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Cummins qsk38 PDF
Cummins qsk38 PDF
Registered Office
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright© 2008
Cummins Inc.
Bulletin 4021528
Printed in U.S.A. 27-MARCH-2008 p174
Service Manual
K38, K50, QSK38 and QSK50
Volume 3
Specifications ........................................................................................................................................... V
Box Type....................................................................................................................................................8-106
Clean..............................................................................................................................................................8-92
Tube Type....................................................................................................................................................8-92
Clean and Inspect for Reuse...........................................................................................................................8-97
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
Preparatory Steps...........................................................................................................................................8-85
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
Inspect for Reuse............................................................................................................................................8-74
Radiator Pressure Cap ....................................................................................................................................8-74
Inspect for Reuse............................................................................................................................................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
Clean and Inspect for Reuse.........................................................................................................................8-127
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
Preparatory Steps.........................................................................................................................................8-121
Spline Drive................................................................................................................................................8-121
Remove.........................................................................................................................................................8-122
Spline Drive................................................................................................................................................8-122
Sea Water Pump Support ..............................................................................................................................8-136
Clean and Inspect for Reuse.........................................................................................................................8-138
K38, K50, QSK38, and QSK50
Page 8-d Section 8 — Cooling System — Group 08
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.
Bearing Separator
Used to hold the bearing when removing it from the shaft.
3375326
Reflective Tape
Used with optical tachometer, Part Number 3377462, to measure the
3377464 rpm of the fan.
Torque Wrench
Used to tighten capscrews 13 to 136 N•m [10 to 100 ft-lb].
3164794
K38, K50, QSK38, and QSK50 Belt Guard
Section 8 — Cooling System — Group 08 Page 8-3
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.
Install
Install the two mounting capscrews, washers, and
alternator belt guard to the front gear cover.
To remove the control rod with spring, remove the two jam
nuts (26), washers (25)(24), and spring (23).
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.
K38, K50, QSK38, and QSK50 Drive Belt, Cooling Fan
Section 8 — Cooling System — Group 08 Page 8-7
Install
Install the belt on the crankshaft and fan hub pulley.
Align the grooves on the belt on the ribs of the pulley.
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.
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 N•m [ 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).
Torque Value: 90 N•m [ 65 ft-lb ]
K38, K50, QSK38, and QSK50 Drive Belt, Cooling Fan
Section 8 — Cooling System — Group 08 Page 8-9
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.
Torque Value: 60 N•m [ 45 ft-lb ]
Install the spacer bushing (17), flat washer (18), lock
washer (19), and capscrew (20) in the lower end of the
control rod (21).
Install the lower end of the control rod on the fan idler are
(22).
Tighten the capscrews.
Torque Value: 60 N•m [ 45 ft-lb ]
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.
Drive Belt, Cooling Fan K38, K50, QSK38, and QSK50
Page 8-10 Section 8 — Cooling System — Group 08
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).
Torque Value: 60 N•m [ 45 ft-lb ]
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
Section 8 — Cooling System — Group 08 Page 8-11
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
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.
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.
Tighten the capscrews.
Torque Value: 285 N•m [ 210 ft-lb ]
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.
Torque Value: 285 N•m [ 210 ft-lb ]
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120•F] 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
Section 8 — Cooling System — Group 08 Page 8-13
Marine Applications
Remove the Straub coupling from the bypass line.
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
Section 8 — Cooling System — Group 08 Page 8-15
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
Torque Value: 40 N•m [ 30 ft-lb ]
Check to be sure the hose (4) is the same length on both
tubes.
Tighten the two hose clamps (5).
Torque Value: 5 N•m [ 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 38 N•m [ 28 ft-lb ]
Capscrews
Finishing Steps
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.
• Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Connect the battery cables. Refer to Procedure
013-009 (Batteries and Cable connections) in
Section 13.
• Operate the engine to normal operating temperature
and pressure, then check for leaks.
K38, K50, QSK38, and QSK50 Coolant Filter
Section 8 — Cooling System — Group 08 Page 8-17
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Remove the pressure cap from the radiator.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
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
Page 8-18 Section 8 — Cooling System — Group 08
Preparatory Steps
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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 can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Drain the cooling system. Refer to Procedure
008-018 (Cooling System) 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.
Coolant Thermostat K38, K50, QSK38, and QSK50
Page 8-20 Section 8 — Cooling System — Group 08
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.
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 82°C [180°
F].
Leak Test
WARNING
Complete this procedure with engine coolant
temperatures below 50°C [120°F]. 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.
K38, K50, QSK38, and QSK50 Coolant Thermostat
Section 8 — Cooling System — Group 08 Page 8-25
Conventional Aftercooling
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
NOTE: Shown is the K38 and K50 thermostat housing.
Although different in appearance, the procedure remains
the same for the QSK series engines.
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.
LTA
Remove the LTA radiator inlet hose (1) and the two main
engine coolant outlet hoses (2) to the radiator.
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.
Install
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.
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.
Coolant Thermostat K38, K50, QSK38, and QSK50
Page 8-28 Section 8 — Cooling System — Group 08
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 seal no more than 0.51 mm [0.020 in] below the
top of the cast edge.
K38, K50, QSK38, and QSK50 Coolant Thermostat
Section 8 — Cooling System — Group 08 Page 8-29
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.
Install the seal no more than 5.1 mm [0.02 in] below the
top of the cast edge.
K38, K50, QSK38, and QSK50 Coolant Thermostat
Section 8 — Cooling System — Group 08 Page 8-31
Finishing Steps
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Install the fan hub bracket (if installed). Refer to
Procedure 008-035 (Fan Hub Bracket) in Section 8.
• 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
008-002 (Drive Belt, Cooling Fan) in Section 8.
• Install the cooling fan (if installed). Refer to
Procedure 008-040 (Fan Cooling) in Section 8.
• Install the heat exchanger (if equipped). Refer to
Procedure 008-053 (Heat Exchanger) in Section 8.
• Install the water filters (if installed). Refer to
Procedure 008-006 (Coolant Filter) in Section 8.
• Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Connect the batteries. Refer to Procedure 013-009
(Batteries and cable connections) in Section 13.
• Operate the engine until the coolant temperature
reaches 70°C [158°F], and then check for leaks.
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
Section 8 — Cooling System — Group 08 Page 8-33
Preparatory Steps
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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 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
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
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).
Coolant Thermostat Housing Support K38, K50, QSK38, and QSK50
Page 8-34 Section 8 — Cooling System — Group 08
Remove the water transfer tubes (2) and (3). Remove the
o-rings.
Discard the o-rings.
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 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.
Dry with compressed air.
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 38 N•m [ 28 ft-lb ]
Capscrews
Torque Value:
Transfer Tube 11 N•m [ 97 in-lb ]
Capscrews
Coolant Thermostat Housing Support K38, K50, QSK38, and QSK50
Page 8-38 Section 8 — Cooling System — Group 08
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 22 N•m [ 16 ft-lb ]
Transfer Tube
Capscrews
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 22 N•m [ 16 ft-lb ]
Transfer Tube
Capscrews
K38, K50, QSK38, and QSK50 Coolant Thermostat Housing Support
Section 8 — Cooling System — Group 08 Page 8-39
Install the upper half or the transfer tube isolator and two
capscrews.
Torque Value:
Upper Half 11 N•m [ 97 in-lb ]
Transfer Tube
Capscrews
Finishing Steps
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.
• Install the heat exchanger (if equipped). Refer to
Procedure 008-053 (Heat Exchanger) in Section 8.
• Install the water filters (if installed). Refer to
Procedure 008-006 (Coolant Filter) in Section 8.
• Install the fan hub bracket (if installed). Refer to
Procedure 008-035 (Fan Hub Bracket) in Section 8.
• 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
008-002 (Drive Belt, Cooling Fan) in Section 8.
• Install the cooling fan (if installed). Refer to
Procedure 008-040 (Fan, Cooling) in Section 8.
• Install the heat exchanger (if equipped). Refer to
Procedure 008-053 (Heat Exchanger) in Section 8.
• Install the air cleaner assemblies. Refer to
Procedure 010-013 Air Cleaner Assembly (Engine
Mounted) in Section 10.
• Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Disconnect the battery cables. Refer to Procedure
013-009 (Batteries and Cable connections) in
Section 13.
• Operate the engine to normal operating
temperatures and pressures. Check for leaks.
Cooling System K38, K50, QSK38, and QSK50
Page 8-42 Section 8 — Cooling System — Group 08
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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.
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.
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
Section 8 — Cooling System — Group 08 Page 8-43
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.
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.
K38, K50, QSK38, and QSK50 Cooling System
Section 8 — Cooling System — Group 08 Page 8-45
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.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
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
Page 8-46 Section 8 — Cooling System — Group 08
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the temperature is below 50°C [120°F]
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.
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.
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.
Cooling System - Air or Combustion Gas Test K38, K50, QSK38, and QSK50
Page 8-48 Section 8 — Cooling System — Group 08
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.
K38, K50, QSK38, and QSK50 Cooling System - Air or Combustion Gas Test
Section 8 — Cooling System — Group 08 Page 8-49
Pour the test fluid into the combustion gas test instrument
until it is up to the yellow fill line on the instrument.
Cooling System - Air or Combustion Gas Test K38, K50, QSK38, and QSK50
Page 8-50 Section 8 — Cooling System — Group 08
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.
K38, K50, QSK38, and QSK50 Cooling System - Air or Combustion Gas Test
Section 8 — Cooling System — Group 08 Page 8-51
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.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the temperature is below 50°C [120°F]
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.
Drain the coolant down to where coolant is level with the
water manifold tubes.
Slide the water manifold tubes into the rocker lever
housing.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
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.
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.
Fan Drive Idler Arm Assembly K38, K50, QSK38, and QSK50
Page 8-58 Section 8 — Cooling System — Group 08
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.
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
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.
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.
K38, K50, QSK38, and QSK50 Fan Drive Idler Arm Assembly
Section 8 — Cooling System — Group 08 Page 8-59
Rotate the cap until the pins (1) align with the slots (2) in
the cap.
Remove the cap.
Clean
WARNING
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
Use solvent to clean the parts.
Fan Drive Idler Arm Assembly K38, K50, QSK38, and QSK50
Page 8-60 Section 8 — Cooling System — Group 08
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.
Assemble
Install and position the bushings (9) even with the pivot
arm.
Use vegetable oil. Lubricate the o-ring (10).
Install the part.
Align the pins (1) with the slots (2) in the cap.
Install the cap.
Install
NOTE: Not all engines are equipped with this option.
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
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.
Install the fan belt idler assembly, the three lock washers,
and capscrews.
Torque Value: 60 N•m [ 45 ft-lb ]
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.
Remove
Fan Hub Bracket (Standard)
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.
Remove the capscrews. 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.
Install
NOTE: Not all engines are equipped with this option.
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.
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
(Drive Belt, Cooling Fan) in Section 8.
K38, K50, QSK38, and QSK50 Fan Hub, Belt Driven
Section 8 — Cooling System — Group 08 Page 8-65
Remove
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.
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
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers 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 fan hub.
Dry with compressed air.
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).
Torque Value: 15 N•m [ 133 in-lb ]
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.
K38, K50, QSK38, and QSK50 Fan Hub, Belt Driven
Section 8 — Cooling System — Group 08 Page 8-67
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.
Fan Hub, Belt Driven K38, K50, QSK38, and QSK50
Page 8-68 Section 8 — Cooling System — Group 08
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
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).
Torque Value: 610 N•m [ 450 ft-lb ]
K38, K50, QSK38, and QSK50 Fan Hub, Belt Driven
Section 8 — Cooling System — Group 08 Page 8-69
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).
Torque Value: 20 N•m [ 177 in-lb ]
Install
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.
Install the fan hub, four SAE grade 8 capscrews, and lock
washers. Tighten the capscrews.
Torque Value: 280 N•m [ 207 ft-lb ]
Fan, Cooling K38, K50, QSK38, and QSK50
Page 8-70 Section 8 — Cooling System — Group 08
Finishing 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.
• Install the fan 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.
• Operate the engine and check for proper opertion.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 (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
Section 8 — Cooling System — Group 08 Page 8-71
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.
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Connect the batteries. Refer to Procedure 013-009
(Battery Connections and Cables) in Section 13.
Radiator K38, K50, QSK38, and QSK50
Page 8-72 Section 8 — Cooling System — Group 08
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.
• Operate the engine until the coolant temperature
reaches 88 to 90°C [190 to 195°F].
K38, K50, QSK38, and QSK50 Radiator
Section 8 — Cooling System — Group 08 Page 8-73
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.
• Operate the engine until the coolant temperature
reaches 88 to 90°C [190 to 195°F].
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
Page 8-74 Section 8 — Cooling System — Group 08
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
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.
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.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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.
• Drain the cooling system. Refer to Procedure
008-018.
Remove
Front Mounted Tank
NOTE: Not all engines are equipped with this option.
Detach the coolant vent hoses (6) and (5).
Expansion Tank K38, K50, QSK38, and QSK50
Page 8-76 Section 8 — Cooling System — Group 08
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.
Remove the four capscrews and washers.
Remove the cotter pins (3) and the two hinge pins (2).
Remove the expansion tank (1).
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.
Remove the mounting capscrews and isolators.
Install the lifting straps and connect them to a lifting
device.
Remove the expansion tank.
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.
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.
Dry with compressed air.
Expansion Tank K38, K50, QSK38, and QSK50
Page 8-78 Section 8 — Cooling System — Group 08
Remove the caps from the vent and make up fittings and
drain the expansion tank.
Install
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.
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.
Torque Value: 40 N•m [ 30 ft-lb ]
K38, K50, QSK38, and QSK50 Expansion Tank
Section 8 — Cooling System — Group 08 Page 8-79
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
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.
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 40 N•m [ 30 ft-lb ]
Capscrews
Finishing Steps
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.
• Fill the cooling system. Refer to Procedure 008-018.
• Connect the battery cables. Refer to Procedure
013-009.
• Operate the engine to normal operating temperature
and check for leaks.
K38, K50, QSK38, and QSK50 Heat Exchanger
Section 8 — Cooling System — Group 08 Page 8-81
Figure 1, K38 Marine Plate Type Heat Exchanger Plate Orientation and Plate Location Numbers
Heat Exchanger K38, K50, QSK38, and QSK50
Page 8-82 Section 8 — Cooling System — Group 08
Figure 2, K50 Marine Plate Type Heat Exchanger Plate Orientation and Plate Location Numbers
Heat Exchanger K38, K50, QSK38, and QSK50
Page 8-84 Section 8 — Cooling System — Group 08
Preparatory Steps
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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.
Drain the cooling system.
Refer to Procedure 008-018.
Remove
Tube Type
NOTE: Not all engines are equipped with this option.
Loosen the hose clamps.
Remove the upper heat exchanger outlet pipe (24) and
gaskets (23).
Discard the hose (22) and gaskets.
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.
Plate Type
Remove the vent lines from the expansion tank.
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.
Box Type
Remove the vent lines.
Clean
Tube Type
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
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.
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).
K38, K50, QSK38, and QSK50 Heat Exchanger
Section 8 — Cooling System — Group 08 Page 8-93
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.
Remove the two end top spacer bolts from the top of the
expansion tank.
Heat Exchanger K38, K50, QSK38, and QSK50
Page 8-94 Section 8 — Cooling System — Group 08
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.
Remove the capscrews.
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 tank from the assembly.
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.
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 heat exchanger core.
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
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.
Heat Exchanger K38, K50, QSK38, and QSK50
Page 8-98 Section 8 — Cooling System — Group 08
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.
Box Type
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
Pressure wash, steam clean or flush the core with hot
water.
Heat Exchanger K38, K50, QSK38, and QSK50
Page 8-100 Section 8 — Cooling System — Group 08
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.
Plate Type
Inspect the gasket.
If gaskets are swollen, cracked, or deformed, they must
be replaced.
K38, K50, QSK38, and QSK50 Heat Exchanger
Section 8 — Cooling System — Group 08 Page 8-101
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.
Heat Exchanger K38, K50, QSK38, and QSK50
Page 8-102 Section 8 — Cooling System — Group 08
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.
Torque Value: 61 N•m [ 45 ft-lb ]
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.
Torque Value: 61 N•m [ 45 ft-lb ]
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 N•m [ 190 ft-lb ]
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.
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
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.
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.
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.
Box Type
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.
CAUTION
Apply a coating of high grade (nickel) anti-seize
compound to the bolt threads.
Install the rear heat exchanger housing onto the engine.
Install the sealing ring and the heat exchanger core into
the rear housing and tighten bolts.
Torque Value: 75 N•m [ 55 ft-lb ]
K38, K50, QSK38, and QSK50 Heat Exchanger
Section 8 — Cooling System — Group 08 Page 8-107
Install the sealing ring and the heat exchanger front cover.
Torque Value: 16 N•m [ 144 in-lb ]
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.
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.
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.
Heat Exchanger K38, K50, QSK38, and QSK50
Page 8-110 Section 8 — Cooling System — Group 08
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
reduce the possibility of personal injury, use a hoist
or get assistance to lift the component.
NOTE: Not all engines are equipped with this option.
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.
Torque Value: 135 N•m [ 100 ft-lb ]
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.
K38, K50, QSK38, and QSK50 Heat Exchanger
Section 8 — Cooling System — Group 08 Page 8-111
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 capscrews.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the clamps.
Torque Value: 5 N•m [ 50 in-lb ]
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 capscrews.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the clamps.
Torque Value: 5 N•m [ 44 in-lb ]
Heat Exchanger K38, K50, QSK38, and QSK50
Page 8-112 Section 8 — Cooling System — Group 08
Install the four gaskets (1) and the four connections (2) to
the sea water manifold as shown.
Tighten the capscrews.
Torque Value: 40 N•m [ 30 ft-lb ]
K38, K50, QSK38, and QSK50 Heat Exchanger
Section 8 — Cooling System — Group 08 Page 8-113
Install the hose (3), the clamps, the gasket (4), and the
lower heat exchanger inlet pipe (5) as shown.
Tighten the capscrews.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the hose clamps.
Torque Value: 5 N•m [ 44 in-lb ]
Install the hose (6), the clamps, the gasket (7), and the
lower heat exchanger outlet pipe (8) as shown.
Tighten the capscrews.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the hose clamps.
Torque Value: 5 N•m [ 44 in-lb ]
Install the hose (9), the clamps, the gasket (10), and the
upper heat exchanger inlet pipe (11) as shown.
Tighten the capscrews.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the hose clamps.
Torque Value: 5 N•m [ 44 in-lb ]
Heat Exchanger K38, K50, QSK38, and QSK50
Page 8-114 Section 8 — Cooling System — Group 08
The pipe (14) must be routed between the pipe (15) and
the heat exchangers.
Install the hose (12), the clamps, the gasket (13), and the
upper heat exchanger outlet pipe (14) as shown.
Tighten the capscrews.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the hose clamps.
Torque Value: 5 N•m [ 44 in-lb ]
The sea water pipes are always connected to the ends of
the heat exchangers.
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.
Always tighten the capscrews before tightening the hose
clamps and the V-band clamps.
Torque Value: 20 N•m [ 15 ft-lb ]
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.
Tighten the capscrews.
Torque Value: 40 N•m [ 30 ft-lb ]
K38, K50, QSK38, and QSK50 Heat Exchanger
Section 8 — Cooling System — Group 08 Page 8-115
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.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the hose clamps.
Torque Value: 5 N•m [ 44 in-lb ]
Install the gasket (6) and the lower heat exchanger inlet
pipe (7) as shown.
Tighten the capscrews.
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.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the hose clamps.
Torque Value: 5 N•m [ 44 in-lb ]
Install the hose (11), the hose clamps, the gasket (12), and
the lower heat exchanger outlet pipe (13) as shown.
Tighten the capscrews.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the hose clamps.
Torque Value: 5 N•m [ 50 in-lb ]
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.
Tighten the capscrews.
Install the seal (18) and the V-band clamp to the right bank
pump outlet as shown.
Tighten the V-band clamp.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the hose clamps.
Torque Value: 5 N•m [ 44 in-lb ]
Heat Exchanger K38, K50, QSK38, and QSK50
Page 8-116 Section 8 — Cooling System — Group 08
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.
Tighten the V-band clamp.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the hose clamps.
Torque Value: 5 N•m [ 44 in-lb ]
The pipe (24) must be routed between the pipe (25) and
the heat exchangers.
Install the hose (22), the hose clamps, the gasket (23), and
the upper heat exchanger outlet pipe (24) as shown.
Tighten the capscrews.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the hose clamps.
Torque Value: 5 N•m [ 44 in-lb ]
Install the gasket (6) and the lower heat exchanger inlet
pipe (7) as shown.
Tighten the capscrews.
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.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the hose clamps.
Torque Value: 5 N•m [ 44 in-lb ]
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.
K38, K50, QSK38, and QSK50 Heat Exchanger
Section 8 — Cooling System — Group 08 Page 8-117
Install the o-rings onto the bottom flange of the LTA tubes
and the jacket water manifold as the assembly is lowered
into place.
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.
Torque Value: 365 N•m [ 270 ft-lb ]
Lift the heat exchanger assembly onto the engine.
Finishing Steps
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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.
Fill the cooling system.
Refer to Procedure 008-018.
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
Page 8-122 Section 8 — Cooling System — Group 08
Remove
Spline Drive
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.
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.
K38, K50, QSK38, and QSK50 Sea Water Pump
Section 8 — Cooling System — Group 08 Page 8-123
Remove the cotter pin (5), slotted nut (6), and washer (7).
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.
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.
K38, K50, QSK38, and QSK50 Sea Water Pump
Section 8 — Cooling System — Group 08 Page 8-125
Remove the port plate (17) and mechanical seal (18) from
the drive end of the pump body (14).
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).
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).
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).
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.
Sea Water Pump K38, K50, QSK38, and QSK50
Page 8-128 Section 8 — Cooling System — Group 08
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a 5-percent detergent solution to clean the parts.
Dry with compressed air.
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.
K38, K50, QSK38, and QSK50 Sea Water Pump
Section 8 — Cooling System — Group 08 Page 8-129
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.
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.
Sea Water Pump K38, K50, QSK38, and QSK50
Page 8-130 Section 8 — Cooling System — Group 08
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:
Torque Value: 160 N•m [ 120 ft-lb ]
If the nut requires a [1.125 in] wrench:
Torque Value: 110 N•m [ 80 ft-lb ]
The larger nut is recommended.
Sea Water Pump K38, K50, QSK38, and QSK50
Page 8-132 Section 8 — Cooling System — Group 08
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.
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).
K38, K50, QSK38, and QSK50 Sea Water Pump
Section 8 — Cooling System — Group 08 Page 8-133
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).
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).
Torque Value: 5 N•m [ 44 in-lb ]
K38, K50, QSK38, and QSK50 Sea Water Pump
Section 8 — Cooling System — Group 08 Page 8-135
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
Page 8-136 Section 8 — Cooling System — Group 08
Install
Spline Drive
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.
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.
Torque Value: 75 N•m [ 55 ft-lb ]
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.
Remove
with Mechanically Actuated Injector
NOTE: Not all engines are equipped with this option.
Remove both of the sea water pump oil supply tubes right
bank and left bank (17).
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 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.
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 sea water pump support and
gear.
Dry with compressed air.
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 sea water pump support.
Dry with compressed air.
Inspect the sea water pump support for damage.
Replace if damage is found.
K38, K50, QSK38, and QSK50 Sea Water Pump Support
Section 8 — Cooling System — Group 08 Page 8-139
Install
with Mechanically Actuated Injector
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.
Torque Value: 30 N•m [ 20 ft-lb ]
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 the component or assembly.
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.
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 N•m [ 25 ft-lb ]
Supplemental Coolant Additive (SCA) K38, K50, QSK38, and QSK50
Page 8-140 Section 8 — Cooling System — Group 08
Finishing Steps
• Install the sea water pump. Refer to Procedure
008-057.
• Open the water supply valve to the sea water pump.
• Operate the engine and check for leaks.
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
Section 8 — Cooling System — Group 08 Page 8-141
WARNING
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to
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
Page 8-142 Section 8 — Cooling System — Group 08
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
Section 8 — Cooling System — Group 08 Page 8-143
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 Water Pump With Inlet Install Impeller Install Shaft Install Spacer Spacer Length
Model Body Connection mm [in]
K38 3030489 3001712 3050453 or 3050442 or 3030487 35.17 [1.385]
3001711 3175527
206456 3050455 or 3050442 or 3030487 35.17 [1.385]
3175069 3175527
3001317 3001712 3050453 or 3050442 or 3175570 23.68 [0.935]
3001711 3175527 If 206194 NONE
-->
206456 3050455 or 3050442 or 3175570 23.68 [0.935]
3175069 3175527 If 206194 NONE
-->
206192 3001712 3050453 or 3050442 or 3175570 23.68[0.935]
3001711 3175527 If 206194 NONE
-->
206456 3050455 or 3050442 or 3175570 23.68 [0.935]
3175069 3175527 If 206194 NONE
-->
K50 3030490 3002108 3050454 or 3050442 or 3030487 35.17 [1.385]
3002106 3175527
3002107 3002108 3050454 or 3050442 or 3175570 23.68 [0.935]
3002106 3175527 NONE
Water Pump K38, K50, QSK38, and QSK50
Page 8-144 Section 8 — Cooling System — Group 08
Preparatory Steps
with Mechanically Actuated Injector
WARNING
Batteries can emit explosive gases. To reduce the
possibility of 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.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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.
• Disconnect the battery cables. Refer to Procedure
013-009 (Battery and Cables Connections) in Section
13.
• Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
• Remove the coolant bypass tube. Refer to Procedure
008-005 (Coolant Bypass Tube) in Section 8.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of 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.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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.
• Disconnect the battery cables. Refer to Procedure
013-009 (Battery and Cables Connections) in Section
13.
• Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
• 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.
K38, K50, QSK38, and QSK50 Water Pump
Section 8 — Cooling System — Group 08 Page 8-145
Remove
with Mechanically Actuated Injector
Disconnect the lower radiator hose from the water pump
inlet.
NOTE: On low temperature aftercooler (LTA) equipped
engines, disconnect the water filter hoses.
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.
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).
Remove the two brackets and U clamps (1) from the low
temperature aftercooler outlet (2) and jacket water bypass
pipes (3).
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
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.
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.
Water Pump K38, K50, QSK38, and QSK50
Page 8-148 Section 8 — Cooling System — Group 08
WARNING
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers 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.
Clean all gasket surfaces.
Use solvent to clean the drive shaft end of the pump.
Dry with compressed air.
Disassemble
with Mechanically Actuated Injector
Remove the following parts:
• Spline coupling (1)
• Mounting gasket (2)
• Adapter plate (3)
• O-ring (4)
• Adapter plate gasket (5).
Discard the o-ring and gasket.
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.
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).
Water Pump K38, K50, QSK38, and QSK50
Page 8-152 Section 8 — Cooling System — Group 08
Inspect
with Mechanically Actuated Injector
NOTE: Three different shafts have been used. The
outside diameter in the bearing area is the same.
Measure the outside diameter
Assemble
with Mechanically Actuated Injector
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).
K38, K50, QSK38, and QSK50 Water Pump
Section 8 — Cooling System — Group 08 Page 8-155
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
The mandrel must contact on the inner race of the
bearing to prevent damage.
Use a hydraulic press to support the shaft as shown.
Use a water pump bearing mandrel, Part Number
3375318 (8), or equivalent.
Push the small bearing (2) on the shaft until it touches the
spacer (5).
CAUTION
The mandrel must contact on the inner race of the
bearing to prevent damage.
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.
Use a water pump bearing mandrel, Part Number
3375318 (8), or equivalent. Use an appropriate mandrel
(4). Use an arbor press. Support the shaft.
Install the bearings.
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.
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.
Water Pump K38, K50, QSK38, and QSK50
Page 8-158 Section 8 — Cooling System — Group 08
Install
with Mechanically Actuated Injector
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.
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.
Torque Value: 60 N•m [ 45 ft-lb ]
Tighten the four cylinder block capscrews to the adapter
plate.
Torque Value: 40 N•m [ 30 ft-lb ]
K38, K50, QSK38, and QSK50 Water Pump
Section 8 — Cooling System — Group 08 Page 8-161
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.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the capscrews that hold the bracket to the hand
hole cover.
Torque Value: 60 N•m [ 45 ft-lb ]
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.
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.
Tighten the capscrews.
Torque Value:
Water Pump 80 N•m [ 59 ft-lb ]
Mounting
Capscrews
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).
Torque Value: 45 N•m [ 33 ft-lb ]
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.
Torque Value: 28 N•m [ 21 ft-lb ]
Water Pump K38, K50, QSK38, and QSK50
Page 8-164 Section 8 — Cooling System — Group 08
Finishing Steps
with Mechanically Actuated Injector
WARNING
Batteries can emit explosive gases. To reduce the
possibility of 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.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Connect the battery cables. Refer to Procedure
013-009 (Battery and Cables Connections) in Section
13.
• Operate the engine to 70°C [160°F] coolant
temperature and check for leaks.
K38, K50, QSK38, and QSK50 Sea Water System Diagnostics
Section 8 — Cooling System — Group 08 Page 8-165
WARNING
Batteries can emit explosive gases. To reduce the
possibility of 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.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Connect the battery cables. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13.
• Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
• 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.
• Operate the engine to 70°C [160°F] coolant
temperature and check for leaks.
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
Page 8-166 Section 8 — Cooling System — Group 08
Test
Attach a vacuum gauge to the inlet side of the sea water
pump.
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.
Remove
Remove the nuts and washers from the ECM cooling plate
mounting studs and remove the ECM cooling plate.
Disassemble
Remove the vibration isolators from the ECM cooling
plate.
ECM Cooling Plate K38, K50, QSK38, and QSK50
Page 8-170 Section 8 — Cooling System — Group 08
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
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.
K38, K50, QSK38, and QSK50 ECM Cooling Plate
Section 8 — Cooling System — Group 08 Page 8-171
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
Install the cooling plate mounting studs onto the block
manifold and cylinder block.
Torque Value:
ECM Mounting 80 N•m [ 59 ft-lb ]
Studs
Install the ECM cooling plate and mounting nuts onto the
mounting studs.
Torque Value:
ECM Cooling 23 N•m [ 17 ft-lb ]
Plate Nuts
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
Control System QSK50 and QSK60 Modular
Common Rail System Series Engines, Bulletin
4021533.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine and check for leaks.
K38, K50, QSK38, and QSK50 ECM Cooling Plate Lines
Section 8 — Cooling System — Group 08 Page 8-175
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause serious personal
injury.
• Drain the cooling system. Refer to Procedure
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.
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.
Torque Value: 15 N•m [ 133 in-lb ]
Finishing Steps
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine and check for leaks.
K38, K50, QSK38, and QSK50
Section 9 — Drive Units — Group 09 Page 9-a
Finishing Steps...............................................................................................................................................9-36
with Mechanically Actuated Injector..............................................................................................................9-36
with Electronically Actuated Injector............................................................................................................. 9-37
Initial Check....................................................................................................................................................9-24
with Electronically Actuated Injector............................................................................................................. 9-24
Install..............................................................................................................................................................9-35
with Mechanically Actuated Injector..............................................................................................................9-35
with Electronically Actuated Injector............................................................................................................. 9-36
Preparatory Steps...........................................................................................................................................9-23
with Mechanically Actuated Injector..............................................................................................................9-23
with Electronically Actuated Injector............................................................................................................. 9-23
Remove.......................................................................................................................................................... 9-24
with Mechanically Actuated Injector..............................................................................................................9-24
with Electronically Actuated Injector............................................................................................................. 9-24
Hydraulic Pump Drive ..................................................................................................................................... 9-37
Assemble........................................................................................................................................................9-40
Clean and Inspect for Reuse...........................................................................................................................9-39
Clean for Rebuild............................................................................................................................................9-39
Disassemble................................................................................................................................................... 9-38
Finishing Steps...............................................................................................................................................9-41
General Information.........................................................................................................................................9-37
Inspect............................................................................................................................................................9-39
Install..............................................................................................................................................................9-41
Preparatory Steps...........................................................................................................................................9-37
Remove.......................................................................................................................................................... 9-37
Hydraulic Pump Drive Gear and Shaft ............................................................................................................9-42
Assemble........................................................................................................................................................9-43
Clean and Inspect for Reuse...........................................................................................................................9-42
Disassemble................................................................................................................................................... 9-42
Rear Gear Drive (Lower Assembly) ................................................................................................................ 9-43
Assemble........................................................................................................................................................9-49
Clean..............................................................................................................................................................9-45
Clean for Rebuild............................................................................................................................................9-47
Disassemble................................................................................................................................................... 9-46
Finishing Steps...............................................................................................................................................9-53
General Information.........................................................................................................................................9-43
Inspect............................................................................................................................................................9-47
Install..............................................................................................................................................................9-51
Preparatory Steps...........................................................................................................................................9-44
Remove.......................................................................................................................................................... 9-44
Rear Gear Drive (Upper Assembly) .................................................................................................................9-53
Assemble........................................................................................................................................................9-61
Clean..............................................................................................................................................................9-58
Clean for Rebuild............................................................................................................................................9-59
Disassemble................................................................................................................................................... 9-55
General Information.........................................................................................................................................9-53
Inspect............................................................................................................................................................9-59
Inspect for Reuse............................................................................................................................................9-58
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
Inspect for Reuse............................................................................................................................................9-65
Service Tools ....................................................................................................................................................9-1
Drive Units........................................................................................................................................................9-1
Water Pump Drive Bushing .............................................................................................................................9-68
Clean and Inspect for Reuse...........................................................................................................................9-68
Mechanically Actuated Injector.....................................................................................................................9-68
Install..............................................................................................................................................................9-69
Mechanically Actuated Injector.....................................................................................................................9-69
Remove.......................................................................................................................................................... 9-68
K38, K50, QSK38, and QSK50
Section 9 — Drive Units — Group 09 Page 9-c
Service Tools
Drive Units
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.
Coupling Puller
Remove the spline coupling gear from the compressor drive.
3376663
Torque Wrench
Used to tighten capscrews 13 to 136 N•m [10 to 100 ft-lb].
3164794
K38, K50, QSK38, and QSK50 Accessory Drive
Section 9 — Drive Units — Group 09 Page 9-3
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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.
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.
Refer to Procedure 009-004.
• Remove the accessory drive cover, if applicable.
Refer to Procedure 009-039.
• Remove the accessory drive seal, if applicable.
Refer to Procedure 001-003.
Remove
with Mechanically Actuated Injector
Remove the six capscrews.
Remove the accessory drive assembly.
Remove and inspect gasket.
Initial Check
with Mechanically Actuated Injector
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.
Use solvent to clean the outer housing of the accessory
drive.
Accessory Drive K38, K50, QSK38, and QSK50
Page 9-4 Section 9 — Drive Units — Group 09
Disassemble
with Mechanically Actuated Injector
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.
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.
Remove the clamping washer (1).
Remove the gear and shaft assembly.
Remove the pipe plug from the housing.
Use solvent to clean the parts.
K38, K50, QSK38, and QSK50 Accessory Drive
Section 9 — Drive Units — Group 09 Page 9-5
Only remove the gear from the shaft when the gear or the
shaft must be replaced.
Use an arbor press to remove the gear.
Accessory Drive K38, K50, QSK38, and QSK50
Page 9-6 Section 9 — Drive Units — Group 09
Inspect the shaft in the gear fit area for fretting or burrs.
Clean burrs with emery cloth.
Assemble
with Mechanically Actuated Injector
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 235°C [450°F] for not less than one hour,
and not more than six hours.
WARNING
Wear protective clothing to reduce the possibility of
personal injury from burns.
Support the gear.
Slide the shaft into 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.
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.
Install
with Mechanically Actuated Injector
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
Section 9 — Drive Units — Group 09 Page 9-11
Finishing Steps
with Mechanically Actuated Injector
• Install the accessory drive seal, if applicable. Refer
to Procedure 001-003.
• Install the accessory drive pulley, if applicable. Refer
to Procedure 009-004.
• Install the accessory drive cover, if applicable. Refer
to Procedure 009-039.
• 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.
• Operate the engine until the coolant temperature
reaches 71°C [160°F]. Check for coolant leaks.
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.
Standard Bushing
• Measure the inside diameter
Flanged Bushing
• Measure the inside diameter
Install
Mechanically Actuated Injector
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.
CAUTION
The bushings must be pressed in square to the bores
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
Page 9-14 Section 9 — Drive Units — Group 09
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 the shaft in the gear fit area for fretting or burrs.
K38, K50, QSK38, and QSK50 Accessory Drive Gear and Shaft
Section 9 — Drive Units — Group 09 Page 9-15
Assemble
with Mechanically Actuated Injector
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.
WARNING
Wear protective clothing to reduce the risk of
personal injury from burns.
CAUTION
Do not exceed the specified time or temperature.
Damage to the gear teeth will result.
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 235°C [450°F].
WARNING
Wear protective clothing to reduce the risk of
personal injury from burns.
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.
Remove the woodruff key (3). Remove the oil slinger (4).
Discard the slinger.
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 rick of personal injury.
Use solvent and a clean cloth. Clean the pulley wear
sleeve.
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
Section 9 — Drive Units — Group 09 Page 9-19
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.
After the press fit has been relieved, remove the wear
sleeve by hand.
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.
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
Page 9-22 Section 9 — Drive Units — Group 09
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.
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.
Clean the alternator drive and accessory drive pulley with
steam or solvent .
Dry with compressed air.
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
Section 9 — Drive Units — Group 09 Page 9-23
Finishing Steps
• Install and adjust the alternator belt. Refer to
Procedure 013-005 (Alternator Drive Pulley) in
Section 9.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
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.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the fuel pump. Refer to Procedure 005-016.
• 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 fuel pump. Refer to Procedure 005-016.
• Remove the accessory drive pulley. Refer to
Procedure 009-004.
• Remove the accessory drive cover (if applicable).
Refer to Procedure 009-039.
• Remove the accessory drive seal (if applicable).
Refer to Procedure 001-003.
Fuel Pump Drive K38, K50, QSK38, and QSK50
Page 9-24 Section 9 — Drive Units — Group 09
Remove
with Mechanically Actuated Injector
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.
Initial Check
with Electronically Actuated Injector
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.
Use solvent to clean the outer housing of the fuel pump
drive.
K38, K50, QSK38, and QSK50 Fuel Pump Drive
Section 9 — Drive Units — Group 09 Page 9-25
Disassemble
with Electronically Actuated Injector
Remove the straight thread o-ring plug from the fuel pump
drive.
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.
Clean the fuel pump drive assembly and inspect it for
reuse.
Clean the pulley and inspect it for reuse.
Inspect the shaft in the gear fit area for fretting or burrs.
Clean burrs with emery cloth.
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 fuel pump drive components.
Dry with compressed air.
Inspect the shaft in the gear fit area for fretting or burrs.
Clean burrs with emery cloth.
Assemble
with Mechanically Actuated Injector
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 235°C [450°F] for not less than one hour,
and not more than six hours.
WARNING
Wear protective clothing to reduce the possibility of
personal injury from burns.
Support the gear.
Slide the shaft into the gear until the shoulder of the shaft
touches the gear.
K38, K50, QSK38, and QSK50 Fuel Pump Drive
Section 9 — Drive Units — Group 09 Page 9-31
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.
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 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.
Fuel Pump Drive K38, K50, QSK38, and QSK50
Page 9-32 Section 9 — Drive Units — Group 09
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 204°C [400°F] for not less than one hour,
and not more than six hours.
WARNING
Wear protective clothing to reduce the possibility of
personal injury from burns.
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.
Fuel Pump Drive K38, K50, QSK38, and QSK50
Page 9-34 Section 9 — Drive Units — Group 09
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.
Install
with Mechanically Actuated Injector
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
necessary to engage the gears.
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.
Torque Value: 60 N•m [ 40 ft-lb ]
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.
Finishing Steps
with Mechanically Actuated Injector
• Install the accessory drive pulley. Refer to Procedure
009-004.
• Install the air compressor. Refer to Procedure
012-014.
• Install the fuel pump. Refer to Procedure 005-016.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine to 70°C [160°F] coolant
temperature and check for leaks.
K38, K50, QSK38, and QSK50 Hydraulic Pump Drive
Section 9 — Drive Units — Group 09 Page 9-37
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
Page 9-38 Section 9 — Drive Units — Group 09
Disassemble
Remove the locktight capscrews and if fitted the lock
washers. Remove the cover (if equipped).
Remove and discard the gasket.
WARNING
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers recommendation
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.
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.
WARNING
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to
reduce the risk of personal injury.
Use solvent. Clean all the parts.
Inspect
Check the grooved surface of the thrust bearing for
damage.
Measure the thickness.
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.
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
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.
Torque Value: 60 N•m [ 44 ft-lb ]
Finishing Steps
• Install the hydraulic pump. Refer to the OEM service
manual.
Hydraulic Pump Drive Gear and Shaft K38, K50, QSK38, and QSK50
Page 9-42 Section 9 — Drive Units — Group 09
WARNING
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to
reduce the risk of personal injury.
Use solvent. Clean the shaft and gear.
Dry with compressed air.
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.
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
Page 9-44 Section 9 — Drive Units — Group 09
Preparatory Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arching, remove the negative
(-) battery cable first and attach the negative (-) battery
cable last.
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.
• Disconnect the air supply to the starter. Refer to
Procedure 012-022.
• Disconnect the batteries. Refer to Procedure
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
Troubleshooting and Repair Manual Electronic
Control System QSK50 and QSK60 Modular
Common Rail System Series Engines, Bulletin
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.
K38, K50, QSK38, and QSK50 Rear Gear Drive (Lower Assembly)
Section 9 — Drive Units — Group 09 Page 9-45
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.
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
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Use solvent or steam. Clean the rear gear drive.
Gear Backlash
mm in
0.08 MIN 0.003
0.30 MAX 0.012
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.
Remove the upper (6) and lower (7) gears, and the four
thrust bearings (8).
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 risk 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 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).
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.
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
side of the housing.
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.
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.
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.
Rear Gear Drive (Lower Assembly) K38, K50, QSK38, and QSK50
Page 9-52 Section 9 — Drive Units — Group 09
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
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.
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).
Torque Value: 90 N•m [ 65 ft-lb ]
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.
Torque Value: 60 N•m [ 45 ft-lb ]
K38, K50, QSK38, and QSK50 Rear Gear Drive (Upper Assembly)
Section 9 — Drive Units — Group 09 Page 9-53
Finishing Steps
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.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arching, remove the negative
(-) battery cable first and attach the negative (-) battery
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
components. See the equipment manufacturer's
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
Troubleshooting and Repair Manual Electronic
Control System QSK50 and QSK60 Modular
Common Rail System Series Engines, Bulletin
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.
• Operate the engine and check for leaks.
Remove
NOTE: Not all engines are equipped with this option.
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
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: 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.
K38, K50, QSK38, and QSK50 Rear Gear Drive (Upper Assembly)
Section 9 — Drive Units — Group 09 Page 9-55
Disassemble
WARNING
The 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: 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
Do not damage the housing, port covers, or support
assemblies when separating the parts. An oil leak can
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.
Rear Gear Drive (Upper Assembly) K38, K50, QSK38, and QSK50
Page 9-56 Section 9 — Drive Units — Group 09
CAUTION
Do not damage the housing, port covers, or support
assemblies when separating the parts. An oil leak can
result.
Remove the parts.
• Capscrews and lock washers (13)
• Support and bushing assembly (14)
• O-ring (15)
• Thrust bearing (16)
Discard the o-ring.
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 pipe plug (25) from the bottom of the housing.
Remove the upper cover plate (26) and the gasket (27).
Rear Gear Drive (Upper Assembly) K38, K50, QSK38, and QSK50
Page 9-58 Section 9 — Drive Units — Group 09
Clean
WARNING
The 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: 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
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
CAUTION
Do not use solvent that will harm the silicone rubber
o-rings in the drive.
Use solvent or steam. Clean the drive.
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.
WARNING
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to
reduce the risk of personal injury.
Use solvent. Clean the parts.
Inspect
Check all parts for damage or wear.
Rear Gear Drive (Upper Assembly) K38, K50, QSK38, and QSK50
Page 9-60 Section 9 — Drive Units — Group 09
Shaft Protrusion
mm in
85.47 MIN 3.365
85.98 MAX 3.385
Assemble
Install the pipe plug (25) in the bottom of the housing.
Torque Value: 20 N•m [ 15 ft-lb ]
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.
Torque Value: 41 N•m [ 30 ft-lb ]
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.
Rear Gear Drive (Upper Assembly) K38, K50, QSK38, and QSK50
Page 9-62 Section 9 — Drive Units — Group 09
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.
Torque Value: 163 N•m [ 120 ft-lb ]
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.
Torque Value: 68 N•m [ 50 ft-lb ]
Use clean engine oil. Lubricate the thrust bearing (12), the
shaft (11), and the bushing in the housing.
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 (12) on the shaft (11).
With the short end first, install the shaft through the thrust
bearing and into the bushing.
CAUTION
The oil grooves in the thrust bearing must be toward
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).
Torque Value: 68 N•m [ 50 ft-lb ]
K38, K50, QSK38, and QSK50 Rear Gear Drive (Upper Assembly)
Section 9 — Drive Units — Group 09 Page 9-63
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.
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.
Torque Value: 47 N•m [ 35 ft-lb ]
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.
Torque Value: 47 N•m [ 35 ft-lb ]
Install a new cover plate gasket (6) and the cover plate (5).
Install the lock washers and the capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]
NOTE: If an alternator or a pump is to be installed on the
drive, tighten the capscrews to a torque of 366 N•m [270
ft-lb].
Rear Gear Drive (Upper Assembly) K38, K50, QSK38, and QSK50
Page 9-64 Section 9 — Drive Units — Group 09
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
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: 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.
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.
Torque Value: 90 N•m [ 65 ft-lb ]
K38, K50, QSK38, and QSK50 Rear Gear Drive Gear and Shaft (Upper Assembly)
Section 9 — Drive Units — Group 09 Page 9-65
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).
Torque Value: 90 N•m [ 60 ft-lb ]
Clean
Use clean engine oil. Clean the parts.
Assemble
WARNING
To reduce the possibility of severe burns, wear
protective gloves when installing the heated ring gear.
CAUTION
Do not exceed the specified time or temperature.
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 235°C [450°F].
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.
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.
WARNING
To reduce the possibility of severe burns, wear
protective gloves when installing the heated ring gear.
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
Page 9-68 Section 9 — Drive Units — Group 09
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
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to
reduce the risk of personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Standard Bushing
Use solvent to clean the housing.
Dry with compressed air.
K38, K50, QSK38, and QSK50 Water Pump Drive Bushing
Section 9 — Drive Units — Group 09 Page 9-69
Flanged Bushing
Clean and inspect all parts.
NOTE: The oil drillings must be open and free of any
blockage.
Install
Mechanically Actuated Injector
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
Page 9-70 Section 9 — Drive Units — Group 09
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.
Assemble
Mechanically Actuated Injector
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.
Remove
NOTE: A capscrew fitted to the end of the shaft will
prevent damage to the threads.
Install the capscrew (1). Use a puller (2), ST-647, or
equivalent. Remove the pulley from the water pump drive
shaft.
Woodward Governor Drive K38, K50, QSK38, and QSK50
Page 9-72 Section 9 — Drive Units — Group 09
Install
CAUTION
Do not use a hammer to position the pulley. The thrust
bearings in the water pump drive can be damaged and
the water pump drive can fail.
Use the pulley installation tool kit, Part Number 3376326.
Install the appropriate adapter (1) in the pusher (2).
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 and 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 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.
Remove the tool and adapter.
Finishing Steps
• Install alternator belt. Refer to Procedure 013-005.
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.
Clean and Inspect for Reuse
WARNING
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to
reduce the risk of personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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.
Disassemble
with Mechanically Actuated Injector
Remove the locknut (1) and the retaining washer (2).
Discard the locknut.
Woodward Governor Drive K38, K50, QSK38, and QSK50
Page 9-74 Section 9 — Drive Units — Group 09
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).
WARNING
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to
reduce the risk 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 parts. Dry with compressed air.
Inspect
with Mechanically Actuated Injector
Measure the seal and bearing bores in the support (9).
Check the shaft and gear for damage. Measure the shaft
at the locations illustrated.
Assemble
with Mechanically Actuated Injector
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).
Woodward Governor Drive K38, K50, QSK38, and QSK50
Page 9-78 Section 9 — Drive Units — Group 09
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.
End Clearance
mm in
0.05 MIN 0.002
0.10 MAX 0.004
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.
Notes
K38, K50, QSK38, and QSK50
Section 10 — Air Intake System — Group 10 Page 10-a
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
Clean and Inspect for Reuse........................................................................................................................10-167
Center-Mount...........................................................................................................................................10-167
Air Cleaner Assembly (Engine-Mounted) ......................................................................................................10-61
Clean and Inspect for Reuse......................................................................................................................... 10-64
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
Inspect for Reuse..........................................................................................................................................10-67
Air Crossover (Center-Mount Aftercooler) ....................................................................................................10-68
Clean and Inspect for Reuse......................................................................................................................... 10-68
Finishing Steps............................................................................................................................................. 10-69
with Mechanically Actuated Injector............................................................................................................10-69
Install............................................................................................................................................................10-69
with Mechanically Actuated Injector............................................................................................................10-69
Preparatory Steps......................................................................................................................................... 10-68
with Mechanically Actuated Injector............................................................................................................10-68
Remove.........................................................................................................................................................10-68
with Mechanically Actuated Injector............................................................................................................10-68
Air Intake Restriction .................................................................................................................................... 10-71
Measure........................................................................................................................................................10-71
Air Leaks, Air Intake and Exhaust Systems .................................................................................................10-69
Inspect for Reuse..........................................................................................................................................10-69
Service Tools ...................................................................................................................................................10-1
Air Intake System............................................................................................................................................10-1
Turbocharger .................................................................................................................................................10-73
Assemble......................................................................................................................................................10-99
Clean............................................................................................................................................................10-91
Clean and Inspect for Reuse......................................................................................................................... 10-96
Disassemble..................................................................................................................................................10-94
Finishing Steps............................................................................................................................................10-129
MAI..........................................................................................................................................................10-129
with Electronically Actuated Injector..........................................................................................................10-129
General Information.......................................................................................................................................10-73
with Mechanically Actuated Injector............................................................................................................10-73
Inspect for Reuse..........................................................................................................................................10-91
Install..........................................................................................................................................................10-101
with Mechanically Actuated Injector..........................................................................................................10-101
with Electronically Actuated Injector..........................................................................................................10-126
Measure........................................................................................................................................................10-98
Preparatory Steps......................................................................................................................................... 10-75
MAI............................................................................................................................................................10-75
with Electronically Actuated Injector............................................................................................................10-76
Remove.........................................................................................................................................................10-77
with Mechanically Actuated Injector............................................................................................................10-77
with Electronically Actuated Injector............................................................................................................10-88
Turbocharger Axial Clearance ....................................................................................................................10-137
Finishing Steps............................................................................................................................................10-140
Measure......................................................................................................................................................10-138
Preparatory Steps........................................................................................................................................10-137
K38, K50, QSK38, and QSK50
Section 10 — Air Intake System — Group 10 Page 10-c
Service Tools
Air Intake 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.
Torque Wrench
An inch-pound dial-type torque wrench.
3824783
Torque Wrench
Used to tighten capscrews 13 to 136 N•m [10 to 100 ft-lb].
3164794
Anti-Seize Compound
Lubricant that speeds assembly and disassembly of studs, bolts,
3824879 capscrews, flanges, and fittings.
Fluorescent Tracer
Used to determine the source of oil leaks. It must be used with a
3376891 black light.
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.
Exploded View
Aftercooler, Outboard
Aftercooler, Outboard
Reference Quantity (per Engine)
Number Description K38 K50
1 Connection, Air Crossover 2 2
2 Clamp, Vee-Band 2 2
3 Connection, Air Crossover 2 2
4 Seal, O-Ring 4 4
5 Connection, Air Crossover 2 2
6 Seal, Dust 2 2
7 Connection, Air Crossover 2 2
8 Gasket, Connection 4 4
K38, K50, QSK38, and QSK50 Aftercooler
Section 10 — Air Intake System — Group 10 Page 10-7
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 1 1
2)
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) 2 2
(Refer to Note 1)
30 Manifold, Air Intake ( Right Bank Rear, Left Bank Front) 2 2
(Refer to Note 1)
31 Tube, Water Inlet (Right Bank Rear) (Refer to Notes 1 and 1 1
2)
32 Tube, Water Outlet (Right Bank Rear) (Refer to Notes 1 1 1
and 2)
33 Elbow, 90 Degree (to the Rocker Lever Housing) (Refer to 1 1
Note 2)
Reference
Number Description Quantity
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
Page 10-12 Section 10 — Air Intake System — Group 10
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 (Battery Cables and Connections) in Section
13.
• Drain the coolant. Refer to Procedure 008-018
(Cooling System) in Section 8.
K38, K50, QSK38, and QSK50 Aftercooler Assembly
Section 10 — Air Intake System — Group 10 Page 10-13
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
• 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.
• Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
Remove
with Mechanically Actuated Injector
Center Mount Aftercooler
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.
Aftercooler Assembly K38, K50, QSK38, and QSK50
Page 10-14 Section 10 — Air Intake System — Group 10
WARNING
This assembly or 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.
NOTE: Older engines have eight support bracket to the
support leg capscrews (2)
Remove the 12 capscrews (2).
Remove the aftercooler assembly (3).
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: 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.
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.
Remove all of the capscrews. Remove the aftercooler
assembly (2) and the gaskets.
Remove the rectangular seal sleeves (28).
Discard the seals and gaskets.
Aftercooler Assembly K38, K50, QSK38, and QSK50
Page 10-18 Section 10 — Air Intake System — Group 10
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.
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
with Mechanically Actuated Injector
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.
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
Discard the gaskets.
Remove the o-rings (6) from the inner adapters (4).
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.
Low Temperature Aftercooler (LTA) System
NOTE: This procedure is performed while the intake
manifold (aftercooler housing) remains on the engine.
Remove the fourteen capscrews (27), washers (26), and
spacers (29).
Aftercooler Assembly K38, K50, QSK38, and QSK50
Page 10-22 Section 10 — Air Intake System — Group 10
Pressure Test
with Mechanically Actuated Injector
Plug one coolant connection with a hose and pipe plug.
Tighten the hose clamps.
Attach an air line with an air pressure regulator and gauge
to the other coolant connection.
Heating the tank of water to 50°C [122°F] 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.
Aftercooler Assembly K38, K50, QSK38, and QSK50
Page 10-24 Section 10 — Air Intake System — Group 10
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.
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.
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.
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
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 all gasket surfaces.
Use solvent or steam. Clean the parts.
K38, K50, QSK38, and QSK50 Aftercooler Assembly
Section 10 — Air Intake System — Group 10 Page 10-25
Assemble
with Mechanically Actuated Injector
Center Mount Aftercooler
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.
Torque Value: 25 N•m [ 20 ft-lb ]
Repeat this step for the other side of the assembly.
Install the new cover plate gaskets (5) and plates (4).
Torque Value: 25 N•m [ 20 ft-lb ]
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.
K38, K50, QSK38, and QSK50 Aftercooler Assembly
Section 10 — Air Intake System — Group 10 Page 10-27
Standard System
Install the element (10) in the manifold (8). Install the eight
capscrews (9) that contain the captive spring washers.
Torque Value: 25 N•m [ 20 ft-lb ]
Aftercooler Assembly K38, K50, QSK38, and QSK50
Page 10-28 Section 10 — Air Intake System — Group 10
Install a new gasket (7) and cover (6). Install the 21 captive
capscrews and flat washers (5).
Torque Value: 25 N•m [ 20 ft-lb ]
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.
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.
K38, K50, QSK38, and QSK50 Aftercooler Assembly
Section 10 — Air Intake System — Group 10 Page 10-29
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.
Aftercooler Assembly K38, K50, QSK38, and QSK50
Page 10-30 Section 10 — Air Intake System — Group 10
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.
Check the four aftercooler element locating pins for proper
location.
Install
with Mechanically Actuated Injector
WARNING
This assembly or 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.
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.
Center Mount Aftercooler
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.
Torque Value: 60 N•m [ 45 ft-lb ]
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).
Torque Value: 25 N•m [ 20 ft-lb ]
Tighten the two capscrews (10).
Torque Value: 40 N•m [ 30 ft-lb ]
Aftercooler Assembly K38, K50, QSK38, and QSK50
Page 10-34 Section 10 — Air Intake System — Group 10
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.
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.
K38, K50, QSK38, and QSK50 Aftercooler Assembly
Section 10 — Air Intake System — Group 10 Page 10-35
Install two o-ring seals (11) on the tube (12) for the air
crossover. Install the dust seal (13) on the tube.
Use engine oil or Lubriplate™ 105, Part Number 3163087,
multi-purpose lubricant. Lubricate the seals.
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.
Torque Value: 9 N•m [ 80 in-lb ]
Use a mallet. Tap around the clamp to be sure it is seated.
Tighten the clamp nut.
Torque Value: 9 N•m [ 80 in-lb ]
Continue tapping and tightening the clamp nut until it does
not turn at the specified torque after tapping.
Aftercooler Assembly K38, K50, QSK38, and QSK50
Page 10-36 Section 10 — Air Intake System — Group 10
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.
Outboard Aftercooler - LTA Cooling System
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.
Aftercooler Assembly K38, K50, QSK38, and QSK50
Page 10-38 Section 10 — Air Intake System — Group 10
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).
Torque Value: 25 N•m [ 20 ft-lb ]
Tighten the t-bolt clamps.
Torque Value: 8 N•m [ 70 in-lb ]
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.
Torque Value: 40 N•m [ 30 ft-lb ]
Center the hose (18) over the gap between the
connections (15 and 17).
K38, K50, QSK38, and QSK50 Aftercooler Assembly
Section 10 — Air Intake System — Group 10 Page 10-39
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).
Torque Value: 9 N•m [ 80 in-lb ]
Aftercooler Assembly K38, K50, QSK38, and QSK50
Page 10-40 Section 10 — Air Intake System — Group 10
Install the tube clamps (7) and (8) on water transfer tubes
(5) and (6). Install capscrews (9).
Torque Value: 45 N•m [ 35 ft-lb ]
Check dust seals (29).
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.
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.
Install the air transfer tube between the aftercooler and the
turbocharger (marine only).
Install and tighten the hose clamps.
Torque Value: 11 N•m [ 96 in-lb ]
Finishing Steps
MAI
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Operate the engine and check for leaks.
Aftercooler Assembly K38, K50, QSK38, and QSK50
Page 10-44 Section 10 — Air Intake System — Group 10
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• 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
Common Rail System, Bulletin 4021533.
• 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).
• Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Operate the engine and check for leaks.
K38, K50, QSK38, and QSK50 Aftercooler Assembly (Center-Mount)
Section 10 — Air Intake System — Group 10 Page 10-45
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose or in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
• Drain the coolant. Refer to Procedure 008-018.
• Remove the coolant outlet pipes. Refer to Procedure
010-075.
Remove
with Mechanically Actuated Injector
Center Mount Aftercooler
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.
WARNING
This assembly or 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.
NOTE: Older engines have eight support bracket to the
support leg capscrews (2)
Remove the 12 capscrews (2).
Remove the aftercooler assembly (3).
Disassemble
with Mechanically Actuated Injector
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.
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
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
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.
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.
Assemble
with Mechanically Actuated Injector
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.
Torque Value: 25 N•m [ 20 ft-lb ]
Repeat this step for the other side of the assembly.
Install the new cover plate gaskets (5) and plates (4).
Torque Value: 25 N•m [ 20 ft-lb ]
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
with Mechanically Actuated Injector
WARNING
This assembly or 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.
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.
Torque Value: 60 N•m [ 45 ft-lb ]
Aftercooler Assembly (Center-Mount) K38, K50, QSK38, and QSK50
Page 10-52 Section 10 — Air Intake System — Group 10
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).
Torque Value: 25 N•m [ 20 ft-lb ]
Tighten the two capscrews (10).
Torque Value: 40 N•m [ 30 ft-lb ]
Finishing Steps
with Mechanically Actuated Injector
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose or in accordance with local
environmental regulations.
• Install the aftercooler water outlet tubes. Refer to
Procedure 010-075.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine and check for leaks.
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.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
This procedure describes several arrangements.
Outboard Aftercooler - Standard Cooling System
Outboard Aftercooler - LTA Cooling System
Center Mount Aftercooler
• Disconnect the batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13.
• Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
• Remove air coolant plumbing. Refer to Procedure
010-002 (After Cooler Assembly) in Section 10.
Remove
Standard
NOTE: This procedure is performed while the intake
manifold (aftercooler housing) remains on the engine.
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
Section 10 — Air Intake System — Group 10 Page 10-57
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.
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.
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.
Aftercooler Element K38, K50, QSK38, and QSK50
Page 10-58 Section 10 — Air Intake System — Group 10
Center-Mount
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.
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.
Remove both of the aftercooler covers (13) and gaskets
(14).
Remove the aftercooler cores (15) and the gaskets (14)
from the housing (16).
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.
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 010-002 (Aftercooler Assembly) in
Section 10.
LTA
Clean and check the element for reuse.
K38, K50, QSK38, and QSK50 Aftercooler Element
Section 10 — Air Intake System — Group 10 Page 10-59
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.
Torque Value: 25 N•m [ 20 ft-lb ]
Install a new gasket (7) and cover (6). Install the 21 captive
capscrews and flat washers (5).
Torque Value: 25 N•m [ 20 ft-lb ]
Aftercooler Element K38, K50, QSK38, and QSK50
Page 10-60 Section 10 — Air Intake System — Group 10
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.
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).
NOTE: Each cover contains 18 capscrews.
Install the flat washers, lock washers and capscrews.
Torque Value: 25 N•m [ 20 ft-lb ]
Repeat this step for the other side of the assembly.
Finishing Steps
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Install air and coolant plumbing. Refer to Procedure
010-002.
• Fill the cooling system. Refer to Procedure 008-018
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Operate the engine and check for leaks.
Remove the air cleaner air inlet tube support brackets and
mounting hardware.
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
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.
Remove the air filter assembly from the air cleaner
bracket.
K38, K50, QSK38, and QSK50 Air Cleaner Assembly (Engine-Mounted)
Section 10 — Air Intake System — Group 10 Page 10-63
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.
Slide the air cleaner out of the retaining straps.
Remove the left bank air cleaner support bracket from the
rear of the engine.
Air Cleaner Assembly (Engine-Mounted) K38, K50, QSK38, and QSK50
Page 10-64 Section 10 — Air Intake System — Group 10
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.
Remove the left bank air cleaner support bracket from the
rear of the engine.
Install
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.
Install the main air cleaner support bracket to the rear of
the engine, use a bolt and washer.
Torque Value: 40 N•m [ 30 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.
Torque Value: 40 N•m [ 30 ft-lb ]
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.
Torque Value: 10 N•m [ 96 in-lb ]
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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)
Section 10 — Air Intake System — Group 10 Page 10-67
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 parts. Dry with compressed air.
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.
• Steam clean the area around the air crossover.
Remove
with Mechanically Actuated Injector
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
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
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
Section 10 — Air Intake System — Group 10 Page 10-69
Install
with Mechanically Actuated Injector
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
with Mechanically Actuated Injector
• Operate the engine and check for leaks.
Turbocharger (010-033)
General Information
with Mechanically Actuated Injector
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:
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
Page 10-74 Section 10 — Air Intake System — Group 10
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.
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-75
Preparatory Steps
MAI
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
• Disconnect the batteries. Refer to Procedure
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.
Turbocharger K38, K50, QSK38, and QSK50
Page 10-76 Section 10 — Air Intake System — Group 10
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
• Disconnect the batteries. Refer to Procedure
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.
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-77
Remove
with Mechanically Actuated Injector
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 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.
Turbocharger K38, K50, QSK38, and QSK50
Page 10-78 Section 10 — Air Intake System — Group 10
WARNING
The 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.
Remove the four capscrews (8) and nuts (9).
Remove the turbocharger and gasket.
Discard the gasket.
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.
Check the hose for damage. Discard the part if it is
damaged.
WARNING
The 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.
Remove the four capscrews (27) and the nuts (28).
Remove the turbocharger and the gasket.
Discard the gasket.
Turbocharger K38, K50, QSK38, and QSK50
Page 10-80 Section 10 — Air Intake System — Group 10
Loosen the hose clamps (24). Remove the clamps and the
hose (23) from the high pressure turbocharger air
connection.
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 six capscrews (7). The heavy flat washers (5)
are special. Remove the support plate (4).
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
The 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.
Remove the low pressure turbocharger (16).
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-83
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.
Check the hose for damage. Discard the part if it is
damaged.
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.
Remove the four capscrews (12) and nuts (14) that hold
the two exhaust connections (9 and 11).
Turbocharger K38, K50, QSK38, and QSK50
Page 10-86 Section 10 — Air Intake System — Group 10
Remove the four capscrews (40) and nuts (42) that hold
the exhaust connection to the turbine housing.
Remove the exhaust connection.
Remove the two capscrews (31) and nuts (25) that hold the
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
The 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.
Remove the two capscrews (35) and nuts (38) that hold the
turbocharger exhaust outlet connection to the bracket.
Remove the turbocharger.
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-87
Detach the oil drain hose from the cylinder block. Remove
the o-ring seal (9).
Discard the o-ring seal.
Check the hose for damage. Discard the part if it is
damaged.
WARNING
The 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.
Remove the four capscrews (3) and the nuts (4). Remove
the turbocharger and gasket.
Discard the gasket.
WARNING
The 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.
Remove the low pressure turbochargers.
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.
Remove the mounting capscrews and lock washers.
Remove the turbocharger and gasket.
Discard the gasket.
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-91
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
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
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Use solvent or steam. Clean the exterior of the
turbocharger.
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.
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-95
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.
Remove the capscrews.
Remove the oil supply fittings and the coolant lines from
the center housing assembly.
Discard the o-rings.
Turbocharger K38, K50, QSK38, and QSK50
Page 10-96 Section 10 — Air Intake System — Group 10
WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
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.
Clean the compressor cover and turbine housing in parts
cleaner to loosen deposits.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Dry the compressor housing with compressed air.
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.
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-97
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 ]
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-99
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.
CAUTION
Do not damage the compressor wheel blades during
assembly.
Assemble the vee-band clamp and compressor cover onto
the turbocharger.
Install
with Mechanically Actuated Injector
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
Center Mount Aftercooler
• KTTA38 and KTTA50 High Pressure, and KT38,
KTA38, and KTA50 Turbochargers with Outboard
Aftercoolers
• KTTA38 Low Pressure Turbochargers
• KTTA50 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.
Turbocharger K38, K50, QSK38, and QSK50
Page 10-102 Section 10 — Air Intake System — Group 10
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
The 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.
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 N•m [ 30 ft-lb ]
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-103
Newer Engines:
Tighten the clamps (2).
Torque Value:
K38 9 N•m [ 80 in-lb ]
K50 15 N•m [ 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 N•m [ 142 in-lb ]
WARNING
The 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: 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.
Apply an anti-seize compound on the threads of the
capscrews.
Install the turbocharger (2), the capscrews or studs (3),
and the nuts (4) if required.
Torque Value:
Turbocharger 40 N•m [ 30 ft-lb ]
Capscrews
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.
Use vegetable oil. Lubricate the o-ring seals.
Install the air inlet pipe in the high pressure turbocharger.
Turbocharger K38, K50, QSK38, and QSK50
Page 10-108 Section 10 — Air Intake System — Group 10
Install the hose (23) and the two t-bolt clamps (24) on the
air inlet pipe and high pressure turbocharger.
WARNING
The 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.
The gasket must be installed so that the raised bead on
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).
Tighten the six capscrews (7) that hold the bracket to the
supports.
Torque Value:
Bracket to 90 N•m [ 66 ft-lb ]
Supports
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-109
Tighten the four capscrews (12) and nuts (18) that hold the
connection to the bracket.
Torque Value:
Connection to 90 N•m [ 66 ft-lb ]
Bracket
Tighten the four capscrews (27) and nuts (28) that hold the
turbocharger to the connection.
Torque Value:
Turbocharger 40 N•m [ 30 ft-lb ]
Connection
Install the hose (11) and the two t-bolt clamps (12) on the
high pressure turbocharger.
Install the two o-ring seals (13) and the dust seal (14) on
the air inlet pipe (15).
Use vegetable oil. Lubricate the o-ring seals.
Install the air inlet pipe in the high pressure turbocharger.
Turbocharger K38, K50, QSK38, and QSK50
Page 10-112 Section 10 — Air Intake System — Group 10
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 40 N•m [ 30 ft-lb ]
Connection
Capscrews
WARNING
The 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.
Use a hoist and lifting strap. Put the turbocharger (16) in
position and push the compressor housing on the air pipe.
Tighten the six capscrews (7) that hold the bracket to the
supports.
Torque Value:
Bracket to 90 N•m [ 66 ft-lb ]
Supports
Tighten the two capscrews (35) and nuts (36) that hold the
turbocharger exhaust outlet connection to the bracket.
Torque Value:
Exhaust Outlet 90 N•m [ 66 ft-lb ]
Connection to
Bracket
Tighten the two capscrews (31) and the nuts (25) that hold
the bracket (32) to the connection (26).
Torque Value:
Bracket 40 N•m [ 30 ft-lb ]
Capscrews
Tighten the four capscrews (40) and nuts (42) that hold the
exhaust connection to the turbine housing.
Torque Value:
Exhaust 90 N•m [ 66 ft-lb ]
Connection
Capscrews
Tighten the two t-bolt clamps (45) on the air inlet pipe.
Torque Value:
T-bolt clamps 7 N•m [ 62 in-lb ]
Turbocharger K38, K50, QSK38, and QSK50
Page 10-116 Section 10 — Air Intake System — Group 10
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 40 N•m [ 30 ft-lb ]
Capscrew
If the fitting is not installed in the plate, install the oil inlet
fitting.
Torque Value:
Fitting Torque 35 N•m [ 26 ft-lb ]
Connect the turbocharger 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 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 40 N•m [ 30 ft-lb ]
Capscrews
Repeat the procedure to install the other turbocharger and
connect the oil supply and the drain hose.
Install the bracket (4), the six lock washers (6), and the six
capscrews (7).
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 40 N•m [ 30 ft-lb ]
Connection
Capscrews
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).
Tighten the six capscrews (7) that hold the bracket to the
supports.
Torque Value:
Support Bracket 95 N•m [ 70 ft-lb ]
Capscrews
Tighten the two capscrews (35) and nuts (38) that hold the
turbocharger exhaust outlet connection to the bracket.
Torque Value:
Bracket 95 N•m [ 70 ft-lb ]
Capscrews
The bracket (32) must be flat against the flange on the air
inlet connection.
Tighten the two capscrews (43) and nuts (34) that hold the
bracket (32) to the support bracket (4).
Torque Value:
Air Inlet 40 N•m [ 30 ft-lb ]
Connection
Capscrews
Turbocharger K38, K50, QSK38, and QSK50
Page 10-124 Section 10 — Air Intake System — Group 10
Tighten the two capscrews (31) and nuts (25) that hold the
bracket (32) to the connection (26).
Torque Value:
Bracket 40 N•m [ 30 ft-lb ]
Connection
Capscrews
Tighten the four capscrews (40) and nuts (42) that hold the
exhaust connection to the turbine housing.
Torque Value:
Exhaust 95 N•m [ 70 ft-lb ]
Connection
Capscrews
Tighten the three capscrews (19) that hold the bracket (21)
to the exhaust outlet connection (17).
Torque Value:
Exhaust Outlet 40 N•m [ 30 ft-lb ]
Connection
Capscrews
Tighten the four capscrews (12) and nuts (14) that hold the
two exhaust connections (9 and 11).
Torque Value:
Exhaust Outlet 95 N•m [ 70 ft-lb ]
Connections
Tighten the four capscrews (49) and nuts (52) that hold the
air intake pipe (47) to the turbocharger compressor outlet.
Torque Value:
Intake Pipe 40 N•m [ 30 ft-lb ]
Capscrews
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).
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.
Tighten the two t-bolt clamps (45) on the air intake pipe
(47) and the turbocharger compressor inlet.
Torque Value:
Intake Pipe 8 N•m [ 71 in-lb ]
Clamps
These clamps need to be tightened again after the engine
has operated a few hours.
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 25 N•m [ 18 ft-lb ]
Turbocharger Oil
Inlet
Install the oil inlet fitting.
Torque Value:
Oil Inlet Fitting 35 N•m [ 26 ft-lb ]
Connect the turbocharger 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 gasket (59), the hose (60), the lock washers (61),
and the capscrews (62) for the low pressure turbocharger
oil drain.
Torque Value:
Turbocharger Oil 25 N•m [ 18 ft-lb ]
Drain
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 N•m [ 30 ft-lb ]
NOTE: The turbocharger oil drain line must run downhill
from the turbocharger to the cylinder block.
WARNING
The 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: 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 45 N•m [ 33 ft-lb ]
Mounting
Capscrews and
Nuts
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-127
WARNING
The 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.
Lift the low pressure turbochargers, using approved lifting
straps, onto the mounting pads and align them with the
inter-stage air transfer connections.
Turbocharger K38, K50, QSK38, and QSK50
Page 10-128 Section 10 — Air Intake System — Group 10
Install the air intake and bracket onto the low pressure
turbocharger and trolly assembly.
Apply anti-seize compound, Part Number 3824394, or
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 48 N•m [ 35 ft-lb ]
Capscrews
K38, K50, QSK38, and QSK50 Turbocharger
Section 10 — Air Intake System — Group 10 Page 10-129
Finishing Steps
MAI
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
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
environmental regulations.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Fill the cooling system. Refer to Procedure 008-018.
• Turn the air on to the air starter (if equipped). Refer
to Procedure 012-022
• Connect the batteries. Refer to Procedure 013-009.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Install the oil drain lines. Refer to Procedure 010-045.
• Install the coolant supply and return lines. Refer to
Procedure 010-041.
• Fill the cooling system. Refer to Procedure 008-018.
• Turn the air on to the air starter (if equipped). Refer
to Procedure 012-022
• Connect the batteries. Refer to Procedure 013-009.
Turbocharger, Water-Cooled K38, K50, QSK38, and QSK50
Page 10-130 Section 10 — Air Intake System — Group 10
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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.
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
environmental regulations.
• Disconnect the batteries. Refer to Procedure
013-009.
• Drain the cooling system. Refer to Procedure
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
Section 10 — Air Intake System — Group 10 Page 10-131
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.
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.
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.
Discard the o-ring and gasket.
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
air crossover tube to the turbocharger.
Remove the air crossover tube and discard the gasket.
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.
Remove the four capscrews and washers from the center
section of the turbocharger and lift the turbocharger off the
turbocharger center support/drain assembly.
Discard the o-ring and gasket.
Setup
NOTE: All views showing the clock marks have been
simplified for clarity.
Verify the correct clocking of the turbocharger.
Install
Left Bank
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.
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.
Right Bank
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.
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.
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• 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
• Fill the cooling system. Refer to Procedure 008-018.
• Connect the batteries. Refer to Procedure 013-009.
• Operate the engine and check for leaks.
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.
Finishing Steps
• Install the intake and exhaust piping to the
turbocharger.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
spray or steam can cause personal injury.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 (Battery Cables and Connections) in Section
13.
• Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
• Remove the turbocharger heat shield (marine
applications only).
Remove
with Electronically Actuated Injector
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.
Discard the o-rings.
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
Page 10-146 Section 10 — Air Intake System — Group 10
Install
with Electronically Actuated Injector
NOTE: Shown is the Two Stage turbocharger, the Single
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 57 N•m [ 42 ft-lb ]
Turbocharger
Fittings
K38, K50, QSK38, and QSK50 Turbocharger Coolant Hoses
Section 10 — Air Intake System — Group 10 Page 10-147
Marine Applications
Install new o-rings on the fittings and the elbow fittings.
Install the fittings.
Tighten the fittings.
Torque Value: 57 N•m [ 42 ft-lb ]
Finishing Steps
EAI
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Fill the cooling system. Refer to Procedure 008-018.
• Install the turbocharger heat shields (marine
applications only).
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Operate the engine and check for leaks.
Remove
Single Stage
Remove the capscrews, washers, and p-clips securing the
turbocharger oil drain lines.
Two Stage
Remove the capscrews, washers and p-clips securing the
turbocharger oil drain lines.
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
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
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use solvent to clean the turbocharger oil drain tubes and
male union adapter elbow.
Dry with compressed air.
K38, K50, QSK38, and QSK50 Turbocharger Oil Drain Line
Section 10 — Air Intake System — Group 10 Page 10-151
Install
with Electronically Actuated Injector
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
washers and capscrews.
Torque Value: 45 N•m [ 33 ft-lb ]
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.
Torque Value: 40 N•m [ 30 ft-lb ]
CAUTION
Do not use sealant or gasket adhesive on the gasket
as this can contaminate the lubricating oil system.
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
washers and capscrews.
Torque Value: 45 N•m [ 33 ft-lb ]
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.
Torque Value: 40 N•m [ 30 ft-lb ]
CAUTION
Do not use sealant or gasket adhesive on the gasket
as this can contaminate the lubricating oil system.
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.
Torque Value: 45 N•m [ 33 ft-lb ]
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.
Torque Value: 40 N•m [ 30 ft-lb ]
Install the turbocharger heat shield (marine applications
only).
K38, K50, QSK38, and QSK50 Turbocharger Oil Supply Line
Section 10 — Air Intake System — Group 10 Page 10-153
Marine Applications
Install new gaskets on the oil drain line.
Install the oil drain line and the mounting capscrews.
Finishing Steps
with Electronically Actuated Injector
• Operate the engine and check for leaks.
Remove
Industrial Applications
WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
WARNING
Some state and federal agencies have determined that
used engine oil can be a 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
environmental regulations.
Single stage turbocharger, remove the oil supply tubes
from the male unions on the turbochargers. Discard the o-
rings.
Remove the oil supply tubes from the male unions on the
engine. Discard the o-rings.
K38, K50, QSK38, and QSK50 Turbocharger Oil Supply Line
Section 10 — Air Intake System — Group 10 Page 10-155
Two Stage
High pressure turbocharger, remove the oil supply tubes
from the male unions on the high pressure turbochargers.
Discard the o-rings.
Remove the oil supply tubes from the male unions on the
engine. Discard the o-rings.
Marine Applications
NOTE: Shown is the right bank oil supply tube. The
procedure is the same for the left bank.
Remove the turbocharger oil supply tubes from the male
unions on the engine.
Discard the o-rings.
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
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris or dirt can cause
personal injury.
Clean the turbocharger oil supply lines and components
with solvent. Dry with compressed air.
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 35 N•m [ 26 ft-lb ]
Fitting to
Turbocharger
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 35 N•m [ 26 ft-lb ]
Fitting to
Turbocharger
K38, K50, QSK38, and QSK50 Turbocharger Oil Supply Line
Section 10 — Air Intake System — Group 10 Page 10-159
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.
Install the turbocharger oil supply tubes to the male unions
on the turbocharger.
Torque Value:
Oil Supply Tube 35 N•m [ 26 ft-lb ]
Fitting to
Turbocharger
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.
Torque Value: 38 N•m [ 28 ft-lb ]
Finishing Steps
with Electronically Actuated Injector
• Install the turbocharger heat shield (marine
applications). Refer to the OEM manual.
• Operate the engine and check for leaks.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 (Battery Cables and Connections) in Section
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.
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Install the intake and exhaust piping to the
turbocharger.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
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
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.
Torque Value: 27 N•m [ 20 ft-lb ]
Aftercooler Housing (Center Mount) K38, K50, QSK38, and QSK50
Page 10-164 Section 10 — Air Intake System — Group 10
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.
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)
Section 10 — Air Intake System — Group 10 Page 10-165
CAUTION
Be sure there is no oil around the holes that were
drilled. Any oil will prevent the proper curing of the
RTV sealant.
Use solvent or steam. Clean the parts.
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.
Aftercooler Housing (Center Mount) K38, K50, QSK38, and QSK50
Page 10-166 Section 10 — Air Intake System — Group 10
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.
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.
Torque Value: 102 N•m [ 75 ft-lb ]
K38, K50, QSK38, and QSK50 Aftercooler Water Outlet Tube
Section 10 — Air Intake System — Group 10 Page 10-167
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.
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 or steam. Clean the parts.
Check the parts for damage. Any parts that are damaged
must be replaced.
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.
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.
Use solvent or steam. Clean the tube.
Aftercooler Water Outlet Tube K38, K50, QSK38, and QSK50
Page 10-168 Section 10 — Air Intake System — Group 10
Service Tools
Exhaust System Dataplate
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.
Anti-Seize Compound
Used to speed asembly and disassembly of studs, bolts, capscrews,
3824879 flanges, and fittings.
Torque Wrench
Used to tighten capscrews 13 to 136 N•m [10 to 100 ft-lb].
3164794
Torque Wrench
Used to tighten capscrews 136 to 813 N•m [100 to 600 ft-lb].
3164798
Exhaust Connection Pipe K38, K50, QSK38, and QSK50
Page 11-2 Section 11 — Exhaust System — Group 11
Remove
Remove the eight nuts and bolts from each flange
connecting the exhaust connection pipe to the exhaust
bellows.
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.
Remove the four capscrews connecting the exhaust
connection pipe to the support bracket.
Remove the exhaust connection pipe.
Discard the gaskets.
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
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
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
Section 11 — Exhaust System — Group 11 Page 11-3
Install
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.
Use new gaskets and install the exhaust connection pipe.
Install the four capscrews connecting the exhaust
connection pipe to the support bracket.
Torque Value: 45 N•m [ 33 ft-lb ]
Finishing Steps
• Install the bolts securing the OEM exhaust
connection to the exhaust connection pipe. Refer to
the manufacturer's installation instructions.
• Operate the engine and check for leaks.
Exhaust Manifold, Dry K38, K50, QSK38, and QSK50
Page 11-4 Section 11 — Exhaust System — Group 11
Preparatory Steps
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before servicing 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
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.
• Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
• 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.
Exhaust Manifold, Dry K38, K50, QSK38, and QSK50
Page 11-6 Section 11 — Exhaust System — Group 11
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
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: 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).
Discard the gaskets.
K38, K50, QSK38, and QSK50 Exhaust Manifold, Dry
Section 11 — Exhaust System — Group 11 Page 11-7
Disassemble
Use a mallet to separate the manifold sections.
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
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
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.
Exhaust Manifold, Dry K38, K50, QSK38, and QSK50
Page 11-8 Section 11 — Exhaust System — Group 11
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
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
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.
Use solvent or steam. Clean the parts.
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.
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.
Exhaust Manifold, Dry K38, K50, QSK38, and QSK50
Page 11-10 Section 11 — Exhaust System — Group 11
Install
KT38 and KTA38 with Dry Exhaust Manifolds
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.
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 must be installed so that the raised bead on
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] 60 N•m [ 44 ft-lb ]
capscrew
Torque Value:
76 mm [3 in] 55 N•m [ 41 ft-lb ]
capscrew with N
stamped on head
Torque Value:
76 mm [3 in] 80 N•m [ 59 ft-lb ]
capscrew without
N stamped on
head
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.
K38, K50, QSK38, and QSK50 Exhaust Manifold, Dry
Section 11 — Exhaust System — Group 11 Page 11-11
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.
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.
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 must be installed so that the raised bead on
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.
Torque Value: 55 N•m [ 41 ft-lb ]
Use a 5/8 inch 12 point socket and a mallet to install each
lockplate (7) on the heads of two capscrews. Do not break
the lockplate.
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.
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 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.
Exhaust Manifold, Dry K38, K50, QSK38, and QSK50
Page 11-12 Section 11 — Exhaust System — Group 11
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.
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.
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
threads of the capscrews.
NOTE: The gasket must be installed so the raised bead
on the gasket is toward the manifold.
Install the gaskets (4), manifold (5), and capscrews. Check
to be sure the gasket is aligned properly with the manifold
and the cylinder head.
Torque Value:
140 mm [5.5 in] 55 N•m [ 41 ft-lb ]
capscrew with N
stamped on head
Torque Value:
140 mm [5.5 in] 80 N•m [ 59 ft-lb ]
and 38 mm [1.5
in] capscrews
without N
stamped on head
NOTE: Capscrews without the N stamped on the head
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.
NOTE: Lockplates are not required on capscrews with
special threads.
Use a 5/8 inch 12 point socket and a mallet to install each
lockplate (6) on the heads of two capscrews. Do not break
the lockplate.
Exhaust Manifold, Dry K38, K50, QSK38, and QSK50
Page 11-14 Section 11 — Exhaust System — Group 11
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.
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.
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
threads of the capscrews.
NOTE: The gasket must be installed so the raised bead
on the gasket is toward the manifold.
Install the gaskets (4), manifold (5), and capscrews. Check
to be sure the gasket is aligned properly with the manifold
and the cylinder head.
Torque Value:
140 mm [5.5 in] 55 N•m [ 41 ft-lb ]
capscrew with N
stamped on head
Torque Value:
140 mm [5.5 in] 80 N•m [ 59 ft-lb ]
and 38 mm [1.5
in] capscrews
without N
stamped on head
NOTE: Capscrews without the N stamped on the head
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.
NOTE: Lockplates are not required on capscrews with
special threads.
Use a 5/8 inch 12 point socket and a mallet to install each
lockplate (6) on the heads of two capscrews. Do not break
the lockplate.
K38, K50, QSK38, and QSK50 Exhaust Manifold, Dry
Section 11 — Exhaust System — Group 11 Page 11-15
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.
Exhaust Manifold, Dry K38, K50, QSK38, and QSK50
Page 11-18 Section 11 — Exhaust System — Group 11
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.
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.
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.
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.
Torque Value: 55 N•m [ 41 ft-lb ]
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.
K38, K50, QSK38, and QSK50 Exhaust Manifold, Dry
Section 11 — Exhaust System — Group 11 Page 11-23
Finishing Steps
On KTTA engines, install the low pressure turbocharger
support brackets.
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.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Install the center mounted aftercooler. Refer to
Procedure 010-002 (Aftercooler Assembly) in
Section 10.
• Install the turbochargers. Refer to Procedure
010-033 (Turbocharger) in Section 10.
• 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.
• Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Operate the engine and check for leaks.
Exhaust Manifold, Wet K38, K50, QSK38, and QSK50
Page 11-24 Section 11 — Exhaust System — Group 11
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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 can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
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
environmental regulations.
• Disconnect the batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13
• Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
• Remove the air intake filter assemblies. Refer to
Procedure 010-013 (Air Cleaner Assembly (Engine-
Mounted)) in Section 10.
• Remove the expansion tank. Refer to Procedure
008-052 (Expansion Tank) in Section 8.
• Remove the exhaust connection pipe. Refer to
Procedure 011-001 (Exhaust Connection Pipe) in
Section 11
• Remove the exhaust bellows. Refer to Procedure
011-018 (Exhaust Manifold, Dry) in Section 11.
• Remove the turbochargers. Refer to Procedure
010-037 (Turbocharger, Water-Cooled) in Section
10.
K38, K50, QSK38, and QSK50 Exhaust Manifold, Wet
Section 11 — Exhaust System — Group 11 Page 11-25
Remove
EAI
NOTE: Shown in this procedure is the QSK50 engine.
Although different in appearance, the procedure remains
the same for the QSK38.
Remove the water hoses from the transfer tubes to the
inlet elbows.
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 of assembly.
Install approved lifting straps and use an approved hoist.
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.
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.
K38, K50, QSK38, and QSK50 Exhaust Manifold, Wet
Section 11 — Exhaust System — Group 11 Page 11-29
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
Section 11 — Exhaust System — Group 11 Page 11-31
Finishing Steps
EAI
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
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
environmental regulations.
• Install the turbochargers. Refer to Procedure
010-037.
• Install the exhaust bellows. Refer to Procedure
011-018.
• Install the exhaust connection pipe. Refer to
Procedure 011-001.
• Install the expansion tank. Refer to Procedure
008-052.
• Install the air intake filter assemblies. Refer to
Procedure 010-013 (Air Cleaner Assembly (Engine-
Mounted)) in Section 10.
• Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Operate the engine and check for leaks.
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 of assembly.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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 can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 (Battery Cables and Connections) in Section
13.
• Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
• Remove the turbochargers. Refer to Procedure
010-033 (Turbocharger) in Section 10.
• 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
Page 11-34 Section 11 — Exhaust System — Group 11
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).
Torque Value: 20 N•m [ 177 in-lb ]
Install the gasket (3), the three lock washers, and the
capscrews (4).
Torque Value: 40 N•m [ 30 ft-lb ]
Install the flat washers, lock washers, and capscrews (5)
through the tab on the tube to the exhaust manifold.
Torque Value: 20 N•m [ 177 in-lb ]
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).
Use vegetable oil. Lubricate the o-ring.
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.
Torque Value: 20 N•m [ 177 in-lb ]
K38, K50, QSK38, and QSK50 Exhaust Manifold (Wet) Water Connections
Section 11 — Exhaust System — Group 11 Page 11-35
Finishing Steps
MAI
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 of assembly.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• 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.
• Install the turbochargers. Refer to Procedure
010-033 (Turbocharger) in Section 10.
• Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Operate the engine and check for leaks.
Bellows K38, K50, QSK38, and QSK50
Page 11-36 Section 11 — Exhaust System — Group 11
Bellows (011-018)
Preparatory Steps
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.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 (Battery Cables and Connections) in Section
13.
• Remove the bolts securing the OEM exhaust
connection to the exhaust connection pipe. Refer to
the manufacturer's instructions.
• Remove the exhaust connection pipe. Refer to
Procedure 011-001 (Exhaust Connection Pipe) in
Section 11.
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.
Remove the eight capscrews and washers to each flange
connecting the exhaust bellows to the turbochargers.
Remove the exhaust bellows and gaskets.
Install
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.
Use new gaskets and install the exhaust bellows.
Install the eight capscrews and washers to each flange
connecting the exhaust bellows to the turbochargers.
Torque Value: 136 N•m [ 100 ft-lb ]
K38, K50, QSK38, and QSK50 Bellows
Section 11 — Exhaust System — Group 11 Page 11-37
Finishing Steps
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.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Install the exhaust connection pipe. Refer to
Procedure 011-001 (Exhaust Connection Pipe) in
Section 11.
• Install the bolts securing the OEM exhaust
connection to the exhaust connection pipe. Refer to
the manufacturer's instructions.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Operate the engine and check for leaks.
Bellows K38, K50, QSK38, and QSK50
Page 11-38 Section 11 — Exhaust System — Group 11
Notes
K38, K50, QSK38, and QSK50
Section 12 — Compressed Air System — Group 12 Page 12-a
Service Tools
Compressed Air 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.
Standard Puller
Used to pull the drive gear. Use with puller capscrews that have M8
ST-647 x 1.25-6H thread.
Mounting Plate
Used to mount the air compressor to the vise.
ST-749
Mounting Plate
Used to mount the air compressor to the vise.
3823596
Coupling Puller
Used to remove the spline coupling hub.
3376663
Service Tools K38, K50, QSK38, and QSK50
Page 12-2 Section 12 — Compressed Air System — Group 12
Anti-Seize Compound
Lubricant that speeds assembly and disassembly of studs, bolts,
3824879 capscrews, flanges, and fittings.
Torque Wrench
An inch-pound dial-type torque wrench
3824783
K38, K50, QSK38, and QSK50 Service Tools
Section 12 — Compressed Air System — Group 12 Page 12-3
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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.
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
Section 12 — Compressed Air System — Group 12 Page 12-5
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.
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.
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
Section 12 — Compressed Air System — Group 12 Page 12-7
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.
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.
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
Section 12 — Compressed Air System — Group 12 Page 12-9
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.
Tighten the capscrews.
Torque Value: 14 N•m [ 120 in-lb ]
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.
Disassemble
WARNING
The unloader valve body is installed with spring
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.
WARNING
The unloader valve body is installed with spring
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.
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.
Tighten the capscrews.
Torque Value: 14 N•m [ 120 in-lb ]
Finishing Steps
Operate the engine and check for leaks.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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.
NOTE: Not all engines are equipped with this option.
• Disconnect the batteries. Refer to Procedure
013-009.
• Drain the cooling system. Refer to Procedure
008-018.
• Disconnect the coolant lines from the air
compressor. Refer to Procedure 012-014.
Air Compressor K38, K50, QSK38, and QSK50
Page 12-14 Section 12 — Compressed Air System — Group 12
Remove
with Mechanically Actuated Injector
Remove the air inlet and outlet connections from the air
compressor.
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.
Remove the capscrews (3). Remove the air compressor.
Remove the spline coupling (1). Remove the gasket (2).
Discard the gasket.
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.
Use solvent and clean the exterior of the air compressor.
Inspect the compressor housing for cracks or other
damage.
End Clearance
mm in
0.04 MIN 0.0015
0.24 MAX 0.0095
Air Compressor K38, K50, QSK38, and QSK50
Page 12-16 Section 12 — Compressed Air System — Group 12
Install
with Mechanically Actuated Injector
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.
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.
Torque Value: 60 N•m [ 45 ft-lb ]
Tighten the six capscrews (4) that hold the support to the
air compressor.
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the two capscrews (7) that hold the support to the
cylinder block.
Torque Value: 60 N•m [ 45 ft-lb ]
K38, K50, QSK38, and QSK50 Air Compressor
Section 12 — Compressed Air System — Group 12 Page 12-17
Finishing Steps
with Mechanically Actuated Injector
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.
• Connect the coolant lines to the air compressor.
Refer to Procedure 012-014.
• Fill the cooling system. Refer to Procedure 008-018.
• Connect the batteries. Refer to Procedure 013-009.
• Operate the engine and check for leaks.
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.
Operate the engine to activate the air compressor.
If the air compressor is pumping, the air governor is
malfunctioning and must be repaired or replaced. See the
manufacturer's instructions.
K38, K50, QSK38, and QSK50 Air Governor (Air Compressor Pumps Continuously)
Section 12 — Compressed Air System — Group 12 Page 12-19
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
Section 12 — Compressed Air System — Group 12 Page 12-21
WARNING
Wear appropriate eye and face protection when using
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.
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.
Notes
K38, K50, QSK38, and QSK50
Section 13 — Electrical Equipment — Group 13 Page 13-a
Service Tools
Electrical Equipment
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.
Digital Multimeter
This is an auto-ranging digital multimeter that includes functions of
3164488 DC and AC voltage, current, resistance, continuity, and diode test. It
comes with test leads and a protective boot that surrounds the meter.
Automotive Meter
This auto-ranging digital multimeter includes the functions of
3164489 frequency, capacitance, and temperature (with a built-in temperature
module). Also included are the functions: RPM, Dwell, Duty Cycle,
and Pulse Width.
Torque Wrench
Used to tighten capscrews 13 to 136 N•m [10 to 100 ft-lb].
3164794
Torque Wrench
Used to tighten capscrews 136 to 813 N•m [100 to 600 ft-lb].
3164798
Service Tools K38, K50, QSK38, and QSK50
Page 13-2 Section 13 — Electrical Equipment — Group 13
Alternator (013-001)
Preparatory Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 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: One of the jam nuts has left-hand threads.
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.
Torque Value: 100 N•m [ 75 ft-lb ]
NOTE: New alternators will not operate correctly until the
pulley mounting nut is correctly torqued.
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
Section 13 — Electrical Equipment — Group 13 Page 13-5
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Adjust the belt tension (if needed). Refer to
Procedure 013-022 (Alternator Adjusting Link) in
Section 13.
• Connect the batteries. Refer to Procedure 013-009
(Battery and Cable Connections) in Section 13.
• Connect the wiring to alternator.
K38, K50, QSK38, and QSK50 Alternator Bracket
Section 13 — Electrical Equipment — Group 13 Page 13-7
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 (Battery Cables and Connections) in Section
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
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
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 parts. Dry with compressed air.
Alternator Bracket K38, K50, QSK38, and QSK50
Page 13-8 Section 13 — Electrical Equipment — Group 13
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).
Torque Value: 90 N•m [ 66 ft-lb ]
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• 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
Section 13 — Electrical Equipment — Group 13 Page 13-9
Remove
Remove the alternator drive belt.
Install
Install the alternator belt.
Alternator Pulley K38, K50, QSK38, and QSK50
Page 13-10 Section 13 — Electrical Equipment — Group 13
Finishing Steps
• Adjust the alternator adjusting link. Refer to
Procedure 013-022 (Alternator Adjusting Link) in
Section 13.
• Start the engine and check for proper operation.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 (Battery Cables and Connections) in Section
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.
Install the capscrew (1). Use a puller (2), ST-647, or
equivalent. Remove the pulley from the water pump drive
shaft.
K38, K50, QSK38, and QSK50 Alternator Pulley
Section 13 — Electrical Equipment — Group 13 Page 13-11
Install
CAUTION
Do not use a hammer to position the pulley. The thrust
bearings in the water pump drive can be damaged and
the water pump drive can fail.
Use the pulley installation tool kit, Part Number 3376326.
Install the appropriate adapter (1) in the pusher (2).
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 and 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 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.
Remove the tool and adapter.
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Install alternator belt. Refer to Procedure 013-005
(Drive Belt, Alternator) in Section 13.
• Disconnect the batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13.
• Start the engine and check for proper operation.
Batteries K38, K50, QSK38, and QSK50
Page 13-12 Section 13 — Electrical Equipment — Group 13
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
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
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
manufacturer's specifications.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
Remove and inspect the battery cables and connections
for cracks or corrosion.
Replace broken terminals, connectors, or cables.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
Install the cables and tighten the battery connections.
Coat the terminals with grease to prevent corrosion.
Starter Magnetic Switch K38, K50, QSK38, and QSK50
Page 13-14 Section 13 — Electrical Equipment — Group 13
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.
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.
If there is no voltage:
• Turn the starter switch to the OFF position.
• 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
Section 13 — Electrical Equipment — Group 13 Page 13-17
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 battery. Refer to Procedure 013-009
(Battery and Cable Connections) in Section 13.
Remove
Remove the electrical connections from the starter motor.
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.
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
Section 13 — Electrical Equipment — Group 13 Page 13-21
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.
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Connect the battery. Refer to Procedure 013-009
(Battery and Cable Connections) in Section 13.
• Operate the starter and check for proper operation.
Alternator Adjusting Link K38, K50, QSK38, and QSK50
Page 13-22 Section 13 — Electrical Equipment — Group 13
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.
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 parts. Dry with compressed air.
Adjust
Loosen the alternator and adjusting link mounting
capscrews.
NOTE: One of the jam nuts has left-hand threads.
Loosen the jam nuts on the adjusting screw.
Notes
K38, K50, QSK38, and QSK50
Section 14 — Engine Testing — Group 14 Page 14-a
Service Tools
Engine Testing
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.
Filter Wench
Used to remove spin on filters.
3400157
Service Tools K38, K50, QSK38, and QSK50
Page 14-2 Section 14 — Engine Testing — Group 14
Engine Control
Used to operator the engine out-of-chassis on the QSK50 engines.
3163890 Used with the Engine Control Harness, Part Number 4918643.
Engine Fuel *Rate/Press Fuel Turbo Inlet Intake Manifold Coolant Temp/ Engine Lube Oil HP or
Speed Temp Air Temp Temp/Press Press Blowby Press Torque
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
Fuel Pressure
This measurement can also be taken using INSITE™
electronic service tool.
Refer to Procedure 005-016.
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.
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 2O [50 in H 2O].
Check the engine oil level. If the level is too high, it can
cause a higher than normal crankcase pressure.
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).
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.
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
Page 14-12 Section 14 — Engine Testing — Group 14
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)
Section 14 — Engine Testing — Group 14 Page 14-13
LTA
All industrial engines require low temperature aftercooler
and, therefore, have unique radiator requirements.
The heat exchanger must be sized to maintain 70°C
[158°F] 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.
Engine Testing (Engine Dynamometer) K38, K50, QSK38, and QSK50
Page 14-14 Section 14 — Engine Testing — Group 14
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50°C [120°F] before adding coolant.
Check the engine coolant level. Refer to Procedure
008-018.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 battery cables before beginning the
following procedure.
Disconnect the OEM harness from the electronic control
module (ECM) (if applicable).
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.
K38, K50, QSK38, and QSK50 Engine Testing (Engine Dynamometer)
Section 14 — Engine Testing — Group 14 Page 14-17
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.
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.
Engine Testing (Engine Dynamometer) K38, K50, QSK38, and QSK50
Page 14-18 Section 14 — Engine Testing — Group 14
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.
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.
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).
Engine Testing (Engine Dynamometer) K38, K50, QSK38, and QSK50
Page 14-20 Section 14 — Engine Testing — Group 14
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 20 [50 in H 20].
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).
Check the engine oil level. If the level is too high, it can
cause a higher than normal crankcase pressure.
Coolant Pressure
kPa psi
241 MAX 35
Engine Testing (Engine Dynamometer) K38, K50, QSK38, and QSK50
Page 14-24 Section 14 — Engine Testing — Group 14
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
665 kPa [95 psi] to the air compressor unloader (1). This
air line must contain a valve between the source and the
unloader.
Attach compressed air load to the air compressor outlet
(2).
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)
Section 14 — Engine Testing — Group 14 Page 14-25
Run-In Instructions
with Mechanically Actuated Injector
The performance of an engine installed in a vehicle can
be tested on a chassis dynamometer.
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.
NOTE: The hole in all of the adapters for the gauge hose
connection is [1/8-inch NPTF].
Minimum Gauge Capacity: 760 mm-Hg [30 in-Hg]
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 43°C [110°F]. The
fuel temperature must not exceed 32°C [90°F] during the
performance check.
K38, K50, QSK38, and QSK50 Engine Run-in (Engine Dynamometer)
Section 14 — Engine Testing — Group 14 Page 14-29
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).
Minimum Gauge Capacity: 649°C [1200°F]
Minimum Gauge Capacity: 254 mm-Hg [10 in-Hg]
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.
Torque Value: 54 N•m [ 40 ft-lb ]
Engine Run-in (Engine Dynamometer) K38, K50, QSK38, and QSK50
Page 14-34 Section 14 — Engine Testing — Group 14
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.
Use 3.5 liters [0.93 U.S. gallon] of oil for each full-flow
filter. Fill all of the filters with oil.
K38, K50, QSK38, and QSK50 Engine Run-in (Engine Dynamometer)
Section 14 — Engine Testing — Group 14 Page 14-35
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.
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.
CAUTION
Do not operate the engine at "IDLE" longer than
specified. Excessive carbon formation will cause
engine damage.
CAUTION
Do not operate the engine at "IDLE" longer than
specified. Excessive carbon formation can cause
engine damage.
CAUTION
Do not crank the electric starting motor for more than
30 seconds. Excessive heat will damage the starting
motor.
"START" the engine.
CAUTION
If the oil pressure is not within specifications, turn the
engine "OFF" immediately. Both low and high oil
pressure will cause engine damage.
CAUTION
Do not operate the engine at "IDLE" longer than
specified. Excessive carbon formation can cause
engine damage.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50°C [120°F] 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 Run-in (Engine Dynamometer) K38, K50, QSK38, and QSK50
Page 14-44 Section 14 — Engine Testing — Group 14
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 battery cables before beginning the
following procedure.
Disconnect the OEM harness from the electronic control
module (ECM) (if applicable).
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.
Engine Run-in (Engine Dynamometer) K38, K50, QSK38, and QSK50
Page 14-46 Section 14 — Engine Testing — Group 14
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.
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.
K38, K50, QSK38, and QSK50 Engine Run-in (Engine Dynamometer)
Section 14 — Engine Testing — Group 14 Page 14-47
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.
Engine - "START"
CAUTION
Do not crank the electric starting motor for more than
30 seconds. Excessive heat will damage the starting
motor.
CAUTION
If the oil pressure is not within specifications, turn the
engine "OFF" immediately. Both low and high oil
pressure will cause engine damage.
"START" the engine. If the engine does not begin
operating after 30 seconds, allow 2 minutes for the electric
starting motor to cool.
CAUTION
Do not operate the engine at "IDLE" longer than
specified. Excessive carbon formation will cause
engine damage.
CAUTION
Do not operate the engine at "IDLE" longer than
specified. Excessive carbon formation can cause
engine damage.
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.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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
Section 14 — Engine Testing — Group 14 Page 14-55
Finishing Steps
• Install the injector. Refer to Procedure 05-09 in the
Troubleshooting and Repair Manual K19, Bulletin
3810307. Refer to Procedure 006-026 in the
Troubleshooting and Repair Manual QSK19 Series
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
Troubleshooting and Repair Manual, Bulletin
3666261. Refer to Procedure 006-026 in the
Troubleshooting and Repair Manual QSK78 Series
Engines Bulletin 3666727. Refer to Procedure
006-026 in the Troubleshooting and Repair Manual
QSK23 Series Engines, Bulletin 4021375.
• Install 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 Series
Engines, Bulletin 3666098. Refer to Procedure 07-09
in the K38 and K50 Troubleshooting and Repair
Manual, Bulletin 3810432. Refer to Procedure
003-009 in the QSK45 and QSK60 Base Engine
Troubleshooting and Repair Manual, Bulletin
3666261. Refer to Procedure 003-009 in the
Troubleshooting and Repair Manual QSK78 Series
Engines Bulletin 3666727. Refer to Procedure
003-009 in the Troubleshooting and Repair Manual
QSK23 Series Engines, Bulletin 4021375.
• Install 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.
K38, K50, QSK38, and QSK50
Section 16 — Mounting Adaptations — Group 16 Page 16-a
Service Tools
Mounting Adaptations
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.
Drill/Ream Fixture
Used to drill and ream dowel holes. Bushings are not included and
ST-1232 must be ordered separately.
Torque Wrench
Used to tighten capscrews 13 to 136 N•m [10 to 100 ft-lb].
3164794
Service Tools K38, K50, QSK38, and QSK50
Page 16-2 Section 16 — Mounting Adaptations — Group 16
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.
WARNING
Use solvent. Clean the bracket, washer, and capscrew.
Dry with compressed air.
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
Page 16-4 Section 16 — Mounting Adaptations — Group 16
WARNING
Batteries can emit explosive gases. To reduce the
possibility of 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.
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.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] 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.
• Disconnect the batteries. Refer to Procedure
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
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.
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
Page 16-6 Section 16 — Mounting Adaptations — Group 16
K38 and K50 engines have four lifting brackets that are
bolted to the cylinder block. Lifting brackets are designed
to lift the engine only.
K38, K50, QSK38, and QSK50 Engine Support Bracket, Front
Section 16 — Mounting Adaptations — Group 16 Page 16-7
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.
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.
Install
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.
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.
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.
K38, K50, QSK38, and QSK50 Engine Support Bracket, Front
Section 16 — Mounting Adaptations — Group 16 Page 16-9
Finishing Steps
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.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of 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.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• 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.
• Connect the batteries. Refer to Procedure 013-009.
Flexplate K38, K50, QSK38, and QSK50
Page 16-10 Section 16 — Mounting Adaptations — Group 16
Flexplate (016-004)
Preparatory Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Disconnect the starter air to prevent accidental
engine starting. Refer to Procedure 012-022.
• Remove the transmission, clutch, and all related
components. Refer to the OEM manual.
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: 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
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to
reduce the risk of personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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
Section 16 — Mounting Adaptations — Group 16 Page 16-11
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.
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
Section 16 — Mounting Adaptations — Group 16 Page 16-13
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.
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Install the transmission, clutch, and all related
components. Refer to the OEM manual.
• Connect the batteries. Refer to Procedure 013-009.
• Connect the starter air. Refer to Procedure 012-022.
• Start the engine. Check equipment operation.
Flywheel K38, K50, QSK38, and QSK50
Page 16-14 Section 16 — Mounting Adaptations — Group 16
Flywheel (016-005)
Preparatory Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
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 the component or assembly.
• Disconnect the batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13.
• Disconnect the air starter to prevent accidental
engine starting. Refer to Procedure 012-022 (Air
Starting Motor) in Section 12.
• Remove the transmission, clutch, and all related
components. Refer to the OEM manual.
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 the component or assembly.
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
Section 16 — Mounting Adaptations — Group 16 Page 16-15
WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause personal injury.
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 or steam to clean the flywheel.
Use a wire brush to clean the crankshaft pilot bore.
Dry with compressed air.
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.
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 the component or assembly.
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
Section 16 — Mounting Adaptations — Group 16 Page 16-17
Finishing Steps
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 the component or assembly.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Install the drive unit and related components. Refer
to the OEM manual.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Connect the air starter. Refer to Procedure 012-022
(Air Starting Motor) in Section 12.
• Start the engine and check for proper operation.
K38, K50, QSK38, and QSK50 Flywheel Housing
Section 16 — Mounting Adaptations — Group 16 Page 16-19
WARNING
Batteries can emit explosive gases. To reduce the
possibility of 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.
WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
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
environmental regulations.
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.
• Disconnect the batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13.
• Disconnect the air starter to prevent accidental
engine starting. Refer to Procedure 012-022 (Air
Starting Motor) in Section 12.
• Remove the transmission, clutch, and all related
components. See the equipment manufacturer's
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
Page 16-20 Section 16 — Mounting Adaptations — Group 16
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: 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.
Remove the flywheel housing.
The dowel pins do not have to be removed unless they
are damaged.
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.
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.
Remove the flywheel housing.
The dowel pins do not have to be removed unless they
are damaged.
Remove the rear seal.
Discard the gasket.
K38, K50, QSK38, and QSK50 Flywheel Housing
Section 16 — Mounting Adaptations — Group 16 Page 16-21
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 risk of personal injury.
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.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use solvent or steam to clean the flywheel housing.
Dry with compressed air.
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.
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.
Flywheel Housing K38, K50, QSK38, and QSK50
Page 16-22 Section 16 — Mounting Adaptations — Group 16
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: The procedure remains the same, even though the
following illustrations show a K19 flywheel housing.
Remove the flywheel housing.
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.
Install the flywheel housing.
Do not tighten the capscrews. The flywheel housing will
need to be aligned.
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.
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 risk of personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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.
K38, K50, QSK38, and QSK50 Flywheel Housing
Section 16 — Mounting Adaptations — Group 16 Page 16-27
Install
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: 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.
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.
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).
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.
K38, K50, QSK38, and QSK50 Flywheel Housing
Section 16 — Mounting Adaptations — Group 16 Page 16-29
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”.
Flywheel Housing K38, K50, QSK38, and QSK50
Page 16-30 Section 16 — Mounting Adaptations — Group 16
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of 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.
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.
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
environmental regulations.
• 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.
• Install the transmission, clutch, and all related
components. See the equipment manufacturer's
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
Troubleshooting and Repair Manual Electronic
Control System, QSK50 and QSK60 Modular
Common Rail System, Bulletin 4021533.
• 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.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Operate the engine to operating temperature. Check
for leaks. Check equipment operation.
Flywheel Ring Gear K38, K50, QSK38, and QSK50
Page 16-32 Section 16 — Mounting Adaptations — Group 16
WARNING
To reduce the possibility of severe burns, wear
protective gloves when installing the heated ring gear.
CAUTION
Do not exceed the specified time or temperature.
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 232°C [450°F]. 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
To reduce the possibility of severe burns, wear
protective gloves when installing the heated ring gear.
CAUTION
Do not exceed 316°C [600°F]. 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 232°C
[450°F].
WARNING
To reduce the possibility of severe burns, wear
protective gloves when installing the heated ring gear.
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
Section 16 — Mounting Adaptations — Group 16 Page 16-33
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.
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
Notes
K38, K50, QSK38, and QSK50
Section 17 — Miscellaneous — Group 17 Page 17-a
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
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.
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
Section 17 — Miscellaneous — Group 17 Page 17-5
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
Section 17 — Miscellaneous — Group 17 Page 17-7
Notes
K38, K50, QSK38, and QSK50
Section 21 — Main Power Generator — Group 21 Page 21-a
K50 C Power
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
To access this document, copy the URL above and paste it into your web browser address bar.
Instrument Panel
The base panel has several built in alarms, as shown in the table below.
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.
K38, K50, QSK38, and QSK50 Generator, Main
Section 21 — Main Power Generator — Group 21 Page 21-5
Instrument Panel
Instrument Panel
Screen Overviews
NOTE: The alarm list is not displayed. It can be accessed from all the pages.
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.
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.
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
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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 or air supply line to the air starter
to prevent accidental engine starting.
K38, K50, QSK38, and QSK50 Bearing, Generator
Section 21 — Main Power Generator — Group 21 Page 21-9
Remove
The non-drive end bracket must be removed in order to
replace the bearing on all frame sizes.
WARNING
To reduce the possibility of property damage and
personal injury from electrical shock, make certain the
unit is isolated from all voltage sources.
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.
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 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.
K38, K50, QSK38, and QSK50 Bearing, Generator
Section 21 — Main Power Generator — Group 21 Page 21-11
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
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.
The end bracket must be supported as it is removed from
the bearing cartridge.
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.
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturers 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.
Clean the bearing cap and bearing cartridge using
solvent.
Dry the components with compressed air.
K38, K50, QSK38, and QSK50 Bearing, Generator
Section 21 — Main Power Generator — Group 21 Page 21-13
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.
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 100°C [212°F] for
1 hour.
Press the bearing into the bearing cartridge.
Bearing, Generator K38, K50, QSK38, and QSK50
Page 21-14 Section 21 — Main Power Generator — Group 21
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.
K38, K50, QSK38, and QSK50 Bearing, Generator
Section 21 — Main Power Generator — Group 21 Page 21-15
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
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.
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.
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.
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• Connect the batteries or air supply line to the air
starter.
K38, K50, QSK38, and QSK50 Bearing, Generator
Section 21 — Main Power Generator — Group 21 Page 21-17
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.
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.
WARNING
To reduce the possibility of property damage and
personal injury from electrical shock, make certain the
unit is isolated from all voltage sources.
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
Section 21 — Main Power Generator — Group 21 Page 21-19
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.
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 letter”R” 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 Marconi
Rectifier
Red Lead 40HF100 M41-1000
Black Lead 40HFR100 M41R1000
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.
Generator (Alternator) Exciter Rotating Diodes K38, K50, QSK38, and QSK50
Page 21-22 Section 21 — Main Power Generator — Group 21
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.
• Operate the engine and check for proper operation.
K38, K50, QSK38, and QSK50 Generator (Alternator) Windings
Section 21 — Main Power Generator — Group 21 Page 21-23
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
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
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• 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.
Refer to Procedure 021-030.
• 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
Page 21-24 Section 21 — Main Power Generator — Group 21
Finishing 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
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
• 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).
Refer to Procedure 013-009 or 012-022.
• Dehumidify the generator prior to placing in service.
Refer to Procedure 021-009.
K38, K50, QSK38, and QSK50 Permanent Magnet Generator
Section 21 — Main Power Generator — Group 21 Page 21-25
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
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.
• Disconnect the batteries or starting air (if installed).
Refer to Procedure 013-009 or 012-022.
Remove
WARNING
To reduce the possibility of property damage and
personal injury from electrical shock, make certain the
unit is isolated from all voltage sources.
Remove the three capscrews and the access cover.
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.
CAUTION
Do not attempt to take the permanent magnet rotor
apart. The magnetic proprieties of the rotor will be
destroyed.
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
Page 21-28 Section 21 — Main Power Generator — Group 21
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.
Finishing Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
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.
• Connect the batteries or starting air (if installed).
Refer to Procedure 013-009 or 012-022.
• Slowly open the fuel supply valve to the engine.
• Operate the engine and check for proper operation.
Generator Rotor K38, K50, QSK38, and QSK50
Page 21-30 Section 21 — Main Power Generator — Group 21
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
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
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
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.
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.
• Disconnect the batteries or starting air (if installed).
Refer to Procedure 013-009 or 012-022.
• 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
rotor. Refer to Procedure 021-030.
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
Section 21 — Main Power Generator — Group 21 Page 21-31
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.
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.
Generator Rotor K38, K50, QSK38, and QSK50
Page 21-32 Section 21 — Main Power Generator — Group 21
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.
There are two capscrews under the generator between the
generator feet. The generator will need to be lifted to
access these two capscrews.
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.
K38, K50, QSK38, and QSK50 Generator Rotor
Section 21 — Main Power Generator — Group 21 Page 21-33
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.
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.
Install
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.
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.
Generator Rotor K38, K50, QSK38, and QSK50
Page 21-34 Section 21 — Main Power Generator — Group 21
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
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.
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
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.
Lift the generator and install the two capscrews under the
generator between the generator feet.
K38, K50, QSK38, and QSK50 Generator Rotor
Section 21 — Main Power Generator — Group 21 Page 21-35
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.
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.
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.
Generator Rotor K38, K50, QSK38, and QSK50
Page 21-36 Section 21 — Main Power Generator — Group 21
Finishing 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
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
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate 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.
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.
• Install the permanent magnetic exciter stator and
rotor. Refer to Procedure 021-030.
• If removed, install the generator to the engine. Refer
to Procedure 021-009.
• Connect the batteries or starting air (if installed).
Refer to Procedure 013-009 or 012-022.
• Slowly open the fuel supply valve to the engine.
• Start the engine and check for proper operation.
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K38, K50, QSK38, and QSK50
Section L — Service Literature Page L-a
Notes
K38, K50, QSK38, and QSK50
Section M — Component Manufacturers Page M-a
Notes
K38, K50, QSK38, and QSK50
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
Specifications...............................................................................................................................................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
Specifications...............................................................................................................................................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
K38, K50, QSK38, and QSK50
Page V-b Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Camshaft (001-008)
Camshaft Thrust End Clearance 0.15 mm MIN 0.006 in
0.33 mm MAX 0.013 in
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
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
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Oversized [Inch]
Standard 190.284 MIN 7.4915
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
Standard 190.284 MIN 7.4915
190.335 MAX 7.4935
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Water Pump Idler Shaft Counter Bore - New 43.18 mm MIN 1.700 in
(13)
43.21 mm MAX 1.701 in
Water Pump Idler Shaft Counter Bore Depth 4.57 mm MIN 0.180 in
- New (14)
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
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Piston (001-043)
Piston Oil Ring Groove Width 4.788 mm MIN 0.1885 in
4.851 mm MAX 0.1910 in
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
K50 And Qsk50 Main Bearing Cap 1 176 N•m [ 130 ft-lb ]
Mounting Capscrews 2 339 N•m [ 250 ft-lb ]
3 Loosen
4 339 N•m [ 250 ft-lb ]
5 +90 degrees
K38, K50, QSK38, and QSK50 Cylinder Block — Group 01
Section V — Specifications Page V-15
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Camshaft (001-008)
45 N•m [ 35 ft-lb ]
Crankshaft (001-016)
Crankshaft Counterweight Capscrews 285 N•m [ 210 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
61 N•m [ 45 ft-lb ]
60 N•m [ 45 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
41 N•m [ 30 ft-lb ]
41 N•m [ 30 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
68 N•m [ 50 ft-lb ]
41 N•m [ 30 ft-lb ]
41 N•m [ 30 ft-lb ]
47 N•m [ 35 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
40 N•m [ 30 ft-lb ]
25 N•m [ 18 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Roller Clearance
(1) 0.23 MIN 0.009
0.61 MAX 0.024
(2) 0.076 MIN 0.003
0.178 MAX 0.007
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
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
Page V-30 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
(005-232)
Fuel Pump Pressurizing Capscrews Fuel 8 N•m [ 71 in-lb ]
Pump Pressurizing Capscrews
K38, K50, QSK38, and QSK50 Injectors and Fuel Lines — Group 06 - Specifications
Section V — Specifications Page V-35
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
5 N•m [ 45 in-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
38 N•m [ 28 ft-lb ]
10 N•m [ 85 in-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Injector (006-026)
45 N•m [ 33 ft-lb ]
9 N•m [ 80 in-lb ]
40 N•m [ 30 ft-lb ]
K38, K50, QSK38, and QSK50 Injectors and Fuel Lines — Group 06
Section V — Specifications Page V-45
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
40 N•m [ 30 ft-lb ]
10 N•m [ 85 ft-lb ]
10 N•m [ 85 ft-lb ]
Injectors and Fuel Lines — Group 06 K38, K50, QSK38, and QSK50
Page V-46 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
40 N•m [ 30 ft-lb ]
45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
K50 High Speed Oil Pump Drive Gear End 0.10 mm MIN 0.004 in
Clearance
0.18 mm MAX 0.007 in
K50 and QSK50 Low Speed Oil Pump 0.20 mm MIN 0.008 in
Compound Gear End Clearance
0.81 mm MAX 0.032 in
K50 and QSK50 Low Speed Oil Pump 0.15 mm MIN 0.006 in
Compound Gear to Drive Gear Backlash
0.25 mm MAX 0.010 in
K50 and QSK50 Low Speed Oil Pump Drive 0.114 mm MIN 0.0045 in
Shaft End Clearance
0.216 mm MAX 0.0085 in
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
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 0.10 mm MIN 0.004 in
Clearance
0.18 mm MAX 0.007 in
K50 and QSK50 Low Speed Oil Pump 0.20 mm MIN 0.008 in
Compound Gear End Clearance
0.81 mm MAX 0.032 in
K50 and QSK50 Low Speed Oil Pump 0.15 mm MIN 0.006 in
Compound Gear to Drive Gear Backlash
0.25 mm MAX 0.010 in
K50 and QSK50 Low Speed Oil Pump Drive 0.114 mm MIN 0.0045 in
Shaft End Clearance
0.216 mm MAX 0.0085 in
Lubricating Pump-to-Rear Crankshaft Gear 0.08 mm MIN 0.003 in
Backlash
0.30 mm MAX 0.012 in
Lubricating Oil System — Group 07 - Torque Values K38, K50, QSK38, and QSK50
Page V-50 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
45 N•m [ 35 ft-lb ]
27 N•m [ 20 ft-lb ]
Lubricating Oil System — Group 07 K38, K50, QSK38, and QSK50
Page V-52 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
27 N•m [ 20 ft-lb ]
34 N•m [ 25 ft-lb ]
40 N•m [ 30 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
40 N•m [ 30 ft-lb ]
47 N•m [ 35 ft-lb ]
41 N•m [ 30 ft-lb ]
61 N•m [ 45 ft-lb ]
Lubricating Oil System — Group 07 K38, K50, QSK38, and QSK50
Page V-54 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
41 N•m [ 30 ft-lb ]
41 N•m [ 30 ft-lb ]
74 N•m [ 55 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
25 N•m [ 18 ft-lb ]
25 N•m [ 18 ft-lb ]
5 N•m [ 44 in-lb ]
Lubricating Oil System — Group 07 K38, K50, QSK38, and QSK50
Page V-56 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
61 N•m [ 45 ft-lb ]
54 N•m [ 40 ft-lb ]
75 N•m [ 55 ft-lb ]
Cooling System — Group 08 K38, K50, QSK38, and QSK50
Page V-66 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
25 N•m [ 20 ft-lb ]
55 N•m [ 40 ft-lb ]
55 N•m [ 40 ft-lb ]
27 N•m [ 20 ft-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 50 in-lb ]
K38, K50, QSK38, and QSK50 Cooling System — Group 08
Section V — Specifications Page V-67
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
40 N•m [ 30 ft-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
20 N•m [ 15 ft-lb ]
40 N•m [ 30 ft-lb ]
Cooling System — Group 08 K38, K50, QSK38, and QSK50
Page V-68 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 50 in-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
40 N•m [ 30 ft-lb ]
5 N•m [ 44 in-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
31 N•m [ 23 ft-lb ]
31 N•m [ 23 ft-lb ]
25 N•m [ 20 ft-lb ]
Cooling System — Group 08 K38, K50, QSK38, and QSK50
Page V-70 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
55 N•m [ 40 ft-lb ]
55 N•m [ 40 ft-lb ]
25 N•m [ 20 ft-lb ]
30 N•m [ 22 ft-lb ]
Pump Impeller Nut Requiring 1.250 Inch 160 N•m [ 120 ft-lb ]
Wrench 110 N•m [ 80 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
60 N•m [ 45 ft-lb ]
Cooling System — Group 08 K38, K50, QSK38, and QSK50
Page V-72 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
60 N•m [ 40 ft-lb ]
K38, K50, QSK38, and QSK50 Drive Units — Group 09
Section V — Specifications Page V-87
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
68 N•m [ 50 ft-lb ]
68 N•m [ 50 ft-lb ]
47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
90 N•m [ 65 ft-lb ]
90 N•m [ 60 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Turbocharger (010-033)
Holset® HC5, HC5A, HX80 or HX85 End 0.05 mm MIN 0.002 in
Clearance
0.13 mm MAX 0.005 in
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
25 N•m [ 20 ft-lb ]
25 N•m [ 20 ft-lb ]
25 N•m [ 20 ft-lb ]
25 N•m [ 20 ft-lb ]
25 N•m [ 20 ft-lb ]
25 N•m [ 20 ft-lb ]
Air Intake System — Group 10 K38, K50, QSK38, and QSK50
Page V-92 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
45 N•m [ 33 ft-lb ]
30 N•m [ 22 ft-lb ]
60 N•m [ 45 ft-lb ]
25 N•m [ 20 ft-lb ]
40 N•m [ 30 ft-lb ]
9 N•m [ 80 in-lb ]
40 N•m [ 30 ft-lb ]
25 N•m [ 20 ft-lb ]
K38, K50, QSK38, and QSK50 Air Intake System — Group 10
Section V — Specifications Page V-93
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
25 N•m [ 20 ft-lb ]
9 N•m [ 80 in-lb ]
9 N•m [ 80 in-lb ]
25 N•m [ 20 ft-lb ]
9 N•m [ 80 in-lb ]
9 N•m [ 80 in-lb ]
9 N•m [ 80 in-lb ]
8 N•m [ 70 in-lb ]
5 N•m [ 50 in-lb ]
25 N•m [ 20 ft-lb ]
Air Intake System — Group 10 K38, K50, QSK38, and QSK50
Page V-94 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
45 N•m [ 35 ft-lb ]
25 N•m [ 20 ft-lb ]
8 N•m [ 70 in-lb ]
8 N•m [ 70 in-lb ]
40 N•m [ 30 ft-lb ]
8 N•m [ 70 in-lb ]
9 N•m [ 80 in-lb ]
9 N•m [ 80 in-lb ]
8 N•m [ 70 in-lb ]
K38, K50, QSK38, and QSK50 Air Intake System — Group 10
Section V — Specifications Page V-95
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
45 N•m [ 35 ft-lb ]
25 N•m [ 20 ft-lb ]
Air Intake System — Group 10 K38, K50, QSK38, and QSK50
Page V-96 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
25 N•m [ 20 ft-lb ]
25 N•m [ 20 ft-lb ]
25 N•m [ 20 ft-lb ]
60 N•m [ 45 ft-lb ]
25 N•m [ 20 ft-lb ]
40 N•m [ 30 ft-lb ]
9 N•m [ 80 in-lb ]
40 N•m [ 30 ft-lb ]
25 N•m [ 20 ft-lb ]
K38, K50, QSK38, and QSK50 Air Intake System — Group 10
Section V — Specifications Page V-97
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
25 N•m [ 20 ft-lb ]
45 N•m [ 35 ft-lb ]
25 N•m [ 20 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Turbocharger (010-033)
Turbocharger Lock Plate 20.3 N•m [ 180 in-lb ]
K38, K50, QSK38, and QSK50 Air Intake System — Group 10
Section V — Specifications Page V-99
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
43 to 47 [ 32 to 35
N•m ft-lb ]
20 N•m [ 180 in-lb ]
22 N•m [ 16 ft-lb ]
11 N•m [ 97 in-lb ]
43 to 47 [ 32 to 35
N•m ft-lb ]
20 N•m [ 180 in-lb ]
22 N•m [ 16 ft-lb ]
11 N•m [ 97 in-lb ]
K38, K50, QSK38, and QSK50 Air Intake System — Group 10
Section V — Specifications Page V-107
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
55 N•m [ 41 ft-lb ]
54 N•m [ 40 ft-lb ]
54 N•m [ 40 ft-lb ]
8 N•m [ 71 in-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Bellows (011-018)
136 N•m [ 100 ft-lb ]
Compressed Air System — Group 12 - Specifications K38, K50, QSK38, and QSK50
Page V-114 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
40 N•m [ 30 ft-lb ]
60 N•m [ 45 ft-lb ]
6 N•m [ 50 in-lb ]
Electrical Equipment — Group 13 - Torque Values K38, K50, QSK38, and QSK50
Page V-116 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Main Oil Rifle Pressure (at Idle) 138 kPa MIN 20 psi
Main Oil Rifle Pressure (at Idle) 138 kPa MIN 20 psi
483 kPa MAX 70 psi
Engine Testing — Group 14 - Torque Values K38, K50, QSK38, and QSK50
Page V-118 Section V — Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Flexplate (016-004)
Flexplate Assembly Capscrews 290 N•m [ 215 ft-lb ]
Flywheel (016-005)
Flywheel Mounting Capscrews 1 150 N•m [ 110 ft-lb ]
2 285 N•m [ 210 ft-lb ]
3 515 N•m [ 380 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
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
Page V-124 Section V — Specifications
Fuel System
Specifications
with Electronically Actuated Injector
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:..........................................................................................................71°C [160°F]
Minimum fuel tank venting rate:.............................................................................................0.472 L/s [60 ft 3/hour]
with Mechanically Actuated Injector
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 11°C above 38°C [1 percent per 10°F above 100°F].
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
Page V-126 Section V — Specifications
Cooling System
Specifications
with Mechanically Actuated Injector
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 94°C [180 to 202°F]
Low Temperature Aftercooler Thermostat Range
....................................................................................................................................66 to 79°C [150 to 175°F]
Top Tank Coolant Temperature (maximum)
Standby Power-Generation................................................................................................................104° [220°]
Prime Power-Generation...............................................................................................................100°C [212°F]
Marine............................................................................................................................................96°C [205°F]
Industrial.........................................................................................................................................95°C [203°F]
Top Tank Coolant Temperature (maximum)
Standby Power-Generation............................................................................................................104°C [212°F]
Prime Power-Generation...............................................................................................................100°C [212°F]
Marine............................................................................................................................................96°C [205°F]
Industrial.........................................................................................................................................95°C [203°F]
Top Tank Coolant Temperature (minimum)..........................................................................................70°C [160°C]
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
with Electronically Actuated Injector
Engine Coolant Circuit
Cooling System Type.................................................................................................................2 Pump - 2 Loop
Minimum Operating Block Coolant Temperature.............................................................................71°C [160°F]
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...............................................................82°C [180°F]
Engine Coolant Circuit Thermostat Fully Open Temperature...........................................................94°C [202°F]
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
Cooling System K38, K50, QSK38, and QSK50
Page V-128 Section V — Specifications
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
Section V — Specifications Page V-131
Electrical System
Specifications
Battery capacity (minimum recommended cold cranking amps):
K38 Generator-Drive
Ambient Temperature.............................................................................................................Above 10°C [50°F]
Cold Cranking Amperes...............................................................................................................................1200
Ambient Temperature.............................................................................................Above 0 to 10°C [32 to 50°F]
Cold Cranking Amperes...............................................................................................................................1280
Ambient Temperature..............................................................................................Above 0 to 32°C [-18 to 0°F]
Cold Cranking Amperes...............................................................................................................................1800
K50 Generator-Drive
Ambient Temperature.............................................................................................................Above 10°C [50°F]
Cold Cranking Amperes...............................................................................................................................1280
Ambient Temperature.............................................................................................Above 0 to 10°C [32 to 50°F]
Cold Cranking Amperes...............................................................................................................................1800
Ambient Temperature..............................................................................................Above 0 to 32°C [-18 to 0°F]
Cold Cranking Amperes...............................................................................................................................1800
K38 and K50 Industrial
Ambient Temperature..............................................................................................................Above -18°C [0°F]
Cold Cranking Amperes...............................................................................................................................1800
K38 and K50 Marine
Ambient Temperature..............................................................................................................Above -18°C [0°F]
Cold Cranking Amperes...............................................................................................................................1800
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.
The following table(s) contain information about Fleetguard® coolant filters service intervals and liquid precharge:
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
Section V — Specifications Page V-137
Water Quality
Calcium Magnesium Maximum 170 ppm as
(hardness) (CaCO3 + MgCO3)
Chloride 40 ppm as (CI)
Sulfur 100 ppm as (SO4)
Coolant Recommendations and Specifications K38, K50, QSK38, and QSK50
Page V-138 Section V — Specifications
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.
Notes
Index
Page X-1
Registered Office
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright© 2008
Cummins Inc.
Bulletin 4021528
Printed in U.S.A. 27-MARCH-2008 p174