Check
Exhaust Valves (A) 0.61 MIN 0.024
0.76 MAX 0.030
Intake Valves (B) 0.28 MIN 0.011
0.43 MAX 0.017
Overhead Set (Travel Method) (003-007)
Injector Travel Verification Specification
(Non-STC and CENTRY)
7.80 mm MIN 0.307 in
7.82 mm MAX 0.308 in
Rocker Lever Assembly (003-009)
Shaft Outside Diameter 34.823 mm MIN 1.3710 in
34.862 mm MAX 1.3725 in
Bushing Bore Inside Diameter
34.887 mm MIN 1.3735 in
34.991 mm MAX 1.3776 in
K38, K50, QSK38, and QSK50 Rocker Levers Group 03 - Torque Values
Ref.No./
Steps
Metric U.S.
.
Rocker Levers Group 03 - Torque Values
Crankcase Breather (External) (003-001)
40 Nm [ 30 ft-lb ]
6 Nm [ 50 in-lb ]
Overhead Set (OBC) (003-006)
Crosshead Adjusting Screws With Adapter
Crosshead Adjusting Screws Without
Adapter
35 Nm [ 25 ft-lb ]
40 Nm [ 30 ft-lb ]
Adjusting Screw 0.68 Nm [ 6 in-lb ]
Adjusting Locknut With Adapter
Adjusting Locknut Without Adapter
45 Nm [ 35 ft-lb ]
60 Nm [ 45 ft-lb ]
Adjusting Screw 11 Nm [ 100 in-lb ]
10 Nm [ 90 in-lb ]
Valve And Injector Adjusting Screw With
Adapter
Valve And Injector Adjusting Screw Without
Adapter
45 Nm [ 35 ft-lb ]
60 Nm [ 45 ft-lb ]
Valve Adjusting Screw 0.7 Nm [ 6 in-lb ]
Rocker Levers Group 03 K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Valve Set - Torque Wrench Method With
Adapter
Valve Set - Torque Wrench Method Without
Adapter
48 Nm [ 35 ft-lb ]
60 Nm [ 44 ft-lb ]
Valve Set - Torque Wrench Method With
Adapter
Valve Set - Torque Wrench Method Without
Adapter
48 Nm [ 35 ft-lb ]
60 Nm [ 44 ft-lb ]
Overhead Set (Travel Method) (003-007)
Valve Adjusting Screw 0.68 Nm [ 6 in-lb ]
Locknut With Adapter 45 Nm [ 35 ft-lb ]
60 Nm [ 45 ft-lb ]
Locknut With Adapter 45 Nm [ 35 ft-lb ]
60 Nm [ 45 ft-lb ]
Rocker Lever Assembly (003-009)
Rocker Lever Mounting Capscrews 95 Nm [ 70 ft-lb ]
Rocker Lever Mounting Capscrews 95 Nm [ 70 ft-lb ]
K38, K50, QSK38, and QSK50 Rocker Levers Group 03
Ref.No./
Steps
Metric U.S.
.
Rocker Lever Cover (003-011)
20 Nm [ 180 in-lb ]
Rocker Lever Capscrews 45 Nm [ 30 ft-lb ]
Rocker Lever Cover Capscrews 40 Nm [ 30 ft-lb ]
40 Nm [ 30 ft-lb ]
Rocker Lever Housing (003-013)
90 Nm [ 66 ft-lb ]
25 Nm [ 18 ft-lb ]
Rocker Lever Housing Capscrews 95 Nm [ 70 ft-lb ]
Cam Followers/Tappets Group 04 - Specifications K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Cam Followers/Tappets Group 04 - Specifications
Cam Follower Assembly (004-001)
Roller Clearance
(1) 0.23 MIN 0.009
0.61 MAX 0.024
(2) 0.076 MIN 0.003
0.178 MAX 0.007
Lever Bore Inside Diameter
22.225 mm MIN 0.875 in
22.276 mm MAX 0.877 in
22.200 mm MAX 0.8740 in
Roller Clearance
(1) 0.23 MIN 0.009
0.61 MAX 0.024
(2) 0.076 MIN 0.003
0.178 MAX 0.007
Lever Bore Inside Diameter 22.225 mm MIN 0.875 in
22.276 mm MAX 0.877 in
22.200 mm MAX 0.8740 in
Grooved (Old) Cam Follower Capscrew
Torque Value
39 Nm MIN 29 ft-lb
42 Nm MAX 31 ft-lb
New Cam Follower Capscrew Torque Value 54 Nm MAX 40 ft-lb
K38, K50, QSK38, and QSK50 Cam Followers/Tappets Group 04
Ref.No./
Steps
Metric U.S.
.
Cam Follower Roller and Pin (004-005)
Roller Identification
Outside Diameter: 41.28 MAX 1.625
Inside Diameter: 19.18 MAX 0.755
Valve 17.07 MAX 0.672
Injector 25.22 MAX 0.993
1
Injector (K2000E, K1800E and K1500E)
28.07 MAX 1.105
Lever Pin Bore Inside Diameter (1)
19.037 mm MIN 0.7495 in
19.057 mm MAX 0.7503 in
Pin Outside Diameter (2) 19.063 mm MIN 0.7505 in
19.075 mm MAX 0.7510 in
Press Fit Between Pin and Lever 0.005 mm MIN 0.0002 in
0.038 mm MAX 0.0015 in
Roller Clearance
(1) 0.23 MIN 0.009
0.61 MAX 0.024
(2) 0.076 MIN 0.003
0.178 MAX 0.007
Cam Followers/Tappets Group 04 - Torque Values K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Cam Followers/Tappets Group 04 - Torque Values
Cam Follower Assembly (004-001)
Cam Follower Capscrews 70 Nm [ 52 ft-lb ]
Cam Follower Cover (004-002)
Cam Follower Capscrews 40 Nm [ 30 ft-lb ]
Cam Follower Cover Capscrews 40 Nm [ 30 ft-lb ]
Lower Bracket Capscrews 40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
Bracket Capscrews 45 Nm [ 33 ft-lb ]
K38, K50, QSK38, and QSK50 Fuel System Group 05 - Specifications
Ref.No./
Steps
Metric U.S.
.
Fuel System Group 05 - Specifications
Fuel Lift Pump (005-045)
Minimum Fuel Lift Pressure
300 kPa MIN 43.5 psi
Fuel System Group 05 - Torque Values K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Fuel System Group 05 - Torque Values
Fuel Pump (005-016)
Fuel Pump Capscrews 68 Nm [ 50 ft-lb ]
Gerotor Capscrews 19 Nm [ 168 in-lb ]
100 Nm [ 74 ft-lb ]
Fuel Pump Support Bracket 113 Nm [ 83 ft-lb ]
K38, K50, QSK38, and QSK50 Fuel System Group 05
Ref.No./
Steps
Metric U.S.
.
Fuel Pump Mounting Capscrews 117 Nm [ 86 ft-lb ]
Intake Manifold Capscrews 58 Nm [ 40 ft-lb ]
Bracket To Bracket Capscrews (2)
Bracket To Engine Block Capscrews (4)
45 Nm [ 33 ft-lb ]
45 Nm [ 33 ft-lb ]
Capscrew To Camshaft Cover 45 Nm [ 33 ft-lb ]
45 Nm [ 33 ft-lb ]
Fuel Pump Gear Pump Check Valve (005-026)
Fuel Pump Check Valve Elbow Jam Nut 5 to 6
Nm
[ 45 to 50
in-lb ]
Fuel Lift Pump (005-045)
Fuel Lift Pump Mounting Capscrews 15 Nm [ 133 in-lb ]
Supply And Discharge Hoses 54 Nm [ 40 ft-lb ]
Fuel System Group 05 K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
(005-232)
Fuel Pump Pressurizing Capscrews Fuel
Pump Pressurizing Capscrews
8 Nm [ 71 in-lb ]
K38, K50, QSK38, and QSK50 Injectors and Fuel Lines Group 06 - Specifications
Ref.No./
Steps
Metric U.S.
.
Injectors and Fuel Lines Group 06 - Specifications
Fuel Drain Line Restriction (006-012)
Fuel drain line Restriction
With check valve 165 MAX 6.5
Without check valve 65 MAX 2.5
Fuel Inlet Restriction (006-020)
Filter Restriction (Clean)
100 mm
Hg
MAX 4 in Hg
Filter Restriction (Dirty)
200 mm
Hg
MAX 8 in Hg
Stage 1 Filter Restriction (Clean) 76 mm Hg MAX 3 in Hg
Stage 1 Filter Restriction (Dirty)
152 mm
Hg
MAX 6 in Hg
Stage 2 Filter Restriction (Clean Filter) 14 kPa MAX 2.03 psi
Stage 2 Filter Restriction (Dirty Filter)
138 kPa MAX 20 psi
Stage 1 Filter Restriction (Clean) 76 mm Hg MAX 3 in Hg
Stage 1 Filter Restriction (Dirty)
152 mm
Hg
MAX 6 in Hg
Stage 2 Filter Restriction (Clean Filter) 28 kPa MAX 4 psi
Stage 1 Filter Restriction (Dirty Filter)
138 kPa MAX 20 psi
Static Injection Timing (006-025)
Cam Follower Capscrew Torque Value
(Excluding K2000E and K1800E)
39 Nm MIN 29 ft-lb
42 Nm MAX 31 ft-lb
Injectors and Fuel Lines Group 06 - Torque Values K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Injectors and Fuel Lines Group 06 - Torque Values
Air in Fuel (006-003)
Fuel Inlet Hose 120 Nm [ 89 ft-lb ]
Fuel Block (006-007)
Valve Seats 55 Nm [ 40 ft-lb ]
Fuel Block Capscrews 40 Nm [ 30 ft-lb ]
Fuel Connection Block (Manifold-Mounted) (006-010)
Revised Type Fuel Connection Block
Mounting Capscrews
5 Nm [ 45 in-lb ]
Fuel Hoses To Fuel Connection Block 25 Nm [ 20 ft-lb ]
14 Nm [ 125 in-lb ]
5 Nm [ 45 in-lb ]
Old Type Fuel Block To Bracket Capscrews 25 Nm [ 20 ft-lb ]
40 Nm [ 30 ft-lb ]
K38, K50, QSK38, and QSK50 Injectors and Fuel Lines Group 06
Ref.No./
Steps
Metric U.S.
.
Fuel Drain Lines (006-013)
Drain Line Manifold Banjo Capscrews 22 Nm [ 16 ft-lb ]
Fuel Drain Manifold Unions 25 Nm [ 18 ft-lb ]
Drain Manifold Banjo Capscrews 22 Nm [ 16 ft-lb ]
Fuel Drain Manifold Fittings 25 Nm [ 18 ft-lb ]
Fuel Drain Manifold Bracket Capscrews 5 Nm [ 44 in-lb ]
Fuel Drain Line Fittings 45 Nm [ 33 ft-lb ]
Air Bleed Line Banjo Capscrew 30 Nm [ 22 ft-lb ]
45 Nm [ 33 ft-lb ]
Injectors and Fuel Lines Group 06 K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Fuel Drain Line Banjo Capscrews 48 Nm [ 35 ft-lb ]
Fuel Filter Head (006-017)
Fuel Filter Adapter 102 Nm [ 75 ft-lb ]
102 Nm [ 75 ft-lb ]
Sensor And Fitting Adapters 102 Nm [ 75 ft-lb ]
Fuel Inlet And Outlet 62 Nm [ 46 ft-lb ]
Filter Spuds 87 Nm [ 65 ft-lb ]
87 Nm [ 65 ft-lb ]
Fuel Hose Fittings Fuel Hose Fittings 55 Nm [ 41 ft-lb ]
55 Nm [ 41 ft-lb ]
Fuel Filter Head Mounting Nut And
Capscrews
45 Nm [ 33 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Fuel Filter Head Bracket (006-018)
38 Nm [ 28 ft-lb ]
325 Nm [ 240 ft-lb ]
38 Nm [ 28 ft-lb ]
Fuel Manifold (Combined) (006-019)
7 Nm [ 60 in-lb ]
10 Nm [ 85 in-lb ]
Fuel Inlet Restriction (006-020)
Threaded O-Ring Plug Threaded O-Ring
Plug
29 Nm [ 21 ft-lb ]
Fuel System Tester Fuel System Tester
Air Bleed Hose
55 Nm [ 41 ft-lb ]
45 Nm [ 33 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Threaded Hex Head O-Ring Plugs
Threaded Hex Head O-Ring Plugs
27 Nm [ 20 ft-lb ]
Fuel System Tester Fuel System Tester
Air Bleed Hose
55 Nm [ 40 ft-lb ]
45 Nm [ 33 ft-lb ]
Threaded Hex Head O-Ring Plugs 27 Nm [ 20 ft-lb ]
Air Bleed Check Valve
Air Bleed Hose
55 Nm [ 41 ft-lb ]
45 Nm [ 33 ft-lb ]
Fuel Manifold (Drain) (006-021)
Drain Manifold Block Capscrews 45 Nm [ 33 ft-lb ]
Fuel Drain Union 70 Nm [ 52 ft-lb ]
Drain Manifold Block Capscrews 20 Nm [ 177 in-lb ]
Ref.No./
Steps
Metric U.S.
.
Check Valve/Union 55 Nm [ 41 ft-lb ]
Fuel Drain Unions 170 Nm [ 125 ft-lb ]
Fuel Manifold (Supply) (006-022)
M27 Stor Plug
M14 Stor Plug
Fuel Inlet Fitting
Outlet Elbow
45 Nm [ 33 ft-lb ]
35 Nm [ 25 ft-lb ]
95 Nm [ 70 ft-lb ]
95 Nm [ 70 ft-lb ]
Fuel Manifold Capscrew 10 Nm [ 85 in-lb ]
Fuel Pump Capscrew 35 Nm [ 26 ft-lb ]
Fuel Supply Lines (006-024)
Gerotor Pump Actuator Union 100 Nm [ 74 ft-lb ]
Fuel Supply Line 65 Nm [ 48 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Gerotor Pump Outlet Union 100 Nm [ 74 ft-lb ]
9 Nm [ 80 in-lb ]
Tee Fitting Locknut 100 Nm [ 74 ft-lb ]
Fuel Pump Inlet To Actuator Union 170 Nm [ 125 ft-lb ]
Gerotor Fuel Supply Line 91 Nm [ 67 ft-lb ]
Fuel Line From Filter To Gerotor Pump Inlet 91 Nm [ 67 ft-lb ]
Line Clamp Capscrews 9 Nm [ 80 in-lb ]
Ref.No./
Steps
Metric U.S.
.
Flexible Fuel Line 91 Nm [ 67 ft-lb ]
Fuel Supply Lines 91 Nm [ 67 ft-lb ]
Stage Two Capscrews 9 Nm [ 81 in-lb ]
Gerotor Pump Outlet Union 100 Nm [ 74 ft-lb ]
Tee Fitting Locknut 100 Nm [ 74 ft-lb ]
Fuel Pump Inlet To Actuator Union 170 Nm [ 125 ft-lb ]
Gerotor Fuel Supply Line 91 Nm [ 67 ft-lb ]
Fuel Line From Manifold To Gerotor Pump
Tee Fitting
91 Nm [ 67 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Static Injection Timing (006-025)
K2000e And K1800e Cam Follower Shaft
Capscrews
65 Nm [ 50 ft-lb ]
Injector (006-026)
45 Nm [ 33 ft-lb ]
Injector Hold Down Capscrew 75 Nm [ 55 ft-lb ]
Injector Hold-Down Clamp Capscrew 1 68 Nm [ 50 ft-lb ]
2 Loosen capscrew completely.
3 30 Nm [ 22 ft-lb ]
4 Rotate the capscrew 60 degrees.
Single Bank Idle Valve (006-031)
9 Nm [ 80 in-lb ]
9 Nm [ 80 in-lb ]
40 Nm [ 30 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
STC Oil Control Valve (Electrical) (006-036)
9 Nm [ 80 in-lb ]
40 Nm [ 30 ft-lb ]
STC Oil Control Valve (Mechanical) (006-037)
Stc Bracket Capscrews 27 Nm [ 20 ft-lb ]
Sensing, Return, Oil Drain Line 7 Nm [ 60 in-lb ]
27 Nm [ 20 ft-lb ]
STC Oil Manifold (006-038)
7 Nm [ 60 in-lb ]
20 Nm [ 15 ft-lb ]
10 Nm [ 85 ft-lb ]
10 Nm [ 85 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
STC Wiring Harness (006-042)
40 Nm [ 30 ft-lb ]
40 Nm [ 30 ft-lb ]
Injector Supply Lines (High Pressure) (006-051)
Injector Plug 45 Nm [ 33 ft-lb ]
45 Nm [ 33 ft-lb ]
45 Nm [ 33 ft-lb ]
Timing Mark Pointer (006-053)
20 Nm [ 180 in-lb ]
Fuel Pressure Relief Valve (006-061)
Mechanical Dump Valve 135 Nm [ 100 ft-lb ]
K38, K50, QSK38, and QSK50 Lubricating Oil System Group 07 - Specifications
Ref.No./
Steps
Metric U.S.
.
Lubricating Oil System Group 07 - Specifications
Lubricating Oil Filter Head (007-015)
Load (7) 249 N MIN 56.0 lbf
286 N MAX 64.4 lbf
Load (7)
51 N MIN 11.5 lbf
57 N MAX 12.8 lbf
Lubricating Oil Filter Head, Aluminum (007-020)
Pressure Regulator Spring (27) Part
Number 206187
Free Length: 124 MIN 4.88
128 MAX 5.02
Working Height (6): 60.96 NOM 2.40
Pressure Regulator Spring (27) Part
Number 206187
Load (7): 189 MIN 42.5
222 MAX 49.9
Filter Bypass Valve Spring (15) Part
Number 205659
Free Length: 102 MIN 4.03
106 MAX 4.18
Working height (6): 63.5 NOM 2.50
Filter Bypass Valve Spring (15) Part
Number 205659
Load (7): 249 MIN 56.0
286 MAX 64.4
Piston Cooling Regulator Valve Spring
(10) Part Number 205349
Free Length: 60.7 MIN 2.39
64.5 MAX 2.54
Working height (6): 44.4 NOM 1.75
Piston Cooling Regulator Valve Spring
(10) Part Number 205349
Load (7): 51 MIN 11.5
57 MAX 12.8
Lubricating Oil High Pressure Relief Valve (007-021)
K38 High Pressure Relief Valve Spring
182.6 MAX 7.19
Load (7): 729 MIN 164
164 MAX 192
94.7 MAX 3.73
Load (7): 391 MIN 88
463 MAX 104
Lubricating Oil System Group 07 K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Lubricating Oil Pump (007-031)
K38 Oil Pump Drive Gear End Clearance
0.10 mm MIN 0.004 in
0.18 mm MAX 0.007 in
K50 High Speed Oil Pump Drive Gear End
Clearance
0.10 mm MIN 0.004 in
0.18 mm MAX 0.007 in
K50 and QSK50 Low Speed Oil Pump
Compound Gear End Clearance
0.20 mm MIN 0.008 in
0.81 mm MAX 0.032 in
Compound Gear to Drive Gear Backlash
0.15 mm MIN 0.006 in
0.25 mm MAX 0.010 in
K50 and QSK50 Low Speed Oil Pump Drive
Shaft End Clearance
0.114 mm MIN 0.0045 in
0.216 mm MAX 0.0085 in
Oil Pump Bushing Inside Diameter 38.164 mm MIN 1.5025 in
38.227 mm MAX 1.5050 in
Oil Pump Shaft Outside Diameter
38.082 mm MIN 1.4993 in
38.100 mm MAX 1.5000 in
K38, K50, QSK38, and QSK50 Lubricating Oil System Group 07
Ref.No./
Steps
Metric U.S.
.
Oil Pump Drive Gear Inside Diameter 38.031 mm MIN 1.4973 in
38.057 mm MAX 1.4983 in
K38 Oil Pump Drive Gear End Clearance 0.10 mm MIN 0.004 in
0.18 mm MAX 0.007 in
K50 High Speed Oil Pump Drive Gear End
Clearance
0.10 mm MIN 0.004 in
0.18 mm MAX 0.007 in
Compound Gear End Clearance
0.20 mm MIN 0.008 in
0.81 mm MAX 0.032 in
Compound Gear to Drive Gear Backlash
0.15 mm MIN 0.006 in
0.25 mm MAX 0.010 in
K50 and QSK50 Low Speed Oil Pump Drive
Shaft End Clearance
0.114 mm MIN 0.0045 in
0.216 mm MAX 0.0085 in
Lubricating Pump-to-Rear Crankshaft Gear
Backlash
0.08 mm MIN 0.003 in
0.30 mm MAX 0.012 in
Lubricating Oil System Group 07 - Torque Values K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Lubricating Oil System Group 07 - Torque Values
Lubricating Oil Filter Head (007-015)
Filter Adapter 95 Nm [ 70 ft-lb ]
200 Nm [ 148 ft-lb ]
Pipe Or Restrictor Plug 20 Nm [ 15 ft-lb ]
Spring Stop Capscrew 47 Nm [ 35 ft-lb ]
Cover Plate Capscrews 41 Nm [ 30 ft-lb ]
Retainer Capscrew 47 Nm [ 35 ft-lb ]
Cover Plate Capscrews 47 Nm [ 35 ft-lb ]
20 Nm [ 177 in-lb ]
Threaded Plug 122 Nm [ 90 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Straight Thread Plugs 20 Nm [ 177 in-lb ]
Lubrication Oil Filter Head Mounting
Capscrews
40 Nm [ 30 ft-lb ]
Lubrication Oil Filter Head Mounting
Capscrews
47 Nm [ 35 ft-lb ]
Lubricating Oil Filter Head (Remote-Mounted) (007-017)
200 Nm [ 150 ft-lb ]
45 Nm [ 35 ft-lb ]
Lubricating Oil Filter Head, Aluminum (007-020)
27 Nm [ 20 ft-lb ]
27 Nm [ 20 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
27 Nm [ 20 ft-lb ]
34 Nm [ 25 ft-lb ]
Rectangular Ring Seal Capscrew 47 Nm [ 35 ft-lb ]
Lubricating Oil Pan (007-025)
Adapter Plate Capscrews
Oil Pan Drain Plugs
45 Nm [ 33 ft-lb ]
45 Nm [ 33 ft-lb ]
Lubricating Oil Pan Adapter (007-027)
60 Nm [ 45 ft-lb ]
Lubricating Oil Pressure Regulator (Main Rifle) (007-029)
25 Nm [ 18 ft-lb ]
40 Nm [ 30 ft-lb ]
Lubricating Oil Pump (007-031)
68 Nm [ 50 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Compound Idler Gear Capscrew 169 Nm [ 125 ft-lb ]
40 Nm [ 30 ft-lb ]
47 Nm [ 35 ft-lb ]
Lubricating Oil Pump Capscrews 95 Nm [ 70 ft-lb ]
Lubricating Oil Suction Tube (Block-Mounted) (007-035)
41 Nm [ 30 ft-lb ]
41 Nm [ 30 ft-lb ]
61 Nm [ 45 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
41 Nm [ 30 ft-lb ]
41 Nm [ 30 ft-lb ]
Lubricating Oil Temperature Gauge (007-038)
Oil Pan Plug 47 Nm [ 35 ft-lb ]
Lubricating Oil Cooler Cover (007-045)
Steel Lock Washers
Copper Flat Washers
Oil Cooler Lock Nuts
40 Nm [ 30 ft-lb ]
35 Nm [ 25 ft-lb ]
95 Nm [ 70 ft-lb ]
Pre-Lubricating Oil Pump (007-063)
Prelub High-Volume Pump Bracket
Capscrews M12
Prelub High-Volume Pump Bracket
Capscrews M10
80 Nm [ 59 ft-lb ]
78 Nm [ 58 ft-lb ]
Prelub High-Volume Pump U-Shaped
Bracket Capscrews
30 Nm [ 22 ft-lb ]
74 Nm [ 55 ft-lb ]
163 Nm [ 120 ft-lb ]
45 Nm [ 33 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
190 Nm [ 140 ft-lb ]
45 Nm [ 33 ft-lb ]
Eliminator Filter (007-067)
Eliminator Filtering Unit Distributor Cover
Capscrews
35 Nm [ 26 ft-lb ]
25 Nm [ 18 ft-lb ]
Eliminator Filter Head Capscrews 35 Nm [ 26 ft-lb ]
Eliminator Internal And External Flange
Assembly Plugs
20 Nm [ 177 in-lb ]
25 Nm [ 18 ft-lb ]
5 Nm [ 44 in-lb ]
Ref.No./
Steps
Metric U.S.
.
Hydraulic Motor Capscrews 25 Nm [ 18 ft-lb ]
Hydraulic Motor Return Pipe Banjo Screw 40 Nm [ 30 ft-lb ]
Eliminator Cover Capscrews 25 Nm [ 18 ft-lb ]
Eliminator Filter Bracket Capscrews 67 Nm [ 50 ft-lb ]
Eliminator Hand Hole Cover Capscrews 40 Nm [ 30 ft-lb ]
Eliminator Mounting Capscrews 40 Nm [ 30 ft-lb ]
40 Nm [ 30 ft-lb ]
Eliminator Pipe Plugs 10 Nm [ 96 in-lb ]
K38, K50, QSK38, and QSK50 Cooling System Group 08 - Specifications
Ref.No./
Steps
Metric U.S.
.
Cooling System Group 08 - Specifications
Engine Thermostat Initial Opening
Temperature
82.2 C MIN 180 F
94.4 C MAX 202 F
LTA Thermostat Initial Opening Temperature
73.8 C MIN 165 F
86.1 C MAX 187 F
Fan Drive Idler Arm Assembly (008-029)
38.087 mm MIN 1.4995 in
38.113 mm MAX 1.5005 in
0.03 mm MIN 0.001 in
0.15 mm MAX 0.006 in
Bearing End Clearance 0.025 mm MIN 0.001 in
0.150 mm MAX 0.006 in
Sea Water Pump Impeller Side Clearance
0.18 mm MIN 0.007 in
0.23 mm MAX 0.009 in
Water Pump Shaft Outside Diameter
(Bearing Area)
30.010 mm MIN 1.1816 in
30.020 mm MAX 1.1820 in
Water Pump Shaft Outside Diameter
(Impeller End)
24.999 mm MIN 0.9842 in
25.009 mm MAX 0.9846 in
Water Pump Impeller Inside Diameter (17) 24.919 mm MIN 0.9811 in
24.945 mm MAX 0.9821 in
Water Pump Impeller Bore Inside Diameter
(17)
24.932 mm MIN 0.9816 in
24.958 mm MAX 0.9826 in
Cooling System Group 08 K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
K38 and K50 Water Pump Body Bore
Inside Diameter
Water Seal (21) 53.60 MIN 2.110
54.10 MAX 2.130
Oil Seal (22) 38.05 MIN 1.498
38.10 MAX 1.500
Water Seal (23) 61.997 MIN 2.4408
62.009 MAX 2.4412
Oil Seal (24) 71.996 MIN 2.8345
72.012 MAX 2.8351
K38, K50, QSK38, and QSK50 Cooling System Group 08 - Torque Values
Ref.No./
Steps
Metric U.S.
.
Cooling System Group 08 - Torque Values
Belt Guard (008-001)
Vibration Guard Capscrews 25 Nm [ 18 ft-lb ]
Rear Guard Housing Capscrews
Auxiliary Drive Guard Capscrews
40 Nm [ 30 ft-lb ]
15 Nm [ 133 in-lb ]
Drive Belt, Cooling Fan (008-002)
Fan Idler Capscrew 45 Nm [ 35 ft-lb ]
Upper And Lower Control Rod Capscrew 90 Nm [ 65 ft-lb ]
Upper Control Rod Capscrew 60 Nm [ 45 ft-lb ]
60 Nm [ 45 ft-lb ]
Shock Absorber Capscrews 60 Nm [ 45 ft-lb ]
Adjusting Capscrew 285 Nm [ 210 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Coolant Bypass Tube (008-005)
Thermostat Support Capscrews 40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
Upper Flange Capscrews Upper Flange
Capscrews
38 Nm [ 28 ft-lb ]
Lower Flange Capscrews Lower Flange
Capscrews
28 Nm [ 20 ft-lb ]
U-Bolts U-Bolts 21 Nm [ 186 in-lb ]
Straub Coupling Straub Coupling 30 Nm [ 22 ft-lb ]
Thermostat Housing 45 Nm [ 33 ft-lb ]
Radiator Hose Clamps 6 Nm [ 50 in-lb ]
K38, K50, QSK38, and QSK50 Cooling System Group 08
Ref.No./
Steps
Metric U.S.
.
Lta Thermostat Housing 45 Nm [ 33 ft-lb ]
6 Nm [ 50 in-lb ]
Lta Capscrews 45 Nm [ 33 ft-lb ]
Lta Thermostat Housing 45 Nm [ 33 ft-lb ]
Straub Couplings 28 Nm [ 21 ft-lb ]
6 Nm [ 50 in-lb ]
Thermostat Housing Capscrews 40 Nm [ 30 ft-lb ]
Coolant Thermostat Housing Support (008-015)
Water Outlet Capscrews Water Outlet
Capscrews
Transfer Tube Capscrews Transfer Tube
Capscrews
38 Nm [ 28 ft-lb ]
11 Nm [ 97 in-lb ]
Lta Thermostat Housing Capscrews Lta
Thermostat Housing Capscrews
38 Nm [ 28 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Lta Thermostat Cover Capscrews Lta
Thermostat Cover Capscrews
60 Nm [ 44 ft-lb ]
Left Bank Transfer Tube Capscrews Left
Bank Transfer Tube Capscrews
22 Nm [ 16 ft-lb ]
Right Bank Transfer Tube Capscrews Right
Bank Transfer Tube Capscrews
22 Nm [ 16 ft-lb ]
Hose Clamps Hose Clamps 8 Nm [ 71 in-lb ]
Upper Half Transfer Tube Capscrews
Upper Half Transfer Tube Capscrews
11 Nm [ 97 in-lb ]
Retaining Clamps Retaining Clamps 38 Nm [ 28 ft-lb ]
Upper Flange Capscrews Upper Flange
Capscrews
38 Nm [ 28 ft-lb ]
Bypass Tube U-Bolts Bypass Tube U-Bolts 22 Nm [ 16 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Straub Coupling Straub Coupling 30 Nm [ 22 ft-lb ]
Fan Drive Idler Arm Assembly (008-029)
203 Nm [ 150 ft-lb ]
Pulley Assembly Capscrews 47 Nm [ 35 ft-lb ]
Fan Belt Idler Assembly Capscrew 60 Nm [ 45 ft-lb ]
Fan Hub Bracket (008-035)
366 Nm [ 270 ft-lb ]
365 Nm [ 270 ft-lb ]
Fan Hub Pipe Plugs 15 Nm [ 133 in-lb ]
Ref.No./
Steps
Metric U.S.
.
Fan Hub Locknut 610 Nm [ 450 ft-lb ]
Fan Hub Capscrews 20 Nm [ 177 in-lb ]
Fan Hub Capscrews 280 Nm [ 207 ft-lb ]
Fan, Cooling (008-040)
135 Nm [ 100 ft-lb ]
Expansion Tank (008-052)
Expansion Tank Capscrews 40 Nm [ 30 ft-lb ]
Expansion Tank Capscrews 40 Nm [ 30 ft-lb ]
61 Nm [ 45 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
61 Nm [ 45 ft-lb ]
54 Nm [ 40 ft-lb ]
Guide Pin Bolts 256 Nm [ 190 ft-lb ]
Shield Capscrews 9 Nm [ 80 in-lb ]
Tighten All 8 Top Bolts 256 Nm [ 190 ft-lb ]
Bracket Capscrew 31 Nm [ 23 ft-lb ]
16 Nm [ 144 in-lb ]
75 Nm [ 55 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
16 Nm [ 144 in-lb ]
25 Nm [ 20 ft-lb ]
55 Nm [ 40 ft-lb ]
55 Nm [ 40 ft-lb ]
27 Nm [ 20 ft-lb ]
135 Nm [ 100 ft-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 50 in-lb ]
Ref.No./
Steps
Metric U.S.
.
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
40 Nm [ 30 ft-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
20 Nm [ 15 ft-lb ]
40 Nm [ 30 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 50 in-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
40 Nm [ 30 ft-lb ]
5 Nm [ 44 in-lb ]
Bolts, Lower Bracket 35 Nm [ 25 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Bolts
Clips
78 Nm [ 57 ft-lb ]
17 Nm [ 144 in-lb ]
Bolts, Jacket Water Manifold 31 Nm [ 23 ft-lb ]
31 Nm [ 23 ft-lb ]
31 Nm [ 23 ft-lb ]
365 Nm [ 270 ft-lb ]
16 Nm [ 144 in-lb ]
16 Nm [ 144 in-lb ]
25 Nm [ 20 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
55 Nm [ 40 ft-lb ]
55 Nm [ 40 ft-lb ]
25 Nm [ 20 ft-lb ]
30 Nm [ 22 ft-lb ]
Lockplates And Nuts 34 Nm [ 25 ft-lb ]
Pump Impeller Nut Requiring 1.250 Inch
Wrench
160 Nm [ 120 ft-lb ]
110 Nm [ 80 ft-lb ]
Vee Band Clamp 20 Nm [ 15 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Seal Collar Locknut 50 Nm [ 37 ft-lb ]
Impeller And Distance Ring Retaining
Screws
5 Nm [ 44 in-lb ]
Sea Water Pump Impeller 175 Nm [ 129 ft-lb ]
Suction Bend And Pump Assembly Screws 25 Nm [ 221 in-lb ]
Sea Water Pump Mounting Capscrews 75 Nm [ 55 ft-lb ]
Sea Water Pump Support (008-058)
30 Nm [ 20 ft-lb ]
60 Nm [ 45 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Tube Nuts 35 Nm [ 25 ft-lb ]
Support Bracket Capscrews 60 Nm [ 45 ft-lb ]
Water Manifold (008-061)
34 Nm [ 25 ft-lb ]
Drive Key And Self-Locking Capscsrew 20 Nm [ 177 in-lb ]
Water Pump Capscrews 47 Nm [ 35 ft-lb ]
Water Pump Support Bracket Capscrews 41 Nm [ 30 ft-lb ]
15 Nm [ 135 in-lb ]
Fuel Pump To Pump Drive Capscrews 60 Nm [ 45 ft-lb ]
40 Nm [ 30 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Water Pump Inlet Housing Capscrews 40 Nm [ 30 ft-lb ]
60 Nm [ 45 ft-lb ]
Bypass Connection Capsrews 40 Nm [ 30 ft-lb ]
45 Nm [ 35 ft-lb ]
5.6 Nm [ 50 in-lb ]
Water Pump Mounting Capscrews 80 Nm [ 59 ft-lb ]
Jacket Water Inlet Capscrews 45 Nm [ 33 ft-lb ]
Jacket Water Radiator Inlet Capscrews 45 Nm [ 33 ft-lb ]
Low Temperature Aftercooler Bypass Pipe
Clamp Capscrews
45 Nm [ 33 ft-lb ]
Bypass Pipe Capscrews 45 Nm [ 33 ft-lb ]
28 Nm [ 21 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
U Clamps Nuts 45 Nm [ 33 ft-lb ]
ECM Cooling Plate (008-128)
Coolant Return Tee 25 Nm [ 18 ft-lb ]
Coolant Supply Elbow 25 Nm [ 18 ft-lb ]
Ecm Mounting Studs 80 Nm [ 59 ft-lb ]
Ecm Cooling Plate Nuts 23 Nm [ 17 ft-lb ]
ECM Cooling Plate Lines (008-130)
Coolant Adapters 15 Nm [ 133 in-lb ]
Male Connectors 15 Nm [ 133 in-lb ]
Ref.No./
Steps
Metric U.S.
.
Supply And Return Colant Line Nuts 15 Nm [ 133 in-lb ]
Coolant Line Brackets 45 Nm [ 33 ft-lb ]
Bracket Capacrews 45 Nm [ 33 ft-lb ]
Drive Units Group 09 - Specifications K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Drive Units Group 09 - Specifications
Accessory Shaft End Clearance
0.05 mm MIN 0.002 in
0.30 mm MAX 0.012 in
Accessory Drive Bushing Inside Diameter
49.95 mm MIN 1.967 in
50.03 mm MAX 1.970 in
Accessory Drive Busing Thrust Face
Distance
45.370 mm MIN 1.786 in
45.450 mm MAX 1.789 in
Accessory Drive Lovejoy Coupling Inside
Diameter
25.377 mm MIN 0.999 in
25.407 mm MAX 1.000 in
Accessory Drive Spline Coupling Inside
Diameter
25.255 mm MIN 0.994 in
25.278 mm MAX 0.996 in
Accessory Drive Bushing Bore Inside
Diameter
60.00 mm MIN 2.362 in
60.05 mm MAX 2.364 in
Accessory Drive Shaft Outside Diameter
Measurements
(1) 34.964 MIN 1.376
34.976 MAX 1.377
(2) 43.928 MIN 1.729
43.940 MAX 1.730
(3) 44.370 MIN 1.747
44.630 MAX 1.757
(4) 45.070 MIN 1.774
45.082 MAX 1.775
(5) 49.820 MIN 1.961
49.832 MAX 1.962
(6) 25.424 MIN 1.001
25.436 MAX 1.001
K38, K50, QSK38, and QSK50 Drive Units Group 09
Ref.No./
Steps
Metric U.S.
.
Accessory Drive Gear Inside Diameter 44.98 mm MIN 1.771 in
45.02 mm MAX 1.772 in
Accessory Drive Gear to Shaft Distance 0.05 mm MAX 0.002 in
Accessory Drive Shaft End Clearance
0.05 mm MIN 0.002 in
0.30 mm MAX 0.012 in
Accessory Drive End Clearance
0.13 mm MIN 0.005 in
0.29 mm MAX 0.011 in
Accessory Drive Bushing (009-002)
Housing Inside Diameter 36.73 mm MIN 1.446 in
36.75 mm MAX 1.447 in
Housing Inside Diameter 39.61 mm MIN 1.559 in
39.64 mm MAX 1.561 in
Accessory Drive Gear and Shaft (009-003)
Gear Inside Diameter 39.73 mm MIN 1.564 in
39.75 mm MAX 1.565 in
Drive Units Group 09 K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
39.802 mm MAX 1.5670 in
Accessory Drive Pulley (009-004)
Accessory Drive Pulley Inside Diameter
34.912 mm MIN 1.3745 in
34.938 mm MAX 1.3755 in
Alternator Drive Pulley Inside Diameter 35.00 mm MIN 1.378 in
35.03 mm MAX 1.379 in
Fuel Pump Shaft End Clearance 0.14 mm MIN 0.006 in
0.27 mm MAX 0.011 in
Fuel Pump Drive Bushing Inside Diameter 49.95 mm MIN 1.967 in
50.03 mm MAX 1.970 in
Fuel Pump Drive Busing Thrust Face
Distance
45.370 mm MIN 1.786 in
45.450 mm MAX 1.789 in
Fuel Pump Drive End Clearance. 0.05 mm MIN 0.002 in
0.30 mm MAX 0.012 in
Ref.No./
Steps
Metric U.S.
.
Fuel Pump Drive Spline Coupling Inside
Diameter
25.255 mm MIN 0.994 in
25.278 mm MAX 0.996 in
Fuel Pump Drive Bushing Bore Inside
Diameter
60.00 mm MIN 2.362 in
60.05 mm MAX 2.364 in
Fuel Pump Drive Shaft Outside Diameter
Measurements
(1) 34.964 MIN 1.376
34.976 MAX 1.377
(2) 39.662 MIN 1.561
39.740 MAX 1.564
(3) 39.789 MIN 1.566
39.801 MAX 1.567
(4) 49.820 MIN 1.961
49.832 MAX 1.962
Fuel Pump Drive Gear Inside Diameter
39.725 mm MIN 1.564 in
39.751 mm MAX 1.565 in
Fuel Pump Drive Gear to Shaft Distance 0.05 mm MAX 0.002 in
Fuel Pump Drive Shaft End Clearance 0.05 mm MIN 0.002 in
0.30 mm MAX 0.012 in
0.05 mm MAX 0.002 in
Ref.No./
Steps
Metric U.S.
.
Fuel Pump Drive Shaft End Clearance 0.14 mm MIN 0.006 in
0.27 mm MAX 0.011 in
Fuel Pump Drive End Clearance 0.14 mm MIN 0.006 in
0.27 mm MAX 0.011 in
Hydraulic Pump Drive Bushing Inside
Diameter
38.13 mm MIN 1.501 in
38.25 mm MAX 1.506 in
2.273 mm MIN 0.0895 in
2.299 mm MAX 0.0905 in
Shaft Outside Diameter (1) 38.062 mm MIN 1.4985 in
38.075 mm MAX 1.4990 in
50.749 mm MIN 1.9980 in
50.762 mm MAX 1.9985 in
Hydraulic Pump Bushing Inside Diameter 50.813 mm MIN 2.0005 in
50.902 mm MAX 2.0040 in
End Clearance
0.10 mm MIN 0.004 in
0.48 mm MAX 0.019 in
Ref.No./
Steps
Metric U.S.
.
Hydraulic Pump Drive Gear and Shaft (009-019)
Hydraulic Pump Drive Gear Inside Diameter
44.399 mm MIN 1.7480 in
44.425 mm MAX 1.7490 in
Hydraulic Pump Drive Shaft Outside
Diameter
44.450 mm MIN 1.7500 in
44.463 mm MAX 1.7505 in
Gear Backlash 0.08 mm MIN 0.003 in
0.30 mm MAX 0.012 in
Gear End Clearance 0.10 mm MIN 0.004 in
0.25 mm MAX 0.010 in
63.513 mm MAX 2.5005 in
Gear Bushing Inside Diameter 63.564 mm MIN 2.5025 in
63.627 mm MAX 2.5050 in
2.41 mm MAX 0.095 in
Ref.No./
Steps
Metric U.S.
.
Cylinder Block Side Bore Inside Diameter 63.411 mm MIN 2.4965 in
63.449 mm MAX 2.4980 in
Rear Seal Side Bore Inside Diameter 63.513 mm MIN 2.5005 in
63.538 mm MAX 2.5015 in
Gear End Clearance
0.10 mm MIN 0.004 in
0.25 mm MAX 0.010 in
Gear Lash
0.08 mm MIN 0.003 in
0.30 mm MAX 0.012 in
Gear Lash 0.08 mm MIN 0.003 in
0.30 mm MAX 0.012 in
Gear End Clearance 0.10 mm MIN 0.004 in
0.25 mm MAX 0.010 in
63.55 mm MIN 2.502 in
63.63 mm MAX 2.505 in
Ref.No./
Steps
Metric U.S.
.
Support Bushing Inside Diameter 63.55 mm MIN 2.502 in
63.63 mm MAX 2.505 in
63.513 mm MAX 2.5005 in
Shaft Protrusion
85.47 mm MIN 3.365 in
85.98 mm MAX 3.385 in
2.36 mm MIN 0.093 in
2.41 mm MAX 0.095 in
Gear Lash
0.08 mm MIN 0.003 in
0.30 mm MAX 0.012 in
Shaft End Clearance
0.10 mm MIN 0.004 in
0.25 mm MAX 0.010 in
Rear Gear Drive Gear and Shaft (Upper Assembly) (009-028)
Gear Step Outside Diameter
63.627 mm MIN 2.5050 in
63.640 mm MAX 2.5055 in
Ref.No./
Steps
Metric U.S.
.
Gear or Adapter Bore Inside Diameter 63.53 mm MIN 2.501 in
63.55 mm MAX 2.502 in
Shaft Protrusion 85.47 mm MIN 3.365 in
85.98 mm MAX 3.385 in
Water Pump Drive Bushing (009-030)
Housing Bore Inside Diameter 47.63 mm MIN 1.875 in
47.65 mm MAX 1.876 in
44.48 mm MIN 1.751 in
44.58 mm MAX 1.755 in
Water Pump Drive Gear and Shaft (009-031)
39.776 mm MIN 1.5660 in
39.802 mm MAX 1.5670 in
Gear Inside Diameter 39.726 mm MIN 1.5640 in
39.751 mm MAX 1.5650 in
0.05 mm MIN 0.002 in
0.10 mm MAX 0.004 in
Ref.No./
Steps
Metric U.S.
.
Seal Bore Inside Diameter (14) 57.12 mm MIN 2.249 in
57.18 mm MAX 2.251 in
Bearing Bore Inside Diameter (15)
61.991 mm MIN 2.4406 in
62.017 mm MAX 2.4416 in
34.976 mm MAX 1.3770 in
25.257 mm MIN 1.0050 in
25.540 mm MAX 1.0055 in
25.009 mm MAX 0.9846 in
20.676 mm MAX 0.8140 in
Governor Drive Gear Inside Diameter 24.971 mm MIN 0.9831 in
24.986 mm MAX 0.9837 in
Jaw Coupling Hub Bore Inside Diameter 20.625 mm MIN 0.8120 in
20.638 mm MAX 0.8125 in
End Clearance 0.05 mm MIN 0.002 in
0.10 mm MAX 0.004 in
Drive Units Group 09 - Torque Values K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Drive Units Group 09 - Torque Values
Accessory Drive Housing Pipe Plug 8 Nm [ 75 in-lb ]
Accessory Drive Coupling Capscrew 9.525
Mm [0.375 In] Capscrew Length
Accessory Drive Coupling Capscrew 12.7
45 Nm [ 35 ft-lb ]
100 Nm [ 75 ft-lb ]
Accessory Drive Mounting Capscrews 45 Nm [ 33 ft-lb ]
Fuel Pump Drive Housing Pipe Plug 8 Nm [ 75 in-lb ]
Fuel Pump Drive Coupling Capscrew 9.525
Fuel Pump Drive Coupling Capscrew 12.7
45 Nm [ 35 ft-lb ]
100 Nm [ 75 ft-lb ]
Straight Thread Plug 6 Nm [ 55 in-lb ]
60 Nm [ 40 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Fuel Pump Drive Mounting Capscrews 45 Nm [ 33 ft-lb ]
27 Nm [ 20 ft-lb ]
Hydraulic Pump Drive Capscrews 60 Nm [ 44 ft-lb ]
Rear Gear Drive Lower Assembly
Capscrews
90 Nm [ 65 ft-lb ]
Rear Gear Drive Lower Unit Cover Plate
Capscrews
60 Nm [ 45 ft-lb ]
20 Nm [ 15 ft-lb ]
41 Nm [ 30 ft-lb ]
163 Nm [ 120 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
68 Nm [ 50 ft-lb ]
68 Nm [ 50 ft-lb ]
47 Nm [ 35 ft-lb ]
47 Nm [ 35 ft-lb ]
47 Nm [ 35 ft-lb ]
90 Nm [ 65 ft-lb ]
90 Nm [ 60 ft-lb ]
41 Nm [ 30 ft-lb ]
K38, K50, QSK38, and QSK50 Air Intake System Group 10 - Specifications
Ref.No./
Steps
Metric U.S.
.
Air Intake System Group 10 - Specifications
Air Intake Restriction (010-031)
Vacuum Gauge or Water Manometer
Restrictions
635 mm
H
2
O
MAX 25 in H
2
O
Holset HC5, HC5A, HX80 or HX85 End
Clearance
0.05 mm MIN 0.002 in
0.13 mm MAX 0.005 in
Holset HC5, HC5A, HX80 or HX85
Compressor Impeller Radial Clearance
0.15 mm MIN 0.006 in
0.46 mm MAX 0.018 in
Holset HC5, HC5A, HX80 or HX85 Turbine
Wheel Radial Clearance
0.20 mm MIN 0.008 in
0.53 mm MAX 0.021 in
Holset HT100 End Clearance 0.05 mm MIN 0.002 in
0.15 mm MAX 0.006 in
Holset HT100 Compressor Impeller Radial
Clearance
0.25 mm MIN 0.010 in
0.46 mm MAX 0.018 in
Holset HT100 Turbine Wheel Radial
Clearance
0.38 mm MIN 0.015 in
0.53 mm MAX 0.021 in
AiResearch T-18A Impeller and Turbine
0.08 mm MIN 0.003 in
0.18 mm MAX 0.007 in
AiResearch T-18A Bearing Radial
Clearance
0.20 mm MIN 0.008 in
0.46 mm MAX 0.018 in
Turbocharger Axial Clearance (010-038)
Holset HX5 - Axial Clearance
0.05 mm MIN 0.002 in
0.13 mm MAX 0.005 in
Air Intake System Group 10 K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Holset HX5 - Compressor Impeller Radial
Clearance
0.15 mm MIN 0.006 in
0.46 mm MAX 0.018 in
Holset HX5 - Turbine Wheel Radial
Clearance
0.20 mm MIN 0.008 in
0.53 mm MAX 0.021 in
BBC (RR-151) and (RR-153) End Clearance
0.09 mm MIN 0.004 in
0.13 mm MAX 0.005 in
BBC (RR-151) and (RR-153) Bearing
Radial Clearance
RR-153 0.55 MAX 0.021
RR-151 0.75 MAX 0.030
AiResearch T-18A End Clearance
0.10 mm MIN 0.004 in
0.23 mm MAX 0.009 in
Turbocharger Radial Bearing Clearance (010-047)
AiResearch T-18A Impeller and Turbine
0.08 mm MIN 0.003 in
0.18 mm MAX 0.007 in
K38, K50, QSK38, and QSK50 Air Intake System Group 10 - Torque Values
Ref.No./
Steps
Metric U.S.
.
Air Intake System Group 10 - Torque Values
Aftercooler Assembly (010-002)
25 Nm [ 20 ft-lb ]
25 Nm [ 20 ft-lb ]
25 Nm [ 20 ft-lb ]
25 Nm [ 20 ft-lb ]
25 Nm [ 20 ft-lb ]
25 Nm [ 20 ft-lb ]
25 Nm [ 20 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
16 Nm [ 145 in-lb ]
Air Intake Manifold Capscrews 45 Nm [ 35 ft-lb ]
45 Nm [ 33 ft-lb ]
30 Nm [ 22 ft-lb ]
60 Nm [ 45 ft-lb ]
25 Nm [ 20 ft-lb ]
40 Nm [ 30 ft-lb ]
9 Nm [ 80 in-lb ]
40 Nm [ 30 ft-lb ]
25 Nm [ 20 ft-lb ]
K38, K50, QSK38, and QSK50 Air Intake System Group 10
Ref.No./
Steps
Metric U.S.
.
Aftercooler Assembly Capscrew 1 25 Nm [ 20 ft-lb ]
2 45 Nm [ 35 ft-lb ]
25 Nm [ 20 ft-lb ]
9 Nm [ 80 in-lb ]
9 Nm [ 80 in-lb ]
6 Nm [ 140 in-lb ]
25 Nm [ 20 ft-lb ]
9 Nm [ 80 in-lb ]
9 Nm [ 80 in-lb ]
9 Nm [ 80 in-lb ]
8 Nm [ 70 in-lb ]
5 Nm [ 50 in-lb ]
25 Nm [ 20 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
45 Nm [ 35 ft-lb ]
25 Nm [ 20 ft-lb ]
8 Nm [ 70 in-lb ]
8 Nm [ 70 in-lb ]
40 Nm [ 30 ft-lb ]
8 Nm [ 70 in-lb ]
9 Nm [ 80 in-lb ]
9 Nm [ 80 in-lb ]
8 Nm [ 70 in-lb ]
Ref.No./
Steps
Metric U.S.
.
45 Nm [ 35 ft-lb ]
Cast Iron Housing Capscrews Cast Iron
Housing Capscrews
Aluminum Housing Capscrews Aluminum
Housing Capscrews
Coolant Connection Clamps Coolant
Connection Clamps
65 Nm [ 48 ft-lb ]
53 Nm [ 39 ft-lb ]
5 Nm [ 44 in-lb ]
Turbocharger Outlet And Air Crossover
Hose Clamps
9 Nm [ 80 in-lb ]
45 Nm [ 35 ft-lb ]
142 Nm [ 105 ft-lb ]
Transfer Tube Hose Clamps 11 Nm [ 96 in-lb ]
Aftercooler Assembly (Center-Mount) (010-003)
25 Nm [ 20 ft-lb ]
25 Nm [ 20 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
25 Nm [ 20 ft-lb ]
25 Nm [ 20 ft-lb ]
25 Nm [ 20 ft-lb ]
60 Nm [ 45 ft-lb ]
25 Nm [ 20 ft-lb ]
40 Nm [ 30 ft-lb ]
9 Nm [ 80 in-lb ]
40 Nm [ 30 ft-lb ]
25 Nm [ 20 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Aftercooler Assembly (Outboard) (010-004)
45 Nm [ 35 ft-lb ]
Aftercooler Element (010-008)
25 Nm [ 20 ft-lb ]
25 Nm [ 20 ft-lb ]
45 Nm [ 35 ft-lb ]
25 Nm [ 20 ft-lb ]
Air Cleaner Assembly (Engine-Mounted) (010-013)
Main Support Bracket 40 Nm [ 30 ft-lb ]
Vibration Isolator Nuts 20 Nm [ 177 in-lb ]
Ref.No./
Steps
Metric U.S.
.
Support Bracket Capscrews 41 to 47
Nm
[ 30 to 35
ft-lb ]
Air Cleaner Straps 40 Nm [ 30 ft-lb ]
Air Inlet Tubing 10 Nm [ 96 in-lb ]
Air Leaks, Air Intake and Exhaust Systems (010-024)
Intake Air System Hose Clamps 8 Nm [ 71 in-lb ]
Intake Air System Capscrews 20 Nm [ 15 ft-lb ]
Turbocharger V-Band Clamps 8 Nm [ 71 in-lb ]
Turbocharger Lock Plate 20.3 Nm [ 180 in-lb ]
Ref.No./
Steps
Metric U.S.
.
Turbocharger Vee-Band Clamp 12 Nm [ 106 in-lb ]
K38
K50
9 Nm [ 80 in-lb ]
15 Nm [ 133 in-lb ]
Capscrews 16 Nm [ 142 in-lb ]
Flange Capscrews 40 Nm [ 30 ft-lb ]
Turbocharger Capscrews 40 Nm [ 30 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Flange Capscrews 40 Nm [ 30 ft-lb ]
Turbocharger Support Capscrews 270 Nm [ 199 ft-lb ]
Bracket To Supports 90 Nm [ 66 ft-lb ]
Connection To Bracket 90 Nm [ 66 ft-lb ]
Turbocharger Connection 40 Nm [ 30 ft-lb ]
Vee-Band Clamp 7 Nm [ 62 in-lb ]
Ref.No./
Steps
Metric U.S.
.
T-Bolt Clamps 9 Nm [ 80 in-lb ]
Capscrews
Flange Capscrews
40 Nm [ 30 ft-lb ]
40 Nm [ 30 ft-lb ]
Exhaust Outlet Connection Capscrews 40 Nm [ 30 ft-lb ]
Bracket To Supports 90 Nm [ 66 ft-lb ]
Exhaust Outlet Connection To Bracket 90 Nm [ 66 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Air Intake Connection To Bracket 40 Nm [ 30 ft-lb ]
Exhaust Connection Capscrews 90 Nm [ 66 ft-lb ]
Vee-Band Clamp 7 Nm [ 62 in-lb ]
T-Bolt Clamps 7 Nm [ 62 in-lb ]
Oil Inlet Capscrew
Fitting Torque
40 Nm [ 30 ft-lb ]
35 Nm [ 26 ft-lb ]
Oil Drain Capscrews
Oil Drain Flange Capscrews
40 Nm [ 30 ft-lb ]
40 Nm [ 30 ft-lb ]
Turbocharger Mounting Capscrews 40 Nm [ 30 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Oil Inlet Capscrews 40 Nm [ 30 ft-lb ]
Exhaust Outlet Capscrews 40 Nm [ 30 ft-lb ]
Air Intake Connection Capscrews 40 Nm [ 30 ft-lb ]
Air Inlet Connection Capscrews 40 Nm [ 30 ft-lb ]
Bracket Connection Capscrews 40 Nm [ 30 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Exhaust Connection Capscrews
Exhaust Outlet Connection Capscrews
95 Nm [ 70 ft-lb ]
40 Nm [ 30 ft-lb ]
Exhaust Outlet Connections 95 Nm [ 70 ft-lb ]
Vee-Band 9 Nm [ 80 in-lb ]
Intake Pipe Capscrews 40 Nm [ 30 ft-lb ]
Intake Pipe Clamps 8 Nm [ 71 in-lb ]
Low Pressure Turbocharger Oil Inlet
Oil Inlet Fitting
25 Nm [ 18 ft-lb ]
35 Nm [ 26 ft-lb ]
Turbocharger Oil Drain
Hose Flange
25 Nm [ 18 ft-lb ]
40 Nm [ 30 ft-lb ]
Turbocharger Mounting Capscrews And
Nuts
45 Nm [ 33 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Exhaust Connection Capscrews And Nuts 95 Nm [ 70 ft-lb ]
Air Intake Connection Capscrews And Nuts
Interstage Hose Clamp
48 Nm [ 35 ft-lb ]
8 Nm [ 71 in-lb ]
Air Intake Capscrews 48 Nm [ 35 ft-lb ]
Exhaust Adapter Capscrews 48 Nm [ 36 ft-lb ]
Turbocharger, Water-Cooled (010-037)
V-Band Clamp 1 20 Nm [ 177 in-lb ]
2 Loosen 2 to 3 turns
3 18 to 20
Nm
[ 160 to
177 in-lb ]
Ref.No./
Steps
Metric U.S.
.
Turbocharger Capscrews Turbocharger
Capscrews
136 Nm [ 100 ft-lb ]
Turbocharger To Center Section Mounting
Capscrews Turbocharger To Center
Section Mounting Capscrews
102 to 115
Nm
[ 75 to 85
ft-lb ]
43 to 47
Nm
[ 32 to 35
ft-lb ]
20 Nm [ 180 in-lb ]
22 Nm [ 16 ft-lb ]
11 Nm [ 97 in-lb ]
Turbocharger Capscrews Turbocharger
Capscrews
136 Nm [ 100 ft-lb ]
Turbocharger To Center Section Mounting
Capscrews Turbocharger To Center
Section Mounting Capscrews
102 to 115
Nm
[ 75 to 85
ft-lb ]
43 to 47
Nm
[ 32 to 35
ft-lb ]
20 Nm [ 180 in-lb ]
22 Nm [ 16 ft-lb ]
11 Nm [ 97 in-lb ]
Ref.No./
Steps
Metric U.S.
.
Turbocharger Coolant Hoses (010-041)
Water And Turbocharger Fittings 57 Nm [ 42 ft-lb ]
Turbocharger Supply Line Fittings 54 Nm [ 40 ft-lb ]
Thermostat Housing And Turbocharger
Fittings
57 Nm [ 42 ft-lb ]
Turbocharger Drain Line Fittings 54 Nm [ 40 ft-lb ]
Bracket Capscrews 9 Nm [ 80 in-lb ]
Elbow Fittings 57 Nm [ 42 ft-lb ]
Coolant Supply And Return Hoses 54 Nm [ 40 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Turbocharger Oil Drain Line (010-045)
Turbocharger Drain Tube Capscrews 45 Nm [ 33 ft-lb ]
40 Nm [ 30 ft-lb ]
Turbocharger Drain Tube P-Clips 40 Nm [ 30 ft-lb ]
High Pressureturbocharger Drain Tube
Capscrews
45 Nm [ 33 ft-lb ]
40 Nm [ 30 ft-lb ]
Turbocharger Drain Tube P-Clips 40 Nm [ 30 ft-lb ]
Low Pressureturbocharger Drain Tube
Capscrews
45 Nm [ 33 ft-lb ]
40 Nm [ 30 ft-lb ]
Turbocharger Oil Supply Line (010-046)
Oil Supply Tube Fitting To Turbocharger Oil
Supply Tube Fitting To Turbocharger
35 Nm [ 26 ft-lb ]
Oil Supply Tube Fitting To Male Union Oil
Supply Tube Fitting To Male Union
35 Nm [ 26 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
P-Clip To Cylinder Head Capscrews P-Clip
To Cylinder Head Capscrews
P-Clip To Injector Cover Plate Capscrews P-
Clip To Injector Cover Plate Capscrews
20 Nm [ 15 ft-lb ]
42 Nm [ 31 ft-lb ]
35 Nm [ 26 ft-lb ]
35 Nm [ 26 ft-lb ]
P-Clip To Cylinder Head Capscrews P-Clip
To Cylinder Head Capscrews
P-Clip To Injector Cover Plate Capscrews P-
Clip To Injector Cover Plate Capscrews
20 Nm [ 15 ft-lb ]
42 Nm [ 31 ft-lb ]
35 Nm [ 26 ft-lb ]
35 Nm [ 26 ft-lb ]
P-Clip To Cylinder Head Capscrews
P-Clip To Injector Cover Plate Capscrews
20 Nm [ 15 ft-lb ]
42 Nm [ 31 ft-lb ]
Turbocharger Oil Supply Tubes 38 Nm [ 28 ft-lb ]
Ref.No./
Steps
Metric U.S.
.
Oil Supply Tubes Male Union Turbocharger 24 to 27
Nm
[ 18 to 20
ft-lb ]
Male Union Oil Supply Tubes 24 to 27
Nm
[ 18 to 20
ft-lb ]
Aftercooler Housing (Center Mount) (010-073)
27 Nm [ 20 ft-lb ]
102 Nm [ 75 ft-lb ]
K38, K50, QSK38, and QSK50 Exhaust System Group 11 - Torque Values
Ref.No./
Steps
Metric U.S.
.
Exhaust System Group 11 - Torque Values
Exhaust Connection Pipe (011-001)
Exhaust Connection Pipe To Support
Bracket Capscrews
45 Nm [ 33 ft-lb ]
Exhaust Connection Pipe To Exhaust
Bellows Capscrews
195 Nm [ 140 ft-lb ]
Exhaust Manifold, Dry (011-007)
Kt38 And Kta38 Dry Exhaust Manifold 38
Mm [1.5 In] Capscrews 38 Mm [1.5 In]
Capscrew
Kt38 And Kta38 Dry Exhaust Manifold 76
Mm [3.0 In] Capscrews 76 Mm [3 In]
Capscrew With N Stamped On Head
76 Mm [3 In] Capscrew Without N Stamped
On Head
60 Nm [ 44 ft-lb ]
55 Nm [ 41 ft-lb ]
80 Nm [ 59 ft-lb ]
Ktta38 Dry Exhaust Manifold Capscrews 55 Nm [ 41 ft-lb ]
Kt38 And Kta38 Dry Exhaust Manifold (With
Center Mount Turbochargers) Capscrews
55 Nm [ 41 ft-lb ]
Kta50 Dry Exhaust Manifold 140 Mm [5.5 In]
(With 140 Mm [5.5 In] Capscrew With N
Stamped On Head
(Without 140 Mm [5.5 In] And 38 Mm [1.5 In]
Capscrews Without N Stamped On Head
55 Nm [ 41 ft-lb ]
80 Nm [ 59 ft-lb ]
(With 140 Mm [5.5 In] Capscrew With N
Stamped On Head
(Without 140 Mm [5.5 In] And 38 Mm [1.5 In]
Capscrews Without N Stamped On Head
55 Nm [ 41 ft-lb ]
80 Nm [ 59 ft-lb ]
Exhaust System Group 11 K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
55 Nm [ 41 ft-lb ]
54 Nm [ 40 ft-lb ]
54 Nm [ 40 ft-lb ]
Tighten The Marine Application V-Band
Clamp
Tighten The Industrial Application V-Band
Clamp
17 Nm [ 150 in-lb ]
5 Nm [ 44 in-lb ]
Exhaust Manifold, Wet (011-008)
54 to 61
Nm
[ 40 to 45
ft-lb ]
20 Nm [ 177 in-lb ]
8 Nm [ 71 in-lb ]
Exhaust Manifold (Wet) Water Connections (011-016)
20 Nm [ 177 in-lb ]
40 Nm [ 30 ft-lb ]
20 Nm [ 177 in-lb ]
20 Nm [ 177 in-lb ]
K38, K50, QSK38, and QSK50 Exhaust System Group 11
Ref.No./
Steps
Metric U.S.
.
20 Nm [ 177 in-lb ]
Bellows (011-018)
136 Nm [ 100 ft-lb ]
Compressed Air System Group 12 - Specifications K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Compressed Air System Group 12 - Specifications
End Clearance
0.04 mm MIN 0.0015 in
0.24 mm MAX 0.0095 in
K38, K50, QSK38, and QSK50 Compressed Air System Group 12 - Torque Values
Ref.No./
Steps
Metric U.S.
.
Compressed Air System Group 12 - Torque Values
Air Compressor Unloader and Valve Assembly (012-013)
Holset Ss, E-Type, And St Unloader
Capscrews
14 Nm [ 120 in-lb ]
Holset Qe Unloader Capscrew 27 Nm [ 20 ft-lb ]
60 Nm [ 45 ft-lb ]
40 Nm [ 30 ft-lb ]
60 Nm [ 45 ft-lb ]
6 Nm [ 50 in-lb ]
Electrical Equipment Group 13 - Torque Values K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Electrical Equipment Group 13 - Torque Values
Alternator (013-001)
Alternator Pully Mounting Nut 100 Nm [ 75 ft-lb ]
Alternator Brace Capscrews 90 Nm [ 65 ft-lb ]
Belt Guard Capscrews 45 Nm [ 35 ft-lb ]
Alternator Bracket (013-003)
90 Nm [ 66 ft-lb ]
Starting Motor (013-020)
Cast Iron Flywheel Housing Cast Iron
Flywheel Housing
Aluminium Flywheel Housing Aluminium
Flywheel Housing
215 Nm [ 160 ft-lb ]
195 Nm [ 145 ft-lb ]
Alternator Adjusting Link (013-022)
Nut 1 Nut 1
Nut 2 Nut 2
Nut 3 Nut 3
95 Nm [ 70 ft-lb ]
70 Nm [ 55 ft-lb ]
95 Nm [ 70 ft-lb ]
K38, K50, QSK38, and QSK50 Engine Testing Group 14 - Specifications
Ref.No./
Steps
Metric U.S.
.
Engine Testing Group 14 - Specifications
Engine Testing (Chassis Dynamometer) (014-002)
Engine Blowby 10-mm [0.406-in] Orifice
rpm = All ratings
New/Rebuilt Engine 127 MAX 5
Used Engine 330 MAX 13
Low Idle (Minimum Allowable) 138 MAX 20
At 1200 rpm (Minimum Allowable) 207 MAX 30
Engine Testing (Engine Dynamometer) (014-005)
Low Idle 138 MIN 20
Rated rpm 413 MIN 60
Coolant Pressure 241 kPa MAX 35 psi
Engine Run-in (Engine Dynamometer) (014-006)
Main Oil Rifle Pressure (at Idle) 138 kPa MIN 20 psi
138 kPa MIN 20 psi
138 kPa MIN 20 psi
483 kPa MAX 70 psi
Engine Testing Group 14 - Torque Values K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Engine Testing Group 14 - Torque Values
Engine Testing (Engine Dynamometer) (014-005)
60 Nm [ 44 ft-lb ]
48 Nm [ 35 ft-lb ]
Engine Run-in (Engine Dynamometer) (014-006)
54 Nm [ 40 ft-lb ]
Engine Compression (014-012)
Injector Hold Down 54 Nm [ 40 ft-lb ]
K38, K50, QSK38, and QSK50 Mounting Adaptations Group 16 - Specifications
Ref.No./
Steps
Metric U.S.
.
Mounting Adaptations Group 16 - Specifications
Engine Support Bracket, Front (016-002)
Front Support Bore Diameter
210.03 mm MIN 8.269 in
210.08 mm MAX 8.271 in
Front Support Bore
210.03 mm MIN 8.269 in
210.08 mm MAX 8.271 in
Mounting Adaptations Group 16 - Torque Values K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Mounting Adaptations Group 16 - Torque Values
Engine Lifting Brackets (016-001)
Lifting Bracket Capscrew 270 Nm [ 200 ft-lb ]
Engine Support Bracket, Front (016-002)
300 Nm [ 220 ft-lb ]
300 Nm [ 200 ft-lb ]
Flexplate (016-004)
Flexplate Assembly Capscrews 290 Nm [ 215 ft-lb ]
Flexplate Mounting Capscrews 1 150 Nm [ 110 ft-lb ]
2 285 Nm [ 210 ft-lb ]
3 515 Nm [ 380 ft-lb ]
Flywheel (016-005)
Flywheel Mounting Capscrews 1 150 Nm [ 110 ft-lb ]
2 285 Nm [ 210 ft-lb ]
3 515 Nm [ 380 ft-lb ]
Flywheel Housing (016-006)
Flywheel Housing Capscrew 1 102 Nm [ 75 ft-lb ]
2 203 Nm [ 150 ft-lb ]
3 366 Nm [ 270 ft-lb ]
K38, K50, QSK38, and QSK50 Mounting Adaptations Group 16
Ref.No./
Steps
Metric U.S.
.
Flywheel Housing Capscrews 366 Nm [ 270 ft-lb ]
Flywheel Housing Capscrews 7/16-14 In
Capscrews
Flywheel Housing Capscrews 3/4-10 In
Capscrews
90 Nm [ 66 ft-lb ]
366 Nm [ 270 ft-lb ]
Front Support Capscrews 298 Nm [ 220 ft-lb ]
Main Power Generator Group 21 - Torque Values K38, K50, QSK38, and QSK50
Ref.No./
Steps
Metric U.S.
.
Main Power Generator Group 21 - Torque Values
Bearing, Generator (021-027)
End Bracket Capscrews 60 Nm [ 45 ft-lb ]
Bearing Cartridge Capscrews 45 Nm [ 35 ft-lb ]
Permanent Magnet Generator (021-030)
Center Rotor Retaining Capscrew 20 to 27
Nm
[ 15 to 20
ft-lb ]
Permanent Magnet Exciter Stator
Capscrews
20 to 27
Nm
[ 15 to 20
ft-lb ]
Generator Rotor (021-031)
End Bracket Capscrews 60 Nm [ 45 ft-lb ]
Bearing Cartridge Capscrews 45 Nm [ 35 ft-lb ]
K38, K50, QSK38, and QSK50 General Engine
General Engine
General Specifications
Listed below are general specifications for the KTA38 and QSK38 engines. Additional specifications can be found in
each system section.
Engine Type
KTA38 ...........................................................................................................4 cycle, 60 degree vee, 12 cylinder
QSK38...........................................................................................................4 cycle, 60 degree vee, 12 cylinder
Bore and Stroke................................................................................................159 mm [6.25 in] x 159 mm [6.25 in]
Displacement............................................................................................................................37.7 liters [2301 in
3
]
Aspiration..................................................................................................................Turbocharged and Aftercooled
Engine Weight (dry, estimated):
KTA38-C...................................................................................................................................3719 kg [8199 lb]
KTA38-G...................................................................................................................................4201 kg [9261 lb]
KTA38-M...................................................................................................................................4218 kg [9299 lb]
Crankshaft Rotation (viewed from the front of the engine)..........................................................................Clockwise
Firing Order KTA38.......................................................................................1R-6L-5R-2L-3R-4L-6R-1L-2R-5L-4R-3L
Firing Order QSK38 Electronic Reference..........................................................................2-11-10-3-6-7-12-1-4-9-8-5
Compression Ratio:..........................................................................................................................13.5:1 to 15.5:1
Valve and Injector Settings:
Exhaust..................................................................................................................................0.69 mm [0.027 in]
Intake.....................................................................................................................................0.36 mm [0.014 in]
Listed below are general specifications for the KTA50, QSK50 and QSK50 CM850 engines. Additional specifications
can be found in each system section.
Engine Type
KTA50 ...........................................................................................................4 cycle, 60 degree vee, 16 cylinder
QSK50...........................................................................................................4 cycle, 60 degree vee, 16 cylinder
Bore and Stroke................................................................................................159 mm [6.25 in] x 159 mm [6.25 in]
Displacement............................................................................................................................50.3 liters [3068 in
3
]
Aspiration..................................................................................................................Turbocharged and Aftercooled
Engine Weight (dry, estimated):
KTA50-C................................................................................................................................4853 kg [10,700 lb]
KTA50-G................................................................................................................................5361 kg [11,820 lb]
KTA50-M................................................................................................................................5431 kg [11,973 lb]
QSK50, Generator Set Single-Stage with electronically actuated injectors...............................5620 kg [12,390 lb]
QSK50, Industrial Two-Stage with electronically actuated injectors.........................................6050 kg [13,338 lb]
Crankshaft Rotation (viewed from the front of the engine)..........................................................................Clockwise
Firing Order
Pre-September 1986............................................................1R-1L-3R-3L-7R-7L-5R-5L-8R-8L-6R-6L-2R-2L-4R-4L
After September 1986..........................................................1R-1L-3R-3L-2R-2L-5R-4L-8R-8L-6R-6L-7R-7L-4R-5L
QSK50 Electronic Reference.....................................................................2-1-6-5-4-3-10-7-16-15-12-11-14-13-8-9
Compression Ratio
with mechanically actuated injectors............................................................................................13.5:1 to 15.5:1
with electronically actuated injectors (all applications).................................................................................15.0:1
Valve and Injector Settings:
Exhaust.................................................................................................................................0.069 mm [0.027 in]
Intake.....................................................................................................................................0.36 mm [0.014 in]
Maximum Overspeed Capacity...................................................................................................................2150 rpm
Maximum allowable installed engine power angle........................................................................................6 degree
Maximum allowable installed engine tilt angle.............................................................................................6 degree
NOTE: Injector settings are not required for engines with electronically actuated injectors.
General Engine K38, K50, QSK38, and QSK50
This illustration illustrates the cylinder numbering
sequence for the KTA38 and QSK38 engines.
RB = Right-bank of cylinders
LB = Left-bank of cylinders.
To determine the right and left bank on the KTA38 and
QSK38 engines, stand at the rear of the engine and face
the front.
When referencing system electronics, a standard cylinder
numbering system has been adopted. This is only used
for the electronic system components on engines with
electronically actuated injectors.
This graphic illustrates the intake and exhaust valve
locations for the KTA38 engine.
This graphic illustrates the cylinder numbering sequence
for the KTA50 engine.
RB = Right-bank of cylinders
LB = Left-bank of cylinders.
This graphic illustrates the intake and exhaust valve
locations for the KTA50 engine.
K38, K50, QSK38, and QSK50 Fuel System
Fuel System
Specifications
Typical fuel filter restriction:
Clean fuel filter:.....................................................................................................................26 mm-Hg [1 in-Hg]
Typical fuel filter restriction:
Maximum fuel supply restriction at fuel pump inlet:
With clean fuel filter element(s) at maximum fuel flow.....................................................127 mm-Hg [5 in-Hg]
Typical fuel filter restriction
Maximum fuel supply restriction at fuel pump inlet:
With dirty fuel filter element(s) at maximum fuel flow.......................................................229 mm-Hg [9 in-Hg]
Maximum fuel drain restriction:
Before (or without) check valve..........................................................................................254 mm-Hg [10 in-Hg]
Maximum fuel inlet temperature:..........................................................................................................71C [160F]
Minimum fuel tank venting rate:.............................................................................................0.472 L/s [60 ft 3/hour]
Engine Idle Speed.............................................................................................................................650 to 725 rpm
.................................................................................................................................................................................
Maximum Fuel Inlet Restriction (at rated power)
Clean Fuel Filter...............................................................................................................102 mm-Hg [4.0 in-Hg]
Maximum Fuel Inlet Restriction (at rated power)
Dirty Fuel Filter.................................................................................................................203 mm-Hg [8.0 in-Hg]
Maximum Fuel Drain Line Restriction (at high idle, no load)
No Check Valves................................................................................................................64 mm-Hg [2.5 in-Hg]
Check Valves....................................................................................................................165 mm-Hg [6.5 in-Hg]
Fuel Check Valve between Fuel Filter and Fuel Pump
Minimum Opening Pressure........................................................................................................2.1 kPa [0.3 psi]
Fuel Check Valve between Fuel Pump and Cylinder Head
Opening Pressure...........................................................................................................21 to 55 kPa [3 to 8 psi]
Fuel Check Valve in Fuel Drain Line
Opening Pressure................................................................................................13 to 25 mm-Hg [1/4 to 1/2 psi]
Minimum Engine Cranking Speed................................................................................................................150 rpm
Minimum Fuel Tank Air Venting Capability
With 64 mm-Hg [2.5 in-Hg] or less fuel drain restriction................................................425 liter/hr [15 cubic ft/hr]
Derate Engine Fuel Rate for High Altitude............................4 percent per 300 m [1000 ft] above 3600 m [12,000 ft].
Derate Engine Fuel Rate for Hot Weather..........2 percent per 11C above 38C [1 percent per 10F above 100F].
Shutoff Valve Solenoid Coil Resistance
12 VDC............................................................................................................................................6 to 10 ohms
24 VDC..........................................................................................................................................26 to 40 ohms
Lubricating Oil System K38, K50, QSK38, and QSK50
Lubricating Oil System
Specifications
Lubricating Oil Pressure, Main Oil Rifle (15W-40 oil at 107C [225F]):
Maximum at rated rpm................................................................................................................483 kPa [70 psi]
Minimum at rated rpm.................................................................................................................310 kPa [40 psi]
Minimum at idle rpm...................................................................................................................138 kPa [20 psi]
Maximum oil pressure spike on a cold engine..........................................................................1655 kPa [240 psi]
Maximum lubricating oil flow to all accessories...................................................................57 liters/min [15 gpm]
Lubricating Oil Temperature - Maximum in Sump...............................................................................121C [250F]
K38 Lubricating Oil Pan Capacity
Center (one piece casting) Sump
Low Level................................................................................................................................87 liter [23 gal]
High Level.............................................................................................................................114 liter [30 gal]
Subbase Sump
Low Level..............................................................................................................................129 liter [34 gal]
Front, Center, Rear Sump
Front, Center, Rear (deep) Sump
Subbase
Front and Front-Center, Rear and Rear-Center (deep) Sump
Rear-Center and Front-Center Sump
Front and Front-Center, Rear and Rear-Center Sump
Maximum Oil Consumption....................................................................................................0.47 liter/hr [0.50 qt/hr]
Lubricating Oil Temperature - Maximum in Sump...............................................................................110C [230F]
Lubricating Oil Pan Capacity
High Level..................................................................................................................................185 liter [49 gal]
Low Level...................................................................................................................................129 liter [34 gal]
Cooling System
Specifications
Coolant Capacity (engine only)
KT38......................................................................................................................................104 liters [27.5 gal]
KTA38....................................................................................................................................118 liters [32.7 gal]
KTA Marine (with heat exchanger).............................................................................................155 liters [41 gal]
KTA Industrial and Generator.................................................................................................161 liters [42.5 gal]
KTA50 Marine...........................................................................................................................197 liters [52 gal]
KTA50 Marine (with heat exchanger).........................................................................................227 liters [60 gal]
NOTE: Maximum allowable draw down at 20 percent of system capacity (whichever is greater).
KT38, KTA38................................................................................................................................21 liters [22 qt]
KTTA38........................................................................................................................................23 liters [24 qt]
KTA50..........................................................................................................................................26 liters [28 qt]
KTTA50, K2000.............................................................................................................................29 liters [31 qt]
Engine Thermostat.......................................................................................................82 to 94C [180 to 202F]
Low Temperature Aftercooler Thermostat Range
....................................................................................................................................66 to 79C [150 to 175F]
Top Tank Coolant Temperature (maximum)
Standby Power-Generation................................................................................................................104 [220]
Prime Power-Generation...............................................................................................................100C [212F]
Marine............................................................................................................................................96C [205F]
Industrial.........................................................................................................................................95C [203F]
Top Tank Coolant Temperature (maximum)
Standby Power-Generation............................................................................................................104C [212F]
Prime Power-Generation...............................................................................................................100C [212F]
Marine............................................................................................................................................96C [205F]
Industrial.........................................................................................................................................95C [203F]
Top Tank Coolant Temperature (minimum)..........................................................................................70C [160C]
Maximum Coolant Pressure
Without Pressure Cap
KT38, KTA38, KTTA38................................................................................................................241 kPa [35 psi]
KTA50........................................................................................................................................283 kPa [41 psi]
KTTA50, K2000...........................................................................................................................345 kPa [50 psi]
With Pressure Cap (minimum)
Marine........................................................................................................................................103 kPa [15 psi]
Non-Marine.....................................................................................................................................48 kPa [7 psi]
Coolant Expansion Volume
Percentage of system capacity (minimum).............................................................................................5 percent
Engine Coolant Circuit
Cooling System Type.................................................................................................................2 Pump - 2 Loop
Minimum Operating Block Coolant Temperature.............................................................................71C [160F]
Minimum Fill Rate........................................................................................................................19 L/m [5 gpm]
Maximum Initial Fill Time....................................................................................................................40 Minutes
Minimum Water Pump Inlet Pressure with Fully Deaerating Cooling System..............................34 kPa [10 in-Hg]
Maximum Static Head of Coolant Above Crankshaft Centerline.......................................................18.3 m [60 ft]
Minimum Pressure Cap Rating at Sea Level.................................................................................76 kPa [11 psi]
Maximum Pressure Cap Rating at Sea Level...............................................................................103 kPa [15 psi]
Minimum Coolant Expansion space (percentage of total cooling system capacity)..................................6 percent
Coolant Capacity - Engine only...............................................................................................140 liters [147.9 qt]
Coolant Capacity - Low Temperature Aftercooler........................................................................30 liters [31.7 qt]
Maximum Recommended External Coolant Flow Restriction in Engine Circuit............................82.7 kPa [12 psi]
Engine Coolant Circuit Thermostat Opening Temperature...............................................................82C [180F]
Engine Coolant Circuit Thermostat Fully Open Temperature...........................................................94C [202F]
Maximum Allowable Deaeration Time.................................................................................................25 minutes
Acceptable types of deaeration systems.....................................................................................Fully Deaerating
Maximum Drawdown (percentage of total cooling system capacity)......................................................11 percent
Low Temperature Aftercooler (LTA) Circuit
Low Temperature Aftercooler Circuit Thermostat Opening Temperature..........................................46C [115F]
Low Temperature Aftercooler Circuit Thermostat Fully Open Temperature......................................57C [135F]
Maximum Recommended External Coolant Restriction in LTA Circuit (1P-2L or 2P-2L)...............82.7 kPa [12 psi]
K38, K50, QSK38, and QSK50 Air Intake System
Air Intake System
Specifications
Maximum Intake Air Restriction (heavy duty air cleaner)
Dirty Filter....................................................................................................................63.5 cm-H
2
O [25 in-H
2
O]
Maximum Intake Air Restriction (heavy duty air cleaner)
Clean Filter................................................................................................................30.48 cm-H
2
O [12 in-H
2
O]
Minimum Dirt Holding Capacity With Heavy Duty Air Cleaner......................................................................25 g/cfm
Recommended Intake Piping Size (inside diameter) - QSK50 With Electronically Actuated Injectors.....15.2 cm [6 in]
Exhaust System K38, K50, QSK38, and QSK50
Exhaust System
Specifications
Maximum allowable back pressure imposed by piping and silencer..........................................75 mm-Hg [3.0 in-Hg]
Exhaust Restriction at Rated Power (maximum)
KTA38-G3/G4/G5, KTA50-G1/G2, Industrial (except K2000E), and Marine...........................76 mm Hg [3.0 in Hg]
KTA38-G6/G7 and KTA50-G3/G6/G7/G8/G9........................................................................51 mm Hg [2.0 in Hg]
Industrial (K2000E).............................................................................................................38 mm Hg [1.5 in Hg]
Normal exhaust pipe diameter
KT(A)38, KTTA38, KTA50............................................................................................................152 mm [6 inch]
KTTA50......................................................................................................................................203 mm [8 inch]
K38, K50, QSK38, and QSK50 Electrical System
Electrical System
Specifications
Battery capacity (minimum recommended cold cranking amps):
K38 Generator-Drive
Ambient Temperature.............................................................................................................Above 10C [50F]
Cold Cranking Amperes...............................................................................................................................1200
Ambient Temperature.............................................................................................Above 0 to 10C [32 to 50F]
Ambient Temperature..............................................................................................Above 0 to 32C [-18 to 0F]
K50 Generator-Drive
Ambient Temperature.............................................................................................................Above 10C [50F]
Ambient Temperature.............................................................................................Above 0 to 10C [32 to 50F]
Ambient Temperature..............................................................................................Above 0 to 32C [-18 to 0F]
K38 and K50 Industrial
Ambient Temperature..............................................................................................................Above -18C [0F]
K38 and K50 Marine
Ambient Temperature..............................................................................................................Above -18C [0F]
Cold cranking amphere ratings are based on two 12VDC batteries in series.
Battery Cable Sizes - American Wire Gauge (maximum length in starting circuit)
Number 00 6.1 m [20 ft]
Number 000 8.2 m [27 ft]
Number 0000 or two Number 0 (see note) 10.7 m [35 ft]
Two Number 00 13.7 m [45 ft]
NOTE: Two strands of number 0 cable can be used instead or one number 0000 cable, provided all connections are
carefully made to maintain equal current flow in each parallel cable.
Reserve Capacity 640 minutes
Minimum Cranking Speed Without Starting Aids 150 rpm
Starting Circuit Resistance (maximum) 0.002 ohms
Batteries (Specific Gravity)
Battery State of Charge Specific Gravity (at 27C [80F])
100 % 1.260 to 1.280
75% 1.230 to 1.250
50% 1.200 to 1.220
25% 1.170 to 1.190
DISCHARGED 1.110 to 1.130
Compressed Air System K38, K50, QSK38, and QSK50
Compressed Air System
Specifications
The following specifications are for a upright two-cylinder air compressor.
Cylinders................................................................................................................................................................2
Compressor Capacity (at 1250 rpm).........................................................................14.2 liter [30.00 cfm] per second
Piston Displacement...................................................................................................................676 cc [41.3 C.I.D.]
Bore...........................................................................................................................................92.08 mm [3.625 in]
Stroke.................................................................................................................................................50.8 mm [2 in]
Speed..................................................................................................................................................Engine speed
Cooling..............................................................................................................................................Engine coolant
Lubrication...............................................................................................................................Engine lubricating oil
Plumbing Line Sizes:
Coolant Inlet and Outlet (pipe fitting)..........................................................................................[0.3750 in NPTF]
Air Inlet (inside diameter).......................................................................................................22.22 mm [0.875 in]
Air Outlet (minimum inside diameter).....................................................................................15.88 mm [0.625 in]
Height, Overall (approximate)..........................................................................................................34.3 cm [13.5 in]
Width, Overall (approximate)............................................................................................................... 17.8 cm [7 in]
Length, Overall (approximate).......................................................................................................28.7 cm [11.30 in]
Weight (approximate)...................................................................................................................... 33.5 kg [74.5 lb]
The following specifications are for a tilted two-cylinder air compressor.
Cylinders................................................................................................................................................................2
Compressor Capacity (at 1250 rpm).........................................................................16.1 liter [34.00 cfm] per second
Piston Displacement...................................................................................................................773 cc [47.2 C.I.D.]
Bore.......................................................................................................................................... 98.43 mm [3.875 in]
Stroke................................................................................................................................................ 50.8 mm [2 in]
Speed................................................................................................................................................. Engine speed
Cooling............................................................................................................................................. Engine coolant
Lubrication.............................................................................................................................. Engine lubricating oil
Plumbing Line Sizes:
Coolant Inlet and Outlet (pipe fitting)..........................................................................................[0.3750 in NPTF]
Air Inlet (inside diameter).......................................................................................................22.22 mm [0.875 in]
Air Outlet (minimum inside diameter).........................................................................................12.7 mm [0.50 in]
Height, Overall (approximate)........................................................................................................40.1 cm [15.80 in]
Width, Overall (approximate)........................................................................................................ 27.3 cm [10.75 in]
Length, Overall (approximate).......................................................................................................28.7 cm [11.30 in]
Weight (approximate).......................................................................................................................36.3 kg [80.0 lb]
K38, K50, QSK38, and QSK50 Cummins/Fleetguard Filter Specifications
Cummins/Fleetguard Filter Specifications
Specifications
Fleetguard/Nelson is a subsidiary of Cummins Inc. Fleetguard/Nelson filters are developed through joint testing at
Cummins Inc. and Fleetguard/Nelson. Fleetguard/Nelson filters are standard on new Cummins engines. Cummins
Inc. recommends their use.
Fleetguard/Nelson products meet all Cummins Source Approval Test standards to provide the quality filtration
necessary to achieve the engine's design life. If other brands are substituted, the purchaser should insist on products
that the supplier has tested to meet Cummins Inc. high-quality standards.
Cummins Inc. can not be responsible for problems caused by non-genuine filters that do not meet Cummins Inc.
performance or durability requirements.
Filter Type Cummins Part Number Fleetguard Part Number
Lubricating Oil (full-flow) 3889310 LF670
3310169 LF3325
3313305 LF3363
3313305 LF3363
Lubricating Oil (bypass) 3889311 LF777
Lubricating Oil (venturi combo without
Centinel)
3101870 LF9024
Lubricating Oil (venturi combo for use
with Centinel)
4197219 LF9034
Fuel Filter (20 micron, water
separation)
3313306 FF202
Fuel Filter (10 micron, water
separation)
3089916 FS1006
Fuel Filter, Stage 2 (3 micron) with
electronically Actuated Injector
4964100 FF5634
Fuel and Water Seperator, Statge 1 (7
micron) with electronically Actuated
Injector
FS19763
Coolant Filter 4058964 WF2073
The following table(s) contain information about Fleetguard coolant filters service intervals and liquid precharge:
Standard Service Interval Fleetguard Filter Part Numbers
SCA Units Diesel Coolant Additive2
(Fleetcool)
Diesel Coolant Additive4
2 WF2050 WF2070
4 WF2051 WF2071
6 WF2052 WF2072
8 WF2053 WF2073
12 None WF2074
15 WF2054 WF2075
23 WF2055 WF2076
Chemical Free WF2077 WF2077
Standard Service Interval Fleetguard Liquid Additive Part Numbers
SCA Units Amount Diesel Coolant Additive2
(Fleetcool)
5 0.47 liter [1 pt] DCA30L DCA60L
Cummins/Fleetguard Filter Specifications K38, K50, QSK38, and QSK50
Standard Service Interval Fleetguard Liquid Additive Part Numbers
SCA Units Amount Diesel Coolant Additive2
(Fleetcool)
20 1.89 liter [2 qt] DCA35L DCA65L
40 3.78 liter [1 gal] DCA40L DCA70L
200 18.9 liter [5 gal] DCA45L DCA75L
2200 208 liter [55 gal] DCA50L DCA80L
Extended Service Fleetguard Filter Part Numbers
SCA Units Extended Service Filter Notes
15 WF2121 Slow Release
Chemical Free WF2122 Normal duty
Chemical Free WF2123 Severe Duty (40-percent more media
than WF2122)
Note: Extended Service Filters are designed for use with Extended Service Compleat.
Extended Service Fleetguard Liquid Additive Part Numbers
SCA Units Amount Extended Service Extender Liquid
8.4 0.47 liter [1 pt] CC2843
16.8 0.95 liter [1 qt] CC2840
3696 208 liter [55 gal] CC2841
K38, K50, QSK38, and QSK50 Fuel Recommendations and Specifications
Fuel Recommendations and Specifications
General Information
WARNING
Do not mix gasoline, alcohol, or gasohol with diesel fuel. This mixture can cause an explosion.
Cummins Inc. recommends the use of ASTM number 2 diesel fuel. The use of number 2 diesel fuel will result in
optimum engine performance. At operating temperatures below 0C [32F], acceptable performance can be obtained
by using blends of number 2D and number 1D. The use of lighter fuels can reduce fuel economy.
The viscosity of the fuel must 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 Engines, Bulletin 3379001. See Procedure
205-001 (Additional Service Literature) in Section L for ordering information.
Lubricating Oil Recommendations and Specifications K38, K50, QSK38, and QSK50
Lubricating Oil Recommendations and Specifications
General Information
The use of quality engine lubricating oils combined with appropriate oil drain and filter change intervals are a critical
factor in maintaining engine performance and durability.
Cummins Inc., recommends the use of a high quality SAE 15W-40, low ash engine oil for natural gas engines.
The specifications for oils meeting Cummins recommended SAE 15W-40 oil blends are as follows:
Cummins Inc., Oil Recommendations
Viscosity 15W-40
API CG Quality
Neutralization No (TBN) 5/5.5
Calcium (ppm) 1200
Phosphorus (ppm) 250-350 ppm
Zinc (ppm) 250-350 ppm
Sulfated Ash (%W) 0.4/0.5
TAN (ASTM D664) 0.5/0.7
CAUTION
A sulfated ash limit of 0.5 percent has been placed on all stationary engine lubricating oil recommended for
use in Cummins natural gas engines. Higher ash oil can cause valve and/or piston damage and lead to
excessive oil consumption and degradation of the catalyst.
For further details and discussion of engine lubricating oils for Cummins engines, refer to a Cummins Authorized
Repair Facility.
K38, K50, QSK38, and QSK50 Coolant Recommendations and Specifications
Coolant Recommendations and
Specifications
Fully Formulated Coolant/Antifreeze
Use low-silicate antifreeze that meets ASTM4985
(GM6038M specification) criteria.
Fully formulated coolant must meet ASTM D-6210/
D-6211.
Cummins Inc. recommends using either a 50/50 mixture
of good-quality water and fully formulated antifreeze, or
fully formulated coolant when filling the cooling system.
Good-quality water is important for cooling system
performance. Excessive levels of calcium and magnesium
contribute to scaling problems, and excessive levels of
chlorides and sulfates cause cooling system corrosion.
Water Quality
Calcium Magnesium
(hardness)
Maximum 170 ppm as
(CaCO
3
+ MgCO
3
)
Chloride 40 ppm as (CI)
Sulfur 100 ppm as (SO
4
)
Coolant Recommendations and Specifications K38, K50, QSK38, and QSK50
Cummins Inc. recommends Fleetguard antifreeze
coolants including ES Compleat containing DCA4 Plus,
Fleetcool EX containing DCA2 Plus, and ES Optimax
Organic Acid Technology (OAT), which meet the
requirements of Cummins Engineering Standard 14603.
However, Cummins Inc., Chevron Texaco and Shell have
agreed that Chevron Texaco, Shell Rotella and their
private label counterpart Extended Life OAT coolants,
which do not meet the elastomer compatibility section of
Cummins Engineering Standard 14603 are acceptable for
extended service interval use, assuming the initial coolant
fill requirements were met from the vehicles' original
equipment manufacturer (OEM).
Mid-Range, Heavy-Duty and High Horsepower engine
overhauls, or repairs involving the replacement of the
following components, using this Extended Life OAT
coolant must discard the coolant and replace it with new
coolant.
Rocker lever housing gasket
Lubricating oil cooler housing gasket
Cylinder head gasket
Thermostat housing gasket
If the replacement coolant is Chevron Texaco, Shell
Rotella or their private label counterpart Extended Life
OAT coolants, which do not meet the elastomer
compatibility section of Cummins Engineering Standard
14603, then the coolant must be treated by adding 0.24
liters [8 oz] of liquid silicate fluid for every 45.5 liters [12
gal] of total coolant system volume. It is critical to not
overtreat the coolant with silicate fluid.
To obtain order forms or ask questions relative to ordering
the silicate fluid, contact:
Silicate Fluid Order Program
P.O. Box 27388
Houston, TX
77277-7388
Phone: 800-346-9041
Fax: 800-876-5317
For further details and discussion of engine coolant for
Cummins engines, refer to Cummins Coolant
Requirements and Maintenance, Bulletin 3666132.
Fully formulated antifreeze must be mixed with good-
quality water at a 50/50 ratio (40- to 60-percent working
range). A 50/50 mixture of antifreeze and water gives a
-36C [-33F] freezing point and a 108C [226F] boiling
point, which is adequate for locations in North America.
The actual lowest freezing point of ethylene glycol
antifreeze is at 68 percent. Using higher concentrations of
antifreeze will raise the freezing point of the solution and
increase the possibility of a silica gel problem.
K38, K50, QSK38, and QSK50 Coolant Recommendations and Specifications
A refractometer must be used to measure the freezing
point of the coolant accurately. Use Fleetguard
refractometer, Part Number CC2800 or CC2806.
Do not use a floating ball hydrometer. Using floating ball
hydrometers can give an incorrect reading.
Cooling System Sealing Additives
Do not use sealing additives in the cooling system. The
use of sealing additives will:
Build up in coolant low-flow areas
Plug the radiator and oil cooler
Possibly damage the water pump seal.
Cooling System Soluble Oils
Do not use soluble oils in the cooling system. The use of
soluble oils will:
Corrode brass and copper
Damage heat transfer surfaces
Damage seals and hoses.
Drive Belt Tension K38, K50, QSK38, and QSK50
Drive Belt Tension
Tension Chart
SAE Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used*
Click-type Burroughs N lbf N lbf
0.380 in 3822524 620 140 270 to 490 60 to 110
0.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822525 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 890 200 360 to 710 80 to 160
10 rib 3822525 3823138 1110 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
12 rib K section 3822525 3823138 1330 300 890 to 1070 200 to 240
NOTE: This chart does not apply to automatic belt tensioners.
* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
K38, K50, QSK38, and QSK50 Capscrew Markings and Torque Values
Capscrew Markings and Torque Values
General Information
CAUTION
When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew
being replaced. Using the wrong capscrews can result in engine damage.
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface
of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.
The following examples indicate how capscrews are identified:
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-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque
wrench. Example: 6 ft-lb equals 72 in-lb.
Capscrew Markings and Torque Values - Metric
Body Size Torque Torque Torque
Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb
6 9 5 7 4 13 10 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 23 17 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 65 50 30 25 70 50 30 25
12 80 60 55 40 115 85 55 40 125 95 55 40
14 125 90 90 65 180 133 90 65 195 145 90 65
16 195 140 140 100 280 200 140 100 290 210 140 100
18 280 200 180 135 390 285 180 135 400 290 180 135
20 400 290 550 400
Capscrew Markings and Torque Values - U.S. Customary
Capscrew Markings and Torque Values K38, K50, QSK38, and QSK50
Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum
Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb
1/4 - 20 9 7 8 6 15 11 8 6
1/4 - 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
5/16 - 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
3/8 - 24 40 30 35 25 60 45 35 25
7/16 - 14 60 45 45 35 90 65 45 35
7/16 - 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
1/2 - 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
9/16 - 18 150 110 115 85 210 155 115 85
5/8 - 11 180 135 150 110 255 190 150 110
5/8 - 18 210 155 160 120 290 215 160 120
3/4 - 10 325 240 255 190 460 340 255 190
3/4 - 16 365 270 285 210 515 380 285 210
7/8 - 9 490 360 380 280 745 550 380 280
7/8 - 14 530 390 420 310 825 610 420 310
1 - 8 720 530 570 420 1100 820 570 420
1 - 14 800 590 650 480 1200 890 650 480
K38, K50, QSK38, and QSK50 Fraction, Decimal, Millimeter Conversions
Fraction, Decimal, Millimeter Conversions
Conversion Chart
Fraction inch mm Fraction inch mm
1/64 0.0156 0.397 33/64 0.5156 13.097
1/32 0.0313 0.794 17/32 0.5313 13.494
3/64 0.0469 1.191 35/64 0.5469 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.0781 1.984 37/64 0.5781 14.684
3/32 0.0938 2.381 19/32 0.5938 15.081
7/64 0.1094 2.778 39/64 0.6094 15.478
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.1406 3.572 41/64 0.6406 16.272
5/32 0.1563 3.969 21/32 0.6563 16.669
11/64 0.1719 4.366 43/64 0.6719 17.066
3/16 0.1875 4.763 11/16 0.6875 17.463
13/64 0.2031 5.159 45/64 0.7031 17.859
7/32 0.2188 5.556 23/32 0.7188 18.256
15/64 0.2344 5.953 47/64 0.7344 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.2656 6.747 49/64 0.7656 19.447
9/32 0.2813 7.144 25/32 0.7813 19.844
19/64 0.2969 7.541 51/64 0.7969 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.3281 8.334 53/64 0.8281 21.034
11/32 0.3438 8.731 27/32 0.8438 21.431
23/64 0.3594 9.128 55/64 0.8594 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.3906 9.922 57/64 0.8906 22.622
13/32 0.4063 10.319 29/32 0.9063 23.019
27/64 0.4219 10.716 59/64 0.9219 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.4531 11.509 61/64 0.9531 24.209
15/32 0.4688 11.906 31/32 0.9688 24.606
31/64 0.4844 12.303 63/64 0.9844 25.003
1/2 0.5000 12.700 1 1.0000 25.400
Conversion Factor: 1 inch = 25.4 mm
Newton-Meter to Foot-Pound Conversions K38, K50, QSK38, and QSK50
Newton-Meter to Foot-Pound Conversions
Conversion Chart
Nm ft-lb Nm ft-lb Nm ft-lb
1 9 in-lb 55 41 155 114
5 44 in-lb 60 44 160 118
6 53 in-lb 65 48 165 122
7 62 in-lb 70 52 170 125
8 71 in-lb 75 55 175 129
9 80 in-lb 80 59 180 133
10 89 in-lb 85 63 185 136
11 97 in-lb 90 66 190 140
12 106 in-lb 95 70 195 144
14 124 in-lb 100 74 200 148
15 133 in-lb 105 77 205 151
16 142 in-lb 110 81 210 155
18 159 in-lb 115 85 215 159
20 15 ft-lb 120 89 220 162
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184
NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.
K38, K50, QSK38, and QSK50 Pipe Plug Torque Values
Pipe Plug Torque Values
Torque Table
Size Torque Torque
Thread Actual Thread O.D. In Aluminum Components In Cast Iron or
Steel Components
in in Nm ft-lb Nm ft-lb
1/16 0.32 5 45 in-lb 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100
Tap-Drill Chart - U.S. Customary and Metric K38, K50, QSK38, and QSK50
Tap-Drill Chart - U.S. Customary and Metric
General Information
NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size for
approximately 60% and 75% of full thread depth. Generally, it is recommended that drill sizes be selected in the 60%
range as these sizes will provide about 90% of the potential holding power. Drill sizes in the 75% range are
recommended for shallow hole tapping (less than 1 1/2 times the hole diameter) in soft metals and mild steel.
K38, K50, QSK38, and QSK50 Weights and Measures - Conversion Factors
Weights and Measures - Conversion Factors
Conversion Chart
Quantity U.S. Customary Metric
From U.S.
Customary
To Metric
Multiply By
From Metric
To U.S.
Customary
Multiply By
Unit Name Abbreviation Unit Name Abbreviation
Area
sq. inch
in
2
sq. millimeters
mm
2
645.16 0.001550
sq. centimeters
cm
2
6.452 0.155
sq. foot
ft
2
sq. meter
m
2
0.0929 10.764
Fuel
Consumption
pounds per
horsepower hour
lb/hp-hr grams per kilowatt
hour
g/kW-hr 608.277 0.001645
Fuel
Performance
miles per gallon mpg kilometers per liter km/l 0.4251 2.352
gallons per mile gpm liters per kilometer l/km 2.352 0.4251
Force pounds force lbf Newton N 4.4482 0.224809
Length
inch in millimeters mm 25.40 0.039370
foot ft millimeters mm 304.801 0.00328
Power horsepower hp kilowatt kW 0.746 1.341
Pressure
pounds force per
sq. inch
psi kilopascal kPa 6.8948 0.145037
inches of mercury in Hg kilopascal kPa 3.3769 0.29613
inches of water in H
2
O kilopascal kPa 0.2488 4.019299
inches of mercury in Hg millimeters of
mercury
mm Hg 25.40 0.039370
inches of water in H
2
O millimeters of
water
mm H
2
O 25.40 0.039370
bars bars kilopascals kPa 100.001 0.00999
bars bars millimeters of
mercury
mm Hg 750.06 0.001333
Temperature fahrenheit F centigrade C (F-32) 1.8 (1.8 x C) +32
Torque
pound force per
foot
ft-lb Newton-meter Nm 1.35582 0.737562
pound force per
inch
in-lb Newton-meter Nm 0.113 8.850756
Velocity miles/hour mph kilometers/hour kph 1.6093 0.6214
Volume:
liquid
displacement
gallon (U.S.) gal. liter l 3.7853 0.264179
gallon (Imp*) gal. liter l 4.546 0.219976
cubic inch
in
3
liter l 0.01639 61.02545
cubic inch
in
3
cubic centimeter
cm
3
16.387 0.06102
Weight (mass) pounds (avoir.) lb kilograms kg 0.4536 2.204623
Work
British Thermal
Unit
BTU joules J 1054.5 0.000948
British Thermal
Unit
BTU kilowatt-hour kW-hr 0.000293 3414
horsepower hours hp-hr kilowatt-hour kW-hr 0.746 1.341
Weights and Measures - Conversion Factors K38, K50, QSK38, and QSK50
Notes
Index
Page X-1
Accessory Drive ...........................................................................................9-3
Assemble....................................................................................................9-8
with Mechanically Actuated Injector........................................................9-8
Disassemble...............................................................................................9-4
Finishing Steps.........................................................................................9-11
with Mechanically Actuated Injector......................................................9-11
Initial Check................................................................................................9-3
Inspect for Reuse........................................................................................9-6
Install........................................................................................................9-10
Preparatory Steps.......................................................................................9-3
Remove......................................................................................................9-3
Accessory Drive Bushing ...........................................................................9-11
Inspect for Reuse......................................................................................9-12
Mechanically Actuated Injector..............................................................9-12
Install........................................................................................................9-13
Remove....................................................................................................9-11
Accessory Drive Cover ...............................................................................9-79
Install........................................................................................................9-79
Accessory Drive Gear and Shaft ................................................................9-14
Assemble..................................................................................................9-15
Disassemble.............................................................................................9-14
Accessory Drive Pulley ..............................................................................9-16
Clean and Inspect for Reuse.....................................................................9-17
Install........................................................................................................9-18
POSE...................................................................................................9-19
Remove....................................................................................................9-16
Accessory Drive Pulley Wear Sleeve .........................................................9-19
Install........................................................................................................9-21
Remove....................................................................................................9-19
Additional Service Literature .......................................................................L-1
General Information....................................................................................L-1
Aftercooler ..................................................................................................10-3
Exploded View..........................................................................................10-4
General Information..................................................................................10-3
Aftercooler Assembly ...............................................................................10-12
Assemble................................................................................................10-25
with Mechanically Actuated Injector.....................................................10-25
with Electronically Actuated Injector....................................................10-32
Clean and Inspect for Reuse...................................................................10-24
Disassemble...........................................................................................10-19
Finishing Steps.......................................................................................10-43
MAI.....................................................................................................10-43
Install......................................................................................................10-33
Preparatory Steps...................................................................................10-12
MAI.....................................................................................................10-12
Pressure Test..........................................................................................10-23
Remove..................................................................................................10-13
Aftercooler Assembly (Center-Mount) .....................................................10-45
Assemble................................................................................................10-49
Disassemble...........................................................................................10-46
Finishing Steps.......................................................................................10-53
Install......................................................................................................10-51
Pressure Test..........................................................................................10-48
Remove..................................................................................................10-45
Aftercooler Assembly (Outboard) ............................................................10-53
Inspect for Reuse....................................................................................10-53
Install......................................................................................................10-54
Remove..................................................................................................10-53
Aftercooler Element .................................................................................10-56
Finishing Steps.......................................................................................10-61
Standard.............................................................................................10-58
LTA.....................................................................................................10-58
Center-Mount......................................................................................10-59
Install......................................................................................................10-59
Standard.............................................................................................10-59
LTA.....................................................................................................10-60
Center-Mount......................................................................................10-61
Remove..................................................................................................10-56
Standard.............................................................................................10-56
LTA.....................................................................................................10-57
Center-Mount......................................................................................10-58
Aftercooler Housing (Center Mount) ......................................................10-162
Modify...................................................................................................10-162
KTA50...............................................................................................10-162
Aftercooler Water Inlet Tube ..................................................................10-167
Clean and Inspect for Reuse.................................................................10-167
Center-Mount....................................................................................10-167
Aftercooler Water Outlet Tube ...............................................................10-167
Center-Mount....................................................................................10-167
Air Cleaner Assembly (Engine-Mounted) .................................................10-61
Install......................................................................................................10-64
Remove..................................................................................................10-61
Air Cleaner Element .................................................................................10-66
Pressure Test..........................................................................................10-66
LTA.....................................................................................................10-66
Air Compressor ........................................................................................12-13
Finishing Steps.......................................................................................12-18
Install......................................................................................................12-16
Remove..................................................................................................12-14
Air Compressor (Oil Carryover) ...............................................................12-22
Air Compressor Carbon Buildup ................................................................12-4
Inspect......................................................................................................12-4
Air Compressor Pin Bore Wear ..................................................................12-6
Initial Check..............................................................................................12-6
Air Compressor Unloader and Valve Assembly ........................................12-9
Assemble................................................................................................12-11
Holset QE230, QE296, and QE338 A/C Model...................................12-11
Disassemble...........................................................................................12-10
Holset QE230, QE296, and QE338 A/C Model...................................12-10
Finishing Steps.......................................................................................12-13
Initial Check..............................................................................................12-9
Air Connection Pipe (Turbocharger to Turbocharger) ............................10-67
Clean......................................................................................................10-67
Air Crossover (Center-Mount Aftercooler) ...............................................10-68
Finishing Steps.......................................................................................10-69
Install......................................................................................................10-69
Remove..................................................................................................10-68
Air Governor (Air Compressor Pumps Continuously) .............................12-19
Initial Check............................................................................................12-19
Air Governor (Air Compressor Will Not Pump) ........................................12-18
Initial Check............................................................................................12-18
Air Intake Restriction ...............................................................................10-71
Measure..................................................................................................10-71
Air Intake System .....................................................................................V-129
Specifications.........................................................................................V-129
Air Leaks, Air Intake and Exhaust Systems ............................................10-69
Air Leaks, Compressed Air System .........................................................12-21
Initial Check............................................................................................12-21
Air Starting Motor .....................................................................................12-23
General Information................................................................................12-23
Alternator ....................................................................................................13-3
Finishing Steps.........................................................................................13-6
Install........................................................................................................13-4
Index
Page X-2
Preparatory Steps.....................................................................................13-3
Remove....................................................................................................13-3
Alternator Adjusting Link .........................................................................13-22
Adjust.....................................................................................................13-23
Alternator Drive Pulley ...............................................................................9-21
Finishing Steps.........................................................................................9-23
Install........................................................................................................9-22
Remove....................................................................................................9-21
Alternator Pulley .......................................................................................13-10
Finishing Steps.......................................................................................13-11
Install......................................................................................................13-11
Remove..................................................................................................13-10
Alternator Bracket ......................................................................................13-7
Finishing Steps.........................................................................................13-8
Install........................................................................................................13-8
Remove....................................................................................................13-7
Batteries ...................................................................................................13-12
Inspect....................................................................................................13-12
Battery Cables and Connections .............................................................13-13
Initial Check............................................................................................13-13
Bearing, Generator .....................................................................................21-8
Clean......................................................................................................21-18
Internal...............................................................................................21-18
External..............................................................................................21-18
Finishing Steps.......................................................................................21-16
Install......................................................................................................21-13
Lubrication for the Power Components....................................................21-17
Remove....................................................................................................21-9
Bellows .....................................................................................................11-36
Finishing Steps.......................................................................................11-37
Install......................................................................................................11-36
Remove..................................................................................................11-36
Belt Guard ....................................................................................................8-3
Clean and Inspect for Reuse.......................................................................8-4
Install..........................................................................................................8-4
Remove......................................................................................................8-3
Capscrew ....................................................................................................17-1
Magnetic Crack Inspect.............................................................................17-1
Capscrew Markings and Torque Values ..................................................V-141
Capscrew Markings and Torque Values - Metric......................................V-141
Capscrew Markings and Torque Values - U.S. Customary.......................V-141
General Information................................................................................V-141
Component Manufacturers' Addresses ......................................................M-1
Air Compressors........................................................................................M-1
Air Cylinders..............................................................................................M-1
Air Heaters................................................................................................M-1
Air Starting Motors.....................................................................................M-1
Alternators.................................................................................................M-1
Auxiliary Brakes.........................................................................................M-1
Belts..........................................................................................................M-1
Catalytic Converters...................................................................................M-1
Coolant Level Switches..............................................................................M-1
Clutches....................................................................................................M-1
Coolant Heaters.........................................................................................M-2
Drive Plates...............................................................................................M-2
Electric Starting Motors..............................................................................M-2
Electronic Switches....................................................................................M-2
Engine Protection Controls.........................................................................M-2
Fan Clutches.............................................................................................M-2
Fans..........................................................................................................M-2
Fault Lamps...............................................................................................M-2
Filters........................................................................................................M-2
Flexplates..................................................................................................M-2
Fuel Coolers..............................................................................................M-2
Fuel Pumps...............................................................................................M-2
Fuel Warmers............................................................................................M-2
Gauges......................................................................................................M-3
Governors..................................................................................................M-3
Heat Sleeves.............................................................................................M-3
Hydraulic and Power Steering Pumps........................................................M-3
In-Line Connectors.....................................................................................M-3
Oil Heaters................................................................................................M-3
Prelubrication Systems..............................................................................M-3
Radiators...................................................................................................M-3
Throttle Assemblies...................................................................................M-3
Torque Converters.....................................................................................M-3
Compressed Air System ..........................................................................V-132
Coolant Bypass Tube .................................................................................8-12
Industrial...............................................................................................8-14
Marine Applications..............................................................................8-14
Finishing Steps.........................................................................................8-16
Install........................................................................................................8-15
Industrial...............................................................................................8-15
Remove....................................................................................................8-12
Industrial...............................................................................................8-12
Coolant Filter ..............................................................................................8-17
Install........................................................................................................8-17
Remove....................................................................................................8-17
Coolant Recommendations and Specifications ......................................V-137
Cooling System Sealing Additives...........................................................V-139
Cooling System Soluble Oils...................................................................V-139
Fully Formulated Coolant/Antifreeze.......................................................V-137
Coolant Temperature Gauge ......................................................................8-11
Coolant Thermostat ....................................................................................8-18
Finishing Steps.........................................................................................8-32
Install........................................................................................................8-27
Conventional Aftercooling.....................................................................8-27
LTA......................................................................................................8-28
with Electronically Actuated Injector......................................................8-29
Gas Compression.................................................................................8-30
Leak Test..................................................................................................8-24
LTA......................................................................................................8-26
Remove....................................................................................................8-19
LTA......................................................................................................8-20
Test..........................................................................................................8-23
Coolant Thermostat Housing Support .......................................................8-32
LTA......................................................................................................8-37
Finishing Steps.........................................................................................8-41
Install........................................................................................................8-37
LTA......................................................................................................8-37
Remove....................................................................................................8-33
Cooling System ..........................................................................................8-42
Drain.........................................................................................................8-42
Fill............................................................................................................8-44
Flush........................................................................................................8-42
Cooling System ........................................................................................V-127
with Mechanically Actuated Injector....................................................V-127
with Electronically Actuated Injector....................................................V-127
Cooling System Diagnostics ......................................................................8-54
Inspect......................................................................................................8-54
Cooling System - Air or Combustion Gas Test .........................................8-46
Test..........................................................................................................8-46
Overflow Method...................................................................................8-46
Sight Glass Method...............................................................................8-47
Air Compressor.....................................................................................8-48
Combustion Gas Leak...........................................................................8-49
Cylinder Head and Cylinder Liner..........................................................8-52
Cummins Customized Parts Catalog ...........................................................L-3
General Information....................................................................................L-3
Ordering the Customized Parts Catalog......................................................L-3
Ordering by Telephone...........................................................................L-3
Ordering On-Line....................................................................................L-3
Cummins/Fleetguard Filter Specifications ............................................V-133
Cup Plug .....................................................................................................17-2
Install........................................................................................................17-3
Remove....................................................................................................17-2
Drive Belt Tension ...................................................................................V-140
Tension Chart.........................................................................................V-140
Drive Belt, Alternator .................................................................................13-9
Finishing Steps.......................................................................................13-10
Install........................................................................................................13-9
Remove....................................................................................................13-9
Drive Belt, Cooling Fan ................................................................................8-5
Adjust.......................................................................................................8-11
Index
Page X-3
Inspect for Reuse........................................................................................8-7
Install..........................................................................................................8-8
Remove......................................................................................................8-5
Dynamometer Worksheet ...........................................................................14-4
Worksheet................................................................................................14-4
ECM Cooling Plate ....................................................................................8-169
Assemble................................................................................................8-173
Disassemble...........................................................................................8-169
Finishing Steps.......................................................................................8-174
Install......................................................................................................8-174
Remove..................................................................................................8-169
ECM Cooling Plate Lines ..........................................................................8-175
Finishing Steps.......................................................................................8-178
Install......................................................................................................8-177
Remove..................................................................................................8-175
Electrical System .....................................................................................V-131
Batteries (Specific Gravity)......................................................................V-131
Engine Compression ................................................................................14-52
Finishing Steps.......................................................................................14-56
Pressure Differential Test........................................................................14-54
Setup......................................................................................................14-53
Engine Lifting Brackets ..............................................................................16-3
Install........................................................................................................16-3
Remove....................................................................................................16-3
Engine Mounts ..........................................................................................16-33
Engine Run-in (Engine Dynamometer) .....................................................14-25
Run-In Instructions..................................................................................14-25
Engine Run-in (Without Dynamometer) ...................................................14-11
Run-In Instructions..................................................................................14-11
Engine Support Bracket, Front ..................................................................16-5
Finishing Steps.........................................................................................16-9
Install........................................................................................................16-8
Remove....................................................................................................16-5
Engine Testing (Chassis Dynamometer) ...................................................14-5
Test..........................................................................................................14-5
Engine Speed (rpm)..............................................................................14-5
Fuel Pressure.......................................................................................14-6
Fuel Rate..............................................................................................14-6
Fuel Inlet Restriction.............................................................................14-6
Fuel Drain Line Restriction....................................................................14-6
Intake Manifold Pressure......................................................................14-7
Intake Manifold Air Temperature Control - Chassis Dynamometer test.....14-
7
Intake Air Restriction.............................................................................14-8
Intake Manifold Air Temperature Control - Chassis Dynamometer test.....14-
8
Engine Blowby......................................................................................14-8
Lubricating Oil Pressure......................................................................14-10
Air Compressor...................................................................................14-11
Starting Motor.....................................................................................14-11
Engine Testing (Engine Dynamometer) ...................................................14-12
Install......................................................................................................14-12
Coolant Plumbing...............................................................................14-12
Intake Air Temperature Control...........................................................14-13
LTA.....................................................................................................14-13
Test....................................................................................................14-13
Engine Throttle Control.......................................................................14-15
Test........................................................................................................14-19
Engine Speed (rpm)............................................................................14-20
Fuel Drain Line Restriction..................................................................14-20
Intake Air Restriction...........................................................................14-20
Exhaust Air Restriction........................................................................14-21
Engine Blowby....................................................................................14-21
Lubricating Oil Pressure......................................................................14-23
Engine Coolant Pressure.....................................................................14-23
Air Compressor...................................................................................14-24
Starting Motor.....................................................................................14-24
Exhaust Connection Pipe ...........................................................................11-2
Finishing Steps.........................................................................................11-3
Install........................................................................................................11-3
Remove....................................................................................................11-2
Exhaust Manifold (Wet) Water Connections ............................................11-33
MAI.....................................................................................................11-34
Finishing Steps.......................................................................................11-35
MAI.....................................................................................................11-35
Install......................................................................................................11-34
MAI.....................................................................................................11-34
Remove..................................................................................................11-33
MAI.....................................................................................................11-33
Exhaust Manifold, Dry ................................................................................11-4
Assemble..................................................................................................11-9
Disassemble.............................................................................................11-7
Finishing Steps.......................................................................................11-23
Install......................................................................................................11-10
KT38 and KTA38 with Dry Exhaust Manifolds......................................11-10
KTTA38 with Dry Exhaust Manifolds....................................................11-11
KT38 and KTA38 with Dry Exhaust Manifolds......................................11-11
KTA50 Dry Exhaust Manifolds.............................................................11-13
KTTA50 Dry Exhaust, Log Type Manifolds..........................................11-14
K50 Dry Exhaust, Pulse Type Manifolds..............................................11-15
K38 and K50 Bellows Manifold............................................................11-20
Remove....................................................................................................11-6
Exhaust Manifold, Wet .............................................................................11-24
EAI.....................................................................................................11-26
Finishing Steps.......................................................................................11-31
EAI.....................................................................................................11-31
Install......................................................................................................11-28
EAI.....................................................................................................11-28
EAI.....................................................................................................11-24
Remove..................................................................................................11-25
EAI.....................................................................................................11-25
Exhaust Restriction ..................................................................................11-31
Measure..................................................................................................11-31
Exhaust System .......................................................................................V-130
Expansion Tank ..........................................................................................8-75
Finishing Steps.........................................................................................8-80
Install........................................................................................................8-78
Remove....................................................................................................8-75
Fan Clutch, Viscous ...................................................................................8-55
Measure...................................................................................................8-55
Fan, Cooling ...............................................................................................8-70
Finishing Steps.........................................................................................8-71
Install........................................................................................................8-71
Remove....................................................................................................8-70
Fan Drive Idler Arm Assembly ...................................................................8-56
Assemble..................................................................................................8-60
Clean........................................................................................................8-59
Disassemble.............................................................................................8-58
Finishing Steps.........................................................................................8-62
Install........................................................................................................8-62
Remove....................................................................................................8-57
Fan Hub Bracket .........................................................................................8-62
Install........................................................................................................8-64
Remove....................................................................................................8-63
Fan Hub, Belt Driven ..................................................................................8-64
Assemble..................................................................................................8-67
Disassemble.............................................................................................8-66
Finishing Steps.........................................................................................8-70
Install........................................................................................................8-69
Remove....................................................................................................8-65
Fan Shroud Assembly ................................................................................8-70
Flexible Hose ..............................................................................................17-3
Flexplate ...................................................................................................16-10
Finishing Steps.......................................................................................16-13
Install......................................................................................................16-12
Measure..................................................................................................16-12
Face Runout.......................................................................................16-12
Remove..................................................................................................16-10
Index
Page X-4
Flywheel ....................................................................................................16-14
Finishing Steps.......................................................................................16-18
Install......................................................................................................16-16
Remove..................................................................................................16-14
Flywheel Housing .....................................................................................16-19
Finishing Steps.......................................................................................16-31
Install......................................................................................................16-27
Measure..................................................................................................16-28
Alignment...........................................................................................16-28
Redowel..................................................................................................16-21
Remove..................................................................................................16-20
Flywheel Ring Gear ..................................................................................16-32
Assemble................................................................................................16-32
Fraction, Decimal, Millimeter Conversions .............................................V-143
Conversion Chart....................................................................................V-143
Fuel Pump Drive .........................................................................................9-23
Assemble..................................................................................................9-30
Disassemble.............................................................................................9-25
Finishing Steps.........................................................................................9-36
Initial Check..............................................................................................9-24
Install........................................................................................................9-35
Remove....................................................................................................9-24
Fuel Recommendations and Specifications ............................................V-135
Fuel System .............................................................................................V-125
with Electronically Actuated Injector....................................................V-125
with Mechanically Actuated Injector....................................................V-125
General Engine .........................................................................................V-123
General Specifications............................................................................V-123
Generator (Alternator) Exciter Rotating Diodes ......................................21-18
Finishing Steps.......................................................................................21-22
Install......................................................................................................21-21
Remove..................................................................................................21-19
Generator (Alternator) Windings ..............................................................21-23
Clean......................................................................................................21-23
Finishing Steps.......................................................................................21-24
Generator Fuse Holder ...............................................................................21-1
Generator Rotor ........................................................................................21-30
Finishing Steps.......................................................................................21-36
Install......................................................................................................21-33
Remove..................................................................................................21-30
Generator, Main ..........................................................................................21-1
Instrument Panel...................................................................................21-2
Heat Exchanger ..........................................................................................8-81
Assemble................................................................................................8-101
Tube Type..........................................................................................8-101
Plate Type..........................................................................................8-103
Box Type............................................................................................8-106
Clean........................................................................................................8-92
Tube Type............................................................................................8-92
Tube Type............................................................................................8-97
Plate Type............................................................................................8-98
Box Type..............................................................................................8-99
Disassemble.............................................................................................8-92
Tube Type............................................................................................8-92
Plate Type............................................................................................8-93
Box Type..............................................................................................8-95
Exploded View..........................................................................................8-81
Finishing Steps.......................................................................................8-121
Inspect....................................................................................................8-100
Tube Type..........................................................................................8-100
Plate Type..........................................................................................8-100
Box Type............................................................................................8-101
Install......................................................................................................8-110
Tube Type..........................................................................................8-110
Plate Type..........................................................................................8-116
Box Type............................................................................................8-119
Pressure Test..........................................................................................8-108
Tube Type..........................................................................................8-108
Box Type............................................................................................8-110
Remove....................................................................................................8-85
Tube Type............................................................................................8-85
Plate Type............................................................................................8-88
Box Type..............................................................................................8-90
Hydraulic Pump Drive ................................................................................9-37
Assemble..................................................................................................9-40
Clean for Rebuild......................................................................................9-39
Disassemble.............................................................................................9-38
Finishing Steps.........................................................................................9-41
Inspect......................................................................................................9-39
Install........................................................................................................9-41
Remove....................................................................................................9-37
Hydraulic Pump Drive Gear and Shaft .......................................................9-42
Assemble..................................................................................................9-43
Disassemble.............................................................................................9-42
Low-Temperature Aftercooler (LTA) Water Pump ...................................8-168
Maintenance Check................................................................................8-168
Lubricating Oil Recommendations and Specifications ...........................V-136
Lubricating Oil System ............................................................................V-126
Newton-Meter to Foot-Pound Conversions .............................................V-144
Permanent Magnet Generator ..................................................................21-25
Finishing Steps.......................................................................................21-29
Install......................................................................................................21-27
Remove..................................................................................................21-25
Pipe Plug ....................................................................................................17-4
Install........................................................................................................17-4
Remove....................................................................................................17-4
Pipe Plug Torque Values .........................................................................V-145
Torque Table..........................................................................................V-145
Radiator ......................................................................................................8-72
Test..........................................................................................................8-72
Radiator Hoses ...........................................................................................8-74
Radiator Pressure Cap ...............................................................................8-74
Pressure Test...........................................................................................8-75
Rear Gear Drive (Lower Assembly) ...........................................................9-43
Assemble..................................................................................................9-49
Clean........................................................................................................9-45
Disassemble.............................................................................................9-46
Finishing Steps.........................................................................................9-53
Inspect......................................................................................................9-47
Install........................................................................................................9-51
Remove....................................................................................................9-44
Rear Gear Drive (Upper Assembly) ............................................................9-53
Assemble..................................................................................................9-61
Clean........................................................................................................9-58
Disassemble.............................................................................................9-55
Inspect......................................................................................................9-59
Install........................................................................................................9-64
Remove....................................................................................................9-54
Rear Gear Drive Gear and Shaft (Upper Assembly) ..................................9-65
Assemble..................................................................................................9-66
Clean........................................................................................................9-65
Disassemble.............................................................................................9-65
Sea Water Hoses ......................................................................................8-168
Inspect....................................................................................................8-168
Sea Water Pump .......................................................................................8-121
Assemble................................................................................................8-128
Gear Driven........................................................................................8-128
Index
Page X-5
Spline Driven......................................................................................8-132
Gear Driven........................................................................................8-127
Spline Driven......................................................................................8-128
Disassemble...........................................................................................8-122
Gear Driven........................................................................................8-122
Spline Driven......................................................................................8-125
Finishing Steps.......................................................................................8-136
Spline Drive........................................................................................8-136
Gear Driven........................................................................................8-121
Install......................................................................................................8-136
Spline Drive........................................................................................8-136
Spline Drive........................................................................................8-121
Remove..................................................................................................8-122
Spline Drive........................................................................................8-122
Sea Water Pump Support .........................................................................8-136
Finishing Steps.......................................................................................8-140
Install......................................................................................................8-139
Remove..................................................................................................8-137
Sea Water System Diagnostics ................................................................8-165
Inspect....................................................................................................8-165
Pressure Test..........................................................................................8-167
Test........................................................................................................8-166
Service Literature Ordering Location ..........................................................L-2
Contact Information....................................................................................L-2
Service Tools ...............................................................................................8-1
Cooling System...........................................................................................8-1
Service Tools ...............................................................................................9-1
Drive Units..................................................................................................9-1
Service Tools ..............................................................................................10-1
Air Intake System......................................................................................10-1
Service Tools ..............................................................................................11-1
Exhaust System Dataplate........................................................................11-1
Service Tools ..............................................................................................12-1
Compressed Air System............................................................................12-1
Service Tools ..............................................................................................13-1
Electrical Equipment.................................................................................13-1
Service Tools ..............................................................................................14-1
Engine Testing..........................................................................................14-1
Service Tools ..............................................................................................16-1
Mounting Adaptations...............................................................................16-1
Starter Magnetic Switch ...........................................................................13-14
Starter Solenoid ........................................................................................13-17
Voltage Check.........................................................................................13-17
Starter Switch ...........................................................................................13-16
Test........................................................................................................13-16
Starting Motor ...........................................................................................13-20
Finishing Steps.......................................................................................13-21
Install......................................................................................................13-21
Remove..................................................................................................13-20
Straight Thread Plug ..................................................................................17-5
Install........................................................................................................17-6
Remove....................................................................................................17-5
Supplemental Coolant Additive (SCA) .....................................................8-140
Maintenance Check................................................................................8-140
Tap-Drill Chart - U.S. Customary and Metric ...........................................V-146
Turbocharger ............................................................................................10-73
Assemble................................................................................................10-99
Clean......................................................................................................10-91
Disassemble...........................................................................................10-94
Finishing Steps.....................................................................................10-129
MAI...................................................................................................10-129
with Electronically Actuated Injector..................................................10-129
Install....................................................................................................10-101
with Mechanically Actuated Injector...................................................10-101
Measure..................................................................................................10-98
MAI.....................................................................................................10-75
Remove..................................................................................................10-77
Turbocharger Axial Clearance ...............................................................10-137
Finishing Steps.....................................................................................10-140
Measure................................................................................................10-138
Preparatory Steps.................................................................................10-137
Turbocharger Blade Damage .................................................................10-140
Inspect for Reuse..................................................................................10-140
Turbocharger Compressor Seal Leaks ..................................................10-141
Inspect..................................................................................................10-141
Turbocharger Coolant Hoses .................................................................10-144
Finishing Steps.....................................................................................10-148
EAI....................................................................................................10-148
Inspect for Reuse..................................................................................10-146
EAI....................................................................................................10-146
Install....................................................................................................10-146
Marine Applications...........................................................................10-148
EAI....................................................................................................10-144
Remove................................................................................................10-144
Turbocharger Oil Drain Line ..................................................................10-148
Finishing Steps.....................................................................................10-153
Install....................................................................................................10-151
Remove................................................................................................10-149
Single Stage.....................................................................................10-149
Two Stage.........................................................................................10-149
Turbocharger Oil Supply Line ................................................................10-153
Finishing Steps.....................................................................................10-161
Install....................................................................................................10-158
Industrial Applications.......................................................................10-158
Two Stage.........................................................................................10-158
Low Pressure Turbocharger..............................................................10-159
Remove................................................................................................10-154
Industrial Applications.......................................................................10-154
Two Stage.........................................................................................10-155
Low Pressure Turbocharger..............................................................10-155
Turbocharger Radial Bearing Clearance ................................................10-161
Finishing Steps.....................................................................................10-162
Measure................................................................................................10-161
Turbocharger, Water-Cooled ..................................................................10-130
Finishing Steps.....................................................................................10-137
Install....................................................................................................10-134
Left Bank..........................................................................................10-134
Right Bank........................................................................................10-136
Remove................................................................................................10-131
Left Bank..........................................................................................10-131
Right Bank........................................................................................10-132
Setup....................................................................................................10-133
Water Manifold .........................................................................................8-141
Water Pump ..............................................................................................8-142
Assemble................................................................................................8-154
Disassemble...........................................................................................8-149
Finishing Steps.......................................................................................8-164
Inspect....................................................................................................8-152
Install......................................................................................................8-160
Index
Page X-6
Remove..................................................................................................8-145
Water Pump Drive Bushing ........................................................................9-68
Install........................................................................................................9-69
Remove....................................................................................................9-68
Water Pump Drive Gear and Shaft .............................................................9-70
Assemble..................................................................................................9-71
Disassemble.............................................................................................9-70
Water Pump Drive Pulley ...........................................................................9-71
Finishing Steps.........................................................................................9-72
Install........................................................................................................9-72
Remove....................................................................................................9-71
Weights and Measures - Conversion Factors .........................................V-147
Woodward Governor Drive .........................................................................9-72
Assemble..................................................................................................9-77
Disassemble.............................................................................................9-73
Inspect......................................................................................................9-75
Service Manual
Volume 3
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Bulletin 4021528
Printed in U.S.A. 27-MARCH-2008
p174
Cummins Inc.
Box 3005
Columbus, Indiana, U.S.A., 47202
Registered Office
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright
2008
Cummins Inc.
281522_Cummins_CovV3.mpc:281522_Cummins_CovV3 3/28/08 7:07 AM Page 1

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