4021528-vol3

281522_Cummins_CovV3.mpc:281522_Cummins_CovV3

3/28/08

7:07 AM

Page 1

Service Manual K38, K50, QSK38 and QSK50 Volume 3

Cummins Inc. Box 3005 Columbus, Indiana, U.S.A., 47202

Registered Office Cummins Ltd. 49 - 51 Gresham Road, Staines, Middlesex TW18 2BD, England Registration 573951 England Copyright© 2008 Cummins Inc.

Bulletin 4021528 Printed in U.S.A. 27-MARCH-2008

p174



Copyright© 2008 Cummins Inc. All rights reserved

Bulletin 4021528 Printed 27-MARCH-2008

Foreword This manual contains instructions for troubleshooting and repairing this engine in the chassis, complete rebuild procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing of accessory and component suppliers is located in Section M - Component Manufacturers. Suppliers can be contacted directly for any information not covered in this manual. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i - Introduction. The manual is organized to guide a service technician through the logical steps of identifying and correcting problems related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment manufacturer for repair procedures. The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures. When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended item. A series of specific service manuals (for example: Troubleshooting and Repair, Specifications, and Alternative Repair) are available and can be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office listing is located in Service Literature (Section L). Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement. Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating your comments. The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS (1-800-343-7357) toll free in the U.S. and Canada. The latest technology and the highest quality components are used to manufacture Cummins engines. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts.

Table of Contents Section

Cooling System — Group 08 ....................................................................................................................

8

Drive Units — Group 09 ...........................................................................................................................

9

Air Intake System — Group 10 ................................................................................................................

10

Exhaust System — Group 11 ...................................................................................................................

11

Compressed Air System — Group 12 ......................................................................................................

12

Electrical Equipment — Group 13 ............................................................................................................

13

Engine Testing — Group 14 .....................................................................................................................

14

Mounting Adaptations — Group 16 .........................................................................................................

16

Miscellaneous — Group 17 ......................................................................................................................

17

Main Power Generator — Group 21 .........................................................................................................

21

Service Literature .....................................................................................................................................

L

Component Manufacturers .......................................................................................................................

M

Specifications ...........................................................................................................................................

V

Back .......................................................................................................................................................... back

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Page 8-a

Section 8 — Cooling System — Group 08 Section Contents Page Belt Guard .........................................................................................................................................................8-3 Clean and Inspect for Reuse.............................................................................................................................8-4 Install................................................................................................................................................................8-4 Remove............................................................................................................................................................8-3 Coolant Bypass Tube ......................................................................................................................................8-12 Clean and Inspect for Reuse...........................................................................................................................8-14 Industrial......................................................................................................................................................8-14 Marine Applications......................................................................................................................................8-14 Finishing Steps...............................................................................................................................................8-16 Install..............................................................................................................................................................8-15 Industrial......................................................................................................................................................8-15 Marine Applications......................................................................................................................................8-15 Preparatory Steps...........................................................................................................................................8-12 Remove.......................................................................................................................................................... 8-12 Industrial......................................................................................................................................................8-12 Marine Applications......................................................................................................................................8-13 Coolant Filter ...................................................................................................................................................8-17 Install..............................................................................................................................................................8-17 Remove.......................................................................................................................................................... 8-17 Coolant Temperature Gauge ...........................................................................................................................8-11 Inspect for Reuse............................................................................................................................................8-11 Coolant Thermostat .........................................................................................................................................8-18 Finishing Steps...............................................................................................................................................8-32 General Information.........................................................................................................................................8-18 Inspect for Reuse............................................................................................................................................8-23 Install..............................................................................................................................................................8-27 Conventional Aftercooling.............................................................................................................................8-27 LTA..............................................................................................................................................................8-28 with Electronically Actuated Injector............................................................................................................. 8-29 Gas Compression.........................................................................................................................................8-30 Leak Test........................................................................................................................................................8-24 Conventional Aftercooling.............................................................................................................................8-25 LTA..............................................................................................................................................................8-26 Preparatory Steps...........................................................................................................................................8-19 Remove.......................................................................................................................................................... 8-19 Conventional Aftercooling.............................................................................................................................8-19 LTA..............................................................................................................................................................8-20 with Electronically Actuated Injector............................................................................................................. 8-22 Test................................................................................................................................................................ 8-23 Coolant Thermostat Housing Support ............................................................................................................8-32 Clean and Inspect for Reuse...........................................................................................................................8-37 LTA..............................................................................................................................................................8-37 Finishing Steps...............................................................................................................................................8-41 General Information.........................................................................................................................................8-32 Install..............................................................................................................................................................8-37 LTA..............................................................................................................................................................8-37 Preparatory Steps...........................................................................................................................................8-33 Remove.......................................................................................................................................................... 8-33 Cooling System ...............................................................................................................................................8-42 Drain...............................................................................................................................................................8-42 Fill...................................................................................................................................................................8-44 Flush...............................................................................................................................................................8-42 Cooling System Diagnostics ...........................................................................................................................8-54 Inspect............................................................................................................................................................8-54 Cooling System - Air or Combustion Gas Test ..............................................................................................8-46 Test................................................................................................................................................................ 8-46 Overflow Method..........................................................................................................................................8-46

Page 8-b


Sight Glass Method......................................................................................................................................8-47 Air Compressor............................................................................................................................................8-48 Combustion Gas Leak..................................................................................................................................8-49 Cylinder Head and Cylinder Liner.................................................................................................................8-52 Drive Belt, Cooling Fan .....................................................................................................................................8-5 Adjust............................................................................................................................................................. 8-11 Inspect for Reuse..............................................................................................................................................8-7 Install................................................................................................................................................................8-8 Remove............................................................................................................................................................8-5 ECM Cooling Plate .........................................................................................................................................8-169 Assemble......................................................................................................................................................8-173 Clean and Inspect for Reuse.........................................................................................................................8-170 Disassemble..................................................................................................................................................8-169 Finishing Steps.............................................................................................................................................8-174 Install............................................................................................................................................................8-174 Preparatory Steps.........................................................................................................................................8-169 Remove.........................................................................................................................................................8-169 ECM Cooling Plate Lines ...............................................................................................................................8-175 Finishing Steps.............................................................................................................................................8-178 Inspect for Reuse..........................................................................................................................................8-176 Install............................................................................................................................................................8-177 Preparatory Steps.........................................................................................................................................8-175 Remove.........................................................................................................................................................8-175 Expansion Tank ...............................................................................................................................................8-75 Clean and Inspect for Reuse...........................................................................................................................8-77 Finishing Steps...............................................................................................................................................8-80 Install..............................................................................................................................................................8-78 Preparatory Steps...........................................................................................................................................8-75 Remove.......................................................................................................................................................... 8-75 Fan Clutch, Viscous ........................................................................................................................................8-55 Measure..........................................................................................................................................................8-55 Fan, Cooling ....................................................................................................................................................8-70 Finishing Steps...............................................................................................................................................8-71 Install..............................................................................................................................................................8-71 Preparatory Steps...........................................................................................................................................8-70 Remove.......................................................................................................................................................... 8-70 Fan Drive Idler Arm Assembly ........................................................................................................................8-56 Assemble........................................................................................................................................................8-60 Clean..............................................................................................................................................................8-59 Disassemble................................................................................................................................................... 8-58 Finishing Steps...............................................................................................................................................8-62 Install..............................................................................................................................................................8-62 Preparatory Steps...........................................................................................................................................8-56 Remove.......................................................................................................................................................... 8-57 Fan Hub Bracket ..............................................................................................................................................8-62 Clean and Inspect for Reuse...........................................................................................................................8-63 General Information.........................................................................................................................................8-62 Install..............................................................................................................................................................8-64 Remove.......................................................................................................................................................... 8-63 Fan Hub, Belt Driven .......................................................................................................................................8-64 Assemble........................................................................................................................................................8-67 Clean and Inspect for Reuse...........................................................................................................................8-65 Disassemble................................................................................................................................................... 8-66 Finishing Steps...............................................................................................................................................8-70 Install..............................................................................................................................................................8-69 Preparatory Steps...........................................................................................................................................8-64 Remove.......................................................................................................................................................... 8-65 Fan Shroud Assembly .....................................................................................................................................8-70 Inspect for Reuse............................................................................................................................................8-70 Heat Exchanger ...............................................................................................................................................8-81 Assemble......................................................................................................................................................8-101 Tube Type..................................................................................................................................................8-101 Plate Type..................................................................................................................................................8-103


Page 8-c

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

Page 8-d


with Mechanically Actuated Injector............................................................................................................8-138 with Electronically Actuated Injector............................................................................................................8-138 Finishing Steps.............................................................................................................................................8-140 Install............................................................................................................................................................8-139 with Mechanically Actuated Injector............................................................................................................8-139 with Electronically Actuated Injector............................................................................................................8-140 Preparatory Steps.........................................................................................................................................8-136 Remove.........................................................................................................................................................8-137 with Mechanically Actuated Injector............................................................................................................8-137 with Electronically Actuated Injector............................................................................................................8-137 Sea Water System Diagnostics .....................................................................................................................8-165 General Information.......................................................................................................................................8-165 Inspect..........................................................................................................................................................8-165 Pressure Test................................................................................................................................................8-167 Test...............................................................................................................................................................8-166 Service Tools ....................................................................................................................................................8-1 Cooling System.................................................................................................................................................8-1 Supplemental Coolant Additive (SCA) ..........................................................................................................8-140 Maintenance Check.......................................................................................................................................8-140 Water Manifold ..............................................................................................................................................8-141 Clean and Inspect for Reuse.........................................................................................................................8-141 Water Pump ...................................................................................................................................................8-142 Assemble......................................................................................................................................................8-154 with Mechanically Actuated Injector............................................................................................................8-154 Clean and Inspect for Reuse.........................................................................................................................8-148 with Mechanically Actuated Injector............................................................................................................8-148 with Electronically Actuated Injector............................................................................................................8-149 Disassemble..................................................................................................................................................8-149 with Mechanically Actuated Injector............................................................................................................8-149 Finishing Steps.............................................................................................................................................8-164 with Mechanically Actuated Injector............................................................................................................8-164 with Electronically Actuated Injector............................................................................................................8-165 General Information.......................................................................................................................................8-142 with Mechanically Actuated Injector............................................................................................................8-142 Inspect..........................................................................................................................................................8-152 with Mechanically Actuated Injector............................................................................................................8-152 Install............................................................................................................................................................8-160 with Mechanically Actuated Injector............................................................................................................8-160 with Electronically Actuated Injector............................................................................................................8-162 Preparatory Steps.........................................................................................................................................8-144 with Mechanically Actuated Injector............................................................................................................8-144 with Electronically Actuated Injector............................................................................................................8-144 Remove.........................................................................................................................................................8-145 with Mechanically Actuated Injector............................................................................................................8-145 with Electronically Actuated Injector............................................................................................................8-145


Service Tools Page 8-1

Service Tools Cooling System

The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location.

Tool No.

Tool Description Gear Puller Used to remove the water pump pulley and impeller.

ST-647

Pulley Installation Tool Used to install drive pulleys. 3376326

Water Pump Bearing Mandrel Used to press the bearing and shaft into the water pump body. 3375318

Water Pump Bearing Mandrel Used to install the front water pump oil seal into the water pump body. 3375319

Bearing Separator Used to hold the bearing when removing it from the shaft. 3375326

Thermostat Seal Driver Used to install thermostat seal. 3375411

Tool Illustration



Tool No.

Tool Description Pipe Sealant

3375066

Used when installing pipe plugs or cup plugs on the engine in order to prevent leaks.

Digital Optical Tachometer Used to measure the rpm of the fan. 3377462

Reflective Tape 3377464

Used with optical tachometer, Part Number 3377462, to measure the rpm of the fan.

Cooling System Test Kit - Fleetguard® Used to measure supplemental cooling additive (SCA) concentration. CC-2602

Snap-On Pry Bar Used to remove thermostat seals. 1650

Torque Wrench Used to tighten capscrews 13 to 136 N•m [10 to 100 ft-lb]. 3164794

Tool Illustration


Belt Guard (008-001) Remove Remove the two capscrews and washers connecting the auxiliary drive guard from the vibration damper guard. Loosen the two capscrews from the rear of the gear housing securing the auxiliary drive guard to the gear housing. Remove the auxiliary drive guard.

Remove the four capscrews, washers, and isolators from the vibration damper guard. Remove the vibration damper guard.

Remove the capscrews and washers from the alternator mounting bracket to the alternator belt guard.

Remove the two mounting capscrews and washers from the front of the alternator belt guard to the front gear cover. Remove the alternator belt guard.

Belt Guard Page 8-3

Belt Guard Page 8-4


Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Use solvent to clean the belt guards. Dry with compressed air. Inspect the belt guards and brackets for cracks or other damage. If damaged, they must be replaced. Inspect the isolators for damage. If the isolators are hard and brittle, they must be replaced.

Install Install the two mounting capscrews, washers, and alternator belt guard to the front gear cover.

Install the capscrews and washers to the alternator belt guard through the alternator mounting bracket. Operate the engine and check for proper operation.


Install the vibration damper guard, four capscrews, washers, and isolators to the front gear cover. Torque Value: Vibration Guard Capscrews

25 N•m

[ 18 ft-lb ]

Install the auxiliary drive guard. Install the two capscrews on the rear of the gear housing securing the auxiliary drive guard to the gear housing. Torque Value: Rear Guard Housing Capscrews

40 N•m

[ 30 ft-lb ]

Install the two capscrews and washers connecting the auxiliary drive guard to the vibration damper guard. Torque Value: Auxiliary Drive Guard Capscrews

15 N•m [ 133 in-lb ]

Operate the engine and check for proper operation.

Drive Belt, Cooling Fan (008-002) Remove NOTE: The back side idler system uses one of two types of control rods (turnbuckles) or a shock absorber. Refer to the OEM service manual for the instructions that apply to the engine being serviced. Remove the back side idler end of the shock absorber, solid control rod (turnbuckle), or control rod tensioner assembly. Loosen the upper capscrew (31). Remove the lower capscrew (31). NOTE: One of the jam nuts on the solid control rod (turnbuckle) has left hand threads. Loosen the solid control rod (turnbuckle) jam nuts (11). Turn the adjusting screw (10) until the spacer (1) is not touching the end of the slot in the control rod (9).

Drive Belt, Cooling Fan Page 8-5



Remove the capscrew (7), washers (2)(3), and spacers (1). Remove the control rod assembly from the idler assembly.

To remove the control rod with spring, remove the two jam nuts (26), washers (25)(24), and spring (23).

Remove the following parts: • Capscrew (20) • Lock washer (19) • Washer (18) • Spacer (17) • Capscrew (14) • Lock washer (13) • Washer (12) • Control rod (15).

WARNING The fan belt idler is under tension. Do not allow hands to get between the idler, fan, or the fan hub. Failure to do so can result in personal injury. Use a 8-point socket and breaker bar or large wrench to hold the idler in position against the spring tension. Remove the capscrews from the spring cap. Slowly turn the wrench until the spring tension is relieved. Remove the fan belt.


NOTE: The fan center distance is the distance between the crankshaft and fan center lines. On systems that use a two pulley fan drive (without idler pulley) with a 508 mm [20 in], 559 mm [22 in], or 610 mm [24 in] fan center, loosen the bolts that pass through the slotted holes in the fan hub bracket. Loosen the fan hub adjusting screw.

On engines that use a two pulley drive with a 711 mm [28 in] fan center distance, loosen the bolts that pass through the slotted holes and fan hub bracket of the 711 mm [28 in] fan center system. The adjusting screw (16) is below the fan hub. The locknut (17) must be loosened before loosening the fan hub adjusting screw.

Remove the fan belt.

Inspect for Reuse Inspect the fan belt for the following: • Cracks • Glazing • Tears or cuts.




Install Install the belt on the crankshaft and fan hub pulley. Align the grooves on the belt on the ribs of the pulley.

WARNING 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 ]


NOTE: The fan belt must be installed and under the tension of the fan idler arm spring to adjust the control rod. The fan belt and a portion of the flat washer are not shown for clarity. Turn the adjusting screw (10) until the end of the slot on the lower control rod end (9) is touching the spacer (1). One of the nuts has left handed threads. Hold the adjusting screw and tighten the two jam nuts (11).

To install the control rod with spring, install the flat washer (12), lock washer (13), and capscrews (14) in the upper end of the control rod (15). Install the control rod in the fan support (16). Tighten the capscrew. 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.




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.


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 ]

Coolant Temperature Gauge (008-004) Inspect for Reuse Check for a blown fuse. Check the wiring from the gauge to the sending unit for broken connection(s).

Coolant Temperature Gauge Page 8-11

Coolant Bypass Tube Page 8-12


Use a temperature gauge of known accuracy to check the existing gauge. Replace the gauge or sending unit if faulty.

Coolant Bypass Tube (008-005) Preparatory Steps WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 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).


Marine Applications Remove the Straub coupling from the bypass line.

Remove the U-bolts from the bypass tube.

Remove the capscrews and washers from the lower flange connecting the bypass tube to the water pump. Remove the lower section of the bypass tube. Discard the gasket.

Remove the capscrews and washers from the upper flange connecting the bypass tube to the thermostat housing. Remove the upper section of the bypass tube. Discard the gasket.




Clean and Inspect for Reuse Industrial WARNING Wear safety glasses or a face shield, as well as protective clothing, to prevent personal injury when using a steam cleaner or high-pressure water. Use a gasket scraper and wire brush to clean the gasket sealing surfaces. Use steam to clean the tubes.

Check the tube gasket sealing face and tube for damage. Replace if it is cracked or otherwise damaged. Replace the hose and hose clamps.

Marine Applications WARNING Wear safety glasses or a face shield, as well as protective clothing. Hot stem can cause serious personal injury. Use a gasket scraper and wire brush to clean the gasket sealing surfaces. Use steam to clean the tubes and Straub coupling.

Check the tube gasket sealing face and tube for damage. Inspect the Straub coupling for wear or other damage. Replace if cracked or otherwise damaged. Replace the hose clamps.


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 Capscrews

38 N•m

[ 28 ft-lb ]

Install the lower section of the bypass tube. Install the capscrews and washers to the lower flange connecting the bypass tube to the water pump. Torque Value: Lower Flange Capscrews

28 N•m

[ 20 ft-lb ]




Check the gap between the upper and lower bypass tubes. The gap must not exceed 17 mm [0.70 in].

Install the U-bolts for the bypass tube. Torque Value: U-Bolts

21 N•m [ 186 in-lb ]

Install the Straub coupling onto the bypass line. Torque Value: Straub Coupling

30 N•m

[ 22 ft-lb ]

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.


Coolant Filter (008-006) Remove 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 Filter Page 8-17

Coolant Thermostat Page 8-18


Install the coolant filter. Turn the coolant filter clockwise until the seal touches the coolant filter head. Turn the coolant filter an additional ½ to ¾ of a turn after contact. Turn the valve (1) on the coolant filter head to the ON position.

Coolant Thermostat (008-013) General Information The K38 and K50 engines must have thermostats that do not have a vent. The K50 thermostats contain a nitrile rubber seat vulcanized to the brass collar at the barrel seat. This seat prevents coolant leakage and wear. The thermostat with the rubber seat must be used on K50 engines. The thermostat with the rubber seat is not required for the K38 engine, but can be installed. The Low Temperature Aftercooling (LTA) arrangement uses four coolant thermostats and one LTA thermostat, the LTA thermostat has a knurled flange and is located in the center position between the engine coolant thermostats. Thermostat, Part Number 3046191, must be used in all K50 engines to prevent premature thermostat failures. This thermostat is designed to withstand the higher flow of the K50 engine and incorporates a nitrile rubber seal for reduced leakage and improved seating. This thermostat was released in July, 1985, engine serial number first 33109759. The standard thermostat will fail at low hours if installed in the K50 engines. This thermostat was fitted to all K38 engines from May, 1993, engine serial number first 33124382.


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.




Remove the 12 capscrews. Remove the thermostat housing and gasket. Discard the gasket.

Remove the thermostats and seals from the thermostat housing.

LTA Remove the pipe plug from the lower water transfer connection on aftercooler core on each bank to drain the aftercooler plumbing on engines equipped with LTA.

Remove the tube clamps (1) and the aftercooler plumbing on both banks. Loosen the capscrews (2) on the water transfer connection to allow flexibility. Remove the water transfer tubes.


Remove the radiator hoses from the thermostat housing.

Remove the vent lines from the thermostat housing (1). Remove the four water bypass tube capscrews (2).

Remove the 14 capscrews and the heat shield. Remove the thermostat housing and gasket.

Remove the four main thermostats and the one knurled LTA thermostat in the center. The main and LTA thermostats are not interchangeable.




with Electronically Actuated Injector Remove the two Straub couplings on the thermostat outlet tube on marine engines. Remove the hose clamps and hoses for the industrial engines (not shown).

Disconnect the vent line from the thermostat outlet tube. Remove the capscrews and washers from the thermostat outlet connections to the outlet tube tube. Remove the outlet tube and discard the gaskets.

Remove the six capscrews, washers, cover plate, and gaskets from the LTA thermostat housing.

Remove the LTA thermostats and seals from the thermostat housing.


Inspect for Reuse Check the thermostat for wear or damage. If the barrel of the thermostat is worn or fretted, it must be replaced.

Test Check the thermostat marking to see when the thermostat is designed to open. The rated nominal temperature is marked on the side of the thermostat. The design temperature of the thermostat is 82°C [180° F]. Engine Thermostat Initial Opening Temperature °C °F 82.2 MIN 180 94.4 MAX 202 LTA Thermostat Initial Opening Temperature °C °F 73.8 MIN 165 86.1 MAX 187 Continue to apply heat until the water reaches the full open temperature for the specific thermostat being tested. The temperature is 12°C [22°F] above nominal opening temperature. At that temperature, measure the open distance of the thermostat. The minimum open distance at full open temperature is 9.52 mm [0.375 in].




Remove the container from the heat.

With the thermostat open, check for wear or other damage. If the seat of the thermostat is worn or fretted, it must be replaced. Check to see if the thermostat returns to the closed position. If the barrel of the thermostat is worn or fretted, it must be replaced.

Leak Test WARNING Complete this procedure with engine coolant temperatures below 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.


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. Install two hoses of the same size on the thermostat housing outlets long enough to reach a remote dry container. Install and tighten the hose clamps on the housing outlets. Place the end of the hoses in two dry containers.

Operate the engine at rated rpm for 1 minute. Shut the engine off, and measure the amount of coolant collected in each container. The amount of coolant collected in either container must not exceed 200 cc [7 fluid oz].

If more than 200 cc [7 fluid oz] of coolant is collected from either container, the thermostat or thermostat seal is leaking. Remove the thermostat and test operation as described in the Test section.




LTA Remove the LTA radiator inlet hose (1) and the two main engine coolant outlet hoses (2) to the radiator.

Coolant flow from the thermostat housing indicates a thermostat is stuck in the open position. Replace the thermostats.

Install a hose from the LTA Thermostat housing to a remote container (1). Install a hose from each of the main engine thermostat coolant outlets to a common remote container (2). Partially fill each hose with coolant. Place the end of each hose in their respective containers. Allow the hoses to drain in this position. Remove the coolant from the containers.

Operate the engine at rated rpm for 1 minute. Turn off the engine and measure the amount of coolant in the container. The amount of coolant collected from the main engine thermostats must not exceed 400 cc [14 fluid oz].


Remove the draincock (3). Use a gauge of 420 kPa [60 psi] minimum capacity. Remove any coolant from the container collecting the LTA thermostat leakage.

Start the engine. Note the block coolant pressure. Increase the engine speed until the coolant pressure reaches 170 kPa [25 psi]. Maintain this engine speed for 1 minute. Shut the engine off and measure the amount of coolant collected in the container.

The amount of coolant collected from the LTA thermostat must not exceed 100 cc [3.5 fluid oz]. If more is collected, the thermostat or thermostat seal is leaking. Remove the thermostat(s) and test.

Install 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.




Install the thermostat by pushing on the outer rim. NOTE: If the engine being serviced is a K50, be sure the thermostat is installed. The K50 thermostats contain a nitrile rubber seat vulcanized to the brass collar at the barrel seat. This seat prevents coolant leakage and wear. The thermostat with the rubber seat must be on K50 engines. The thermostat with the rubber seat is not required for the K38 engine, but can be installed.

Install the thermostat housing. Torque Value: Thermostat Housing

45 N•m

[ 33 ft-lb ]

On K38 and K50 engines, install the two upper radiator hoses. Tighten the hose clamps. Torque Value: 6 N•m [ 50 in-lb ] On the QSK38 and QSK50 engines, connect the water lines to the triangle, three bolt flanges, using new gaskets.

LTA The seal must be installed with the part number up. Use a mallet and seal driver Part Number, 3375411. Install the seal. Install the seal no more than 0.51 mm [0.020 in] below the top of the cast edge.


Install the thermostat by pushing on the outer rim.

Install the four main engine thermostats and the one knurled LTA thermostat.

Install the thermostat housing. Torque Value: 45 N•m [ 33 ft-lb ] Install the radiator hoses at the thermostat housing. Tighten the hose clamps. Torque Value: 6 N•m [ 50 in-lb ]

with Electronically Actuated Injector Install the LTA thermostat seals and thermostats into the thermostat housings.




Install the new gasket, thermostat cover, washers, and capscrews into the LTA thermostat housing. Tighten the capscrews Torque Value: 45 N•m [ 33 ft-lb ]

Install new gaskets and the thermostat outlet tube, washers, and capscrews to the outlet connection of the LTA thermostat housing. Tighten the capscrews Torque Value: 45 N•m [ 33 ft-lb ] Install the vent line to the thermostat outlet tube.

Install the two Straub couplings onto the thermostat outlet tube on marine engines. Torque Value: 28 N•m [ 21 ft-lb ] Install the hose and two hose clamps onto the thermostat outlet tubes on industrial engines (not shown). Tighten the hose clamps. Torque Value: 6 N•m [ 50 in-lb ]

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.


Install the thermostat by pushing on the outer rim. The K50 thermostats contain a nitrile rubber seat vulcanized to the brass collar at the barrel seat. This seat prevents coolant leakage and wear. The thermostat with the rubber seat must be on K50 engines. The thermostat with the rubber seat is not required for the KTA38GC engine, but can be installed.

Install the thermostat housing. Torque Value: 40 N•m [ 30 ft-lb ]


Coolant Thermostat Housing Support Page 8-32


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.

Coolant Thermostat Housing Support (008-015) General Information Thermostat Support The thermostat support assembly contains a support and two thermostat housings. Each thermostat housing contains two thermostats. The support assembly also provides for connection of the water outlet tubing for the cylinder head, air compressor, aftercooler, and a mounting provision for coolant filters. The low temperature aftercooler thermostat housing does not include a mounting provision for coolant filters. A revised thermostat housing support with 6.35 mm [0.25 inch] vent holes located higher in the support for improved venting replaced the previous housing in February of 1992, engine serial number first 33121370. The support housing with 19.05 mm [0.75 inch] holes remained in production. Thermostat Seal Each thermostat housing contains two thermostat seals. The thermostat seal for K38 and K50 engines was changed. The revised seal has a sealing element that is thicker. This sealing element prevents fretting and leakage resulting from the higher coolant flow required in K38 and K50 engines. The thin seal is installed on other Cummins® engines. The thick seal must be used on K38 and K50 engines. Heat Shield All KT38, KTA38, and KTA50 engines with a center mount aftercooler or air transfer housing must have a heat shield installed on the right bank thermostat housing. This heat shield is required to prevent damage to the outlet hose from the heat of the exhaust outlet of the turbocharger. KTA38 and KTA50 engines with outboard aftercoolers do not require the heat shield. The thermostat housing mounted design replaced the coolant outlet hose mounted design in February of 1983, engine serial number first 33107562, a revised thermostat housing was also released to accommodate the revised heat shield. The older heat shield must not be installed again or failure of the right bank coolant outlet hose will result.


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 (EngineMounted) 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).




Remove the water transfer tubes (2) and (3). Remove the o-rings. Discard the o-rings.

Low Temperature Aftercooling Thermostat Support. Remove the Straub coupling from the bypass line.

Remove the U-bolts from the bypass tube.

Remove the capscrews and washers from the upper flange connecting the bypass tube to the thermostat housing. Remove the upper section of the bypass tube. Discard the gasket.


NOTE: The following step must be carried out on both engine banks. Remove the capscrews and retaining clamps from the water tubes to the aftercoolers.

NOTE: The following step must be carried out on both engine banks. Loosen the hose clamps connecting the transfer tubes to the rubber tee between the aftercoolers. Separate the transfer tubes from the rubber tees.

Remove the capscrew and clamp from the right bank upper transfer tube on the LTA thermostat housing. Remove the transfer tube and discard the o-rings.

Remove the two capscrews and upper half of the transfer tube isolator.




Remove the one capscrew, washer, and clamp from the left bank transfer tube. Remove the transfer tube and discard the o-rings.

Remove the six capscrews, gasket, and thermostat cover. Remove the LTA thermostats and seals. Discard the cover gaskets and thermostat seals.

Remove the four mounting capscrews, washers, and LTA thermostat housing.

Remove the transfer tube isolation bracket and water outlets from the thermostat housing. Discard the o-ring and gaskets.


Clean and Inspect for Reuse LTA 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. Check for cracks or corrosion damage around the o-ring seal bores. Check for damaged threads and gasket surfaces.

Install LTA Use new gaskets and o-rings and install the water outlets and transfer tube isolation bracket onto the thermostat housing. Torque Value: Water Outlet Capscrews

38 N•m

[ 28 ft-lb ]

Torque Value: Transfer Tube Capscrews

11 N•m

[ 97 in-lb ]




Install the thermostat housing, washers, and capscrews. Torque Value: LTA Thermostat Housing Capscrews

38 N•m

[ 28 ft-lb ]

Install new thermostat seals, thermostats, new cover gasket, and cover. Install the six washers and capscrews. Torque Value: LTA Thermostat Cover Capscrews

60 N•m

[ 44 ft-lb ]

Install two new o-rings on the left bank transfer tube and lubricate them with vegetable oil. Install the transfer tube, clamp, and one washer and capscrew. Torque Value: Left Bank Transfer Tube Capscrews

22 N•m

[ 16 ft-lb ]

Install two new o-rings on the right bank transfer tube and lubricate them with vegetable oil. Install the transfer tube, clamp, and one washer and capscrew. Torque Value: Right Bank Transfer Tube Capscrews

22 N•m

[ 16 ft-lb ]


NOTE: The following step must be carried out on both engine banks. Install the transfer tubes into the rubber tees. Tighten the hose clamps at the rubber tee between the aftercoolers. Torque Value: Hose Clamps

8 N•m

[ 71 in-lb ]

Install the upper half or the transfer tube isolator and two capscrews. Torque Value: Upper Half Transfer Tube Capscrews

11 N•m

[ 97 in-lb ]

NOTE: The following step must be carried out on both engine banks. Install the retaining clamps, washers, and capscrews to the water tubes to the aftercoolers. Torque Value: Retaining Clamps

38 N•m

[ 28 ft-lb ]

Use a new gasket and install the washers and capscrews on the upper flange connecting the bypass tube to the thermostat housing. Torque Value: Upper Flange Capscrews

38 N•m

[ 28 ft-lb ]




Install the U-bolts on the bypass tube. Torque Value: Bypass Tube Ubolts

22 N•m

[ 16 ft-lb ]

Install the Straub coupling on the bypass line. Torque Value: Straub Coupling

30 N•m

[ 22 ft-lb ]


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 Page 8-42


Cooling System (008-018) Drain 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. Check for damaged hoses and loose or damaged hose clamps. Replace as required. Check the radiator for leaks, damage, and buildup of dirt. Clean and replace as required.

Flush RESTORE™ (cooling system cleaner) is a heavy-duty cooling system cleaner that removes corrosion products, silica gel, and other deposits. The performance of RESTORE™ is dependent on time, temperature, and concentration levels. An extremely scaled or flowrestricted 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.


Do not remove the coolant filters.

CAUTION Fleetguard® Restore™ (cooling system cleaner) contains no antifreeze. Do not allow the cooling system to freeze during the cleaning operation. Close all petcocks to avoid air entrapment in the cooling system. Immediately add 3.8 liters [1 gal] of Fleetguard® Restore™, or equivalent, for each 38 to 57 liters [10 to 15 gal] of cooling system capacity, and fill the system with plain water. Turn the heater temperature switch to HIGH to allow maximum coolant flow through the heater core. The blower does not have to be on. Operate the engine at a coolant temperature of at least 85°C [185°F] for 1 to 1-½ hours. Shut the engine off. Drain the cooling system.

Fill the cooling system with clean water.




Operate the engine at high idle for 5 minutes with the coolant temperature above 85°C [185°F]. Shut the engine off. Drain the cooling system. If the water drained is still dirty, the system must be flushed again until the water is clean.

Install a new coolant filter. Fill the cooling system with fully formulated coolant. Use additional SCA to bring the coolant to the correct SCA concentration level. Refer to Procedure 018-004 (Coolant Recommendations and Specifications) in Section 18.

Install the pressure cap. Operate the engine until the coolant reaches a temperature of 70°C [158°F] and check for coolant leaks. Minimum Cooling System Pressure Cap Capacity 48 kPa [ 7 psi ]

Fill Make sure the radiator draincocks and aftercooler core drain valves are closed. Open the cooling system venting petcocks. Install the lower radiator hose(s). Refer to Procedure 008-045 (Radiator Hoses) in Section 8.


Use fully formulated coolant to fill the cooling system. Use the correct units of SCA to obtain the correct cooling system protection. Refer to Procedure 018-004 (Coolant Recommendations and Specifications) in Section V.

CAUTION Fill the cooling system slowly to avoid trapping air in the cooling system. Air trapped in the system can cause water pump cavitation and inadequate coolant level. Begin filling the cooling system with coolant. Fill until a continuous stream of coolant begins to flow from each opened petcock in the coolant system. Close each petcock as the continuous stream of coolant begins to flow from that petcock. Fill the system with the coolant to the bottom of the radiator fill neck. Install the cooling system pressure cap. Operate the engine until the coolant reaches a temperature of 85°C [185°F]. Check for leaks.

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 Page 8-46


Cooling System - Air or Combustion Gas Test (008-019) Test Overflow Method 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.

Operate the engine at rated rpm until it reaches a temperature of 85°C [185°F] with the thermostat open. Check for a continuous flow of air bubbles from the hose in the water container. A continuous flow of bubbles can be the result of: • Air compressor cylinder head leak • Cylinder head combustion gas leak • Incorrect cylinder protrusion • Cracked or broken cylinder liners.

If air is not in the system, perform the following: • Remove the test equipment • Check the coolant level and fill if necessary • Install the correct radiator pressure cap • Operate the engine to a temperature of 80°C [180° F] • Check for coolant leaks.



Sight Glass Method Install a clear Pyrex® tube in the water connection between the engine radiator and the thermostat housing. If desired, the Pyrex® tube can be installed in the vent line between the thermostat housing and the radiator.

WARNING Use wire lace to cover the tube and hose. Personal injury can result if the Pyrex® tube separates from the hoses. Use the appropriate sight glass for the hose size used. Sight Glass Part Number 3377405 3377406 3377407 3377408 3377409 3377410 3377411 3377412

Outside diameter mm 25.4 31.8 50.8 57.2 63.5 69.9 76.2 88.9

in [1.00] [1.25] [2.00] [2.25] [2.50] [2.75] [3.00] [3.50]

Shut off the coolant filter to avoid discoloration of coolant and obscured visibility

WARNING Use wire lace to cover the tube and hose. Personal injury can result if the Pyrex® tube separates from the hoses. Connect the tube and hose with a wire lace.



Operate the engine at 75 percent of rated rpm until it reaches an operating temperature of 85°C [185°F]. Check for a continuous flow of air bubbles in the hose.

A continuous flow of air bubbles indicates excessive air in the system. Continue to operate the engine for 25 minutes. If the flow of bubbles does not stop, check for the following: • Air compressor cylinder head leak • Cylinder head combustion gas leak • Incorrect cylinder protrusion • Cracked or broken cylinder liners.

If no air is found in the system or if the flow of bubbles stops within 25 minutes, perform the following: Remove the test equipment Check the coolant level and fill if necessary Install the correct radiator pressure cap Operate the engine until it reaches a temperature of 85° C [185°F], and check for coolant leaks.

Air Compressor CAUTION The air compressor discharge mustbe disconnected at the compressor. This will allow the compressor to discharge air to the atmosphere to prevent the compressor from overheating during this test. CAUTION Do not operate the engine over 5 minutes with the components isolated from the cooling system. Component damage can result. Disconnect the air compressor discharge line.


Disconnect and plug the coolant supply and coolant drain lines, from the air compressor. Repeat the sight glass method or overflow method test. If air is not found in the cooling system with the air compressor isolated, replace the air compressor cylinder head gasket. See to the Holset Master Repair Manual, Bulletin 3666121.

Combustion Gas Leak Combustion Gas Test Use Part Number 3822985 Combustion Gas Tester or equivalent, to test for combustion gases in the cooling system. NOTE: It is recommended that the cooling system contain a mixture of 50 percent antifreeze and 50 percent water during the combustion gas leak test. The use of water only can result in a color change in the test fluid from blue to turquoise or light green during the test. This is not an indication of a combustion gas leak.

Drain the coolant level down approximately 50 mm [2 in] below the radiator cap seal ledge in the radiator fill neck.

Pour the test fluid into the combustion gas test instrument until it is up to the yellow fill line on the instrument.




Insert the rubber tip of the combustion gas leak test instrument in the radiator fill neck. Hold the instrument down firmly and turn back and forth to make sure that an air tight seal is formed between the tester and radiator fill neck.

Start the engine and run at high idle for approximately 30 minutes. Monitor the engine temperature and color of the test fluid during engine operation. Do not allow the engine temperature to exceed 100°C [212°F) during the test.

If the color of the test fluid changes from blue to yellow anytime during the test, combustion gases are leaking into the cooling system. Discontinue the test if the color of the test fluid changes from blue to yellow.

If the color of the test fluid does not change from blue to yellow during the 30 minutes test period, return the engine to low idle.


Check the test instrument to make sure that it is firmly sealed in the radiator fill neck.

Insert the tip of the rubber ball into the hole in the top of the test instrument. Squeeze the rubber ball 2 to 3 minutes to draw air from the radiator through the test fluid. If the color of the test fluid remains blue, combustion gases are not entering the cooling system. If the color of the test fluid changes from blue to yellow, combustion gases are entering the cooling system and further investigation is required to determine the source of the combustion leak.

NOTE: As the cooling system warms up to operating temperature air will be expelled through the combustion gas tester in the form of bubbles in the test fluid. This is due to normal expansion of the coolant. Do not mistake the presence of air bubbles in the tester as combustion gases or air leaks into the cooling system. A change in the color of the test fluid from blue to yellow is the only indication of combustion gas in the cooling system.

A positive result from the combustion leak tester indicates one or more of the following problems: • Cylinder liner protrusion incorrect • Cracked cylinder liner • Cylinder head or gasket leakage NOTE: Discard the tester fluid if it has indicated positive.




A negative result from the combustion leak tester coupled with a continuous flow of air bubbles from the previous test indicates the following: • Defective fan, shutter or heater air control valve • Air compressor head or head gasket leakage • Air entrained due to incorrect fill and inadequate cooling system venting

Defective Air Control Valve To check the air control valve perform the following: • Remove air pressure from the tank that supplies the valve in question • Disconnect the air supply line from the valve. Install a plug in the air supply line

• Repeat the test. If no air is found in the cooling system, the air control valve is defective and must be replaced.

Cylinder Head and Cylinder Liner A cracked or defective cylinder head will pressurize the cooling system and force the coolant out the overflow tube. Check the cylinder head gasket. Refer to Procedure 002-004 (Cylinder Head) in Section 2.


A cracked or porous cylinder liner will pressurize the cooling system and force coolant out the overflow tube.

To determine the cylinder liner that is leaking, perform the following: • Remove the water pump. Refer to Procedure 008-062 (Water Pump) in Section 8. • Remove the collar. • Install the water pump without the collar (20).

WARNING 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. Operate the engine at low idle for a maximum of 4 minutes. Check inside the water passage of each rocker lever housing for air bubbles. Air bubbles in the coolant indicate a porous or cracked cylinder liner. A defective cylinder liner must be replaced. Refer to Procedure 001-028 (Cylinder Liner) in Section 1.


Cooling System Diagnostics Page 8-54


If bubbles are not detected, install the water tubes and water pump collar.

Fill the cooling system. Refer to Procedure 008-018 (Cooling System) in Section 8.

Cooling System Diagnostics (008-020) Inspect 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.

Check the coolant level if necessary. NOTE: If coolant is added, additional DCVA4 (or equivalent) is required.


Fan Clutch, Viscous (008-028) Measure WARNING To reduce the possibility of personal injury, keep hands, long hair, jewelry, and loose-fitting or torn clothing away from fans and other moving parts. Use an optical tachometer, Part Number 3377462, or a strobe light to measure the fan rpm.

Mark a spot on the fan so the rpm can be measured. Mark another spot on the vibration damper to measure engine rpm. NOTE: When using the Cummins reflective optical tachometer, use a piece of reflective tape Part Number 3377464, to mark the spot.

Measure the fan pulley diameter (A). If the fan pulley diameter is 419 mm [16.50 inch], measure the crankshaft pulley diameter (B).

Fan Clutch, Viscous Page 8-55

Fan Drive Idler Arm Assembly Page 8-56


Operate the engine. Read and compare the fan rpm to specifications. Belt Driven Fan Fan Pulley Diameter Crank Pulley Diameter mm in mm in 419 [16.5] 163 [6.40]

419

[16.5]

406

[16.0]

380

[14.94]

317.5

[12.50]

203

[8.00]

Fan rpm

0.4 x engine rpm 0.5 x engine rpm 0.5 x engine rpm 0.55 x engine rpm 0.64 x engine rpm

If the fan rpm is not correct, check the following: • Belt • Viscous fan element • Fan clutch thermal control valve.

Fan Drive (008-029)

Idler

Arm

Assembly

Preparatory Steps NOTE: Not all engines are equipped with this option. • Remove the cooling fan. Refer to Procedure 008-040 (Fan, Cooling) in Section 8. • Remove the fan belt. Refer to Procedure 008-002 (Drive Belt, Cooling Fan) in Section 8.


Remove NOTE: Two types of control rods or a shock absorber are used. See the instructions that apply to the engine being serviced. Shock absorber: Remove the two capscrews (31) , the two spacers (29), the spacer (28) and the shock absorber

Solid control rod: Loosen the jam nuts (11). Turn the adjusting Screw (10) until the spacer (1) is not touching the end of the slot in the control rod (9). NOTE: One of the jam nuts has left-hand threads.

Remove the capscrews (4) and (7), the washers (2) and (3) and the spacers (1). Remove the control rod assembly.

Control Rod with Spring: Remove the two jam nuts (26). Remove the washers (25) and (24) and the spring (23). NOTE: This type of control rod is on engines that have an adjustable fan hub only.




Remove the parts. - (20) Capscrew - (19) Washer, Lock - (18) Washer - (17) Spacer - (14) Capscrew - (13) Washer, Lock - (12) Washer - (15) Control Red

WARNING 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.


Rotate the cap until the pins (1) align with the slots (2) in the cap. Remove the cap.

Use a vise. Support the pivot arm assembly. Remove the following parts: • Capscrew (3) • Plain washer (4) • Thrust bearing (5) • Pivot arm (6) • Thrust bearing (7) • Spring (8).

NOTE: The pivot arm (6) contains an external wear sleeve to prevent the spring from contacting the arm. The wear sleeve can be replaced using the same method as the coolant pump drive wear sleeve. Remove the following parts. • Bushing (9) • O-ring (10). Discard the o-ring.

Clean WARNING When using solvents, acids or alkaline materials for cleaning, follow the manufacturers recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. Use solvent to clean the parts.




Check the shaft for wear. Make sure the shaft is tight in the support. If the shaft has grooves in the surface or is loose, the support and the shaft must be replaced as an assembly. Shaft Outside Diameter mm 38.087 38.113

MIN MAX

in 1.4995 1.5005

Assemble Install and position the bushings (9) even with the pivot arm. Use vegetable oil. Lubricate the o-ring (10). Install the part.

Use a vise to hold the support as shown. Install the spring on the support. The end of the spring must be positioned on the spring stop as shown.

Use water pump type grease. Lubricate the thrust bearings (5) and (7). Install the parts. Torque Value: 203 N•m [ 150 ft-lb ]


Align the pins (1) with the slots (2) in the cap. Install the cap.

Use water pump type grease. Lubricate the pivot arm assembly until the grease begins to come from under the cap.

Install the pulley assembly to the pivot arm assembly. Tighten the capscrews. Torque Value: 47 N•m [ 35 ft-lb ]


Fan Hub Bracket Page 8-62


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.

Fan Hub Bracket (008-035) General Information Two revised fan brackets for all two pulley fan drives on K2000, KTA50-C1800, KTTA50-C1800, and KTA50-C1600 engines were released in January, 1992, ESN 33121123. The revised fan brackets are not interchangeable. The bolt span between them has increased, therefore, both revised brackets must be used together with the correct hardware. These changes replace the original two pulley design that was announced in July, 1989. The security of the bolted joint between the fan bracket and fan bracket support was also improved. A revised clamping plate is being used along with a 12 point capscrew and plain washer to improve the integrity. The torque value for the 12 point capscrew is 258 N•m [190 ft-lb]. The use of the clamping plate eliminates issues associated with a single washer clamping over a single hole.


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.

Fan Hub Bracket (Revised) Remove the mounting capscrews (15) and lock washers (14). Remove the fan hub bracket.

Clean and Inspect for Reuse WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. Clean the support with steam.

Check the support for cracks or fretting. NOTE: If the support must be replaced, be sure to install the correct part. All fan supports are not the same because of fan center location and spacing from the cylinder block.

Fan Hub Bracket Page 8-63

Fan Hub, Belt Driven Page 8-64


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.

One Piece Bracket Install guide pins in two of the fan support capscrew holes in the cylinder block for alignment. Install the fan hub bracket (14) over the guide pins. Install the lock washers (15) and mounting capscrews (16). Remove the guide pins and install the remaining lock washers and capscrews. Torque Value: 366 N•m [ 270 ft-lb ]

Two piece bracket Install the heavy nut (17) on the adjusting capscrew. Install the adjusting capscrew into the bottom of the boss in the fan bracket support (13). Install the retaining ring (18) into the groove of the adjusting capscrew. Install guide pins in two of the six fan support capscrew holes in the cylinder block for alignment. Install the fan bracket support (13) over the guide pins. Install the lock washers (14) and capscrews (15). Remove the guide pins and install the remaining lock washers and capscrews. Torque Value: 365 N•m [ 270 ft-lb ]

Fan Hub, Belt Driven (008-036) Preparatory Steps WARNING This component weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly. • Remove the cooling fan. Refer to Procedure 008-040 (Fan Cooling) in Section 8. • Remove the fan belt. Refer to Procedure 008-002 (Drive Belt, Cooling Fan) in Section 8.


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).

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 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. Check the seal for leaks. Check the shaft (1) for damage. Check the pulley exterior (2) for damage. If the shaft or pulley are damaged, the fan hub must be rebuilt.

Poly Vee pulley groove wear can be measured by placing a gauge ball or drill bit in the pulley groove and checking the protrusion with a straight edge. If the gauge ball or drill bit is below the pulley peaks, the pulley must be replaced. All KV engines use either a K or L section pulley belt.




To determine which gauge ball or drill bit can be used, measure the A dimension and compare to the dimensions of K and L section pulleys. Poly Vee - Pulley Reuse Guidelines Belt Type A B K-Section 3.56 mm [0.140 3 mm [0.12 in] in] gauge ball or a number 31 drill bit L-Section 4.70 mm [0.185 4 mm [0.16 in] in] gauge ball or a number 20 drill bit

Check the clearance. Bearing End Clearance mm 0.03 0.15

MIN MAX

in 0.001 0.006

If the clearance is not within the specifications, the fan hub must be rebuilt. Rotate the pulley to check for rough or damaged bearings. If the fan hub does not rotate freely, the fan hub must be rebuilt.

Remove the pipe plugs (3) (if fitted). Install a grease fitting in one of the holes. Use a grease gun and water pump type grease. Pump grease into the hub until it begins to come out of the open plug hole. Remove the grease fitting. Install the pipe plugs (3). 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.


NOTE: If force is required, use an arbor press. Support the pulley (6) and push on the small end of the shaft (7). Remove the pulley assembly (6) from the shaft (7). Remove and tag the front roller bearing (8) for future identification. Remove the pipe plugs (9) (if fitted).

Turn the pulley assembly (6) over. Remove the oil seal (10). Remove the rear roller bearing (11) and tag for future identification. Remove the inner bearing spacer (12). NOTE: Do not remove the outer bearing spacer.

Assemble CAUTION Do not lubricate the seal surface of the shaft. The seal and seal surface must be clean and dry. Failure to do so can result in seal failure. NOTE: Excessive grease will affect the end float reading. Lightly grease the bearing (11) with Mobiplex® 48 grease, or equivalent. Install the bearing in the hub. Apply Loctite® 675, or equivalent, to the outside diameter of the seal. Install the seal (10), use a mandrel with the flat unseamed face toward the shoulder of the driver and press the seal in until it bottoms.




Install the fan hub seal end first over the shaft and make sure no damage occurs to the seal. The rear bearing must slide easily on the shaft. If it does not, check for chips or burrs. Install the inner bearing spacer (12). The following spacers are available to provide correct end clearance when the fan hub has been assembled. The following listing is for two spacer style fan hubs: • 3627681 - 63.906 mm [2.5160 in] length • 3627682 - 63.995 mm [2.5195 in] length • 3627683 - 64.084 mm [2.5230 in] length • 3627684 - 64.173 mm [2.5265 in] length. The following listing is for other fan hubs: • 3627677 - 51.562 mm [2.0300 in] length • 3627678 - 51.689 mm [2.0350 in] length • 3627679 - 51.816 mm [2.0400 in] length • 3627680 - 51.943 mm [2.0450 in] length • 3628830 - 52.019 mm [2.0480 in] length Lightly grease the front bearing (8). Install the bearing. The bearing must slide easily over the shaft. If it does not, check for chips and burrs.

CAUTION Remove all grease from the threads on the shaft before installing the locknut. Grease on the threads reduce the torque retention of the locknut. Install the hardened washer (5). Install the lock nut (4). Torque Value: 610 N•m [ 450 ft-lb ]



Use a dial indicator to measure the bearing end clearance. Bearing End Clearance mm 0.025 0.150

MIN MAX

in 0.001 0.006

If the clearance is not within specifications, rebuild the fan hub with a suitable size spacer. Check the bearing end clearance.

CAUTION Do not use more grease than specified. Too much grease will cause excessive heating and failure. Use Mobiplex® 48 grease, or equivalent, to fill the cavity with 120 cc of grease. Grease the inner race, fit the spacer, and inner race, Install the hardened washer (5). Install the lock nut (4). Check the bearing end clearance. Install the o-ring (3) on the fan pilot (2). Lubricate the o-ring with vegetable oil. Install the fan pilot and o-ring. Install the capscrews (1). 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 Page 8-70


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.

Fan Shroud Assembly (008-038) Inspect for Reuse Inspect the fan shroud for the correct fan clearance. See the vehicle manufacturer's specifications and the appropriate installation recommendations bulletin. Inspect the fan shroud for cracks, air leaks, or other damage. Replace the part if damaged. Consult the manufacturer's instructions.

Fan, Cooling (008-040) Preparatory Steps WARNING 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


Remove the fan

Install CAUTION Replace the original equipment fan with a fan of the identical part number. Cummins Engine Co., Inc. must approve any other fan changes. Using a fan with a different part number can result in failure, causing damage to personal injury.

Install the fan. Tighten the mounting capscrews. Torque Value: 135 N•m [ 100 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 Connections and Cables) in Section 13.

Fan, Cooling Page 8-71

Radiator Page 8-72


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].


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 Page 8-73

Radiator Pressure Cap Page 8-74


• Close valve “2” and open valve “1”. Record the pressure at the water pump inlet. • Compare the two pressure readings. If they differ by more than 35 kPa [5 psi], the radiator core or piping is obstructed.

Radiator Hoses (008-045) Inspect for Reuse WARNING 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.

Radiator Pressure Cap (008-047) Inspect for Reuse Inspect the rubber seal of the pressure cap for damage. Inspect the radiator fill neck for cracks or other damage. Refer to the radiator manufacturer's operating instructions if the fill neck is damaged. Make sure the correct radiator cap is being used. The pressure rating must be 48 kPa [7 psi] or greater.


Pressure Test Pressure-test the radiator cap. The pressure cap must seal within 14 kPa [2 psi] of the value printed on the cap, or it must be replaced.

Expansion Tank (008-052) Preparatory Steps WARNING 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 Page 8-75



Detach both ends of the coolant make-up hose (4). Remove the hose. Check the hose for damage. Discard the part if it is damaged.

WARNING 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).

Top Mounted Tank Detach the coolant vent hoses.

Remove the coolant make up lines.


Remove the coolant filter. Refer to Procedure 008-006.

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.

Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. 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.




Cap off the vent line and makeup hose fitting. Fill the expansion tank with clean water.

Install a pressure tester to the expansion tank and apply a maximum of 172 kPa [25 psi] of pressure. Check for leaks. If any leaks are found they must be repaired.

Remove the caps from the vent and make up fittings and drain the expansion tank.

Install WARNING 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 ]


Connect the coolant make-up hose (4) to the fitting on the right bank side of the expansion tank and to the fitting in the water pump inlet housing.

Connect the two coolant vent hoses (5) to the fittings in the expansion tank and to the fittings on the top of the thermostat housing. If the engine is equipped with a center mount type aftercooler, connect the two vent hoses (6) to the fittings on the top of the aftercooler coolant outlet fittings and to the fittings on the expansion tank.

WARNING 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 Capscrews

40 N•m

Install the coolant make up line.

[ 30 ft-lb ]




Attach the coolant vent hoses.

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.


Heat Exchanger Page 8-81

Heat Exchanger (008-053) Exploded View

Figure 1, K38 Marine Plate Type Heat Exchanger Plate Orientation and Plate Location Numbers



Heat Exchanger (008-053) Exploded View A. Lower Manifold

B. Tank.



Heat Exchanger (008-053) Exploded View

Figure 2, K50 Marine Plate Type Heat Exchanger Plate Orientation and Plate Location Numbers



Heat Exchanger (008-053) Exploded View A. Lower Manifold

A. Tank


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.

Loosen the hose clamps. Remove the V-band clamp. Remove the right bank pump inlet pipe (20) and the seal (21). Discard the hose (19) and seal.

Loosen the hose clamps Remove the four capscrews. Remove the upper heat exchanger inlet pipe (15) and the gasket (17). Discard the hose and gasket. Remove the V-band clamp. Remove the right bank pump outlet pipe (16) and seal (18). Discard the seal.




Loosen the hose clamps. Remove the four capscrews. Remove the lower heat exchanger outlet pipe (13) and gasket (12). Discard the hose (11) and gasket.

Loosen the hose clamps. Remove the four capscrews. Remove the lower heat exchanger inlet pipe (7) and gasket (6). Discard the hose and gasket. Remove the V-band clamp. Remove the left bank pump outlet pipe (9) and the seal (10). Discard the seal.

Loosen the hose clamps. Remove the V-band clamp. Remove the left bank pump inlet pipe (5). Discard the seal (4).

Remove the four sea (raw) water manifold connections (2) and the gaskets (1). Discard the gaskets.


Heat Exchanger Pipes, Engine Water If the pipe from the water pump inlet connection to the heat exchanger outlet pipe (17) has not been removed, remove the pipe now. Loosen the hose clamps. Remove the eight capscrews. Remove the outlet pipes (17, 14) and gaskets (15, 18). Remove the hose (16). Discard the hose and gasket.

Loosen the eight hose clamps. Remove the four capscrews. Remove the pipes (8, 10) and the gasket (11). Remove the hoses (9). Discard the gasket and hoses.

Loosen the hose clamps. Remove the four capscrews. Remove the pipe (5) and gasket (6). Discard the hose and gasket.

A portion of the heat exchanger support is not shown for clarity. Loosen the hose clamps. Remove the two capscrews (3). Remove the engine outlet pipes (2, 1). Discard the hoses.




WARNING This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component. Remove the capscrews. Remove the upper heat exchanger (2). Remove the lower heat exchanger (1).

Plate Type Remove the vent lines from the expansion tank.

Disconnect and remove the coolant outlet tube.

Disconnect the sea water pump prime discharge line from heat exchanger sea water outlet connection.


Disconnect the sea water inlet and outlet tube.

Attach a chain fall or other lifting equipment with straps around the heat exchanger assembly as shown.

Remove the six jacket water manifold bolts that hold the jacket water manifold to the thermostat housing. Remove the four LTA transfer tube mounting bolts that hold the tubes to the thermostat housing.

Disconnect the lower mounting bracket bolts that fasten the bracket to the engine block.




Lift the heat exchanger assembly away from the engine.

Box Type Remove the vent lines.

Remove the coolant inlet connection.

Remove the sea water outlet connection and sea water priming discharge hose.


Remove the sea water inlet connection.

Remove the coolant outlet tube.

Remove the Low Temperature Aftercooled (LTA) coolant outlet tubes.

Attach the proper lifting equipment with straps around the heat exchanger assembly as shown. Remove the four heat exchanger support bracket mounting bolts from engine block and lift the box type heat exchanger away from the engine.




Clean Tube Type WARNING 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 oring seal. Remove the six zinc electrode plugs (1).

CAUTION Do not damage the housing or cover when separating the parts. If the parts are damaged, a leak will result. The open end of the housing has one notch. Turn the open end cover so that the notch is aligned with the notch in the housing. Use a mallet and brass drift to move the o-ring seal from core. Remove the 12 capscrews (7) and lock washers, open end cover (8), and the gasket (9) from the housing (5).


Remove the cooler core (10) and the gasket (4) from the housing (5).

Plate Type Remove the two flange bolts from the drain tube. The drain tube will stay in the expansion tank during the disassembly process.

If installed, remove the support brackets from both sides of the expansion tank. More current versions of the heat exchanger assembly, with cast front support brackets, do not have the side brackets installed.

Remove the two end top spacer bolts from the top of the expansion tank.




Loosen the bolts 1 through 6 that hold the expansion tank against the plate pack, in the sequence shown.

CAUTION Do not loosen each bolt completely. The expansion tank must not be more than 12 mm [.50 in] from level; as this will cause the plate pack and tank to bind on the Low Temperature Aftercooled (LTA) tubes and the drain tubes causing damage to them and the o-rings. 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.

Remove the shield by removing the 10 capscrews that mount the shield to the spacers.


Use a paint marker to draw a diagonal line across the plate pack as shown. The line will help identify plate arrangement and benefit the assembly procedure.

WARNING Wear protective gloves for protection against sharp edges. Remove the plates from the assembly. The plates have sharp edges.

Box Type This procedure can be performed with the heat exchanger on or off the engine. Drain the engine coolant if the heat exchanger is engine mounted. Remove the vent lines.

Remove the coolant inlet connection.




Remove the sea water outlet connection and pump priming hose.

Remove the sea water inlet connection.

Remove the coolant outlet tube.

Remove the heat exchanger front cover.


WARNING 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.

Remove the Low Temperature Aftercooled (LTA) inlet and outlet tubes.

Remove the heat exchanger rear housing.

Clean and Inspect for Reuse 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.




Use a brass rod or a copper rod that has an outside diameter of 8 mm [0.313 in]. Use the rod to clean the tubes.

Plate Type CAUTION Incorrect orientation of the gaskets can cause overheating and sea water to enter the cooling system. Observe the orientation of the gasket for assembly accuracy. Remove each gasket from the plate one at a time. Clean each plate.

Clean the plate with a soft brush and running water.


If deposits are present that are difficult to remove, spray the plate with a high pressure water hose. If brushing and high pressure water does not properly clean the plates, the deposits on the plates can be evaluated. Use the information in the following lists to determine what solvents to use. Incrustation • Calcium carbonate (corrosion products - clean with nitric acid). • Calcium sulphate (metal oxides - clean with sulfamic acid). • Silicates (silt - clean with citric acid, alumina - clean with phosphric acid, diatomic organisms and their excrement of various colors - clean with complexing agents EDT, A, and NTA). Biological Growth • Slime - Clean with alkaline cleaning agents. • Bacteria - clean with sodium hydroxide. • Nematodes - Clean with sodium hydroxide. • Protozoa - Cleaning effect can be considerably increased by the addition of small quantities of hypochlorite or agents for the formation of complexes and surfactants. Concentration maximum: Four Percent. Temperature maximum: 60°C [140° F]. Solvents That Can Not be Used • Ketones (acetone, methyletylketone, methylisobutylketone) • Esters (ethylacetate, butylacetate) • Halogenated hydrocarbons (chloro-thene, carbon tetrachloride, freons) • Aromatics (benzene, toluene). Box Type WARNING 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.




Inspect Tube Type Check the parts for cracks or other damage. Replace any damaged parts. To pressure test the cooler core, see the Pressure Test step in this procedure.

Check the length of each electrode. If more than 1/2 of the length is missing, the plug must be replaced.

If more than 5 percent of the tubes are plugged or have been closed by an earlier repair, the core must be replaced.

Plate Type Inspect the gasket. If gaskets are swollen, cracked, or deformed, they must be replaced.


Box Type Check for damaged tubes and eroded or corroded o-ring sealing surfaces in the front cover and rear housing.

Assemble Tube Type CAUTION One end of the housing has one notch, and one end has two notches. The cooler core and the open end cover must be installed on the end that has only one notch. If the heat exchanger is not assembled correctly, the engine will overheat because the water pipe will not be connected correctly.

CAUTION The notch in the core and the notch on the housing must be in alignment. If the parts are not in alignment, the coolant flow through the heat exchanger will be faulty and the engine will overheat. Install the gasket (4). Align a notch on the gasket with the notch on the core. The capscrew holes will also be in alignment. Install the cooler core (10) in the housing (5). Align the notches on the core, gasket, and housing.




CAUTION A notch in the gasket and the notch on the cover must be in alignment with the notch in the housing. If the parts are not in alignment, the coolant flow through the heat exchanger will be faulty and the engine will overheat. Install the gasket (9). Align the notches. Check to be sure the center rib on the gasket is in proper position on the center rib of the cover. Install the open end cover (8). Align the notches. Install the 12 capscrews (7) and lock washers. NOTE: Install capscrews that are 44 mm [1.750 in] in length for this end of the assembly. 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 ] Install the six zinc electrode plugs (1). Torque Value: 54 N•m [ 40 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 ]

The orientation of the plates is different on a K38 engine than it is on the K50 engine. See the10 digit I.D. number (1). See: Figure 1 for K38 engines Figure 2 for K50 engines. During the plate assembly process, make sure the ribs on alternating plates are pointing in opposite directions, as shown in Figures 1 and 2.

CAUTION Incorrect orientation of the gaskets can cause overheating and sea water to enter the cooling system. Place the gaskets back onto the plates one at a time. Make sure the tabs are locked into the slots and orientated correctly. Gaskets will always be facing up during the plate assembly process. See Figures 1 and 2 for plate orientation and identification numbers. After the plates are assembled in the engine, make sure the profile shows a honey-comb pattern and the gasket tabs alternate position. If this pattern is not shown throughout the entire plate pack, the plates must be rearranged.




Install the spacers and the shield. Torque Value: Shield capscrews

9 N•m

[ 80 in-lb ]

CAUTION Pushing the LTA tubes too deep into the expansion tank, can damage the tube's o-ring. Remove the drain and LTA tubes. Install the o-ring and crevice seal onto the drain and LTA tubes and install them into the expansion tank assembly approximately 25 mm [1 in] deep.

WARNING 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.

Install the six-plate pack clamping bolts with the NordLock® washers as shown. The longer serrations, or cams, of each Nord-Lock® washer must be oriented toward the other in order for the assembly to work properly.


Finger tighten the bolts in the sequence pattern shown until the plate pack begins to compress. Tighten bolts, one through six, in 14 N•m [124 in-lb] increments in the sequence shown so the expansion tank comes down evenly. Stop tightening bolts when expansion tank is touching all 6 spacers.

CAUTION During the tightening process the expansion tank must not be more than 12 mm [.5 in] from level; otherwise the plate pack and tank may bind on the Low Temperature Aftercooled (LTA) drain tubes and damage the o-rings.

Measure the plate stack distance, as a double-check. The plate stack distance should match what is on the data sticker on the heat exchanger bracket. K38 A Dimension 142 to 147 mm [ 5.6 to 5.8 in ] K50 A Dimension 181 to 183 mm [ 7.0 to 7.3 in ]

Install two end-guide top bolts with Nord-Lock® washers. The longer serrations, or cams, of each Nord-Lock® washer must be oriented toward the other in order for the assembly to work properly. Tighten all eight top bolts. Torque Value: Tighten all 8 Top Bolts

256 N•m

[ 190 ft-lb ]




NOTE: Engines with cast iron front support brackets do not need the side brackets installed. Install the side brackets, if they were installed initially. Tighten the capscrews. Torque Value: Bracket Capscrew

31 N•m

[ 23 ft-lb ]

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.

Connect LTA inlet and outlet tubes. Tighten the bolts. Torque Value: 16 N•m [ 144 in-lb ]

Install the sealing ring and the heat exchanger core into the rear housing and tighten bolts. Torque Value: 75 N•m [ 55 ft-lb ]


Install the sealing ring and the heat exchanger front cover. Torque Value: 16 N•m [ 144 in-lb ]

Install the coolant outlet tube. Tighten the bolts. Torque Value: 25 N•m [ 20 ft-lb ]

Install the sea water inlet connection. Tighten the bolts. Torque Value: 55 N•m [ 40 ft-lb ]

Install the sea water outlet connection and pump priming hose. Tighten the bolts. Torque Value: 55 N•m [ 40 ft-lb ]




Install the coolant inlet connection. Torque Value: 27 N•m [ 20 ft-lb ]

Install the vent lines.

Pressure Test Tube Type The most convenient method to pressure test the cooler core is with the heat exchanger assembled. More items must be fabricated to test the core separately. No tool is available from Cummins, Inc., to test the core separately. For both tests it is necessary to use two of the heat exchanger piping connections (1), gaskets (2), hoses (3) and hose clamps (4). Install the connections, gaskets, and hoses on the open end cover plate. Install a plug (5) in one of the hoses using a hose clamp. Install a reducer (6) to connect a source of compressed air supply in the other hose. Test the Heat Exchanger Connect an air supply to a regulator and gauge assembly (7). Connect the outlet hose of the regulator to the fitting on the reducer. Fill the heat exchanger with clear water.


Adjust the regulator to apply 275 kPa [40 psi] to core. Check for air bubbles in engine coolant side of heat exchanger. If air bubbles are visible, core has leak and must be replaced.

CAUTION Install heavy washers between the nuts and the flange on the core to prevent damage to the sealing surface of the core. Test the Heat Exchanger Cooler Core Install the connections, hoses, clamps, plug, and reducer on the open end cover. The two capscrew holes that are 180 degrees apart must remain open. Install the cover (8) and gasket (9) on the flange of the core using at least four capscrews, nuts, and washers.

Use two lengths of threaded rod (10), a plate with holes for the rod (11), a piece of gasket material (12), and nuts and flat washers to seal the open end of the core.

CAUTION Tighten the nuts only enough to seal the gaskets. Do not tighten the nuts excessively or damage to the core will result, preventing its use. Install the items as shown. Connect a regulated compressed air supply to the fitting in the reducer.




Some air will be trapped between the tubes of the core when the core is immersed. Move the core around to allow this trapped air to escape. If the core is leaking, a steady stream of air bubbles will be visible. Immerse the core and testing items in a container of water. Adjust the regulator to apply 275 kPa [40 psi] to the core. Check for air bubbles coming from the core. Be sure the air bubbles are not coming from the area of the testing plates. If air bubbles are visible, the core is leaking and must be replaced.

Box Type Cap off the sea water inlet connection and install the test fittings in the sea water outlet connection. Immerse the core in the tank and apply 172 kPa [25 psi] of shop air for a minimum of 10 minutes. Check for air bubbles coming from the core. If a continuous stream of bubbles appears during the last 5 minutes of the test, the core must be scrapped.

Install Tube Type WARNING The component weights 23 kg [50 lb] or more. To 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.


The upper heat exchanger and a portion of the heat exchanger support are not shown for clarity. Install the engine outlet pipes (1) and (2) on the outlets of the thermostat housing, using the hoses and clamps. Install a flat washer, lock washer, and capscrew (3) through the tab on each pipe to the heat exchanger support. Tighten the capscrews. Torque Value: 40 N•m [ 30 ft-lb ] Tighten the clamps. Torque Value: 5 N•m [ 44 in-lb ] 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 ]




Install the gasket (15), the upper heat exchanger outlet pipe (14), the four lock washers and capscrews to the upper heat exchanger outlet. Install the hose (16) and clamps on the lower heat exchanger outlet pipe (17). Install the hose on the upper heat exchanger outlet pipe. Install the gasket (18), the four lock washers and capscrews to the lower heat exchanger outlet (19). Tighten the capscrews. Torque Value: 40 N•m [ 30 ft-lb ] Tighten the hose clamps. Torque Value: 5 N•m [ 44 in-lb ] A large pipe (not shown) with a flange and a gasket must be installed to the lower heat exchanger outlet pipe (17) and to the engine water pump inlet. The pipe is notinstalled at this time because the pipe is routed under a crossmember of a base rail on engines equipped with base rails. If the engine being serviced has sea water pumps, proceed to “With Sea (Raw) Water Pumps”. Without Seal Water pumps The sea water pipes are always connected to the ends of the heat exchangers. Always tighten the capscrews before tightening the hose clamps. Two clamps are on each end of each hose. Check to be sure the hose is centered over the gap between the pipes. Tighten the capscrews for the pipe before tightening the hose clamps. Install the four gaskets (1) and the four connections (2) to the sea water manifold as shown. Tighten the capscrews. Torque Value: 40 N•m [ 30 ft-lb ]


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 ]




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 ]


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 ]




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.


Install the o-rings onto the bottom flange of the LTA tubes and the jacket water manifold as the assembly is lowered into place.

Install the lower mounting bracket bolts that fasten the bracket to the engine block. Torque Value: Bolts, Lower Bracket

35 N•m

[ 25 ft-lb ]

Install the four bolts that hold the Low Temperature Aftercooled (LTA) tube to the thermostat housing Tighten the bolts. Torque Value: Bolts

78 N•m

[ 57 ft-lb ]

Install the clips and bolt and tighten. Install the ring retainer clip from the drain pipe and tighten the bolts. Torque Value: Clips

17 N•m [ 144 in-lb ]

Install the jacket water manifold bolts that fasten the manifold to the thermostat housing. Tighten the bolts. Torque Value: Bolts, Jacket Water Manifold

31 N•m

[ 23 ft-lb ]




Connect the sea water pump prime discharge line from the heat exchanger sea water outlet connection.

Connect the sea water inlet and outlet connections. Tighten the capscrews. Torque Value: 31 N•m [ 23 ft-lb ]

Connect the coolant outlet tube and connector. Tighten the capscrews. Torque Value: 31 N•m [ 23 ft-lb ]

Connect the vent lines to the expansion tank.


Box Type Attach the proper lifting equipment with straps around the heat exchanger assembly as shown. Install the four heat exchanger support bracket mounting bolts on the engine block. Torque Value: 365 N•m [ 270 ft-lb ] Lift the heat exchanger assembly onto the engine.

Install the Low Temperature Aftercooled (LTA) coolant inlet pipe. Torque Value: 16 N•m [ 144 in-lb ]

Install the Low Temperature Aftercooled (LTA) coolant outlet pipe. Torque Value: 16 N•m [ 144 in-lb ]

Install the coolant outlet tube. Torque Value: 25 N•m [ 20 ft-lb ]




Install the sea water inlet connection. Torque Value: 55 N•m [ 40 ft-lb ]

Install the sea water outlet connection and pump priming hose. Torque Value: 55 N•m [ 40 ft-lb ]

Install the coolant inlet connection. Torque Value: 25 N•m [ 20 ft-lb ]

Install the vent lines. Torque Value: 30 N•m [ 22 ft-lb ]


Sea Water Pump Page 8-121

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.

Sea Water Pump (008-057) General Information Gear Driven Some K38 and K50 marine series engines are equipped with two sea water pumps. The pumps are mounted on supports on the front gear cover. The supports for the left bank and the right bank are different. The sea water pumps are the same for both the left and right banks. The sea water pump is a gear driven pump, that is driven by the camshaft gear. The sea water pump on K38 and K50 marine series engines contain a paddle type impeller that allows the pump to function in either a clockwise or counterclockwise rotation. When viewed from the front of the engine. The sea water pump on the right bank rotates in a counterclockwise direction. The sea water pump on the left bank rotates in a clockwise direction. The inlet for the sea water pump is the port nearest to the front gear cover to the person's right. The bearings in the sea water pumps on K38 and K50 marine series engines are lubricated by engine oil through drillings in the front gear cover and the pump supports. The sea water pumps on K38 and K50 marine series engines are limited to engine speeds of 2000 rpm or less. Cummins Inc., does not provide sea water pump gears for engine speeds in excess of 2000 rpm. The sea water pumps mounted on K38 and K50 marine series engines are Gilmec, Model 250/700, manufactured by: Gilbert Gilkes & Gordon Ltd. Kendal, Cumbria England LA9 7B2

Preparatory Steps Spline Drive Isolate the water supply to the sea water pump. Disconnect the piping from the sea water pump.



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.


NOTE: This procedure can also apply to check or replace the seal when the pump is installed on the engine. If the work is being performed with the pump installed, the hoses for the pump must be removed. Remove the vee band clamp (1). Use a scribe or a center punch. Put a mark on both ends of the water pump bodies so that they can be assembled correctly.

NOTE: The body is a tight fit. If necessary, use a wooden wedge to aid in the separation of the parts. Put the wedge in the space between the inlet and outlet ports. Insert a wooden hammer handle through the part until the handle is touching the end of the shaft. Pry on the handle. Remove the nondrive end of the body (2). NOTE: The spacer ring (3) can be a tight fit in the nondrive end of the body. It is not necessary to remove the spacer ring if it is secure in the body (2). Remove the o-ring seal (4). Remove the cotter pin (5), slotted nut (6), and washer (7).

Use standard puller ST-647 or equivalent and two 8 - 1.25 x 70 mm capscrews (8). Remove the impeller (9).




Use a drift and a mallet. Remove the key (10) from the impeller. Remove the shims (11). Keep the shims together for future assembly. The thickness of the shims is critical for the performance of the pump.

NOTE: The spacer ring can be a tight fit in the body. If necessary, use two pry bars to remove the ring. Remove the spacer ring (3).

Bend the lockplates. Remove the four nuts (12) and the lockplates (13). NOTE: It will be necessary to use a mallet to separate the parts because of the tight fit between the shaft and the water seal and spacer. Remove the drive end of the body (14), and spacer (15), from the bearing housing and shaft assembly (16).

NOTE: The port plate can be a tight fit in the body after many hours of operation. If necessary, use the special tool available from Gilkes. NOTE: This tool can also be used to remove the port plate from the nondrive end of the body.


Remove the port plate (17) and mechanical seal (18) from the drive end of the pump body (14).

Use a press and an appropriate mandrel. Remove the contact ring (19) from the body.

Spline Driven Remove the eight suction bend mounting capscrews (6). Remove the suction bend (15) from the pump case (13). Remove the o-ring (26).

NOTE: The main impeller uses a left hand thread. Restrain the shaft spline. Use a strap wrench to unscrew the main impeller (27). Remove the spacer (39).




Loosen and remove the three screws (12) that hold the wear ring (11) into position. Remove the wear ring and the visible port plate (9).

Rotate the assembly to remove the lip seal (17) and bevelled circlip (18) from the drive end of the bearing housing (3).

Stand the assembly in a press, supporting it on the square drive end flange. Press down on the shaft end. As the shaft is pressed through the intermediate body (8) and the bearing housing (3), the priming impeller (25) will be released. Take care that the shaft does not fall. Remove the distance ring (10).

Unscrew and remove the locknut (16). Press the bearing (2) and seal collar (19) off the shaft. This can be tight as it is secured with Loctite® 574 threadlocker.


Remove the six screws (6) holding the bearing housing (3) to the intermediate body (8). Be sure to catch the shims (31), (32), (33), and (34). Press the second port plate (9) out of the intermediate body (8). Remove the seal spacer (24). Remove the loose rotating half of the mechanical seal (23) and press out the stationary half.

Remove the seal collar (20), the lip seal (22), and remove the circlip (21) from the bearing housing. The inner race of the roller bearing (5) will drop out. Press out the bearing outer race. Remove the o-ring (1).

Clean and Inspect for Reuse Gear Driven WARNING When using detergents for cleaning, follow the manufacturers recommendations for use. Wear goggles and protective clothing to reduce the risk of personal injury. Use a 5-percent detergent solution to clean the parts. It is important to eliminate all of the grease and dirt from the surfaces that contact the contact ring and the mechanical seal.

Check the impeller (3) and port plate (2) for damage from cavitation. If necessary, replace the parts.




Gilkes recommends the replacement of the mechanical seal only when the contact ring is replaced at the same time. NOTE: This is only a temporary repair for an emergency situation. Cummins Inc., does not recommend the use of this procedure for a permanent repair. The correct repair procedures must be followed as soon as possible. For an emergency repair, the contact ring (1) can be reversed so that the side of the ring that is not worn touches the mechanical seal. Reverse the ring and install it in the rubber boot (2).

Spline Driven WARNING When using detergents for cleaning, follow the manufacturers recommendations for use. To reduce the possibility of personal injury, wear goggles and protective clothing. WARNING 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. Visually inspect all sea water pump components for evidence of cracks, pitting, and any obvious damage. Replace any damaged parts as necessary.

Assemble Gear Driven Use a 5-percent detergent solution. Lubricate the rubber boot. Do not use grease. Use the special tool (22) that is available from Gilkes or use your hands. Install the contact ring (19) in the drive end of the body (14). Be sure the ring touches the bottom of the bore in the body.


Use a 5-percent detergent solution. Lubricate the inside diameter of the contact ring. Install the drive end of the body (14) on the bearing housing and shaft assembly (16). Install the lockplates (13) and the nuts (12). Torque Value: 34 N•m [ 25 ft-lb ] Bend the lockplate tabs over the nuts and the edge of the housing.

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.




Install the drive end of the port plate. The port plate will be approximately 13 mm [0.500 in] below the chamfer when the plate is installed correctly.

Install the spacer (15). Install the shims (11). The shims must touch the drive end of the port plate.

NOTE: The thickness of the shims is critical to the performance of the pump. Use a straight edge (23) or ring that will touch the step in the shaft. Use a feeler gauge (24), to measure the distance from the step on the shaft and the shims (straight edge) to the port plate. This distance is the impeller side clearance. Sea Water Pump Impeller Side Clearance mm in 0.18 MIN 0.007 0.23 MAX 0.009 If the side clearance is not within specifications, remove or install shims (11) until the side clearance is correct. Be sure the contact ring, seal, and port plate are seated properly.


Install the shaft key (10). Apply Loctite® 609 or equivalent, to the shaft and key.

CAUTION Do not use a hammer and mandrel to install the impeller. The bearings in the pump will be damaged. NOTE: Be sure the puller holes in the impeller are positioned toward the nondrive end of the pump. Align the slot in the impeller with the key. Install the impeller on the shaft. Use a mallet with a soft nose. Tap the impeller (1) only until it is straight on the shaft.

CAUTION Do not use too much grease or antiseize compound. If the grease touches the seal, the seal will fail. Use water pump grease or antiseize compound. Apply a light layer to the threads on the shaft. Install the washer (7) and the nut (6). Use the nut to push the impeller on the shaft. The impeller will stop when it contacts the shims.

CAUTION Use this illustration to identify the torque specification for the nut being installed. If the older, smaller nut is torqued to the higher specification, the nut will fail. If the nut requires a [1.250 in] wrench: 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.




CAUTION Do not loosen the nut to align the slots in the nut with the hole in the shaft. Tighten the nut no more than 10 degrees to align the holes. If the slots and holes are not in alignment, change the washer or reduce the thickness of the washer slightly so that a slot and the hole are in alignment at the proper torque. Install the cotter pin (5). Bend the ends of the pin over the nut.

Install the o-ring seal (4) on the spacer ring (3). Install the spacer ring and o-ring seal. Push the o-ring seal under the lip for the vee-band clamp. NOTE: If the nondrive end of the port plate was removed, install the plate in the body so that the lugs on the plate engage the slots in the body.

Install the nondrive end of the body (2). Align the marks scribed on the bodies during disassembly. The center of the inlet and outlet ports must be in alignment within 3 degrees. Install the vee-band clamp (1). Tighten the clamp. Torque Value: 20 N•m [ 15 ft-lb ] Use a plastic hammer. Tap around the vee-band clamp completely. Torque the clamp fasteners again. Continue this step until the fasteners remain at the correct torque after tapping the clamp. Spline Driven Mechanical seals, lip seals, o-rings, spring washers and bearings are not serviceable, and must always be replaced. NOTE: Whenever Loctite® products are mentioned, all surfaces must be clean and grease free in accordance with Loctite® brand recommendations. Press the bearing (2) onto the shaft (4). Press the shaft and bearing assembly into the bearing housing (3) with bevelled circlip (18).


Press the inner race of the roller bearing (5) into position on the shaft. Fully pack this bearing with Shell® ALBIDA “2” grease. Secure the bearing with circlip (21).

Apply Loctite® 574 threadlocker to the face in contact with the shaft. Fit the seal collar (19) over the shaft. Secure with a locknut (16). Torque Value: 50 N•m [ 37 ft-lb ]

Apply Loctite® 641 retainer to the shaft where the seal collar (20) will fit. Press the seal collar into position. Be sure that no excess Loctite® product enters the bearing.

Press the lip seal (22) into position using grease to lubricate the lips. Fit the o-ring (1).




Press the stationary half of the mechanical seal (23) into the intermediate body (8). Use a 5-percent detergent solution to install the seal. Secure the intermediate body to the bearing housing with screws (6) and spring washers (7). Do not fully tighten the screws.

Use the 5-percent detergent solution to fit the rotating half of the mechanical seal (23) over the shaft. NOTE: The seal faces must be clean and dry to operate effectively. Slide the seal spacer (24) over the shaft. Install the drive end port plate (9) with the port at the 9 o'clock position.

NOTE: When pressing the priming impeller onto the shaft, make sure that the shaft end is supported to avoid loading the bearings. Press the priming impeller (25) onto the shaft.

Install the distance ring (10), second port plate (9), and wear ring (11). NOTE: Be sure the port plate fitting rib is located at the 12 o'clock position so it locates between the two dowels on the wear plate. Lubricate the threadlocker.

screw

threads

with

Loctite®

Install the screws (12) and spring washers (37). Torque Value: 5 N•m [ 44 in-lb ]

242


Install the spacer (39). Screw the impeller (27) onto the shaft using Loctite® 242 threadlocker and a strap wrench. Torque Value: 175 N•m [ 129 ft-lb ] Wipe away the excess Loctite®.

NOTE: When installing the suction bend and pump case on the assembly, it is important that the sealing o-rings are lubricated so as not to damage them during assembly. Install a new o-ring (26). Install the suction bend and pump case assembly (13) using screws (6) and spring washers (7).

The side clearance of the priming impeller must be equalized by fitting the appropriate shims (31), (32), (33), and (34) between the bearing housing (3) and the intermediate body (8). Use a feeler gauge to check the maximum, then the minimum clearance. Select the correct shim(s) to equalize the side clearance. Subtract the minimum clearance from the maximum clearance. Add one-half of the difference to the minimum to obtain the correct side clearance dimension. Tighten the screws (6). Torque Value: 25 N•m [ 221 in-lb ] 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 Page 8-136


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.

Sea Water Pump Support (008-058) Preparatory Steps • Close the water supply valve to the sea water pump. • Remove the sea water pump. Refer to Procedure 008-057.


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.

NOTE: Not all engines are equipped with this option. Remove the sea (raw) water pump drive ring gears. Remove the eight 12-point capscrews (3) from each gear. Remove the gears (1) from the camshaft gears (2).

with Electronically Actuated Injector Remove the four capscrews from the support bracket and remove the bracket.




Clean and Inspect for Reuse 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. 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. Inspect the sea water pump support components for damage. Replace if damage is found.

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. 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.


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.

This illustration gives the capscrew lengths required for the supports. Install the pointer (7) on the capscrew for the left bank support as shown. Reference Numbers 8 8 10

Length [7/16-14 x 3 inch] [7/16-14 x 4 1/2 inch] [7/16-14 x 1 3/8 inch]

Install the lock washers and capscrews. Torque Value: 60 N•m [ 45 ft-lb ]

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) Page 8-140


with Electronically Actuated Injector Install the support bracket and four capscrews. Torque Value: Support Bracket Capscrews

60 N•m

[ 45 ft-lb ]

Finishing Steps • Install the sea water pump. Refer to Procedure 008-057. • Open the water supply valve to the sea water pump. • Operate the engine and check for leaks.

Supplemental Coolant Additive (SCA) (008-060) Maintenance Check Supplemental coolant additives, or equivalent, are used to prevent the buildup of corrosion and scale deposits in the cooling system.

CAUTION Inadequate concentration of coolant additives can result in major corrosive damage to cooling system components. Over-concentration can cause the formation of gelatin (gel) that can cause restrictions and plugging. The SCA concentration must not fall below 1.2 units per 3.8 liters [1 gal] or exceed 3 units per 3.8 liters [1 gal]. When changing the coolant, the initial SCA, or equivalent concentration, must be between 1.2 and 3 units per 3.8 liters [1 gal] of coolant (initial charge). The cooling system must be clean before adding SCA, or equivalent. Refer to Procedure 008-018 (Cooling System) in Section 8.


DCA4 is compatible with all permanent-type antifreeze, except methoxy propanol. If methoxy propanol antifreeze is used, reduce the amount of DCA4 by one-third. This will prevent inhibitor loss due to precipitation caused by chemical incompatibility.

If coolant is added between drain intervals, additional SCA, or equivalent, will be required. Check the coolant just before changing the coolant filter. Use only coolant test kit, Fleetguard® Part Number CC2602, to check the coolant additive concentration when SCA is used.

Use the correct Fleetguard® coolant filter to maintain the correct SCA concentration in the system. Maintain the correct concentration by changing the maintenance coolant filter at each oil drain interval.

Water Manifold (008-061) 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. 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 Manifold Page 8-141

Water Pump Page 8-142


Be sure the passages are open. Compare the dimensions (1) and (2) to determine the top (3) of the manifold. With the top of the manifold up, the manifold inlet (4) is the lower passage and the outlet (5) is the upper passage. (1) 48 mm [1.875 in] (2) 38 mm [1.500 in] The manifold must be mounted on the bracket with the top up.

Install the plugs. Torque Value: 34 N•m [ 25 ft-lb ]

Water Pump (008-062) General Information with Mechanically Actuated Injector 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.



The water pump shaft was also changed. The new shaft contains one retaining ring only and requires a spacer between the two bearings. The spacer is different for the single row and double row, front, large bearing. The older shaft contains two retaining rings and does not require a spacer. The older shaft can be installed only when the double row bearing is required. If the older shaft is replaced, the correct bearing and spacer must be installed for the water pump body. The water pump contains an oil seal and a water pump seal. A revised water seal was introduced into production in October, 1997 (Engine Serial Number First 33139138). The cavity between these seals has a vent. The vent prevents contamination of the lubricant or coolant if a seal leaks. Oil and coolant seeping from the vent will not harm the operation of the pump. Check the vent for any obstruction at each scheduled maintenance interval. The recommended interval is 250 hours or 6 months of operation. The water seal was changed from a two piece to a unitized, one piece design. The seal and seat are fastened together in this design. This helps to prevent malfunctions caused by dirt or oil contacting the seal and seat surfaces during installation. A special tool must be used to install the one piece seal so that the seat is installed at the correct dimension from the water pump body. Correct installation results in proper spring tension. Additional information regarding other parts of the cooling system can be found within this section. K50 engines fitted with an low temperature aftercooler (LTA) system use the K38 water pump and water pump inlet connection. The water pump inlet connection is designed for optimum coolant flow split and decreases the possibility of reverse flow through the main radiator core via the bypass tube. A revised larger diameter water bypass tube is also used. The following table details the compatibility of the water pump parts. NOTE: If the shaft does not contain threads in the end for the impeller, the drive key must be omitted. NOTE: If the impeller does not contain a slot on the side that has vanes, the drive key and self-locking capscrew must be omitted. NOTE: If the shaft contains threads in the end for the impeller, and the impeller contains a slot on the side that has vanes, the drive key and self-locking capscrew must be installed. Engine Model K38

Water Pump Body 3030489

With Inlet Connection 3001712 206456

3001317

Install Shaft

3050453 or 3001711 3050455 or 3175069 3050453 or 3001711

3050442 or 3175527 3050442 or 3175527 3050442 or 3175527 If 206194 --> 3050442 or 3175527 If 206194 --> 3050442 or 3175527 If 206194 --> 3050442 or 3175527 If 206194 --> 3050442 or 3175527 3050442 or 3175527

206456

3050455 or 3175069

3001712

3050453 or 3001711

206456

3050455 or 3175069

3030490

3002108

3002107

3002108

3050454 or 3002106 3050454 or 3002106

206192

K50

3001712

Install Impeller

Install Spacer Spacer Length mm [in] 3030487 35.17 [1.385] 3030487

35.17 [1.385]

3175570 NONE

23.68 [0.935]

3175570 NONE

23.68 [0.935]

3175570 NONE

23.68[0.935]

3175570 NONE

23.68 [0.935]

3030487

35.17 [1.385]

3175570 NONE

23.68 [0.935]



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. with Electronically 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 alternator drive belt. Refer to Procedure 013-005 Alternator Drive Belt) in Section 13. • Remove the alternator drive pulley. Refer to Procedure 009-010 (Alternator Drive Pulley) in Section 9.


Remove 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.

Remove the two capscrews and heavy washers (6) that hold the support bracket (4) to the cylinder block. Remove the four capscrews that hold the housing (2) to the water pump (3). Note that the two washers (5) are heavy washers. Remove the support bracket. Pull the housing from the pump. Remove and discard the o-ring (1).

WARNING 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).

with Electronically Actuated Injector NOTE: The procedure for the QSK60 engine is shown. The procedure for the QSK38 and QSK50 engines are similar. Open the drain cock on the engine block (1) and the water pump (2).




Remove the two brackets and U clamps (1) from the low temperature aftercooler outlet (2) and jacket water bypass pipes (3).

1. Remove the hose clamps (1) from the low temperature aftercooler outlet (2) and the jacket water bypass pipe (3). 2. Remove the U clamp (4) from the jacket water bypass pipe (3). 3. Remove the four capscrews (5), low temperature aftercooler outlet (2), and the gaskets. 4. Remove the four capscrews (6), the jacket water bypass pipe (3), and the gaskets. If equipped with Straub clamps, loosen the three capscrews and slide the Straub clamp up onto the upper portion of the low temperature aftercooler outlet and jacket water bypass tubes. Remove the bracket/clamp (1) from the low temperature aftercooler bypass pipe (2). Remove the hose clamp (3) from the low temperature aftercooler bypass pipe (2). Remove the bypass pipe (2). If equipped with Straub clamps, loosen the three capscrews and slide the Straub clamp up onto the upper half of the bypass tube.

Remove the four capscrews and jacket water radiator inlet connection.


Remove the capscrews and jacket water inlet connection.

Remove the two capscrews (2) from the engine block (1) and the water pump support bracket (3). Remove the two capscrews (2) from the water pump (4), and the water pump support bracket (3). Remove the capscrews (2) and the water pump support bracket (3) from the water pump (4), and the engine block (1).

WARNING 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.




Clean and Inspect for Reuse with Mechanically Actuated Injector 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. Rotate the shaft to check the bearings for damage or wear. An end clearance of 0.05 to 0.010 mm [0.002 to 0.004 in] is required. If the bearings are damaged or worn, the pump must be rebuilt.

Check the splines on the shaft and the coupling for damage or wear. If the splines on the shaft are worn or damaged, the pump must be rebuilt. If the splines in the coupling are worn, the coupling must be replaced. If the splines that contact the water pump drive are worn, check the shaft in the drive.


with Electronically Actuated Injector A minor chemical buildup or streaking at the water pump weep hole (1) is normal. Do not repair or replace the water pump unless an actual leak is confirmed. If a leak is confirmed, contact a Cummins® Authorized Repair Location for replacement.

Disassemble 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.

Remove the following parts: • Water inlet connection (6) • Gasket (7) • Support bracket (8) • Draincock (9). Discard the gasket.

Remove the following parts: • Capscrews (10) • Water pump inlet connection (11) • O-ring seal (12). Discard the o-ring.




NOTE: The latest water pumps and rebuilt water pumps with revised shafts or impellers do not contain the drive key and capscrew. Remove the following parts: • Self-locking capscrew (12) • Drive key (13).

CAUTION The puller screw must pass easily through the impeller bore to prevent damage. CAUTION The puller screw must not damage the threads in the shaft if the shaft is to be installed again with an impeller that has a slot for a drive key. Install a short capscrew in the shaft to protect the threads. Use a standard puller, Part Number ST-647, or equivalent. Remove the impeller. Clean and check the impeller for damage. Remove the large retaining ring (14).

Use an arbor press to support the water pump body. Push on the impeller end of the shaft. Remove the bearing and shaft assembly. Discard the water pump seal seat, if equipped.


Remove the following parts: • Oil seal (15) • Water seal (16).

The bearing and shaft assembly can be one of two different designs. The replacement procedure is different for the two designs. The revised bearing and shaft assembly (1), contains a retaining ring (2) nearest to the impeller end of the shaft. The previous bearing and shaft assembly (3), contains a retaining ring (2) nearest to the end of the shaft that is splined. The revised assembly (1) can contain different large bearings (4), and bearing spacers (5). The bearing (4) can be a double or single row bearing. The spacer (5) for the single row bearing is longer. The Water Pump, General Information in this procedure list the correct parts. The previous assembly (3) must contain the double row bearing. The following steps are for the revised design of the water pump. Remove the retaining ring (2).

CAUTION Do not damage the end of the shaft if it is to be installed again. Support the assembly as shown. Use a hydraulic press to support the large bearing (4) as shown. Remove the small bearing (6), spacer (5), and the large bearing (4) from the shaft (7).




The following step is for the previous design of the water pump. Remove the retaining ring (1). Use a water pump bearing separator, Part Number 3375326, or equivalent. Disassemble the parts. Remove the front, large bearing (2), spacer (5), and the rear, small bearing (3)

Inspect 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 Water Pump Shaft Outside Diameter (Bearing Area) mm in 30.010 MIN 1.1816 30.020 MAX 1.1820 Water Pump Shaft Outside Diameter (Impeller End) mm in 24.999 MIN 0.9842 25.009 MAX 0.9846 Measure the shaft outside diameter and the bearing inside diameter Maximum Clearance 0.003 mm [ 0.0001 in ] Maximum Interference 0.018 mm [ 0.007 in ] NOTE: The shaft outside diameter specifications are the same as for the revised design shaft.



Measure the bore inside diameter of Part Numbers 3050454 and 3050455. Water Pump Impeller Inside Diameter (17) mm in 24.919 MIN 0.9811 24.945 MAX 0.9821 Measure the inside diameter. All other part numbers, excluding those listed above are covered by this table. Water Pump Impeller Bore Inside Diameter (17) mm in 24.932 MIN 0.9816 24.958 MAX 0.9826 NOTE: The outside diameter is given for parts identification only. It is not necessary to measure the part. Water Pump Impeller Outside Diameter (18) mm in K38 146 NOM 5.75 K50 171 NOM 6.75 NOTE: The angle is given for parts identification only. It is not necessary to measure the part. NOTE: All K50 water pump impellers have a 78 degree angle. K38 Water Pump Impeller Angle (19) Part Number Angle 3050455 74 degrees 3175069 74 degrees 3050453 67 degrees 3001711 67 degrees Install an impeller with a 74 degree angle only with a water pump inlet connection that has a 16 degree angle. Install an impeller with a 67 degree angle only with a water pump inlet connection that has a 23 degree angle. The Water Pump, General Information in this procedure lists the correct part numbers. K38 and K50 Water Pump Body Bore Inside mm Water Seal (21) 53.60 MIN 54.10 MAX Oil Seal (22) 38.05 MIN 38.10 MAX Water Seal (23) 61.997 MIN 62.009 MAX Oil Seal (24) 71.996 MIN 72.012 MAX

Diameter in 2.110 2.130 1.498 1.500 2.4408 2.4412 2.8345 2.8351



NOTE: The depth of the bore is given for parts identification only. It is not necessary to measure the part. Front Water Pump Bearing Bore Depth in Water Pump Body (25) mm in Body for single 25.4 1.00 row bearing Body for double 36.8 1.45 row bearing

NOTE: The diameter is given for parts identification only. It is not necessary to measure the part. Water Pump Impeller Counterbore Inside Diameter in Water Pump Body (26) Engine Model mm in K38 (revised) 147 5.8 K38 (previous) 160 6.3 K50 (all) 173 6.8

Assemble 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).


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).

Install the retaining ring (2).




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.

Install the retaining ring.

The new oil seal must be installed with the part number positioned down. Use a water pump seal driver, Part Number 3375319, or equivalent. Install the seal. The seal must be even with, or up to no more than 0.51 mm [0.020 in] below the top of the step in the body.

Use an arbor press to support the housing. Use the water pump bearing driver, Part Number 3375318, or equivalent, or push on the end of the shaft. Install the assembly.


The beveled edge must be positioned as shown. Install the large retaining ring.

CAUTION Support the water pump body for installation of the water pump seal. Do not support the shaft. This will prevent damage to the bearings. Use a water pump seal driver, Part Number 3824836, or equivalent (27). Install the new water seal (16). Make sure the shoulder on the seal touches the housing. The installed height of the seal (28) must be 21.36 to 21.87 mm [0.841 to 0.861 in].

CAUTION The seal will malfunction if the spring tension is not correct. One drop of Loctite™ 290 or equivalent, must be applied on the joint between the seat and the shaft. More than one drop of the sealant can contact the sealing surfaces and cause the seal to malfunction. Apply one drop only of Loctite™ 290, or equivalent, to the seal and the parting line of the shaft.

CAUTION If the impeller and shaft have a slot for the drive key, the slots must be aligned before the impeller is pushed on the shaft. If either the impeller or shaft do not have a slot, omit this step. Position the impeller on the shaft so that the slots are aligned.




Apply a smooth coating of Loctite™ 609, or equivalent to the impeller bore.

Use an arbor press and a flat steel plate to support the shaft as shown. Install the impeller until it is even with the end of the shaft.

NOTE: If either the shaft or the impeller does not have a slot for the drive key, omit this step. Install the drive key (13) and the self-locking capscrew (12). Torque Value: 20 N•m [ 177 in-lb ]

Use vegetable oil to lubricate the o-ring. Install the parts. Install the top and right capscrews. Torque Value: 47 N•m [ 35 ft-lb ]


NOTE: Do not tighten the capscrews for the bracket until the pump is installed on the engine. Install the support bracket (8) and capscrews. Install the new gasket (7), connection (6), and capscrews. Torque Value: 41 N•m [ 30 ft-lb ] Install the draincock (9). Torque Value: 15 N•m [ 135 in-lb ]

Use vegetable oil to lubricate the new o-ring (4). Install the o-ring in the groove of the adapter plate (3). Install the adapter plate on the body. The thinner side of the plate must be nearest to the water pump body.

Use clean engine oil to lubricate the bearings while rotating the shaft. Use clean engine oil to lubricate the splines on the shaft. Install the spline coupling (1).




Install 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 ]


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 ] Install the bypass connection gaskets. Tighten the capscrews. Torque Value: 40 N•m [ 30 ft-lb ] Tighten the capscrews. Torque Value: 45 N•m [ 35 ft-lb ] Tighten hose clamps. Torque Value: 5.6 N•m [ 50 in-lb ]

Replace the coolant filter. Refer to Procedure 008-006 (Coolant Filter) in Section 8.




Connect the lower radiator hose to the water pump inlet. Connect the water filter lines.

with Electronically 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 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 Mounting Capscrews

80 N•m

[ 59 ft-lb ]

Install the capscrews (2) and the water pump support bracket (3) to the water pump (4), and the engine block (1). Install the two capscrews (2) to the water pump (4), and the water pump support bracket (3). Install the two capscrews (2) to the engine block (1) and the water pump support bracket (3). Torque Value: Support Bracket Capscrews

45 N•m

[ 33 ft-lb ]


Lubricate the new o-ring on the jacket water inlet. Install jacket water inlet and capscrews onto the water pump. Torque Value: Jacket Water Inlet Capscrews

45 N•m

[ 33 ft-lb ]

Install the jacket water radiator inlet connection, gasket and four capscrews. Torque Value: Jacket Water Radiator Inlet Capscrews

45 N•m

[ 33 ft-lb ]

Install the bypass pipe (2). Install the hose clamp (3) on the low temperature aftercooler bypass pipe (2). Install the bracket/clamp (1) to the low temperature aftercooler bypass Pipe (2). Torque Value: 45 N•m [ 33 ft-lb ] If equipped with Straub clamps, slide the Straub clamp down onto the lower half of the bypass tube.

Install the jacket water bypass pipe (3), gaskets and four capscrews (6). Install the low temperature outlet pipe (2), gasket and four capscrews (5). Install the U clamp (4) to the jacket water bypass pipe (3). Install the hose clamps (1) to the low temperature aftercooler outlet (2) and the jacket water bypass pipe (3). 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 ]




Install the bracket and U clamps (1) to the low temperature aftercooler outlet (2) and jacket water bypass pipe (3) Tighten the U clamps. Torque Value: 45 N•m [ 33 ft-lb ]

Close the draincock on the engine block (1) and on the water pump (2).

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.


with Electronically 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. • 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.

Sea Water (008-103)

System

Diagnostics

General Information Typical sea water cooling system: 1. Grate-type strainer located on the bottom of the vessel hull 2. Vessel bottom/hull 3. Sea water inlet valve 4. Hose 5. Sea water strainer 6. Sea water pump tube 7. Sea tube pump 8. Sea water inlet 9. Heat exchanger 10. Sea water outlet.

Inspect Locate and verify that the sea water inlet valve is in the full-open position. If closed or partially closed, open the valve and check the engine temperature.

Sea Water System Diagnostics Page 8-165



Test Attach a vacuum gauge to the inlet side of the sea water pump.

Start the engine.

Check the sea water restriction from idle to rated speed at 200-rpm increments while the vessel is in the dock. Sea water restrictions must be less than 17 kPa [5 in-Hg] under all operating conditions.

If the sea water inlet restriction is above specification, the source of the restriction (1,2,3 or 4) must be found. Troubleshooting and repair of excessive sea water restriction is a vessel manufacturer or vessel owner responsibility and not covered by Cummins® warranty.


If the sea water restriction readings sea water supply for leaks. These built or supplied by Cummins Inc. repair of sea water aeration is Cummins® warranty.

fluctuate, inspect the components are not Troubleshooting and not covered under

It is possible that aeration (gauge fluctuation) will only occur while the vessel is underway, due to the introduction of air.

Pressure Test Attach a pressure gauge to the outlet side of the sea water pump to check pump outlet pressure. Check water pump specifications for proper pressure. Record the pressure reading for the next step.

Attach the pressure gauge to the discharge side of the heat exchanger and check for pressure drop. Be certain to check both pressures under the same operating conditions - for instance, at idle or rated speed.


Low-Temperature Aftercooler (LTA) Water Pump Page 8-168


If the pressure drop between the inlet side of the heat exchanger and the outlet side of the heat exchanger is greater than specification, check for blockage in the heat exchanger. Refer to Procedure 018-018.

Sea Water Hoses (008-104) Inspect NOTE: Shown is a basic sea water system. Although components will different in appearance, the procedure remains the same. Start the engine and inspect all hoses and connections for deterioration. Particles of deteriorated hose can be carried through the sea water system and restrict or clog small passages (especially the heat exchanger) and partially stop circulation. Replace as necessary.

Inspect the sea water system hoses and hose connections for leaks. Replace damaged hoses and clamps, if necessary.

Low-Temperature Aftercooler (LTA) Water Pump (008-109) Maintenance Check with Mechanically Actuated Injector A minor buildup of streaking at the water pump weep hole (1) is normal. Do not repair or replace the water pump (2) unless an actual leak is confirmed. If a leak is confirmed, contact a Cummins® Authorized Repair Location for replacement.


ECM Cooling Plate (008-128) Preparatory Steps • Remove the ECMs. Refer to Procedure 019-031 in the Troubleshooting and Repair Manual Electronic Control System QSK50 and QSK60 Modular Common Rail System Series Engines, Bulletin 4021533. • Drain the cooling system. Refer to Procedure 008-018. • Remove the ECM cooling lines. Refer to Procedure 008-130.

Remove Remove the nuts and washers from the ECM cooling plate mounting studs and remove the ECM cooling plate.

Remove the ECM mounting studs. The upper stud is in the fuel block manifold and the bottom studs are in the cylinder block.

Disassemble Remove the vibration isolators from the ECM cooling plate.

ECM Cooling Plate Page 8-169



Remove the tee adapter from the ECM cooling plate coolant return port (lower).

Remove the drain cock from the tee adapter.

Remove the elbow adapter from the ECM cooling plate coolant supply port (upper).

Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic. Read the manufacturer's instructions before use. Clean the ECM cooling plate, fittings and attaching hardware with cleaning solvent, Cummins Part Number 3824510, or equivalent.


Inspect the ECM cooling plate for any signs of damage, cracks, corrosion, and leaks. Replace if damaged.

Inspect the ECM's mounting threaded holes for any signs of damage. If damage is found, it can be repaired with a screw thread insert, Cummins Part Number 3822699, or equivalent (M8x1.25).

Inspect the threaded supply and return ports for damage or stripped threads, Replace the ECM cooling plate if ports are damaged or stripped.

Inspect the tee adapter for signs of damage or stripped threads. Replace the tee adapter if damaged.




Inspect the elbow adapter for cracks, damage, and stripped threads. Replace the elbow adapter if damaged.

Inspect the drain cock for damage, seizure, and stripped threads. Replace if damaged or seized.

Inspect the ECM mounting studs for corrosion and stripped threads. Replace as necessary.

Inspect the vibration isolators for cracks, wear, or damage. Replace if necessary.


Inspect the ECM coolant supply and return lines for cracks, damage, age, wear, or leakage. Inspect the fitting on each end of the cooling lines for damage and stripped threads. Replace damaged coolant lines.

Assemble If reusing the drain cock, apply thread sealer, Part Number 3375066, or equivalent to the threads. If a new draincock is to be used, the threads will already have sealant applied. Install the drain cock into the tee. Hand tighten.

Install new o-rings on the return tee adapter and install it in the ECM cooling plate return port. Torque Value: Coolant Return Tee

25 N•m

[ 18 ft-lb ]

Install new o-rings on the supply elbow adapter and install it in the ECM cooling plate supply port. Torque Value: Coolant Supply Elbow

25 N•m

[ 18 ft-lb ]




Install the vibration isolators on the ECM cooling plate.

Install Install the cooling plate mounting studs onto the block manifold and cylinder block. Torque Value: ECM Mounting Studs

80 N•m

[ 59 ft-lb ]

Install the ECM cooling plate and mounting nuts onto the mounting studs. Torque Value: ECM Cooling Plate Nuts

23 N•m

[ 17 ft-lb ]

Finishing Steps • Install the ECM cooling lines. Refer to Procedure 008-130. • Install the ECMs. Refer to Procedure 019-031 in the Troubleshooting and Repair Manual Electronic 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.


ECM Cooling Plate Lines (008-130) Preparatory Steps 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.

Remove the electronic control module (ECM) cooling plate supply and return lines.

ECM Cooling Plate Lines Page 8-175



Remove the brackets from the coolant lines.

Remove the male connectors and adapters from the Low Temperature Aftercooler lines. Discard the o-rings.

Inspect for Reuse Inspect the coolant lines for cracks, damage, age wear, or leakage. Inspect the fittings on both ends of the coolant lines for damage and stripped fittings. Replace if damage is found.

Inspect the connectors and adapters for cracks, damaged and stripped threads. Replace if damage is found.


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 ]

If the male connectors are being reused, apply sealant, Cummins® Part Number 3375066, or equivalent, to the threads of the connectors. If installing new male connectors, sealant is already applied to the threads. Install the male connectors into each of the adapters. Torque Value: 15 N•m [ 133 in-lb ]

Install the electronic control module (ECM) coolant plate supply and return lines. Torque Value: 15 N•m [ 133 in-lb ]

Install the electronic control module (ECM) coolant line brackets. Torque Value: 45 N•m [ 33 ft-lb ]




Attach the bracket to the cam follower cover and air compressor housing. Torque Value: 45 N•m [ 33 ft-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

Section 9 — Drive Units — Group 09 Section Contents Page Accessory Drive ................................................................................................................................................9-3 Assemble..........................................................................................................................................................9-8 with Mechanically Actuated Injector................................................................................................................9-8 Disassemble.....................................................................................................................................................9-4 with Mechanically Actuated Injector................................................................................................................9-4 Finishing Steps...............................................................................................................................................9-11 with Mechanically Actuated Injector..............................................................................................................9-11 Initial Check......................................................................................................................................................9-3 with Mechanically Actuated Injector................................................................................................................9-3 Inspect for Reuse..............................................................................................................................................9-6 with Mechanically Actuated Injector................................................................................................................9-6 Install..............................................................................................................................................................9-10 with Mechanically Actuated Injector..............................................................................................................9-10 Preparatory Steps.............................................................................................................................................9-3 with Mechanically Actuated Injector................................................................................................................9-3 Remove............................................................................................................................................................9-3 with Mechanically Actuated Injector................................................................................................................9-3 Accessory Drive Bushing ................................................................................................................................9-11 Inspect for Reuse............................................................................................................................................9-12 Mechanically Actuated Injector.....................................................................................................................9-12 Install..............................................................................................................................................................9-13 Mechanically Actuated Injector.....................................................................................................................9-13 Remove.......................................................................................................................................................... 9-11 Mechanically Actuated Injector.....................................................................................................................9-11 Accessory Drive Cover ....................................................................................................................................9-79 Install..............................................................................................................................................................9-79 Accessory Drive Gear and Shaft .....................................................................................................................9-14 Assemble........................................................................................................................................................9-15 with Mechanically Actuated Injector..............................................................................................................9-15 Disassemble................................................................................................................................................... 9-14 with Mechanically Actuated Injector..............................................................................................................9-14 Inspect for Reuse............................................................................................................................................9-14 with Mechanically Actuated Injector..............................................................................................................9-14 Accessory Drive Pulley ...................................................................................................................................9-16 Clean and Inspect for Reuse...........................................................................................................................9-17 Install..............................................................................................................................................................9-18 POSE...........................................................................................................................................................9-19 Remove.......................................................................................................................................................... 9-16 Accessory Drive Pulley Wear Sleeve ..............................................................................................................9-19 Clean and Inspect for Reuse...........................................................................................................................9-20 Install..............................................................................................................................................................9-21 Remove.......................................................................................................................................................... 9-19 Alternator Drive Pulley ....................................................................................................................................9-21 Clean and Inspect for Reuse...........................................................................................................................9-22 Finishing Steps...............................................................................................................................................9-23 Install..............................................................................................................................................................9-22 Preparatory Steps...........................................................................................................................................9-21 Remove.......................................................................................................................................................... 9-21 Fuel Pump Drive ..............................................................................................................................................9-23 Assemble........................................................................................................................................................9-30 with Mechanically Actuated Injector..............................................................................................................9-30 with Electronically Actuated Injector............................................................................................................. 9-33 Clean and Inspect for Reuse...........................................................................................................................9-27 with Mechanically Actuated Injector..............................................................................................................9-27 with Electronically Actuated Injector............................................................................................................. 9-28 Disassemble................................................................................................................................................... 9-25 with Electronically Actuated Injector............................................................................................................. 9-25

Page 9-b


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


Page 9-c

Mechanically Actuated Injector.....................................................................................................................9-68 Water Pump Drive Gear and Shaft ..................................................................................................................9-70 Assemble........................................................................................................................................................9-71 Mechanically Actuated Injector.....................................................................................................................9-71 Disassemble...................................................................................................................................................9-70 Mechanically Actuated Injector.....................................................................................................................9-70 Inspect for Reuse............................................................................................................................................9-70 Mechanically Actuated Injector.....................................................................................................................9-70 Water Pump Drive Pulley ................................................................................................................................9-71 Finishing Steps...............................................................................................................................................9-72 Install..............................................................................................................................................................9-72 Preparatory Steps...........................................................................................................................................9-71 Remove..........................................................................................................................................................9-71 Woodward Governor Drive ..............................................................................................................................9-72 Assemble........................................................................................................................................................9-77 with Mechanically Actuated Injector..............................................................................................................9-77 Clean and Inspect for Reuse...........................................................................................................................9-73 Clean for Rebuild............................................................................................................................................9-75 with Mechanically Actuated Injector..............................................................................................................9-75 Disassemble...................................................................................................................................................9-73 with Mechanically Actuated Injector..............................................................................................................9-73 General Information.........................................................................................................................................9-72 with Mechanically Actuated Injector..............................................................................................................9-72 Inspect............................................................................................................................................................9-75 with Mechanically Actuated Injector..............................................................................................................9-75

Page 9-d


This Page Left Intentionally Blank



Service Tools Drive Units


Tool No.

Tool Description Gear Puller Used to remove drive pulleys and impellers.

ST-647

Coupling Puller Remove the spline coupling gear from the compressor drive. 3376663

AV Seal Removal/Installation Kit Used to remove and install AV seals from oil drillings. 3823154

Pulley Installation Tool Contains a variety of adaptors used to assemble pulleys onto shafts. 3376326

Pulley Adaptor Kit 3824502

Used with Pulley Installation Tool, Part Number 3376326, to assemble pulleys onto shafts.

Accessory Drive Oil Seal Installer 3824922

Used to assemble accessory drive oil seals into the front gear cover with the accessory drive installed to the front cover.

Tool Illustration



Tool No.

Tool Description Sealant (RTV)

3377132

Applied to the portion of the cover that will be in the bore of the front cover.


Tool Illustration


Accessory Drive (009-001) Preparatory Steps with Mechanically Actuated Injector 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 Page 9-3



Use a dial indicator to measure the accessory drive shaft end clearance. Accessory Shaft End Clearance mm in 0.05 MIN 0.002 0.30 MAX 0.012

Disassemble 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.

Use a jaw puller to remove the lovejoy or spline type coupling. Remove the capscrew from 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.


Measure the inside diameter of the busings. Accessory Drive Bushing Inside Diameter mm in 49.95 MIN 1.967 50.03 MAX 1.970 If the inside diameter of either bushing is not within specification, both bushings must be replaced.

Check the grooved surfaces of the bushings (1) for damage. Measure the distance from the outside of the thrust faces of the two bushings. Accessory Drive Busing Thrust Face Distance mm in 45.370 MIN 1.786 45.450 MAX 1.789 If the distance between the two thrust faces is not within specification, both bushings must be replaced.

Remove the flanged bushing from the drive housing using a brass drift (1), taking care not to damage the bushing bore.

Only remove the gear from the shaft when the gear or the shaft must be replaced. Use an arbor press to remove the gear.




Inspect for Reuse with Mechanically Actuated Injector Check the inner diameter of the coupling for damage. If damage is found the coupling must be replaced. Measure the inside diameter of the coupling. Accessory Drive Lovejoy Coupling Inside Diameter mm in 25.377 MIN 0.999 25.407 MAX 1.000 Accessory Drive Spline Coupling Inside Diameter mm in 25.255 MIN 0.994 25.278 MAX 0.996 If the inner diameter of the coupling is not within specification the coupling must be replaced. If the bushing was removed, inspect the housing for scoring and other damage. Replace the housing if damaged.

If the bushing was removed, measure the inside diameter of the bushing bore. Accessory Drive Bushing Bore Inside Diameter mm in 60.00 MIN 2.362 60.05 MAX 2.364 Replace the housing if the bushing bore is not within specifications.


Inspect the shaft in the gear fit area for fretting or burrs. Clean burrs with emery cloth.

Measure the shaft outside diameter. Accessory Drive Shaft Outside Diameter Measurements mm in (1) 34.964 MIN 1.376 34.976 MAX 1.377 (2) 43.928 MIN 1.729 43.940 MAX 1.730 (3) 44.370 MIN 1.747 44.630 MAX 1.757 (4) 45.070 MIN 1.774 45.082 MAX 1.775 (5) 49.820 MIN 1.961 49.832 MAX 1.962 (6) 25.424 MIN 1.001 25.436 MAX 1.001 If the outside diameter is not within specification, the shaft must be replaced. Check the gear teeth and gear bore for damage. Replace the gear if damaged.




Measure the gear inside diameter. Accessory Drive Gear Inside Diameter mm in 44.98 MIN 1.771 45.02 MAX 1.772 If the gear is not within specification, the gear must be replaced.

Assemble 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.

If an arbor press is available, support the gear. Lubricate the shaft with clean engine oil. Press the shaft through the gear until the shoulder of the shaft touches the gear.


CAUTION If the heat method was used to install the gear, allow the gear to air cool. Do not use water or oil to reduce cooling time. Damage to the gear can result. Use a feeler gauge to measure the distance between the shoulder of the shaft and the gear. Accessory Drive Gear to Shaft Distance mm in 0.05 MAX 0.002 If the distance between the gear and the shaft is not within specification, press the gear on until the specification is met.

CAUTION The bushings must be pressed in square to the bores of the housing. The thrust faces of the two bushings must be parallel and concentric. The bushing with the center counterbored must have the pressure applied to the counterbore face and not on the thrust bearing face. Failure to comply can result in distortion of the thrust face. Support the housing. The bushing with the smaller outside diameter is pressed into the output side. Using an arbor press and the shaft as a mandrel, press the bushing into the housing. Turn the housing over and press the remaining bushing into place. Lubricate the grooved surface of the thrust bearing with Lubriplate™ 105, Part Number 3163086, 3163087 or equivalent. Install the gear and shaft assembly into the housing. Install the clamping washer (1) with the beveled edge up. Install the pipe plug into the housing. Tighten the pipe plug. Torque Value: 8 N•m [ 75 in-lb ]




Support the assembly on the gear or the shaft. Use an arbor press and a mandrel to press the coupling onto the shaft until it touches the clamping washer. The clamping washer must be positioned tightly between the coupling and the shoulder of the shaft.

The capscrew must contain an oil drilling if an air compressor is to be mounted on the engine. Install the washer and capscrew. Tighten the capscrew. Torque Value: 9.525 mm [0.375 in] Capscrew Length 12.7 mm [0.50 in] Capscrew Length

45 N•m

[ 35 ft-lb ]

100 N•m

[ 75 ft-lb ]

Rotate the shaft, checking for correct assembly. Use a dial indicator to measure the accessory drive shaft end clearance. Accessory Drive Shaft End Clearance mm in 0.05 MIN 0.002 0.30 MAX 0.012 If the end clearance is not within specifications, make sure the coupling is positioned tightly against the clamping washer.

Install 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.


There is not a requirement to align the index on the drive gear with the marks on the camshaft gear on QSK38 and QSK50 engines. Install the accessory drive assembly, turning the shaft as necessary to engage the gears. Install and tighten the six capscrews. Torque Value: 45 N•m [ 33 ft-lb ]

With the accessory drive installed, measure the end clearance. Accessory Drive End Clearance mm in 0.13 MIN 0.005 0.29 MAX 0.011

Finishing Steps 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.

Accessory Drive Bushing (009-002) Remove Mechanically Actuated Injector Standard Bushing • Remove the accessory drive cover, if equipped. Refer to Procedure 009-039 (Accessory Drive Cover) in Section 9. • Use an arbor press. Support the housing. Use a suitable mandrel. Push the bushing from the housing.

Accessory Drive Bushing Page 9-11



Flanged Bushing • Remove the accessory drive cover, if equipped. Refer to Procedure 009-039 (Accessory Drive Cover) in Section 9. • Remove the bushing from the drive housing using a brass drift (1). Take care not to damage the bushing bore.

Inspect for Reuse Mechanically Actuated Injector Inspect the housing for scoring or other damage.

Standard Bushing • Measure the inside diameter Housing Inside Diameter mm 36.73 36.75

MIN MAX

in 1.446 1.447

Flanged Bushing • Measure the inside diameter Housing Inside Diameter mm 39.61 39.64

MIN MAX

in 1.559 1.561


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. Use a 2.39 mm [0.094 in] diameter rod or a 2.39 mm [0.094 in] hexagon wrench. Check the position and the location of the oil hole in the bushing and the accessory drive housing. The rod must pass through the oil holes in the bushing and into the oil supply drillings in the accessory drive housing. Install the accessory drive cover, if removed. Refer to Procedure 009-039 (Accessory Drive Cover) in Section 9.

CAUTION 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 Page 9-14


Accessory (009-003)

Drive

Gear

and

Shaft

Disassemble with Mechanically Actuated Injector CAUTION Do not drop the shaft during removal from the drive gear. Damage to the part or personal injury can result. Use an arbor press. Support the gear. Push the shaft from the gear. Remove the groove pin. If the pin is damaged, it must be replaced.

Inspect for Reuse with Mechanically Actuated Injector Inspect the gear for cracks and chipped, or broken teeth.

Measure the inside diameter of the drive gear. Gear Inside Diameter mm 39.73 39.75

MIN MAX

in 1.564 1.565

Inspect the shaft in the gear fit area for fretting or burrs.


Accessory Drive Gear and Shaft Page 9-15

Measure the drive shaft outside diameter at the gear fit location. Shaft Outside Diameter mm 39.789 39.802

MIN MAX

in 1.5665 1.5670

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.

Use an arbor press. Support the gear. Apply Lubriplate® 105 or equivalent to the shaft. Align the key with the key slot in the gear. Press the shaft through the gear until the shoulder of the shaft touches the gear. NOTE: If an adequate press is not available, the gear should be heated in an oven.

Accessory Drive Pulley Page 9-16


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.

Accessory Drive Pulley (009-004) Remove NOTE: Install a capscrew in the end of the shaft to prevent damage to the threads. Install the capscrew (1). Use a puller (2), ST-647, or equivalent. Remove the pulley from the accessory drive shaft. NOTE: Some engines have an accessory drive cover instead of a pulley. It is not necessary to remove the cover.


Remove the woodruff key (3). Remove the oil slinger (4). Discard the slinger.

Clean and Inspect for Reuse WARNING When using solvents, acids or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the rick of personal injury. Use solvent and a clean cloth. Clean the pulley wear sleeve.

Check the grooves of the pulley for wear. Check the wear sleeve on the accessory drive pulley for damage. If the wear sleeve requires renewing, refer to Procedure 009-005 (Accessory Drive Pulley Wear Sleeve) in Section 9.

Check the bore of the pulley for damage. Measure the inside diameter Accessory Drive Pulley Inside Diameter mm in 34.912 MIN 1.3745 34.938 MAX 1.3755




Check the bore of the pulley for damage. Measure the inside diameter Alternator Drive Pulley Inside Diameter mm in 35.00 MIN 1.378 35.03 MAX 1.379

Install Install the oil slinger. Install the woodruff key.

CAUTION Do not use a hammer to position the pulley. The thrust bearings in the accessory drive can be damaged, and the part can fail. Use the pulley installation tool kit, Part Number 3376326. Install the appropriate adapter (1) in the pusher (2).


CAUTION Do not lubricate the seal or the wear sleeve on the pulley. The seal and sleeve must be clean and dry or the seal can leak. Use engine oil. Lubricate the outside diameter only of the shaft. Lubricate only the inside diameter of the bore in the pulley. CAUTION The dust lip on the seal must not be folded under when the pulley is installed. To prevent the dust lip (yellow lip) from folding under, bend the lip out by running your finger around the lip 8 to 10 times, applying gentle pressure. Be sure there is no oil on your hand. Avoid touching the seal lip (black lip). The dust lip will remain bent approximately 1 minute, then return slowly to the operating position. Position the pulley on the shaft. Align the keyway in the pulley with the key in the shaft. Use the tool to push the pulley on the shaft until the sleeve on the tool touches the shaft. The pulley will then be even with the end of the shaft. POSE Press-On Shaft Excluder (POSE) Seal CAUTION When installing a new POSE seal, the flat (closed) side of the seal MUST be TOWARD the pulley for correct installation. NOTE: Do not use any kind of lubricant to install the POSE seal. Use your hand to push the POSE seal onto the wear sleeve. Push the POSE seal onto the wear sleeve until the seal is approximately 9 mm [0.375 in] below the end of the wear sleeve.

Accessory Drive Pulley Wear Sleeve (009-005) Remove CAUTION The jaws of the vise MUST have copper plates to prevent damage to the pulley. Put the accessory drive pulley in a vise.

Accessory Drive Pulley Wear Sleeve Page 9-19

Accessory Drive Pulley Wear Sleeve Page 9-20


Grind a 1.57 mm [0.062 in] radius on the cutting edge of a 19.05 mm [0.75 in] chisel. Position the chisel against the wear sleeve. Use a hammer to moderately strike the chisel at four points on the outside diameter of the wear sleeve to relieve the press fit.

After the press fit has been relieved, remove the wear sleeve by hand.

Clean and Inspect for Reuse Use Scotch-Brite® 7448, Part Number 3823258, or equivalent to remove any deposits from the seal area of the pulley. Clean the seal wear area with a clean cloth.

Inspect the seal wear area for damage.


Install Install the wear sleeve on the pulley seal wear surface with the chamfer on the outside diameter of the wear sleeve facing up (away from the pulley). Use installer tool, Part Number 3824508, and an arbor press or mallet. Press the sleeve on the pulley until the installer contacts the pulley.

Inspect the wear sleeve for burrs or other damage.

Alternator Drive Pulley (009-010) Preparatory Steps • Remove the alternator belt. Refer to Procedure 013-005 (Alternator Drive Pulley) in Section 9.

Remove Using puller, Part Number ST-647, remove the pulley from the alternator drive pulley shaft. Remove the puller.

Alternator Drive Pulley Page 9-21

Alternator Drive Pulley Page 9-22


Clean and Inspect for Reuse 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. Inspect the pulley for nicks, cracks, excessive wear, or other damage in the belt grooves.

Install CAUTION Do not use a hammer to drive the pulley into position. The thrust washers will be damaged. Use the pulley pusher kit, Part Number 3376085, and adapter, Part Number 3163272. Install the correct adapter in the pusher. Install the pulley on the shaft. Remove the tool and adapter.


Finishing Steps • Install and adjust the alternator belt. Refer to Procedure 013-005 (Alternator Drive Pulley) in Section 9.

Fuel Pump Drive (009-011) Preparatory Steps 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 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. with Electronically Actuated Injector 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 Page 9-23



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.

Remove the six capscrews from the drive housing flange. Remove the drive and discard the gasket.

with Electronically Actuated Injector Remove the six capscrews from the fuel pump drive housing flange. Remove the fuel pump drive. Remove and inspect the gasket.

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.


Use a dial indicator to measure the fuel pump drive shaft end clearance. Fuel Pump Shaft End Clearance mm in 0.14 MIN 0.006 0.27 MAX 0.011

Disassemble with Electronically Actuated Injector Remove the straight thread o-ring plug from the fuel pump drive.

Remove the mesh screen with a small flat tip screwdriver.

Remove the shaft from the fuel pump drive housing.




Use a press to remove the gear from the shaft.

Measure the inside diameter of the busings. Fuel Pump Drive Bushing Inside Diameter mm in 49.95 MIN 1.967 50.03 MAX 1.970 If the inside diameter of either bushing is not within specification, both bushings must be replaced.

Check the grooved surfaces of the busings (1) for damage. Measure the distance from the outside of the thrust faces of the two bushings. Fuel Pump Drive Busing Thrust Face Distance mm in 45.370 MIN 1.786 45.450 MAX 1.789 If the distance between the two thrust faces is not within specification, both bushings must be replaced.

Remove the flanged bushing from the drive housing using a brass drift (1), taking care not to damage the bushing bore.


Clean and Inspect for Reuse 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. 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. Measure the end clearance. Fuel Pump Drive End Clearance. mm in 0.05 MIN 0.002 0.30 MAX 0.012 NOTE: Oversize thrust bearings are available to adjust the end clearance.

The coupling washer must be clamped tightly between the coupling and the shaft. If the washer is not tight, rebuild the drive unit.





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. 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 screen for cracks or damage. If any damage is present, the screen must be replaced.

Check the inner diameter of the coupling for damage. If damage is found the coupling must be replaced. Measure the inside diameter of the coupling. Fuel Pump Drive Spline Coupling Inside Diameter mm in 25.255 MIN 0.994 25.278 MAX 0.996 If the inner diameter of the coupling is not within specification the shaft must be replaced.


If the bushing was removed, inspect the housing for scoring and other damage. Replace the housing if damaged.

If the bushing was removed, measure the inside diameter of the bushing bore. Fuel Pump Drive Bushing Bore Inside Diameter mm in 60.00 MIN 2.362 60.05 MAX 2.364 Replace the housing if bushing bore is not within specifications.


Measure the shaft outside diameter. Fuel Pump Drive Shaft Outside Diameter Measurements mm in (1) 34.964 MIN 1.376 34.976 MAX 1.377 (2) 39.662 MIN 1.561 39.740 MAX 1.564 (3) 39.789 MIN 1.566 39.801 MAX 1.567 (4) 49.820 MIN 1.961 49.832 MAX 1.962 If the outside diameter is not within specification, the shaft must be replaced.




Check the gear teeth and gear bore for damage. Replace the gear if damaged.

Measure the gear inside diameter. Fuel Pump Drive Gear Inside Diameter mm in 39.725 MIN 1.564 39.751 MAX 1.565 If the gear is not within specification, the gear must be replaced.

Assemble 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.


If an arbor press is available, support the gear. Lubricate the shaft with clean engine oil. Press the shaft through the gear until the shoulder of the shaft touches the gear.

CAUTION If the heat method was used to install the gear, allow the gear to air cool. Do not use water or oil to reduce cooling time. Damage to the gear can result. Use a feeler gauge to measure the distance between the shoulder of the shaft and the gear. Fuel Pump Drive Gear to Shaft Distance mm in 0.05 MAX 0.002 If the distance between the gear and the shaft is not within specification, press the gear on until the specification is met.

CAUTION The bushings must be pressed in square to the bores of the housing. The thrust faces of the two bushings must be parallel and concentric. The bushing with the center counterbore must have the pressure applied to the counterbore face and not on the thrust bearing face. Failure to comply can result in distortion of the thrust face. Support the housing. The bushing with the smaller outside diameter is pressed into the output side. Using an arbor press and the shaft as a mandrel, press the bushing into the housing. Turn the housing over and press the remaining bushing into place.




Lubricate the grooved surface of the thrust bearing with Lubriplate™ 105 or equivalent. Install the gear and shaft assembly into the housing. Install the clamping washer (1) with the beveled edge up.

Support the assembly on the gear or the shaft. Use an arbor press and a mandrel to press the coupling onto the shaft until it touches the clamping washer. The clamping washer must be positioned tightly between the coupling and the shoulder of the shaft. Install the pipe plug into the housing. Tighten the pipe plug. Torque Value: 8 N•m [ 75 in-lb ]

The capscrew must contain an oil drilling if an air compressor is to be mounted on the engine. Install the washer and capscrew. Tighten the capscrew. Torque Value: 9.525 mm [0.375 in] Capscrew Length 12.7 mm [0.50 in] Capscrew Length

45 N•m

[ 35 ft-lb ]

100 N•m

[ 75 ft-lb ]

Rotate the shaft, checking for correct assembly. Use a dial indicator to measure the fuel pump drive shaft end clearance. Fuel Pump Drive Shaft End Clearance mm in 0.05 MIN 0.002 0.30 MAX 0.012 If the end clearance is not within specifications, make sure the coupling is positioned tightly against the clamping washer.


with Electronically Actuated Injector If the bushings where removed, use the shaft as a mandrel and press one bushing into the housing until the underside of the bushing head is flush with the counterbore in the housing. Turn the housing over and press the remaining bushing into place.

Install the shaft into the housing.

WARNING 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.




If an arbor press is available, support the gear. Install the key onto the shaft. Lubricate the shaft with clean engine oil. Press the shaft through the gear until the shoulder of the shaft touches the gear.

CAUTION If the heat method was used to install the gear, allow the gear to air cool. Do not use water or oil to reduce cooling time. Damage to the gear can result. Use a feeler gauge to measure the distance between the shoulder of the shaft and the gear. Accessory Drive Gear to Shaft Distance mm in 0.05 MAX 0.002 If the distance between the gear and the shaft is not within specification, press the gear on until the specification is met. Install the screen into the housing by pushing the screen in by hand.

Install the straight thread o-ring plug. Torque Value: 6 N•m [ 55 in-lb ]


Rotate the shaft, checking for correct assembly. Use a dial indicator to measure the fuel pump drive shaft end clearance. Fuel Pump Drive Shaft End Clearance mm in 0.14 MIN 0.006 0.27 MAX 0.011 If the end clearance is not within specifications, make sure the coupling is positioned tightly against the clamping washer.

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 ] Install the oil slinger. Install the Woodruff Key.




with Electronically 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. Install the gasket onto the pilot of the drive housing cover.

There is not a requirement to align the index on the drive gear with the marks on the camshaft gear on QSK38 and QSK50 engines. Install the fuel pump drive assembly, turning the shaft as necessary to engage the gears. Install and tighten the six capscrews. Torque Value: 45 N•m [ 33 ft-lb ]

With the fuel pump drive installed, measure the end clearance. Fuel Pump Drive End Clearance mm in 0.14 MIN 0.006 0.27 MAX 0.011

Finishing Steps 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.


Hydraulic Pump Drive Page 9-37

with Electronically 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 fuel pump. Refer to Procedure 005-016. • Operate the engine until the coolant temperature reaches 71°C [160°F]. Check for coolant leaks.

Hydraulic Pump Drive (009-016) General Information A hydraulic pump can be mounted on the front or at the rear of the gear cover . The SAE A two-bolt type flange is required to mount a hydraulic pump at the rear of the gear cover. The SAE B fourbolt type flange is required for a hydraulic pump to be mounted on the front of the gear cover. There is a specific drive required to match the different sizes of spline drives required for the optional hydraulic pumps. Engines that do not have a hydraulic pump drive must have parts that block the oil holes in the gear cover and housing for correct engine oil pressure. A four-bolt flange that has a blind plug welded to it must be installed on the front of the gear cover. The blind plug will extend into the bushing, blocking the oil drilling. A three-bolt cover that has two orings must be installed on the rear of the gear housing. A hydraulic pump drive can be installed by removing the blind plug flange and the cover. If only the rear drive port is used, a plain four-bolt cover and gasket must be installed on the front of the cover. If only the front drive port is used, a two-bolt cover and gasket must be installed on the rear of the pump drive.

Preparatory Steps • Remove the hydraulic pump. Refer to the OEM service manual for instructions.

Remove The hydraulic pump drive is removed from the rear of the gear housing. Remove the capscrews and lock washers. Remove the drive assembly, allowing the gear to turn freely as it disengages with the water pump idler gear.



Disassemble Remove the locktight capscrews and if fitted the lock washers. Remove the cover (if equipped). Remove and discard the gasket.

Remove the retaining ring.

Remove the clamping washer. Remove the thrust bearing.

Remove the housing. Remove the thrust bearing.



Clean and Inspect for Reuse 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. Hydraulic Pump Drive Bushing Inside Diameter mm in 38.13 MIN 1.501 38.25 MAX 1.506 Check the drive assembly. Replace if damage is found on the housing or the gear is worn.

Clean for Rebuild WARNING 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. Thrust Bearing Thickness mm 2.273 2.299

MIN MAX

in 0.0895 0.0905

NOTE: Two oversize thrust bearings, 0.03 mm [0.001 in] and 0.05 mm [0.002 in], are available.



Measure the outside diameter of the shaft. Shaft Outside Diameter (1) mm 38.062 38.075

MIN MAX

in 1.4985 1.4990

Shaft Outside Diameter (2) mm 50.749 50.762

MIN MAX

in 1.9980 1.9985

If either the gear or the shaft must be replaced. Refer to Procedure 009-019 (Hydraulic Pump Drive Gear and Shaft) in Section 9. Measure the inside diameter of the bushing. Hydraulic Pump Bushing Inside Diameter mm in 50.813 MIN 2.0005 50.902 MAX 2.0040 If the bushing must be replaced. Refer to Procedure 009-019 (Hydraulic Pump Drive Gear and Shaft) in Section 9.

Assemble Use Lubriplate® Number 105 multi purpose lubricant, or equivalent. Lubricate the grooved surface of the thrust bearing. Position the grooved surface of the thrust bearing as illustrated (3). Slide the shaft in the housing. NOTE: The gear must touch the thrust bearing.

Use Lubriplate® Number 105 multi purpose lubricant, or equivalent. Lubricate the grooved surface of the thrust bearing. With the grooved surface positioned up, slide the thrust bearing over the shaft. The beveled edge of the clamping washer must be positioned against the thrust bearing. Slide the clamping washer over the shaft. The beveled edge of the retaining ring must be positioned as illustrated. Install the retaining ring.



Measure the end clearance. End Clearance mm 0.10 0.48

MIN MAX

in 0.004 0.019

If the end clearance is not within specifications, the assembly must be rebuilt.

Install a new gasket. Install the cover (if equipped). Install the locktight capscrews or if fitted, lock washers and the capscrews. Torque Value: 27 N•m [ 20 ft-lb ]

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 Page 9-42


Hydraulic Pump Drive Gear and Shaft (009-019) Disassemble NOTE: Only remove the gear from the shaft when the gear or the shaft must be replaced. Install the shaft and gear in an arbor press as shown. Use a suitable mandrel to push the shaft from the gear.

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. Use solvent. Clean the shaft and gear. Dry with compressed air.

Measure the inside diameter of the gear if it is to be reused. Hydraulic Pump Drive Gear Inside Diameter mm in 44.399 MIN 1.7480 44.425 MAX 1.7490 Inspect the gear teeth for wear or damage.

Measure the outside diameter of the shaft at the gear location if it is to be reused. Hydraulic Pump Drive Shaft Outside Diameter mm in 44.450 MIN 1.7500 44.463 MAX 1.7505


Rear Gear Drive (Lower Assembly) Page 9-43

Assemble NOTE: If replacing the shaft, make sure that the replacement contains the same number of teeth. Use Loctite® 609 or the equivalent. Apply a smooth layer on the inside diameter of the gear. Use an arbor press. Support the gear as shown with the part number facing down. Press the shaft through the gear until the shaft shoulder touches the gear.

Rear Gear Drive (Lower Assembly) (009-023) General Information Not all engines are equipped with this option. The rear gear drive consists of a lower unit. The total continuous drive capacity of the rear gear drive is 300 kw (400 hp) at 2100 rpm. Previous K38 and K50 engines contained the rear gear drive lower unit so that the customer had the option to install the upper drive. Engines built after September, 1986 do not have this feature. A one piece flywheel housing is used (See Rear Engine Power Takeoff - Shop and Installation Manual, Bulletin 3666040), which incorporates the rear oil seal. CAUTION If the lower rear gear drive contains gears and shafts, but no upper unit, the engine oil must flow through the oil drillings in the housing or failure of the gear bushing will result. On previous engines that did not have an upper unit, a cover plate was installed. Some of these engines have a rear gear housing with expansion plugs installed in the bores for the shafts. The oil drilling in the housing that aligns with the cylinder block left bank oil drilling must have a pipe plug installed on these engines. The cover plate and the oring 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.



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.



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. NOTE: Prevent one of the gears from turning to check to gear backlash. Check the gear backlash. Gear Backlash mm 0.08 0.30

MIN MAX

in 0.003 0.012

Check the gear end clearance. Gear End Clearance mm 0.10 0.25

MIN MAX

in 0.004 0.010

If any of the parts are damaged or not within specifications, the gear drive must be rebuilt.



Disassemble If necessary, remove the cover plate capscrews, the plate (1), if fitted, the gasket (2), and the o-rings (3).

CAUTION The housing must be level on the press or breakage will result. Support the housing in a hydraulic press around the shaft bore on the rear seal side of the housing as illustrated.

Press on the shafts (4) from the cylinder block mounting side of the housing.

Press both shafts (4) from the bores in the housing. Remove and discard the o-rings (5).



Remove the upper (6) and lower (7) gears, and the four thrust bearings (8).

Clean for Rebuild WARNING 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). Shaft Outside Diameter mm 63.500 63.513

MIN MAX

in 2.5000 2.5005

If the shafts are not within specifications, they must be replaced.



Check the gear teeth for damage or wear. The gear bushings are machined after installation in the gear. Do not remove the bushings unless you have the capability of machining the bushings to a precise tolerance. The center of the bore in the bushings must be concentric with the pitch diameter of the gear within 0.066 mm [0.0026 inch] total indicator reading (TIR). The bore must be machined to the following specifications. NOTE: There are two bushings in each gear. Measure the inside diameter of the gear bushings. Gear Bushing Inside Diameter mm in 63.564 MIN 2.5025 63.627 MAX 2.5050 Measure the thrust bearing thickness. Thrust Bearing Thickness mm 2.36 2.41

MIN MAX

in 0.093 0.095

If the thickness of the thrust bearing is not within specifications, the bearing must be replaced.

NOTE: The shaft bores in the housing have different specifications. Measure the shaft bores on the cylinder block mounting side of the housing. Cylinder Block Side Bore Inside Diameter mm in 63.411 MIN 2.4965 63.449 MAX 2.4980


Measure the shaft bores on the rear seal side of the housing. Rear Seal Side Bore Inside Diameter mm in 63.513 MIN 2.5005 63.538 MAX 2.5015 If either bore is not within specifications, the housing must be replaced.

Assemble With the cylinder block mounting side positioned down, put the housing in a hydraulic press.

CAUTION The thrust bearings must be installed with the oil grooves touching the gear. If the steel portion of the bearing is touching the gear, failure will result. Use clean engine oil. Lubricate the thrust bearings. Position a thrust bearing over the shaft bore in the housing.

NOTE: The gears have different helix directions. The gear with the teeth slanted to the left (7) must be installed nearest to the rear seal bore in the housing (lower gear). The gear with the teeth slanted to the right (8) must be installed nearest to the cover plate end of the housing (upper gear). The assembly will not fit on the engine if this installation procedure is not followed.




CAUTION The flat side of the gears (11) must be toward the cylinder block mounting side of the housing. Failure will result if this installation procedure is not followed because the gears will not mesh correctly. The protruding gear hub (12) must be toward the rear seal side of the housing.

Use clean engine oil. Lubricate the gear bushings. Position the gears (7 and 8) in the housing so that the bore in the gear is aligned with the bore in the housing. Install the thrust bearings. The oil grooves in the thrust bearings must touch the gear. Each gear has one thrust bearing on each side of the gear.

CAUTION The new o-rings must be installed in the groove in the shafts that do not have an oil hole. An oil leak will result because the gear bushings will not be lubricated sufficiently if the o-rings are installed wrong. Install a new o-ring in the small groove on each shaft. Use clean engine oil. Lubricate the o-rings and shafts. With the oil groove positioned first, install the shaft into the housing. The oil hole in the side of the shaft must be toward the cover plate end of the housing. Push the shaft through the thrust bearings and gear bushing by hand to be sure they are in alignment. Use a hydraulic press to push the shaft until it is even with the cylinder block side of the housing. The shaft must not protrude. Install the other shaft through the thrust bearings and gear. Press it into the housing until it is even with the cylinder block side of the housing. The shaft must not protrude.



Use a dial indicator. Measure the end clearance of both gears. Gear End Clearance mm 0.10 0.25

MIN MAX

in 0.004 0.010

If the gear end clearance is not within specifications, inspect housing for wear.

Use a dial indicator. Prevent one of the gears from turning to obtain the correct gear lash measurement. Gear Lash mm 0.08 0.30

MIN MAX

in 0.003 0.012

If the gear lash is not within specifications, the gear is worn and should be replaced.

If necessary, install the gasket (2), new o-rings (3), the cover plate (1), and the capscrews.

Install NOTE: Some engines are not equipped with this option. CAUTION Not all of the cylinder blocks contain the oil drillings required for the rear gear drive. Check the rear of the block for the oil drillings. See the second part of the instructions for installing the rear seal housing for the location of the drillings. If the block does not contain the drillings, the rear gear drive lower unit must not be installed unless the gears have been removed. If the block does not have the drillings, the gear drive will fail from lack of lubrication and cause the rear crankshaft gear to fail. CAUTION The rear gear drive lower unit that has the gears must be lubricated by engine oil even if a rear gear drive upper unit is not installed.



CAUTION Do not install a lower unit that has had one or both of the gears removed unless both of the oil drillings in the housing have been plugged. If the holes are not plugged, the engine oil continues to flow through the housing and shafts, and will result in the engine oil pressure being less than specification. If desired, a housing that does not contain gears can be plugged by machining threads for pipe plugs in the holes in the housing that align with the oil holes in the cylinder block. Check to be sure the installed pipe plugs are even with, or below the surface of the housing, or the housing will be damaged when the capscrews are tightened to the block. CAUTION If the shafts are removed from a rear gear drive lower unit that has either the oil drillings plugged or is to be installed on a cylinder block that does not have the oil drillings, all four holes for the shaft must be plugged to prevent contamination. If the holes remain open, the oil in the oil pan will be contaminated. Check to be sure the correct rear crankshaft gear is installed. A gear that is 63 mm [2.5 in] wide must be installed when a rear gear drive lower unit that has gears is installed. Refer to Procedure 001-026. WARNING 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. 2. 3. 4. 5. 6.

Gasket O-rings (2) Cover plate Lock washers Capscrews Nuts.

Torque Value: 60 N•m [ 45 ft-lb ]


Rear Gear Drive (Upper Assembly) 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.

Rear Gear Drive (Upper Assembly) (009-024) General Information Not all engines are equipped with this option. The rear gear drive consists of a lower and an upper unit. The total continuous drive capacity of the rear gear drive is 300 kw (400 hp) at 2100 RPM. Engines built after September 1986 do not have this feature, a one piece flywheel housing is used. See Rear Engine Power Takeoff - Shop and Installation Manual, Bulletin Number 3666040. This assembly has several variations, depending on the type of equipment to be driven by the rear gear drive. The gears and shafts will vary with the number of drive ports, the type of spline installed on the shafts, and the SAE type bolt flange. If an upper unit is installed on an engine that did not have one originally, two roll pins must be installed in the lower unit to align the upper unit. If an upper drive is permanently removed from an engine, the roll pins must be removed to allow the installation of the cover plate. As many as three hydraulic pumps can be installed on the upper unit. In the left and right drive positions (facing the flywheel), the drive ratio is 1:0 multiplied by the engine RPM, and the direction of rotation is counterclockwise. In the center drive position, the drive ratio is 0.75 multiplied by the engine RPM, and the direction of rotation is clockwise.



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.


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.




NOTE: Record the number of splines in the end of the shaft so that the part can be installed correctly. Remove the shaft and gear assembly (11) and the thrust bearing (12).

CAUTION 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.

Prevent the gear and shaft from turning when removing the capscrews. Remove the capscrews (17) that secure the shaft adapter in the gear. CAUTION The gear can fall out when the shaft is removed. Avoid personal injury and damage to the parts. Remove the center shaft and adapter (18) and the thrust bearing (19).

Remove the center gear (20) as shown.


Remove the bushing cover plates (21) and the gaskets (22). NOTE: The plug (23) and the o-ring (24) are installed only in the bores that do not contain a gear and shaft assembly. Remove the plug (23) and the o-ring (24). Discard the oring.

Remove the pipe plug (25) from the bottom of the housing. Remove the upper cover plate (26) and the gasket (27).




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.

Inspect for Reuse Check the parts for damage. Look for scratches or dents.



NOTE: Prevent one of the gears from turning to check to gear lash. Check the gear lash. Gear Lash mm 0.08 0.30

MIN MAX

in 0.003 0.012

If the gear lash is not within specifications, the drive must be rebuilt. Refer to Procedure 009-023.

Check the gear end clearance. Gear End Clearance mm 0.10 0.25

MIN MAX

in 0.004 0.010

If any of the parts are damaged or not within specifications, the gear drive must be rebuilt. Refer to Procedure 009-023.

Clean for Rebuild WARNING 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.



NOTE: All three bushings in the housing have the same specifications. Measure the inside diameter of the bushings. Bushing Inside Diameter mm 63.55 63.63

MIN MAX

in 2.502 2.505

The bushings are machined after installation in the housing. Do not attempt to replace the bushings unless you have the capability of machining the bushing inside diameter to a precise tolerance. If the bushings in the housing are replaced, they must be machined within the above specifications. The bushings must have the same center as the large bores in the housing within 0.10 mm [0.004 inch] total indicator runout. NOTE: All bushings in the supports have the same specification. Measure the inside diameter of the bushings. Support Bushing Inside Diameter mm in 63.55 MIN 2.502 63.63 MAX 2.505 The bushings are machined after installation in the support. Do not attempt to replace the bushings unless you have the capability of machining the bushing inside diameter to a precise tolerance. If the bushings in the support are replaced, they must be machined within the above specifications. The bushings must have the same center as the support pilot (between the o-ring groove and mounting flange) outside diameter within 0.05 mm [0.002 inch]. NOTE: All shafts have the same outside diameter specifications. Measure the outside diameter at each end. Shaft Outside Diameter mm 63.500 63.513

MIN MAX

in 2.5000 2.5005

If the shaft is not within specifications, or the gear is damaged, the gear or shaft must be replaced. Refer to Procedure 009-028. Each shaft must contain a cup plug that has an orifice installed in the bore of the shaft. If the plug is not installed, a low flow of oil to the bushing in the support will result. If the plug does not have an orifice, no oil to the spline will result. Do not remove the plug. The shaft and plug are available as an assembly only.



NOTE: The specification for the shaft protrusion is the same for the adapter on the center shaft and gear assembly (19) as for the shaft and gear on the outboard assembly or assemblies (11). NOTE: Measure from the end of the shaft that contains the drive splines. Measure the shaft protrusion from the gear to check the gear movement on the shaft. Shaft Protrusion mm 85.47 85.98

MIN MAX

in 3.365 3.385

NOTE: All thrust bearings have the same thickness specifications. Measure the thickness of all the thrust bearings. Thrust Bearing Thickness mm 2.36 2.41

MIN MAX

in 0.093 0.095

Oversize thrust bearings are available to adjust end clearance.

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.



Use clean engine oil. Lubricate the shaft, thrust bearing, and the bushing. CAUTION The thrust bearing must be installed so that the oil grooves are toward the gear. If the thrust bearing is not installed correctly, failure will result. Install the thrust bearing (19) on the shaft with the adapter (18). With the short end first, install the adapter and the shaft assembly (18) through the bore of the gear and into the housing. Install the flat washers and capscrews. Torque Value: 163 N•m [ 120 ft-lb ] Install a new o-ring (15) on the center support. Use clean engine oil. Lubricate the o-ring, thrust bearing (16), and the shaft and bushing. CAUTION The oil grooves in the thrust bearing must be toward the gear. If the bearing is not installed correctly, failure will result. Install the thrust bearing on the shaft. Install the center support (14). Install the flat washers and capscrews. 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.

Install a new o-ring (9) on the support (8). Use clean engine oil. Lubricate the thrust bearing, the bushing in the support, and the shaft. CAUTION The 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 ]



NOTE: Prevent one of the gears from turning when measuring the gear lash. Use a dial indicator. Measure the gear lash on all gears. Gear Lash mm 0.08 0.30

MIN MAX

in 0.003 0.012

If any gear lash is not within specifications, the gear must be replaced.

Use a dial indicator. Measure the end clearance of the shafts on all gears through the bore on the cylinder block side of the drive. Shaft End Clearance mm 0.10 0.25

MIN MAX

in 0.004 0.010

NOTE: Oversize thrust bearings are available to adjust the end clearance. If the end clearance is not sufficient, check for debris between the thrust bearings and their connecting parts.

CAUTION The plug and the o-ring must be installed in any bushing bore that does not contain a shaft. If the plug and o-ring are not installed, low oil pressure will result. Install a new o-ring (24) on the plug (23). Use clean engine oil. Lubricate the o-ring. Install the plug in the bore. Push the plug in the bore until the step on the plug touches the bushing. Install new cover plate gaskets (22) and the cover plates (21). Install the flat washers and capscrews. 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].



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. Remove the capscrews (6) from the center drive support. Remove the center support (7). The center support contains an o-ring seal (8), and a thrust bearing (9) between the support and the gear. It is not necessary to remove the seal and the thrust bearing, but they must be installed correctly.

Install the three lock washers (4) and capscrews (5) in the holes that are inside the upper unit. Tighten the fourteen capscrews that connect the upper unit to the lower unit. Torque Value: 90 N•m [ 65 ft-lb ]


Rear Gear Drive Gear and Shaft (Upper Assembly) 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 ]

Rear Gear Drive Gear and Shaft (Upper Assembly) (009-028) Disassemble NOTE: This procedure illustrates replacing a gear or shaft in the center drive port. The procedure and specifications are the same for the other locations. Support the gear as illustrated. Use a press. Push the shaft (1) out of the gear (2).

Clean Use clean engine oil. Clean the parts.

Inspect for Reuse Check the parts for damage. Measure the outside diameter of the gear step on the shaft. Gear Step Outside Diameter mm 63.627 63.640

MIN MAX

in 2.5050 2.5055



Measure the inside diameter. Gear or Adapter Bore Inside Diameter mm in 63.53 MIN 2.501 63.55 MAX 2.502

Assemble WARNING To reduce the possibility of severe burns, wear protective gloves when installing the heated ring gear. CAUTION 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. There are two methods for positioning and securing the hot gear correctly. Method One (Preferred): Obtain a length of pipe or thick wall tubing that has an inside diameter larger than the shaft and an outside diameter smaller than the hub on the gear or adapter. Cut the pipe or tube so that it is the same length as the shaft protrusion specification. The shaft can now be put spline end down in the pipe or tube, and the gear or adapter installed until it touches the pipe or tube. The tube will then secure the gear or adapter at the proper location on the shaft until the gear or adapter is cool.



Method Two: Apply machinist dye to the gear step area of the shaft. Measure the distance of the protrusion specification from the end of the shaft that contains the splines. Use a scribe (3) to mark a line in the dye that will indicate where the gear is to be located to obtain the correct protrusion. When this method is used, the gear must be moved to the scribed line, then the gear and shaft assembly placed on its side using vee blocks so that the gear will remain in the correct location until it is cool.

Use Lubriplate® No. 105, or equivalent. Lubricate the outside diameter of the shaft. Do not allow the lubricant to obscure any gear position marks. WARNING 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 85.47 85.98

MIN MAX

in 3.365 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 Page 9-68


Water Pump Drive Bushing (009-030) Remove Mechanically Actuated Injector Standard Bushing Use an arbor press. Support the housing as shown. Use a mandrel. Remove the bushings.

Flanged Bushing NOTE: Before removal from the housing measure the bushing inside diameter Use an arbor press. Support the housing as shown. Remove the drive gear (1). Remove the shaft (2). Remove the pipe plug (3).

Clean and Inspect for Reuse Mechanically Actuated Injector 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.


Water Pump Drive Bushing Page 9-69

Flanged Bushing Clean and inspect all parts. NOTE: The oil drillings must be open and free of any blockage.

Standard and Flanged Bushing Measure the inside diameter of the housing bore. Housing Bore Inside Diameter mm 47.63 47.65

MIN MAX

in 1.875 1.876

If the bore is not within specifications, the housing must be replaced.

Flanged Bushing Only NOTE: There are two bushings in the water pump support. Measure the inside diameter of both bushings. Bushing Inside Diameter mm 44.48 44.58

MIN MAX

in 1.751 1.755

If the inside diameter of either bushing is not within specifications, both bushings must be replaced.

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 Page 9-70


Flanged Bushing Use an arbor press (1). Use the shaft (2) as a mandrel. Support the housing (5) and using a spacer (3), press the bushing (4) into place. Repeat the process for the remaining bushing. NOTE: The bushings must be pressed in square to the bores of the casting. The thrust faces of the two bushings must be parallel and concentric.

Lubricate the bushing bores and thrust faces with Lubriplate™ Number 105, or equivalent.

Water Pump Drive Gear and Shaft (009-031) Disassemble Mechanically Actuated Injector Only remove the gear from the shaft when the gear or the shaft must be replaced. Use an arbor press. Support the shaft and gear assembly as shown. Push the shaft from the gear.

Inspect for Reuse Mechanically Actuated Injector Measure the outside diameter of the shaft at the gear location. Shaft Outside Diameter mm 39.776 39.802

MIN MAX

in 1.5660 1.5670


Water Pump Drive Pulley Page 9-71

Measure the inside diameter of the gear. Gear Inside Diameter mm 39.726 39.751

MIN MAX

in 1.5640 1.5650

Inspect the gear teeth for wear or damage.

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.

Water Pump Drive Pulley (00-032) Preparatory Steps • Remove alternator belt. Refer to Procedure 013-005.

Remove NOTE: A capscrew fitted to the end of the shaft will prevent damage to the threads. Install the capscrew (1). Use a puller (2), ST-647, or equivalent. Remove the pulley from the water pump drive shaft.

Woodward Governor Drive Page 9-72


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.

Woodward Governor Drive (009-034) General Information with Mechanically Actuated Injector This drive provides mechanical power to both the governor and the fuel pump. The drive replaces the fuel pump/compressor drive on engines that have an additional governor installed between the governor drive and the Cummins PT® fuel pump. This drive is referred to as a Woodward® Governor Drive. Other types of governors are installed on the governor housing. The drive support does not contain a bushing or thrust bearing. The drive contains a ball bearing at the rear. The front of the shaft is supported by the bushing in the front gear cover of the engine. The drive has a shaft seal that prevents engine oil from entering the oil sump in the governor drive housing.



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. Check the parts for damage. Use your hand to rotate the shaft. Check the bearing for damage. Check the end clearance of the bearing. Bearing End Clearance mm 0.05 0.10

MIN MAX

in 0.002 0.004

If any of the parts are damaged or the bearing is not within specifications, the drive must be rebuilt or replaced.

Disassemble with Mechanically Actuated Injector Remove the locknut (1) and the retaining washer (2). Discard the locknut.



CAUTION Do not damage the threads on the shaft. Use a three-jaw puller. Remove the coupling (3). Remove the governor gear spacer (4) and the key (5).

Use a three-jaw puller. Remove the governor gear (6).

Use an arbor press. Support the drive support (7). Push the shaft and gear assembly out of the bearing and support. Remove the bearing spacer (8) from the shaft (9).

Remove the bearing retaining ring (10). NOTE: The outside diameter of the bearing can be a maximum of 0.008 mm [0.0003 in] larger than the inside diameter of the bearing bore. An arbor press can be used to push the bearing out of the bore. Remove the ball bearing (11).


Use a hammer and a mandrel (12). Remove the oil seal (13) from the housing. Discard the seal.

Clean for Rebuild with Mechanically Actuated Injector 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). Seal Bore Inside Diameter (14) mm in 57.12 MIN 2.249 57.18 MAX 2.251 Bearing Bore Inside Diameter (15) mm in 61.991 MIN 2.4406 62.017 MAX 2.4416 If either bore is not within specifications, the support must be replaced.




Check the shaft and gear for damage. Measure the shaft at the locations illustrated. Shaft Outside Diameter (16) mm 34.963 34.976

MIN MAX

in 1.3765 1.3770


MIN MAX

in 1.0050 1.0055


MIN MAX

in 0.9842 0.9846


MIN MAX

in 0.8135 0.8140

If the shaft is not within specifications, it must be replaced. Refer to Procedure 009-003. NOTE: The drive gear is identical to the gear that is used on the fuel pump/compressor drive. The specifications shown in the referenced procedure for the gear inside diameter and the shaft outside diameter for the gear step are the same for this gear and shaft. NOTE: The shaft outside diameter at the drive step of the hourmeter in the shaft (17) is critical only when the engine is equipped with an hourmeter drive. Measure the inside diameter Governor Drive Gear Inside Diameter mm in 24.971 MIN 0.9831 24.986 MAX 0.9837 Inspect the gear teeth for wear or damage.


Measure the inside diameter Jaw Coupling Hub Bore Inside Diameter mm in 20.625 MIN 0.8120 20.638 MAX 0.8125 If the bore is not within specifications, the coupling must be replaced.

Check the surface of the bearing spacer (8) in the area that contacts the oil seal. If the spacer indicates wear, it must be replaced.

Assemble 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).




CAUTION Be sure the sealing lips of the seal are not rolled. Failure of the seal will result. Install the bearing spacer (8) on the shaft (9). NOTE: The inside diameter of the spacer can be the same size or a maximum of 0.05 mm [0.002 in] larger than the step outside diameter of the shaft. If the spacer and shaft have a tight fit, use engine oil to lubricate the inside diameter of the spacer. Then rotate it clockwise and counterclockwise to install it on the shaft. Use engine oil. Lubricate the seal. Install the shaft, spacer, and the gear assembly through the oil seal until the step on the shaft for the bearing touches the bearing bore.

CAUTION The mandrel inside diameter must contact the inner race of the bearing to prevent damage to the part. The mandrel inside diameter must be larger than the outside diameter of the shaft to prevent damage to the shaft. Use a mandrel (21). Use an arbor press to support the drive gear. Push the bearing and support assembly on the shaft. Push the bearing until the bearing spacer touches the bearing.

The bearing and shaft must rotate freely. Measure the clearance. End Clearance mm 0.05 0.10

MIN MAX

in 0.002 0.004

Use Lubriplate® Number 105 multipurpose lubricant or equivalent, to lubricate the bore of the governor drive gear. Use an arbor press to support the assembly on the drive gear. Use a mandrel to push the governor drive gear on the shaft. Push the gear until it touches the bearing.


Install the governor spacer (4) and the key (5) on the shaft.

Align the keyway in the jaw coupling (3) with the key in the shaft (5). Use a flat piece of steel, such as a mandrel. Use an arbor press to support the shaft as illustrated. Push the jaw coupling on the shaft. Push the coupling until it touches the spacer. Clean away any metal removed by the installation.

Install the retaining washer (2) and a new locknut (1). Torque Value: 41 N•m [ 30 ft-lb ]

Accessory Drive Cover (009-039) Install NOTE: The cover is installed only if the accessory drive or the water pump drive does not have a pulley. Use a sealant (RTV), Part Number 3377132. Apply a bead of sealant to the portion of the cover that will be in the bore of the front cover. Position the cover in the bore. NOTE: Do not bend the cover when pushing it into the bore. If the cover is bent, an oil leak will result. Use a mallet. Push the cover into the bore until the step on the cover touches the front gear housing. Check to be sure the cover is straight in the bore.

Accessory Drive Cover Page 9-79

Accessory Drive Cover Page 9-80


Notes

K38, K50, QSK38, and QSK50 Section 10 — Air Intake System — Group 10

Page 10-a

Section 10 — Air Intake System — Group 10 Section Contents Page Aftercooler .......................................................................................................................................................10-3 Exploded View................................................................................................................................................10-4 General Information.........................................................................................................................................10-3 Aftercooler Assembly ....................................................................................................................................10-12 Assemble......................................................................................................................................................10-25 with Mechanically Actuated Injector............................................................................................................10-25 with Electronically Actuated Injector............................................................................................................10-32 Clean and Inspect for Reuse......................................................................................................................... 10-24 Disassemble..................................................................................................................................................10-19 with Mechanically Actuated Injector............................................................................................................10-19 with Electronically Actuated Injector............................................................................................................10-22 Finishing Steps............................................................................................................................................. 10-43 MAI............................................................................................................................................................10-43 with Electronically Actuated Injector............................................................................................................10-44 Install............................................................................................................................................................10-33 with Mechanically Actuated Injector............................................................................................................10-33 with Electronically Actuated Injector............................................................................................................10-41 Preparatory Steps......................................................................................................................................... 10-12 MAI............................................................................................................................................................10-12 with Electronically Actuated Injector............................................................................................................10-13 Pressure Test................................................................................................................................................10-23 with Mechanically Actuated Injector............................................................................................................10-23 Remove.........................................................................................................................................................10-13 with Mechanically Actuated Injector............................................................................................................10-13 with Electronically Actuated Injector............................................................................................................10-18 Aftercooler Assembly (Center-Mount) ..........................................................................................................10-45 Assemble......................................................................................................................................................10-49 with Mechanically Actuated Injector............................................................................................................10-49 Clean and Inspect for Reuse......................................................................................................................... 10-48 with Mechanically Actuated Injector............................................................................................................10-48 Disassemble..................................................................................................................................................10-46 with Mechanically Actuated Injector............................................................................................................10-46 Finishing Steps............................................................................................................................................. 10-53 with Mechanically Actuated Injector............................................................................................................10-53 Install............................................................................................................................................................10-51 with Mechanically Actuated Injector............................................................................................................10-51 Preparatory Steps......................................................................................................................................... 10-45 with Mechanically Actuated Injector............................................................................................................10-45 Pressure Test................................................................................................................................................10-48 Remove.........................................................................................................................................................10-45 with Mechanically Actuated Injector............................................................................................................10-45 Aftercooler Assembly (Outboard) .................................................................................................................10-53 Inspect for Reuse..........................................................................................................................................10-53 Install............................................................................................................................................................10-54 Remove.........................................................................................................................................................10-53 Aftercooler Element ...................................................................................................................................... 10-56 Finishing Steps............................................................................................................................................. 10-61 Inspect for Reuse..........................................................................................................................................10-58 Standard....................................................................................................................................................10-58 LTA............................................................................................................................................................10-58 Center-Mount.............................................................................................................................................10-59 Install............................................................................................................................................................10-59 Standard....................................................................................................................................................10-59 LTA............................................................................................................................................................10-60 Center-Mount.............................................................................................................................................10-61 Preparatory Steps......................................................................................................................................... 10-56 Remove.........................................................................................................................................................10-56

Page 10-b


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


Page 10-c

Turbocharger Blade Damage ......................................................................................................................10-140 Inspect for Reuse........................................................................................................................................10-140 Turbocharger Compressor Seal Leaks .......................................................................................................10-141 Inspect........................................................................................................................................................10-141 Turbocharger Coolant Hoses ......................................................................................................................10-144 Finishing Steps............................................................................................................................................10-148 EAI...........................................................................................................................................................10-148 Inspect for Reuse........................................................................................................................................10-146 EAI...........................................................................................................................................................10-146 Install..........................................................................................................................................................10-146 with Electronically Actuated Injector..........................................................................................................10-146 Marine Applications..................................................................................................................................10-148 Preparatory Steps........................................................................................................................................10-144 EAI...........................................................................................................................................................10-144 Remove.......................................................................................................................................................10-144 with Electronically Actuated Injector..........................................................................................................10-144 Marine Applications..................................................................................................................................10-145 Turbocharger Oil Drain Line ........................................................................................................................10-148 Clean and Inspect for Reuse........................................................................................................................10-150 Finishing Steps............................................................................................................................................10-153 with Electronically Actuated Injector..........................................................................................................10-153 Install..........................................................................................................................................................10-151 with Electronically Actuated Injector..........................................................................................................10-151 Preparatory Steps........................................................................................................................................10-148 with Electronically Actuated Injector..........................................................................................................10-148 Remove.......................................................................................................................................................10-149 Single Stage.............................................................................................................................................10-149 Two Stage................................................................................................................................................10-149 Turbocharger Oil Supply Line .....................................................................................................................10-153 Clean and Inspect for Reuse........................................................................................................................10-157 Finishing Steps............................................................................................................................................10-161 with Electronically Actuated Injector..........................................................................................................10-161 Install..........................................................................................................................................................10-158 Industrial Applications...............................................................................................................................10-158 Two Stage................................................................................................................................................10-158 Low Pressure Turbocharger......................................................................................................................10-159 Marine Applications..................................................................................................................................10-160 Preparatory Steps........................................................................................................................................10-153 with Electronically Actuated Injector..........................................................................................................10-153 Remove.......................................................................................................................................................10-154 Industrial Applications...............................................................................................................................10-154 Two Stage................................................................................................................................................10-155 Low Pressure Turbocharger......................................................................................................................10-155 Marine Applications..................................................................................................................................10-156 Turbocharger Radial Bearing Clearance .....................................................................................................10-161 Finishing Steps............................................................................................................................................10-162 Measure......................................................................................................................................................10-161 Preparatory Steps........................................................................................................................................10-161 Turbocharger, Water-Cooled .......................................................................................................................10-130 Finishing Steps............................................................................................................................................10-137 Install..........................................................................................................................................................10-134 Left Bank..................................................................................................................................................10-134 Right Bank...............................................................................................................................................10-136 Preparatory Steps........................................................................................................................................10-130 Remove.......................................................................................................................................................10-131 Left Bank..................................................................................................................................................10-131 Right Bank...............................................................................................................................................10-132 Setup..........................................................................................................................................................10-133

Page 10-d





Service Tools Air Intake System


Tool No.

Tool Description Dial depth gauge

ST-537

Used to check for proper nozzle ring crush or end clearance checks on turbochargers.

Pressure Gauge (0 to 689 kPa [0 to 100 psi]) Used to check air cleaner elements for leaks. 3375275

Torque Wrench An inch-pound dial-type torque wrench. 3824783


Anti-Seize Compound 3824879

Lubricant that speeds assembly and disassembly of studs, bolts, capscrews, flanges, and fittings.

Black Light (AC) Used to help identify the source of leaks in the lubricating system. 3824523

Tool Illustration



Tool No.

Tool Description Black Light (DC) Used to inspect for oil or fuel leaks.

3377394

Fluorescent Tracer 3376891

Used to determine the source of oil leaks. It must be used with a black light.

Exhaust Manifold Leak Tester Kit 4918234

Used to pressure test turbocharger gasket, exhaust bellows, exhaust manifold gaskets, and exhaust manifold adapter gasket sealing areas for leaks.

Air Pressure Regulator Used with the exhaust manifold leak tester. 3164231

Nylon Lifting Sling (1 inch by 6 ft) Used to aid in the removal and installation of heavy components. 3375957

Nylon Lifting Sling (2 inch by 6 ft) Used to aid in the removal and installation of heavy components. 3375958

Tool Illustration


Aftercooler Page 10-3

Aftercooler (010-001) General Information Most K38 engines rated at 675 kW (900 HP) and lower are not aftercooled. All K38 engines rated 675 kW (900 HP) and higher are aftercooled. All K50 engines are aftercooled. Engines that are aftercooled can have one or four aftercooler assemblies. New KTA engines and all KTTA, K2000E, K1800E and K1500E engines have four aftercooler assemblies that are located with the intake manifolds. These are referred to as "outboard" or "low profile" aftercoolers. The aftercoolers on older engines are mounted on supports on the top center of the engine. The older aftercoolers are referred to as "center mount" aftercoolers. Center Mount Aftercooler The center mount aftercooler housing for the K50 engine was improved. The housing was modified to allow the installation of cross bolts that prevent leaks from the expansion of the housing from temperature and internal pressure. A procedure to modify the housing for the cross bolts is included in this section of the manual. The parts for the center mount aftercooler supports on K38 and K50 engines were changed. The number of fasteners to mount the bracket to the supports and to the aftercooler housing was increased. A new aftercooler housing can be mounted with the old supports and brackets. The old aftercooler housing can be mounted with the new supports and brackets. Old and new supports and brackets must not be combined. The aftercooler element was changed at the same time the parts for the center mount aftercooler supports were changed. The new element has an end tank that is manufactured of steel. The older element has an end tank that is manufactured from bronze. The old and new elements can be combined in an aftercooler assembly. The side cover plate for the aftercooler was changed on K38 and K50 engines. The mounting flange on the new plate is 25.4 mm [1.000 inch] thick. The mounting flange on the older plate is 13 mm [0.5 inch] thick. The new plate requires [3/8 - 16 x 2.250 inch] capscrews with lock washers and flat washers to attach the plate to the aftercooler housing. K38 and K50 engines manufactured after June 1977 contain different aftercooler elements than the engines manufactured before that date. The new elements contain a water connection nipple that is 69.9 mm [2.75 inch] in length. The nipple on the older elements is 31.8 mm [1.25 inch] in length. If the older elements must be replaced, the aftercooler water inlet and outlet connections must be changed to allow for the longer length. An adapter connection that has a hole is required to prevent coolant from a leaking o-ring seal to enter the cylinders of the engine. The aftercooler water outlet tube must be modified to allow for the longer nipple length and the use of the older thermostat housing support. Outboard Aftercooler Revised aftercooler elements and plumbing was released for all KTTA38, E.S.N. 33112184, and KTTA50, E.S.N. 33112203, engines in April, 1987. All original KTTA aftercooler plumbing was replaced. Older engines can be upfitted by following the procedure in this section. Low Temperature Aftercooling (LTA) System The LTA system was introduced to improve serviceability and to commonize cooling system hardware. LTA is used on KTA50-G3, KTA50-G4, KTTA50-G2, K2000E, K1800E and K1500E engines and utilizes a standard flow cooling system. For a detailed description of the LTA cooling system refer to Section 08 of this manual. An AiResearch® Phase 2 aftercooler element replaced Phase 1 elements in September, 1987, E.S.N. 33112790. A Modine® Phase 3 aftercooler element replaced the Phase 2 element in September, 1988, on C1800 engines from E.S.N. 33114675 and on all other engines from E.S.N. 33114695. A Modine® steel element replaced the copper element on K2000E and K1800E engines in January, 1992, E.S.N. 33121129 and on all other engines in May, 1993, E.S.N. 33124510. A revised aftercooler seal was released for K2000E and K1800E engines that improve the sealing reliability. The new sealing hardware is not interchangeable with intake manifolds. Both the revised seal and intake manifolds must be installed as a package when performing a retrofit. This change took place on engines from January, 1992, E.S.N. 33121129. A revised convoluted hump hose, with two stainless steel rings around the circumference of the hose, was released for KTA/KTTA50 engines. The new hose helps prevent ballooning of the hose. Since the revised hump hose is longer than the hose used previously, a revised air connection must be used. The hose connection will provide a wider air gap between the two pieces of air connection. Do not lubricate the hose. This change was effective from July, 1994, E.S.N. 33128112.



Exploded View

Aftercooler, Center mount Aftercooler, Center mount Reference Number

Description

Quantity (per Engine) K38 K50


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Manifold, Air Intake (Refer to Note 1) (Refer to General Information) Gasket, Intake Manifold Seal, Rectangular Ring Gasket, Air Intake Connection Connection, Air Crossover Connection, Air Intake (Jumper) Seal, Dust (Air Crossover Tube) Seal, O-Ring (Air Crossover Tube) Tube, Air (Air Crossover) Connection, Air Crossover Gasket, Connection Cover, Aftercooler Housing Gasket, Cover and Element Element, Aftercooler Housing, Aftercooler (Refer to Note 1) Seal, O-Ring (Adapter to the Element) Gasket, Flange Connection, Adapter Connection, Water Outlet Seal, Rectangular Tube, Water Outlet Transfer (Refer to Note 1) Brace, Retaining (Refer to Notes 1 and 2) Turbocharger (Refer to Note 1) (See General Information) Seal, O-Ring (Turbocharger Outlet Tube) (Refer to Note 2) Tube, Air (Turbocharger Outlet) (Refer to Note 2) Seal, Dust (Turbocharger Outlet Tube) (Refer to Note 2) Gasket, Turbocharger Connection, Air Crossover Gasket, Connection Connection, Water Inlet Seal, O-Ring Tube, Water Inlet Transfer Connection, Water Inlet Transfer Gasket, Connection (to the Water Header) Support, Aftercooler Housing Plate, Aftercooler Support


4

4

12 24 8 4 2 4 8 4 4 4 2 4 2 1 4 4 4 2 6 2 4 2 4 2 2 2 0 0 2 6 2 2 1 4 2

16 32 8 4 2 4 8 4 4 4 2 4 2 1 4 4 4 2 6 2 4 2 4 2 2 2 2 2 2 6 2 2 1 4 2

Note 1:K38 and K50 parts are different. Note 2:Newer engines have a special hose and special clamps instead of these parts.



Aftercooler, Outboard Aftercooler, Outboard Reference Number 1 2 3 4 5 6 7 8

Description Connection, Air Crossover Clamp, Vee-Band Connection, Air Crossover Seal, O-Ring Connection, Air Crossover Seal, Dust Connection, Air Crossover Gasket, Connection

Quantity (per Engine) K38 K50 2 2 2 2 2 2 4 4 2 2 2 2 2 2 4 4


9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27 29 30 31 32 33

Cover, Aftercooler Screw, Captive Spring Washer [3/8-16 x 1.06 Inch] Element, Aftercooler Gasket, Aftercooler Cover Seal, O-Ring Gasket, Flange Adapter, Connection Clamp, Hose Hose, Elbow (Refer to Note 1) Tube, Water Outlet (Right Bank Front) (Refer to Note 1) Hose, Plain (Refer to Note 1) Coupling, Hose (to the Thermostat Housing) Cover, Thermostat Housing Support Gasket, Cover Gasket, Air Intake Manifold Seal, Rectangular Ring Coupling, Hose (to the Cylinder Block) Tube, Water Inlet (Right Bank Front) (Refer to Notes 1 and 2) Capscrew [3/8-16 x 5.25 Inch] Capscrew [3/8-16 x 6.75 Inch] Manifold, Air Intake ( Right Bank Front, Left Bank Rear) (Refer to Note 1) Manifold, Air Intake ( Right Bank Rear, Left Bank Front) (Refer to Note 1) Tube, Water Inlet (Right Bank Rear) (Refer to Notes 1 and 2) Tube, Water Outlet (Right Bank Rear) (Refer to Notes 1 and 2) Elbow, 90 Degree (to the Rocker Lever Housing) (Refer to Note 2)

Note 1:K50 parts are different. Note 2:The right bank is illustrated. The left bank part is different.


4 32 4 4 16 8 8 32 12 1 3 2 2 2 12 24 4 1

4 32 4 4 16 8 8 32 4 1 11 2 2 2 16 32 4 1

24 24 2

32 32 2

2

2

1

1

1

1

1

1



Aftercooler, Outboard K2000E and K1800E Aftercooler, Outboard K2000E and K1800E Reference Number 1 2 3 4 5 6 7 8 9 10 12 13 14 15 17 18 19 22

Description Clamp, V Band Connection, Air Crossover Clamp, T-bolt Hose, Plain Capscrew, Hexagon Head Pipe, Plug Washer, Spring Gasket, Connection Clamp. T-bolt Hose, Plain Connection Connection, Air Crossover Capscrew, Hexagon Head Capscrew, Hexagon Head Hose, Plain Connection, Air Intake Gasket, Connection Capscrew, Hexagon Head

Quantity 2 1 4 2 16 8 96 4 8 2 2 2 40 40 2 4 4 32


23 24 25 26 27


Gasket, Intake Manifold Seal, Rectangular Ring Manifold, Air Intake RB Front & LB Rear Manifold, Air Intake LB Front & RB Rear Connection, Air Crossover

4 32 2 2 16

Aftercooler, Outboard K1500E Aftercooler, Outboard K1500E Reference Number 1 2 3 4 5 6 7 8 9 10 12 13 14

Description Clamp, V Band Connection, Air Crossover Clamp, T-bolt Hose, Plain Capscrew, Hexagon Head Pipe, Plug Washer, Spring Gasket, Connection Clamp. T-bolt Hose, Plain Connection Connection, Air Crossover Capscrew, Hexagon Head

Quantity 2 1 4 2 16 8 96 4 8 2 2 2 40


15 17 18 19 22 23 24 25 26 27


Capscrew, Hexagon Head Hose, Plain Connection, Air Intake Gasket, Connection Capscrew, Hexagon Head Gasket, Intake Manifold Seal, Rectangular Ring Manifold, Air Intake RB Front & LB Rear Manifold, Air Intake LB Front & RB Rear Connection, Air Crossover

40 2 4 4 32 12 32 2 2 6

Element, Aftercooler K2000E, K1800E and K1500E Element, Aftercooler K2000E, K1800E and K1500E Reference Number 1 2 3 4 5 6 8 9

Description Element, Aftercooler Seal, Aftercooler Connection, Water Transfer Connection, Water Transfer Connection, Water Transfer Seal, O-ring Capscrew, Hexagon Head Plug, Pipe

Quantity 4 4 2 2 2 8 8 4


10 11 12 13 14 15 16

Seal, Rectangular Strip Connection, Water Transfer Seal, Grommet Capscrew, hexagon Head Spacer, Mounting Washer, Spring Draincock


4 4 8 50 50 8 4

Aftercooler, Outboard KTA50-G3, G4 and KTTA50-G2 Aftercooler, Outboard KTA50-G3, G4 and KTTA50-G2 Reference Number 1 2 3 4 5 6 7 8

Description Manifold, Air Intake LB front & RB Rear Manifold, Air Intake RB front & LB Rear Element, Aftercooler Gasket, Cover Clamp, T-bolt Hose, Plain Crossover, Air Clamp, V-band

Quantity 2 2 4 4 4 2 2 2

Aftercooler Assembly Page 10-12

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 35


Connection, Air Intake Clamp, T-bolt Hose, Plain Gasket Capscrew Washer Connection, Air Clamp, T-bolt Connection, Air Hose, Plain Washer, Plain Capscrew Gasket Pipe, Plug Washer, Plain Capscrew Capscrew Washer, Spring Capscrew Seal, Rectangular Ring Spacer Capscrew Gasket, Air Connection Seal, Rectangular Strip

4 4 2 4 8 16 2 4 2 4 8 8 16 2 64 32 32 64 50 32 50 8 4 4

Aftercooler Assembly (010-002) Preparatory Steps MAI 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.


with Electronically Actuated Injector 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.




NOTE: There are four air crossovers. Remove the four capscrews. Pull the crossover (10) and the tube (9) from the aftercooler. Remove the gasket. Remove the tube from the crossover. Remove the o-rings (7). Discard the o-rings. Remove the dust seal (8). If the dust seal is hard or soaked with oil, discard the seal.

Remove the two capscrews (10). Remove the four capscrews (7). Remove the water inlet connection assembly (5). Remove the two rectangular ring seals (4). Remove the gasket (8). Discard the gasket and seals.

WARNING This assembly or component weighs greater than 23 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).

Outboard Aftercooling - Standard Cooling system Old style plumbing with the hoses removed. NOTE: Each of the four aftercoolers has a coolant inlet and outlet tube. Only the tubes for the left bank front are shown. Remove both tubes from all four of the aftercoolers. NOTE: The rocker lever housing end of the outlet tube for the left bank rear aftercooler has a tube nut and a rectangular seal instead of a hose and hose clamps. Remove the capscrew for any support clamp (6). Loosen the hose clamps. Remove the inlet (11) and outlet (12) tubes. Remove the hoses.


New Style Plumbing NOTE: Each of the four aftercoolers has a coolant inlet and outlet tube. Only the tubes for the left bank are shown Remove both tubes from all four of the aftercoolers. Remove the capscrews for any support clamp. Loosen the tube nuts and seals (A). Discard the seals. Loosen the hose clamps at the cylinder block connection (C). Remove the inlet (8) and outlet (D) tubes. Remove the hoses.

Type I - Crossovers with Turbo Retaining Straps Remove the capscrews, the clamps (17) for the turbocharger oil inlet hose and the retaining straps (16).

Remove the vee-band clamp (15). Pull the air crossover (14) and tube (12) from the turbocharger. Remove the dust seal (13), the tube (12) and the o-ring seals.

Remove the capscrews, the aftercooler-to-aftercooler connection assembly and the gaskets.




Type II - Air Crossovers with Hose Connections Loosen all of the hose clamps. Remove the vee-band clamp (18). Pull the air crossover (17) and the hose (16) from the turbocharger. Push the hose (12) on the connection (13) as far as possible. Remove the four capscrews. Remove the connection and gasket. Remove the hose from the connection. Discard the hoses and gasket.

WARNING 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.

Outboard Aftercooler - LTA Cooling System The following procedure should be used in both engine banks. Loosen capscrews on the water transfer connections to create flexibility. Remove the capscrews for any supporting clamp. Remove the water transfer tubes.

Remove the capscrews on the water transfer connections between the aftercooler cores.


Remove the water transfer connections.

Loosen all of the hose clamps. Remove the vee-band clamp (1). Pull the air crossover (2) and the hose (3) from the turbocharger. Push the hose (4) on the connection (5) as far as possible. Remove the four capscrews. Remove the connection and gasket (6). Remove the hose from the connection. Remove the four capscrews. Remove the flange (7) and the gasket (8). Discard the hoses and gaskets.

Loosen hose clamps (18).

WARNING 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.




with Electronically Actuated Injector Remove the hose clamps at the air crossover to turbocharger hose connection and at the aftercooler cover hose connections. Remove the air crossover support capscrews. Slide the hoses back from the air crossover and remove the air crossover.

Remove the eight capscrews from the air transfer bellows. Remove the bellows and discard the gaskets (marine only).

Remove the hose clamps from the air connection tube at the turbocharger connection tube and the aftercooler cover. Slide the hoses onto the connection tube and remove the tube (marine only).

Remove the hose clamps from the rubber tee coolant connections. Slide the air balance tube toward the adjacent aftercooler housing.


WARNING 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.

NOTE: All K50 aftercoolers contain this connection. Newer K38 aftercoolers contain a shorter connection. Remove the four capscrews for each crossover connection. Remove the connections (5) and gaskets (4). Discard the gaskets.




Remove the water outlet connections (6). Remove the rectangular ring or o-ring (7) from the connection. Discard the o-ring.

Remove the four cover plates (4) and gaskets (5). Discard the gaskets.

Remove the four air crossover connections (6), spacers (7), and gaskets (8). Discard the gaskets.

Remove both of the aftercooler covers (13) and gaskets (14). Remove the aftercooler elements (15) and the gaskets (14) from the housing (16).


Standard System NOTE: This procedure is performed while the intake manifold (aftercooler housing) remains on the engine. Remove the parts. 1. Capscrews, lock washers, and flat washers 2. Adapter connections 3. Gaskets Discard the gaskets. Remove the o-rings (6) from the inner adapters (4).

Remove the 21 capscrews and flat washers (5). NOTE: Do not damage the gasket surfaces if it is necessary to use a wedge to separate the parts. Remove the aftercare cover (6). It will be necessary to move the cover so that it will not hit the nipple on the element. Remove the gasket (7) from the intake manifold (8).

Remove the eight captive capscrews (9). Note that the washers on the capscrews are spring-type washers. Remove the element (10) from the intake manifold (8).

WARNING 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).




Remove the aftercooler element from the housing.

Remove the rubber seal from the groove on the aftercooler housing. Inspect the seal. Discard if damaged.

Inspect the rectangular strip seal (3). Discard the seal if it is ripped, cracked, or worn.

with Electronically Actuated Injector Remove the coolant connections from the aftercooler cover and housing. Discard the connection gasket.


Remove the aftercooler cover mounting capscrews, cover, and gasket. Discard the gasket, grommet seal, and o-ring seal.

Remove the aftercooler element and gasket. Remove the aftercooler element and gasket. Discard the seals and gaskets.

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.




Clean and Inspect for Reuse 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. Check the assembly for cracks or other damage. There must be no cracks in the housing or cover. Check the dust seals for excessive oil or hardness. Discard any dust seal that is hard or soaked with oil. If the parts are cracked or otherwise damaged, or there are any indications of gasket leaks, the assembly must be rebuilt. NOTE: If the K50 aftercooler housing does not contain cross bolts, or contains a rib in the center of the housing, it is recommended that the housing be modified for the cross bolts before it is installed again. Refer to Procedure 010-073 (Aftercooler Housing (Center Mount)) in Section 10.

WARNING 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.


Check the air passages for evidence of coolant leaks. If there is any evidence of leaks, the assembly must be rebuilt. Check the parts for cracks or other damage.

Inspect the rectangular strip seal (3). Discard the seal if it is ripped, cracked, or worn.

Assemble 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 four air crossover connection gaskets (8), the spacers (7), the gaskets (8), and the connection (6). Torque Value: 25 N•m [ 20 ft-lb ]




Install the new cover plate gaskets (5) and plates (4). Torque Value: 25 N•m [ 20 ft-lb ]

NOTE: The adapters must be installed so that the water leakage hole is toward the bottom of the aftercooler housing. This hole prevents any coolant leak from entering the aftercooler housing at the water inlet or outlet connections. Install four new adapter connection gaskets (9) and adapters (10) on the nipples for the element.

CAUTION Make sure the correct seal is installed for the water connection. If the wrong seal is installed, a leak will result, leading to engine damage. NOTE: This information applies to the water inlet and outlet connections for the aftercooler. If necessary, install a new rectangular seal ring or a new o-ring on the water outlet connection. Look at the water outlet connection. Install the rectangular ring seal (17) with the connection (18) that does not have the step at the end of the chamfer. Install the o-ring (19) with the connection (20) that has a step at the end of the chamfer. NOTE: The rectangular seal ring is the same part number as the seal on the water outlet tube. The o-ring is the same part number as the seal (10) on the adapter connection (8). The older connection (20) is not available for service.


Install both water outlet connection seals (7) and connections (6). Install the lock washers and capscrews. Torque Value: 25 N•m [ 20 ft-lb ]

NOTE: All K50 aftercoolers contain this connection. Newer K38 aftercoolers contain a shorter connection. Install new air crossover connection gaskets (4) and connections (5). Install the flat washers, lock washers, and capscrews. Torque Value: 25 N•m [ 20 ft-lb ]

NOTE: Lubricate only the o-ring seals that are to be installed immediately in the bore of the housing or connection. This will prevent the exposed o-ring from expanding and collecting dirt. Install two new o-rings (2) on each air tube. Install the dust seals (3) on the air tubes (1). Use vegetable oil. Lubricate the o-ring. Install the air tube in the bore of the housing or connection.

Standard System Install the element (10) in the manifold (8). Install the eight capscrews (9) that contain the captive spring washers. 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 ]

Install two new o-rings (4) in each adapter (2). Use vegetable oil. Lubricate the o-rings. Install new gaskets (3) and the adapters (2). Install the four capscrews with flat washers and lock washers (1). Torque Value: 16 N•m [ 145 in-lb ]

Low Temperature Aftercooler (LTA) The intake manifolds serve as the aftercooler housing. The element is installed through the cast opening in the side of the 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 foam seal into the groove in the aftercooler housing. NOTE: Applying a small amount of (RTV) sealant into the groove aids in holding the foam seal in place. Do not allow sealant on the visible portion of the foam seal.


The length of the seal protruding from each end is then bent and installed into the groove provided to obtain a positive seal with the element mounting flange. The protrusion must be 3 to 6 mm [0.125 to 0.250 inch] outside the housing at both sides. If required, cut the length to this specification.

Apply a light film of vegetable oil to the foam seal at the ends of the housing to reduce drag of the element and prevent damage to the foam seal during element installation.

There are two methods of sealing the aftercooler to element joint: • Gasket/Sealant • Rubber Seal.

Gasket/Sealant Installation NOTE: The gasket was replaced with liquid sealant. Apply two separate, continuous beads of liquid sealant Loctite® 509 (also called Loctite® LMD127) directly to the aftercooler housing. Each sealant bead is to be 1.5 mm [0.060 inch] in diameter. This sealant replaced the conventional gasket. The sealant is an anaerobic substance and will only cure (set up) in the absence of air. The sealant will not begin to cure until the aftercooler element is clamped into the housing. The sealant beads must be continuous strips without gaps, to prevent air leakage. Do not apply an excessive amount of sealant. Extra sealant does not result in a stronger joint.




Install two guide pins in the housing for installing the aftercooler element into the housing. The guide plugs allow installation of the heavy element without disturbing the sealant, if used. Guide pins can be made by cutting the head off a 3/8 inch capscrew. Install the aftercooler element into the aftercooler housing.

Install the 63 mm [2.50 inch] capscrews and washers into the locations shown. Tighten the capscrews just enough to hold the element in place. Remove the two guide pins.

Install the 171 mm [6.750 inch] capscrews and washers into the locations as shown. Tighten the capscrews just enough to hold the element in place. The two remaining holes will be used when the water transfer connections are installed. Use the torque value and sequence in this step.

The sealant cures to 80 percent strength 1 hour after the aftercooler element capscrews are tightened. The sealant is completely cured in 24 hours. Once the engine is filled with coolant and the engine is tested, a small amount of sealant will seep from the joint during the first hour of engine operation. Remove this excess sealant.


Rubber Seal Installation Install the rubber seal into the groove on the aftercooler housing. Make sure the seal is not twisted or damaged.

Install the aftercooler element into the housing. Make sure not to dislocate either the foam seal or the rubber seal. All aftercooler elements are identical and are inserted into the housing with the water inlet and outlet just below the air intake connection.

Install the washers (26) and spacers (29) on the fourteen capscrews (27). Insert the capscrews into the holes shown. The three capscrews (1) can only be installed in the rear intake manifold assemblies at this time. Capscrews will be inserted in the open positions either during the installation of the aftercooler plumbing or the intake manifold assembly. Tighten all of the inserted capscrews just enough to hold the aftercooler element in place.

Use the sequence shown. Tighten the capscrews. Torque Value: 45 N•m [ 35 ft-lb ]




with Electronically 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. Check the four aftercooler element locating pins for proper location.

Install the aftercooler element gasket. Install the upper and lower grommet seals and o-ring seals on the cooler connections. Install the aftercooler element into the housing.

Apply a light coat of anti-seize lubricant, Part Number 3824759, to the aftercooler cover mounting capscrew threads. Install the aftercooler cover and mounting capscrews. Tighten the capscrews in the sequence shown. Torque Value: 45 N•m [ 33 ft-lb ]

Lubricate the o-ring with Lubriplate™ 105, Part Number 3163087, multi-purpose lubricant Install the connection gasket and the seal retainer. Install the flange connector and the mounting capscrews. Tighten the capscrews. Torque Value: 30 N•m [ 22 ft-lb ]


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 ]




If the turbocharger uses a hose connection, slide the hose forward on the connection and tighten the t-bolt clamps. Torque Value: 9 N•m [ 80 in-lb ] NOTE: Installation of the air tube for the AFC (1) is not as difficult if completed before the installation of the water tubes. NOTE: Two aftercooler water outlet tubes are required Install two rectangular seal rings (2) on the water outlet tube. Install the tube, lock washers, and capscrews. Torque Value: 40 N•m [ 30 ft-lb ]

NOTE: Engines that are equipped with a center mount aftercooler have four air crossover assemblies. Use this procedure to install the parts. Install the two o-rings (7) and the dust seal (8) on the tube (9) for the air crossover. Use engine oil or Lubriplate™ 105, Part Number 3163087, multi-purpose lubricant. Lubricate the seals. Install the tube in the air connections on the aftercooler or the air transfer housing. Install the air crossover (10) on the tube. Push the crossover on the tube as far as possible. NOTE: The raised bead on the gasket must be toward the air crossover. Install the gasket (11) and the four lock washers, flat washers, and capscrews. Torque Value: 25 N•m [ 20 ft-lb ] Outboard Aftercooler - Standard Cooling Systems 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.


Use the following steps to tighten the capscrews in the sequence shown. Torque Value: Step1 Step2

25 N•m 45 N•m

[ 20 ft-lb ] [ 35 ft-lb ]

Type 1- Air Crossovers with Retaining Straps NOTE: The engine has two air jumper tube assemblies. The assembly for the left bank is shown. The assembly for the right bank must be installed so that the opening for the air crossover is nearest to the rear of the engine. Install the 2 gaskets (10) and the air jumper tube assembly with the 12 flat washers, 12 lock washers and 12 capscrews. Torque Value: 25 N•m [ 20 ft-lb ]

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.




NOTE: Some engines have clamps (17) for the turbocharger oil inlet hose. The hose must be clamped to the outside of the retainer plates (16). Install the two retainer plates (16), the large flat washers, lock washers and capscrews. Torque Value: 6 N•m [ 140 in-lb ]

Type II - Air Crossover with Hoses Install the hose (12) on the connection (13). Push the hose on the connection as far as possible. Insert the connection and the hose between the two manifold assemblies. Fit the hose over the manifold cover. Install the gasket (14), the four flat washers, lock washers and capscrews. Torque Value: 25 N•m [ 20 ft-lb ] Push the hose on the manifold cover until the ends of the hose are the same distance from the gap between the connection and the cover. Install the two t-bolt clamps (15). Torque Value: 9 N•m [ 80 in-lb ] NOTE: Check to be sure the crossover and the turbocharger compressor housing are aligned properly. Put the crossover in position on the connection (13). Look at the gap between the crossover and the turbocharger housing. If the gap is not the same at the top and bottom, the turbocharger compressor housing must be adjusted Install the hose (16) on the crossover (17). Install the hose and tube on the turbocharger housing. Install the vee-band clamp (18). Torque Value: 9 N•m [ 80 in-lb ] Use a mallet. Tap around the clamp to be sure it is seated. Tighten the nut on the clamp. 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. Install the two t-bolt clamps (19). Torque Value: 8 N•m [ 70 in-lb ]


Old Style Plumbing with Hoses Install the hoses and clamps on the inlet tube 4 and the outlet tube (5). Connect the tubes to the aftercooler, the fitting in the cylinder block and the fitting in the thermostat support as shown. Install the support clamp (6) on the tube with one of the aftercooler mounting capscrews. NOTE: Only one of the four connections is shown here. Torque Value: 5 N•m [ 50 in-lb ]

New Style Plumbing Install the hoses on the water transfer tube (C). Install the o-rings and rectangular seal in the core connections. Lubricate with engine oil or vegetable oil. Tighten the connecting capscrews. Torque Value: 25 N•m [ 20 ft-lb ] Install the clamps. Install inlet tubes (B).

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.




Tighten the capscrews in the sequence shown. Torque Value: 45 N•m [ 35 ft-lb ]

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 ]

Do not position the clamps over the hose beads. The clamps must be positioned between the hose beads and the end of the hose. A portion of the hose must extend outside the clamp. Tighten the t-bolt clamps. 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).


NOTE: Do not position the clamps over the hose beads. The clamps must be positioned between the hose beads and the end of the hose. A portion of the hose must extend outside the clamp. Position the clamps between the end of the hose and bead on the connection. Tighten the clamps. Torque Value: 8 N•m [ 70 in-lb ]

The crossover (7) and the turbocharger must align properly. Put the crossover in position on the connection (17). Check the gap between the crossover (7) and the turbocharger housing. If the gap is not the same at the top and bottom, rotate the crossover connection (17). If this does not provide proper alignment, the turbocharger compressor housing must be adjusted.

If the gap is not the same at the front and rear, rotate the crossover to the position that provides the best possible alignment.

Install the hose (6) on the crossover (7). Then install the crossover on the turbocharger and the flanged connection. Install and tighten the vee-band clamp (8). Torque Value: 9 N•m [ 80 in-lb ]




Tighten the nut on the clamp. Torque Value: 9 N•m [ 80 in-lb ] Tap and tighten the clamp nut until it will not turn at the specified torque after tightening. Install the two t-bolt clamps.

NOTE: Do not position the clamps over the hose beads. The clamps must be positioned between the hose beads and the end of the hose. A portion of the hose must extend outside the clamp Position the hose (6) in the center of the connection and tighten the clamps (5). Torque Value: 8 N•m [ 70 in-lb ]

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).

Install the vent line on the upper water transfer connection on each bank. NOTE: The lines must route horizontal or inclined toward the thermostat housing at all times. Any humps or sags will prevent aftercooler core venting and cause core damage. The length of the short hose between the two manifolds is critical. It must not sag or put excessive stress on the fittings


Install the vent lines from each bank to the cross connection on the thermostat housing.

with Electronically 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. Use a hoist and sling to lift the aftercooler assembly. Install guide studs long enough to protrude from the housing. Install guide studs into the cylinder head in the lower row of mounting holes. Lubricate the air balance tube o-rings with Lubriplate™ 105, Part Number 3163087, multi-purpose lubricant Install the air balance tube. Install the rubber tee coolant connectors.

Install new intake manifold gaskets, with the raised bead of the gasket toward the cylinder head. Use heavy grease to hold in place. Install the aftercooler assembly with a hoist. Align the rubber water connectors and air balance tube while the assembly is being installed over the guide studs.




Install the top row of the aftercooler mounting capscrews (long capscrews). Do not tighten the capscrews. Remove the guide studs and install the lower aftercooler mounting capscrews. Tighten the aftercooler mounting capscrews in the sequence shown. Torque Value: Cast Iron Housing Capscrews Torque Value: Aluminum Housing Capscrews

65 N•m

[ 48 ft-lb ]

53 N•m

[ 39 ft-lb ]

Install and tighten the coolant connection hose clamps. Torque Value: Coolant Connection Clamps

5 N•m

[ 44 in-lb ]

Inspect the air crossover, turbocharger connection and the hoses to make sure they are clean. Install the air crossover, hoses and the hose clamps. Install the air crossover support capscrews. Position the hose clamps 10 mm [0.25 in] from the raised bead on the turbocharger outlet and the air crossover. Torque Value: 9 N•m [ 80 in-lb ] Tighten the air crossover support capscrews. Torque Value: 45 N•m [ 35 ft-lb ]

Install the air connection bellows and two new gaskets (marine only). Install and tighten the eight mounting capscrews. Torque Value: 142 N•m [ 105 ft-lb ]


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.




with Electronically 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 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.


Aftercooler Assembly (Center-Mount) (010-003) Preparatory 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. 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. NOTE: There are four air crossovers. Remove the four capscrews. Pull the crossover (10) and the tube (9) from the aftercooler. Remove the gasket. Remove the tube from the crossover. Remove the o-rings (7). Discard the o-rings. Remove the dust seal (8). If the dust seal is hard or soaked with oil, discard the seal.

Aftercooler Assembly (Center-Mount) Page 10-45



Remove the two capscrews (10). Remove the four capscrews (7). Remove the water inlet connection assembly (5). Remove the two rectangular ring seals (4). Remove the gasket (8). Discard the gasket and seals.

WARNING This assembly or component weighs greater than 23 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.

NOTE: All K50 aftercoolers contain this connection. Newer K38 aftercoolers contain a shorter connection. Remove the four capscrews for each crossover connection. Remove the connections (5) and gaskets (4). Discard the gaskets.


Remove the water outlet connections (6). Remove the rectangular ring or o-ring (7) from the connection. Discard the o-ring.

Remove the four cover plates (4) and gaskets (5). Discard the gaskets.

Remove the four air crossover connections (6), spacers (7), and gaskets (8). Discard the gaskets.

Remove both of the aftercooler covers (13) and gaskets (14). Remove the aftercooler elements (15) and the gaskets (14) from the housing (16).




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.

Clean and Inspect for Reuse with Mechanically Actuated Injector 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. Check the assembly for cracks or other damage. There must be no cracks in the housing or cover. Check the dust seals for excessive oil or hardness. Discard any dust seal that is hard or soaked with oil. If the parts are cracked or otherwise damaged, or there are any indications of gasket leaks, the assembly must be rebuilt. NOTE: If the K50 aftercooler housing does not contain cross bolts, or contains a rib in the center of the housing, it is recommended that the housing be modified for the cross bolts before it is installed again. Refer to Procedure 010-073.


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 four air crossover connection gaskets (8), the spacers (7), the gaskets (8), and the connection (6). Torque Value: 25 N•m [ 20 ft-lb ]

Install the new cover plate gaskets (5) and plates (4). Torque Value: 25 N•m [ 20 ft-lb ]

NOTE: The adapters must be installed so that the water leakage hole is toward the bottom of the aftercooler housing. This hole prevents any coolant leak from entering the aftercooler housing at the water inlet or outlet connections. Install four new adapter connection gaskets (9) and adapters (10) on the nipples for the element.




CAUTION Be sure the correct seal is installed for the water connection. If the wrong seal is installed, a leak will result, leading to engine damage. NOTE: This information applies to the water inlet and outlet connections for the aftercooler. If necessary, install a new rectangular seal ring or a new o-ring on the water outlet connection. Look at the water outlet connection. Install the rectangular ring seal (17) with the connection (18) that does not have the step at the end of the chamfer. Install the o-ring (19) with the connection (20) that has a step at the end of the chamfer. NOTE: The rectangular seal ring is the same part number as the seal on the water outlet tube. The o-ring is the same part number as the seal (10) on the adapter connection (8). The older connection (20) is not available for service. Install both water outlet connection seals (7) and connections (6). Install the lock washers and capscrews. Torque Value: 25 N•m [ 20 ft-lb ]

NOTE: All K50 aftercoolers contain this connection. Newer K38 aftercoolers contain a shorter connection. Install new air crossover connection gaskets (4) and connections (5). Install the flat washers, lock washers, and capscrews. Torque Value: 25 N•m [ 20 ft-lb ]


NOTE: Lubricate only the o-ring seals that are to be installed immediately in the bore of the housing or connection. This will prevent the exposed o-ring from expanding and collecting dirt. Install two new o-rings (2) on each air tube. Install the dust seals (3) on the air tubes (1). Use vegetable oil. Lubricate the o-ring. Install the air tube in the bore of the housing or connection.

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 ]




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 ] If the turbocharger uses a hose connection, slide the hose forward on the connection and tighten the t-bolt clamps. Torque Value: 9 N•m [ 80 in-lb ] NOTE: Installation of the air tube for the AFC (1) is not as difficult if completed before the installation of the water tubes. NOTE: Two aftercooler water outlet tubes are required Install two rectangular seal rings (2) on the water outlet tube Install the tube, lock washers, and capscrews. Torque Value: 40 N•m [ 30 ft-lb ]

NOTE: Engines that are equipped with a center mount aftercooler have four air crossover assemblies. Use this procedure to install the parts. Install the two o-rings (7) and the dust seal (8) on the tube (9) for the air crossover. Use engine oil or Lubriplate™ 105, Part Number 3163087, multi-purpose lubricant. Lubricate the seals. Install the tube in the air connections on the aftercooler or the air transfer housing. Install the air crossover (10) on the tube. Push the crossover on the tube as far as possible. NOTE: The raised bead on the gasket must be toward the air crossover. Install the gasket (11) and the four lock washers, flat washers, and capscrews. Torque Value: 25 N•m [ 20 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.

Aftercooler (010-004)

Assembly

(Outboard)

Remove Remove the aftercooler coolant plumbing. . NOTE: This procedure is performed while the intake manifold (aftercooler housing) remains on the engine.

Remove the capscrews and spring washers. Remove the aftercooler element (3), gasket (4), and rectangular strip seal (35). Discard the gasket.

Inspect for Reuse Clean and check the element for reuse. Refer to Procedure 010-001.

Aftercooler Assembly (Outboard) Page 10-53



Visually inspect the rectangular strip seal (35). Discard the seal if it is ripped, cracked or worn.

Install Install the seal (35) into the groove in the air intake manifold housing (2). If a new seal has been installed, check the length that is protruding outside the housing. This protrusion must be flush to 3 mm [1/8 inch] in length outside the housing at both sides. If required, clip the seal to this length. Install the gasket (4) and the aftercooler core (3). NOTE: All aftercooler cores are identical and are inserted into the housing with the water inlet and outlet just below the air intake connection.

Install the 3 inch capscrews (27) and spring washers (26) into the holes shown. Capscrews at position 1 can only be placed in the rear intake manifold assemblies at this time. Tighten the inserted capscrews just enough to hold the aftercooler element in place.

Install the 6.75 inch capscrews (29) and spring washers into the holes shown. Capscrews will be inserted in the open positions either during the installation of the aftercooler plumbing or the intake manifold assembly. Tighten all of the inserted capscrews just enough to hold the aftercooler core in place.



Install the aftercooler plumbing. Refer to Procedure 010-001.


Aftercooler Element Page 10-56


Aftercooler Element (010-008) Preparatory Steps 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).


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.




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.

Inspect for Reuse Standard Clean and check element for reuse. Refer to Procedure 010-002 (Aftercooler Assembly) in Section 10.

LTA Clean and check the element for reuse.


Inspect the rectangular strip seal (35). Discard the seal if it is ripped, cracked or worn.

Center-Mount Clean and check the element for reuse. Refer to Procedure 010-002 (Aftercooler Assembly) in Section 10.

Install Standard Install the core (10) in the manifold (8). Install the eight capscrews (9) that contain the captive spring washers. 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 ]




LTA Install the seal (35) into the groove in the air intake manifold housing (2). If a new seal has been installed, check the length that is protruding outside the housing. This protrusion must be flush to 3 mm [1/8 inch] in length outside the housing at both sides. If required, clip the seal to this length. Install the gasket (4) and the aftercooler core (3). NOTE: All aftercooler cores are identical and are inserted into the housing with the water inlet and outlet just below the air intake connection.

Install the 3 inch capscrews (27) and spring washers (26) into the holes shown. Capscrews at position 1 can only be placed in the rear intake manifold assemblies at this time. Tighten the inserted capscrews just enough to hold the aftercooler element in place.

Install the 6.75 inch capscrews (29) and spring washers into the holes shown. Capscrews will be inserted in the open positions either during the installation of the aftercooler plumbing or the intake manifold assembly. Tighten all of the inserted capscrews just enough to hold the aftercooler core in place.



Air Cleaner Assembly (Engine-Mounted) Page 10-61

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.

Air Cleaner Assembly Mounted) (010-013)

(Engine-

Remove Remove the air restriction indicator and fitting.



Remove the air cleaner air inlet tube support brackets and mounting hardware.

Loosen the T-bolt clamps at the air cleaner connection.

Slide the air cleaner inlet hose and T-bolt clamps onto the air inlet tube. This will allow access clearance to the air cleaner.

WARNING 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.


Remove the air cleaner strap retaining bolts and nuts.

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 right bank air cleaner support bracket from the rear of the engine.

Remove the left bank air cleaner support bracket from the rear of the engine.




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.

Clean and Inspect for Reuse CAUTION The air cleaner elements can not be pressure washed or submerged in water. Check all hose connections and T-bolt clamps for damage or failures. Check the air cleaner canister and the tubes for any obstructions or damages. Inspect the restriction indicator for any damage. Clean the inside of the air filter canister before installing a new element.

Install WARNING 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 vibration isolators to the air cleaner strap. Tighten the nuts. Torque Value: 20 N•m [ 177 in-lb ]


Install the support brackets on the engine. Install the lock washers and capscrews in the support brackets. Tighten the capscrews. Torque Value: 41 to 47 N•m [ 30 to 35 ft-lb ]

Install the air cleaner straps around the air cleaner and position for correct orientation. Install retaining bolts and nuts at the end of the air cleaner straps. 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 ]

Install all remaining air cleaner air inlet tube support brackets and mounting hardware.


Air Cleaner Element Page 10-66


Install the air restriction indicator and fitting. Hand tighten only.

Air Cleaner Element (010-014) Pressure Test 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.


Leave the element submerged for five minutes to allow the temperature of the element to stabilize. Apply air pressure. Check for leaks. The element leaks when bubbles form faster or from a new location while the tank is pressurized. Air Pressure 448 kPa [ 65 psi ] Replace the element if leaks are discovered. NOTE: A failed aftercooler element will often be coated on the outside with coolant deposits.

Air Connection Pipe (Turbocharger to Turbocharger) (010-018) Clean 1. 2. 3. 4. 5. 6.

T-bolt clamps Hose O-ring seal O-ring seal Dust seal Connection

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.

Inspect for Reuse Check the dust seal for excessive oil or hardness. Discard any dust seal that is hard or soaked with oil. Check the hoses for tears or separation. Discard the part if it is damaged. Check the pipe for damage, cracks, and fretting near the o-ring seal groove. Replace the part if it is damaged.

Air Connection Pipe (Turbocharger to Turbocharger) Page 10-67

Air Crossover (Center-Mount Aftercooler) Page 10-68


Air Crossover Aftercooler) (010-020)

(Center-Mount

Preparatory Steps with Mechanically Actuated Injector 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.

Clean and Inspect for Reuse 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.


Remove the o-rings (1). Discard the o-rings. Remove the dust seals (2). Check the dust seals for excessive oil or hardness. Discard any dust seal that is hard or soaked with oil. Check the bore of the air crossover. Check the o-ring grooves of the tube.

Install with Mechanically Actuated Injector CAUTION Lubricate only the o-ring that will be installed immediately in the bore. Do not lubricate the other oring 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.

Air Leaks, Air Intake and Exhaust Systems (010-024) Inspect for Reuse CAUTION The engine air intake must be filtered to prevent dirt and debris from entering the engine. If intake air piping is damaged or loose, unfiltered air can enter the engine and cause premature wear. Inspect the system for damaged or loose intake piping. Replace damaged pipes. Tighten loose clamps. Torque Value: 8 N•m [ 71 in-lb ]

Air Leaks, Air Intake and Exhaust Systems Page 10-69

Air Leaks, Air Intake and Exhaust Systems Page 10-70


Stall speed is not full power. Operate the engine at rated rpm and load. Listen for a high-pitched noise from the turbocharger.

This type of noise can be caused by an air leak from the following: • Turbocharger-to-aftercooler air supply hose leak • Air crossover-to- aftercooler connection leak • Air crossover-to-intercooler connection leak • Turbocharger-to-exhaust manifold gasket leak • Turbine housing-to-bearing housing sealing surface leak • Compressor housing-to-bearing housing sealing surface leak. If a turbocharger-to-aftercooler air supply hose leak is found, inspect the hose for damage. Replace damaged hose. Refer to Procedure 010-008 (Aftercooler Element) in Section 10. If a air crossover-to-aftercooler connection leak is found, replace the air crossover gasket.

If a air crossover-to-intercooler connection leak is found, inspect for damaged hoses or loose hose clamps. Replace damaged hoses. Tighten loose clamps.


If a turbocharger-to-exhaust manifold gasket leak is found, replace the turbocharger base gasket.

If a turbine housing-to-bearing housing sealing surface leak is found, tighten any loose capscrews. Torque Value: 20 N•m [ 15 ft-lb ] If an air leak is still present, replace the turbocharger.

If a compressor housing-to-bearing housing sealing surface leak is found, tighten the V-band clamps. Torque Value: 8 N•m [ 71 in-lb ] If an air leak is still present, replace the turbocharger.

Air Intake Restriction (010-031) Measure Install a vacuum gauge or water manometer, Part Number 3164875 or equivalent, in the intake air piping between the turbocharger and the air filter. The gauge must have a capacity of 1270 mm [50 in-H²O].

Air Intake Restriction Page 10-71

Air Intake Restriction Page 10-72


NOTE: The gauge adapter (or fitting) must be installed at a 90 degree angle to the air flow in a straight section of pipe. The adapter location must be at least one pipe diameter before the turbocharger. The adapter must not extend through the wall of the air intake tubing. If the adapter must be located in a curve section of tubing, locate it on the flat side of the curve, not in the radius.

Operate the engine at full throttle and rated rpm with maximum load. Record the reading of the gauge or manometer. Vacuum Gauge or Water Manometer Restrictions mm H2O in H2O 635 MAX 25

If restrictions exceeds specifications, do the following: Replace or clean the air filter element. See the equipment manufacturer's instructions.

Inspect the intake air piping for damage. See the equipment manufacturer's instructions. NOTE: If no damage is visible, check the size of the intake air piping. See the Installation recommendations.


Turbocharger Page 10-73

Remove the test equipment.

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: Manufacturer

Bulletin

Model Number and Description

Holset®

3810243

Holset®

3810386

Brown Boveri®

3810325

Brown Boveri®

3810325

AiResearch®

3379091

Model HC5, HC5A, HX80 and HX85 Turbocharger Shop Manual Model HT100 Turbocharger Shop Manual Model RR-151-12, Brown Boveri® Turbocharger Shop Manual Model RR-153, Brown Boveri® Exhaust Gas Turbocharger Shop Manual Model T-18A, Turbocharger Rebuild Manual

Two oil supply hoses are installed on K38 and K50 engines. The length of the hose for KT38, KTA38, and KTA50 engines is 1295 mm [51 in]. The length of the hose for KTTA38 and KTTA5O engines is 1092 mm [43 in]. The turbocharger oil drain assembly for the K38 is shorter on engines with dry type exhaust manifolds than on engines with wet type exhaust manifolds. The turbocharger oil drain assembly for the K50 is the same as that installed on the K38 with a wet type exhaust manifold. The method for connecting the turbocharger oil drain to the cylinder block was changed. Engines with an ESN of 33106693 and greater have a flange and an o-ring seal type connection that is secured with a capscrew. Engines with an ESN of 33106692 and lower have a 90 degree fitting with pipe threads. A revised turbocharger compressor wheel was released for KTA50-G engines in September, 1985, ESN 33110070. Turbochargers with a hose nipple on the compressor discharge and a hose type air crossover were released for use in production on the KTA38 engines in September 1986, ESN 33111500.



A chamfer was added to the diffuser plate on HC5A turbochargers to allow oil drain back to the sump in February, 1987, ESN 33111870. A revised profile, turbocharger mounting gasket was released in August, 1987, ESN 33112713. A turbocharger oil drain hose that is manufactured of flexible hose is available for engines built previously with a one or two piece steel tube for the oil drain hose. The two piece steel tube that is connected by a hump hose is available for service on engines that have AiResearch® turbochargers only. The KTTA50 low pressure turbocharger oil drain hose and drain location was changed in 1988, to provide a better downhill return to the cylinder block. The revised oil drain hose routing also requires a revised turbocharger support, which is modified to provide clearance for the new oil drain hose and a different clamp to retain the oil drain hose. The revised hose drains the oil to drillings on the top deck at the front of the right bank and the left of the rear bank of the cylinder block. The holes used are partially covered by the turbocharger support, this support requires modification or replacement. The mounting capscrew for the flange and o-ring seal type turbocharger drain hose connection was changed from [0.250 inch -20 UNC] to [0.375 inch -16 UNC]. The cylinder block with the smaller holes require a spacer, Part Number 3177195, between the connection flange and the cylinder block at the left bank rear location. If the spacer is not installed, an oil leak will result because the o-ring seal will not be in the bore correctly. The flange on the turbocharger oil drain hose that fits to the turbocharger is different for Holset® and AiResearch® turbochargers. The oil drain hose flange is different for the Brown Boveri® type turbocharger. If the model of turbocharger is changed, the oil drain hose must be changed. A K50 turbine housing with a thickened flange between the capscrew holes to reduce flange distortion was released in February 1988, ESN 33114833. This is for the K50 pulse exhaust manifolds only. Longer studs, nuts and spacers were released for the K50 pulse exhaust manifold in May, 1989, ESN 33115948. The K50 turbocharger mounting flange was completely thickened to improve gasket reliability, the spacer is no longer required for K50 pulse exhaust manifold engines produced in February, 1990, ESN 33117281. The K50 pulse exhaust manifold received a boss to allow use of capscrews in place of studs on engines produced from February, 1990, ESN 33117392. A steel oil supply fitting replaced the brass fitting to prevent torque loss/loosening on engines produced from September 1990, ESN 33118322. The Holset HT100 low pressure turbocharger replaced the Brown Boveri® RR151 turbocharger for C1800B and K2000 engines in January 1991, ESN 33119163. NOTE: The HT100 turbocharger can not be used to replace the Brown Boveri® Model RR153 that is used on the KTTA50-C1800A engines. The Holset® HX80 water-cooled turbocharger design was revised in 1997, to allow for the use of GAS fittings on all coolant passage openings in the casting. O-ring seal fittings are less prone to leakage, and are easier to remove and install. The diffuser plate was also changed to a “sunk wheel” design.


Preparatory Steps MAI WARNING 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.




with Electronically Actuated Injector 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.


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 drain hose from the turbocharger. Remove the gasket (17). Discard the gasket. Check the hose (18) for damage. Discard the part if it is damaged.

Detach the oil inlet hose (16). Removal of the fitting (15) and the o-ring seal (14) is not required unless they are damaged. Remove any support clamps from the hose. Remove the hose. Check the hose for damage. Discard the part if it is damaged.




Newer engines have a hose and clamps between the turbochargers and air transfer housings. The clamps are special high strength parts. Loosen the hose clamps (2).

Older engines have retaining straps. Remove the capscrews and the retaining straps (10). Check the straps for damage. Discard the part if it is damaged.

WARNING 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.

On newer engines, remove the clamps and the hose. Discard the hose. Check the clamps for damage. Discard the part if it is damaged.


On older engines, remove the tube (5). Remove the o-ring seals (4). Discard the seals. Remove the dust seal (3). If the dust seal is hard or soaked with oil, discard the part.

KTTA38 Low Pressure: Remove the oil drain hose (30). Remove the gasket (29) and the o-ring seal (33). Discard the gasket and seal. Check the hose for damage. Discard the part if it is damaged.

Detach the oil inlet hose (16). The removal of the fitting (15) and the o-ring seal (14) is not required unless damaged. Remove any support clamps from the hose. Remove the hose. 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.




Loosen the hose clamps (24). Remove the clamps and the hose (23) from the high pressure turbocharger air connection.

Remove the air connection (21) from the high pressure turbocharger. Remove the o-ring seals (19). Discard the seals. Remove the dust seal (22). If the dust seal is hard or soaked in oil, discard the part.

Remove the four capscrews (12) and nuts (18). The heavy washers (13) and capscrews are special heat resistant parts. Remove the exhaust connection (11) and the exhaust outlet pipe (10).

Remove the vee-band clamp (8) and the exhaust outlet connection (9).


Remove the six capscrews (7). The heavy flat washers (5) are special. Remove the support plate (4).

Remove the socket head capscrew (3). Remove the turbocharger support legs (1).

KTTA50 Low Pressure The Brown Boveri®, Model RR151, turbochargers contain metric fasteners for the oil connection plates. Remove the oil drain hose (48). Remove the gasket (47) and o-ring seal (51). Discard the gasket and seal. Check the hose for damage. Discard the part if it is damaged.

Some Brown Boveri® turbochargers do not contain the adapter plates for the oil inlet. Detach the oil inlet hose. The adapter plates (44) and fittings do not require removal. Remove any support clamps. Remove the hose. Check the hose for damage. Discard the part if it is damaged.




Remove the four capscrews (40) and nuts (42). Remove the gasket. Discard the gasket.

Remove the two capscrews (35) that hold the exhaust side of the turbocharger to the support bracket.

Remove the two capscrews (31) and nuts (34) that hold the intake support bracket to the turbocharger support bracket.

WARNING 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).


Loosen the hose clamps (12). Pull the intake connection pipe (15) from the high pressure turbocharger. Remove and discard the o-ring seals (13) and the hose (11). Remove the dust seal. If the dust seal is hard or soaked with oil, discard the part.

Remove the exhaust connection (11) and outlet pipe (10).

Remove the vee-band clamp (8) and the exhaust outlet connection (9).

Remove the six capscrews (7). Remove the turbocharger support bracket (4).




Remove the socket head capscrews (3). Remove the turbocharger bracket support legs (1).

K2000E Low Pressure Remove the oil drain hose (60). Remove the gasket (59) and o-ring seal (63). Discard the gasket and seal. Check the hose for damage. Discard the part if it is damaged.

Detach the oil inlet hose. Removal of the fitting, plate, (56) and gasket (55) is not required. Remove any support clamps from the hose. Remove the hose. Check the hose for damage. Discard the part if it is damaged.

Remove the heat shield (blanket) from the interstage air hose.


Loosen the two t-bolt clamps (45) on the air intake pipe (47) and the compressor inlet.

Remove the four capscrews (49) and nuts (52) that hold the air intake pipe (47) to the turbocharger compressor outlet. Remove the air intake pipe (47). Check the pipe for damage. Discard the part if it is damaged.

Loosen the vee-band clamp (8).

Remove the four capscrews (12) and nuts (14) that hold the two exhaust connections (9 and 11).




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.


KTTA38, KTTA50, K1500E, K1800E and K2000E High Pressure, and KT38, KTA38, and KTA50 with Outboard Aftercoolers If the engine being serviced is a KT38, KTA38, or KTA50, write a note to detail the direction of the turbocharger exhaust outlet and mark the exhaust manifolds for location. This will aid the assembly process as the exhaust can be either front out or rear out.

Detach the oil drain hose from the cylinder block. Remove the o-ring seal (9). Discard the o-ring seal. Check the hose for damage. Discard the part if it is damaged.

Detach the oil drain hose from the turbocharger. Remove any support clamps and the hose. Remove the gasket (5). Discard the gasket. Check the hose for damage. Discard the part if it is damaged.

Removal of the fitting (15) and the o-ring (14) is not required. Detach the oil inlet hose. Remove any support clamps. Remove the hose. 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.

with Electronically Actuated Injector Remove the low pressure turbocharger air intake and bracket.

Remove the low pressure turbocharger exhaust adapter and bracket.

Remove the eight nuts, plain washers, nuts, capscrews and p-clips from the air transfer connections. Remove the air transfer connections and discard the gaskets.


NOTE: Note the orientation of the capscrews and nuts in the transfer tube prior to removal. The capscrews must be installed in the same orientation during installation. Remove the eight nuts, plain washers, nuts, capscrews and remove the air transfer piping. Discard the gaskets.

WARNING 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.

Loosen and remove the clamps and hoses connecting the turbochargers to the intake manifold.

Remove the clamps from the high pressure turbocharger and air transfer connection. Remove the air transfer from the high pressure turbocharger.




Remove the four capscrews, nuts and washers and remove the exhaust outlet connection from the high pressure turbocharger.

Remove the exhaust outlet clamp and outlet connection from the turbocharger.

Remove the four mounting capscrews, nuts and washers from each high pressure turbocharger.

WARNING 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.


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.

Inspect for Reuse Inspect the turbine and compressor wheels for fretting and broken vanes.

Holset®, model HC5, HC5A, HX80 or HX85 Measure the turbocharger shaft end clearance with a dial depth gauge, Part Number ST-537. Holset® HC5, HC5A, HX80 or HX85 End Clearance mm in 0.05 MIN 0.002 0.13 MAX 0.005 If the end clearance exceeds the specifications, the turbocharger must be replaced or rebuilt. See HC5, HC5A, HX80 or HX85 Turbocharger Shop Manual, Bulletin 3810243, for rebuild instructions.




Use your hand to push the compressor impeller end of the shaft toward the housing. Use a feeler gauge that is not more than 13 mm [0.5 in] wide. Measure the clearance between the impeller and the housing at the minimum clearance point. Holset® HC5, HC5A, HX80 or HX85 Compressor Impeller Radial Clearance mm in 0.15 MIN 0.006 0.46 MAX 0.018 Perform the same measurement procedure for the turbine wheel. Holset® HC5, HC5A, HX80 or HX85 Turbine Wheel Radial Clearance mm in 0.20 MIN 0.008 0.53 MAX 0.021 If the clearance exceeds the specifications, the turbocharger must be replaced or rebuilt. See HC5, HC5A, HX80 or HX85 Turbocharger Shop Manual Bulletin 3810243, for rebuild instructions. Holset®, Model HT100 Holset® HT100 End Clearance mm 0.05 0.15

MIN MAX

in 0.002 0.006

Measure the turbocharger shaft end clearance with a dial depth gauge, Part Number ST-537. If the end clearance exceeds the specifications, the turbocharger must be replaced or rebuilt. See HT100 Turbocharger Shop Manual Bulletin 3810386, for rebuild instructions.


Use your hand to push the compressor impeller end of the shaft toward the housing. Use a feeler gauge that is not more than 13 mm [0.5 in] wide. Measure the clearance between the impeller and the housing at the minimum clearance point. Holset® HT100 Compressor Impeller Radial Clearance mm in 0.25 MIN 0.010 0.46 MAX 0.018 Perform the same measurement procedure for the turbine wheel. Holset® HT100 Turbine Wheel Radial Clearance mm in 0.38 MIN 0.015 0.53 MAX 0.021 If the clearance exceeds the specifications, the turbocharger must be replaced or rebuilt. See HT100 Turbocharger Shop Manual Bulletin 3810386, for rebuild instructions. AiResearch® Method One: Check the radial clearance of both the compressor impeller and turbine wheel. Use your hand to push the compressor impeller or turbine wheel toward the housing. Use a feeler gauge that is not more than 13 mm [0.5 in] wide. Measure the clearance between the impeller and the housing at the minimum clearance point. AiResearch® T-18A Impeller and Turbine Wheel Radial Clearance mm in 0.08 MIN 0.003 0.18 MAX 0.007 If the clearance exceeds the specifications, the turbocharger must be replaced or rebuilt. See Turbocharger Component Shop Manual Bulletin 3379091, for rebuild instructions.




AiResearch® Method Two: To measure the direct bearing radial clearance on the T-18A, place a dial indicator through the oil drain hole as illustrated. Be sure the indicator touches the highest part of the shaft. Move the turbine and compressor wheels by hand to the upper and lower limits. AiResearch® T-18A Bearing Radial Clearance mm in 0.20 MIN 0.008 0.46 MAX 0.018 If the clearance exceeds the specifications, the turbocharger must be replaced or rebuilt. See Turbocharger Component Shop Manual Bulletin 3379091, for rebuild instructions. All models: After the turbocharger has been checked: • Lubricate the bearings with engine oil through the oil inlet fitting • Cover all openings to prevent entry of dirt until installed on the engine.

Disassemble Remove the o-ring and discard.


If the compressor cover has an inlet baffle it can be removed with a flat tip screwdriver. Pry the retaining ring up and remove the retaining ring.

CAUTION Use caution in handling the turbine blades. The turbine blades can be easily damaged when the turbine housing is removed. Remove the turbine housing by bending the lock plate tabs away from the capscrew heads. Remove the capscrews.

Make sure the turbine wheel rotates freely inside the turbine housing. Tap on the turbine housing with a mallet to separate the turbine housing from the bearing housing.

Remove the oil supply fittings and the coolant lines from the center housing assembly. Discard the o-rings.




Clean and Inspect for Reuse 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.

Use a soft bristle brush to remove heavy scale deposits. Wash and dry the parts after brushing.

CAUTION Do not use compressed air to dry or spin the turbine wheel as this can cause damage to the turbocharger bearing system. If chemical and brush cleaning is not effective, bead blast with plastic abrasive media, Part Number 3822735, or equivalent. Wash and dry parts after bead blasting. The center housing rotating assembly can be cleaned with contact cleaner, Part Number 3824510, or equivalent. Do not spray contact cleaner into the oil and coolant ports.


Inspect the compressor cover for cracks, dents, and other damage. Inspect the inside of the compressor cover for signs of scoring or damage from the compressor wheel. Replace the compressor cover, if damaged.

Inspect the turbine housing for cracks and damage. Cracks larger than 10 mm [0.39 in] can cause an exhaust leak. Replace the turbine housing if damage is found. Follow the criteria shown in the illustration.

Minor cracks in the turbine housing internal wall, where exhaust gas flow enters the turbine wheel, is an acceptable condition. The turbine housing can be reused.

Inspect the turbine housing for signs of contact with the turbine wheel. Damaged turbine housings must be replaced.




Inspect the center housing rotating assembly for any signs of cracks, damaged threads, or other damage. Rotate the turbine wheel by hand to make sure it spins freely. Replace the center housing rotating assembly if it is damaged or does not spin freely.

Inspect the compressor wheel for damage, broken, or bent blades. Do not attempt to repair or straighten the blades. Instead, replace the center housing rotating assembly.

Inspect the turbine wheel for damaged, broken, or bent blades. Do not attempt to repair or straighten the blades. Instead, replace the center housing rotating assembly.

Measure Measure the axial clearance with a dial indicator. Replace the center housing rotating assembly if the axial clearance is not within specification: Axial Clearance 0.025 to 0.152 mm [ 0.001 to 0.006 in ]


Measure the radial clearance with a dial indicator. Replace the center housing rotating assembly if the radial clearance is not within specification: Radial Clearance 0.254 to 0.787 mm in ]

[ 0.010 to 0.031

Assemble CAUTION Use caution when handeling the turbine blades. The turbine blades can be easily damaged when installing in the turbine housing. Assemble the center housing rotating assembly on to the turbine housing.

Lubricate the threads of the new capscrews with anti-seize compound, Part Number 3824732, or equivalent. Install the capscrews, with new lock plates, to the turbocharger turbine housing. Torque Value: 20.3 N•m [ 180 in-lb ]

Use a hammer and punch to fold the locking plate onto the flat of the capscrew, to prevent loosening.




Assemble the inlet baffle into the compressor cover and secure with a retaining ring. Hold one end of the retaining ring in the groove. Press the remainder of the retaining ring into position. Use a flat tip screwdriver to make sure the retaining ring is correctly seated in the compressor cover groove.

NOTE: The HX83 Turbocharger uses a titanium compressor wheel. The edge of the wheel is very sharp. Handle the compressor wheel with care. Assemble the compressor housing new o-ring on the turbocharger.

CAUTION Do not damage the compressor wheel blades during assembly. Assemble the vee-band clamp and compressor cover onto the turbocharger.

Place the vee-band clamp in position. Tighten the vee-band clamp. Torque Value: 12 N•m [ 106 in-lb ]


Make sure the compressor wheel and turbine wheel rotate freely.

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.




KT38, KTA38, and KTA50 Turbochargers with Center Mount Aftercooler NOTE: The illustrations show a KTA38. The KTA50 has a longer connection between the aftercooler housing and the turbocharger. The procedure is the same for these models. Newer engines have a hose and clamps to connect the turbocharger to the aftercooler connection. Older engines have a tube with a dust seal and two o-ring seals to connect the turbocharger to the aftercooler connection. The clamps are special to allow a higher torque. Standard t-bolt type clamps can loosen and allow an air leak. Newer Engines: Install the hose (1) and clamps (2) on the aftercooler connection. Do not tighten the clamps. Some of the newer K50 engines have a hose and heavy duty clamps installed over the tube and o-ring as shown in the next picture. Older Engines: Install the dust seal (3) and o-ring seals (4) on the tube (5). Use vegetable oil. Lubricate the o-ring seals. Install the tube in the bore of the aftercooler housing. Push the tube into the bore until it touches the step in the bore.

WARNING 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 ]


Some of the compressor housing is not shown removed for clarity. Check the angle of the oil drain and the alignment of the compressor housing to the aftercooler connection. If the angle or alignment is not correct, adjust the turbocharger oil drain angle, or adjust the turbocharger compressor housing alignment, described later in this section.

Newer Engines: Tighten the clamps (2). Torque Value: K38 K50

9 N•m [ 80 in-lb ] 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 ]

NOTE: Holset® turbochargers have a fitting that has straight threads and requires an o-ring seal. AiResearch® turbochargers have a fitting with pipe threads. The torque value is the same for both types of the fittings. Install the o-ring seal (14) on the oil inlet fitting (15). Install the fitting. Torque Value: Oil Inlet Fitting

35 N•m

[ 26 ft-lb ]

Connect the turbocharger oil inlet hose (16) to the fitting. Install the clamps for the oil inlet hose. The other end of the oil inlet hose must be connected to a fitting in the cylinder block. Refer to Procedure 001-026.




Install the parts. 17. Gasket 18. Hose 19. Lock washers 20. Capscrews Torque Value: Capscrews

40 N•m

[ 30 ft-lb ]

Newer engines have a flange and an o-ring seal type oil drain hose as shown. The newer hose connects to the cylinder block with a capscrew. Older engines have a hose that has a tubing nut and connects to the block with a fitting that has pipe threads. If a flange and an o-ring type connection is installed on an older block, a spacer is required between the hole in the block for the capscrew and the flange. If the spacer is not installed, an oil leak will result. Install the o-ring seal (21) on the hose flange. Use vegetable oil. Lubricate the seal. Install the flange, the lock washer (22), and the capscrew (23). Torque Value: Flange Capscrews

40 N•m

[ 30 ft-lb ]

Repeat this procedure to install the other turbocharger and connect the oil hoses. KTTA38 and KTTA50 High Pressure, and KT38, KTA38, and KTA50 Turbochargers with Outboard Aftercoolers The turbochargers must be mounted on the correct engine bank. KTTA38 and KTTA50 High Pressure: The turbocharger on the left bank must be installed with the compressor housing pointed toward the front of the engine. The turbocharger on the right bank must be installed with the turbine housing pointed toward the front of the engine. KT38, KTA38, and KTA50 with Outboard Aftercoolers: The turbine housing on both turbochargers must point the same direction, either toward the front of the engine or toward the rear of the engine so that the exhaust piping will fit the application.


WARNING 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 Capscrews

40 N•m

[ 30 ft-lb ]

NOTE: Some of the compressor housing is shown removed for clarity. Check the angle of the oil drain. The alignment of the compressor housing to the air crossovers can not be checked until the aftercooler assembly is installed. If the angle is not correct, adjust the turbocharger oil drain angle, described later in this section.

NOTE: Holset® turbochargers have a fitting that has straight threads and requires an o-ring seal. AiResearch® turbochargers have a fitting with pipe threads. The torque value is the same for both types of fittings. Install the o-ring seal (14) on the oil inlet fitting (15). Install the fitting. Torque Value: Oil Inlet Fitting

35 N•m

[ 26 ft-lb ]

Connect the turbocharger oil inlet hose (16) to the fitting. Install the clamps for the oil inlet hose. The other end of the oil inlet hose must be connected to a fitting in the cylinder block. Refer to Procedure 001-026.




Install the parts. 5. Gasket 6. Hose 7. Lock washers 8. Capscrews. Torque Value: Capscrews

40 N•m

[ 30 ft-lb ]

Install the o-ring seal (9) on the hose flange. Use vegetable oil. Lubricate the seal. Install the flange in the bore of the block. Install the lock washer (10) with the capscrew (11). Torque Value: Flange Capscrews

40 N•m

[ 30 ft-lb ]

Repeat this procedure to install the other turbocharger and connect the oil hoses.

KTTA38 Low Pressure Turbochargers NOTE: The engine has two low pressure turbochargers. The illustrations show the installation of one turbocharger. It is recommended that the two low pressure turbochargers be installed at the same time.

The engine has six turbocharger supports. Two are mounted on the front of the right bank and two on the rear of the left bank. One is mounted on the front of the left bank and one on the rear of the right bank. Install the turbocharger supports (1), the lock washers (2), with the socket head capscrews (3). Torque Value: Turbocharger Support Capscrews

270 N•m

[ 199 ft-lb ]


Do not tighten the clamps or fasteners to final torque until the torque value is given. Tighten the parts enough to hold them together, but loose enough to allow the parts to be moved for alignment. Install the parts. 4. Bracket 5. Flat washers, heavy (six) 6. Lock washers (six) 7. Capscrews (six).

Install the vee-band clamp (8) and the exhaust outlet connection (9).

Apply an anti-seize compound to the slip-joints of the exhaust outlet connection (9), exhaust outlet pipe (10), and the turbocharger connection (11). Install the pipe (10) to the connection (9). Install the connection (11) in the pipe (10). Apply an anti-seize compound on the threads of the capscrews (12). Install the four capscrews (12) through the connection and bracket. Install the heavy flat washers (13), the lock washers (17), and the nuts (18).

Install the large o-ring seal (19) and the small o-ring seal (20) on the air inlet pipe (21). Install the dust seal (22) on the air inlet pipe. Use vegetable oil. Lubricate the o-ring seals. Install the air inlet pipe in the high pressure turbocharger.




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). NOTE: Some of the compressor housing is shown removed for clarity. Check the angle of the oil drain. Check the alignment of the compressor housing to the air inlet pipe. If the angle or alignment is not correct, see Turbocharger, Oil Drain Angle, Adjust, or Turbocharger, Compressor Housing Alignment, Adjust, described in this section.

Tighten the six capscrews (7) that hold the bracket to the supports. Torque Value: Bracket to Supports

90 N•m

[ 66 ft-lb ]


Tighten the four capscrews (12) and nuts (18) that hold the connection to the bracket. Torque Value: Connection to Bracket

90 N•m

[ 66 ft-lb ]

Tighten the four capscrews (27) and nuts (28) that hold the turbocharger to the connection. Torque Value: Turbocharger Connection

40 N•m

[ 30 ft-lb ]

Tighten the vee-band clamp (8). Torque Value: Vee-band Clamp

7 N•m

[ 62 in-lb ]

Use a mallet. Tap around the clamp to be sure it is seated. Torque the clamp nut to the same torque value. Continue tapping and tightening the clamp until the nut does not turn at the specified torque after tapping.

Tighten the two t-bolt clamps (24). Torque Value: T-bolt Clamps

9 N•m

[ 80 in-lb ]




NOTE: Holset® turbochargers have a fitting that has straight threads and requires an o-ring seal. AiResearch® turbochargers have a fitting with pipe threads. The torque value is the same for both types of fittings. Install the o-ring seal (14) on the oil inlet fitting (15). Install the fitting. Torque Value: Oil Inlet Fitting

35 N•m

[ 26 ft-lb ]

The other end of the oil inlet hose must be connected to a fitting in the cylinder block. Refer to Procedure 001-026.

Install the parts. 29. Gasket 30. Hose 31. Lock washers 32. Capscrews. Torque Value: Capscrews

40 N•m

[ 30 ft-lb ]

NOTE: Some older KTTA38 engines equipped with AiResearch® low pressure turbochargers have a drain hose that has two pieces connected by a temperature resistant hump hose. Install the o-ring seal (33) on the hose flange. Use vegetable oil. Lubricate the seal. Install the flange, the lock washer (34), and the capscrew (35). Torque Value: Flange Capscrews

40 N•m

[ 30 ft-lb ]

KTTA50 Low Pressure Turbochargers NOTE: The engine has two low pressure turbochargers. The illustrations show the installation of one turbocharger. It is recommended that the two low pressure turbochargers be installed at the same time. The engine has six turbocharger supports. Two are mounted on the front of the right bank, and two are on the rear of the left bank. One is mounted on the front of the left bank, and one on the rear of the right bank. Install the turbocharger supports (1), the lock washers (2), and the socket head capscrews (3). Torque Value: Turbocharger Support Capscrews

270 N•m

[ 199 ft-lb ]


Do not tighten the clamps or fasteners to final torque until the torque value is given. Tighten the parts enough to hold them together, but loose enough to allow the parts to be moved for alignment. Install the bracket (4), the six lock washers (6), and the six capscrews (7).


Apply an anti-seize compound to the slip-joints of the exhaust outlet connection (9), the exhaust outlet pipe (10), and the turbocharger connection (11). Install the pipe (10) on the outlet connection (9). Install the connection (11) in the pipe (10).

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.




CAUTION KTTA50 engines equipped with LOG type exhaust manifolds must have Brown-Boveri Corporation (BBC®), Model Number 153, turbochargers. KTTA50 engines with PULSE type exhaust manifolds must have BBC®, Model Number RR 151, turbochargers. Be sure the correct turbochargers are installed, or damage to the engine can result. CAUTION Newer BBC® RR 153 turbochargers have fastener threads that are U.S. Customary inch. Older BBC® RR 153 turbochargers have fastener threads that are metric millimeter. The fastener threads in all BBC® RR 151 are metric millimeter. Be sure the correct fasteners are installed or the parts can be damaged. NOTE: The exhaust and intake adapters for the BBC® RR 153 and RR 151 appear the same, but have different dimensions. Be sure to install the correct part. Apply an anti-seize compound to the bore of the low pressure turbocharger (16) for the exhaust outlet connection (17), and the threads of the capscrews (19) and (20). The connection must be installed as shown so that the flange with two holes aligns with the bracket. The two capscrews (19) are longer than the six capscrews (20). Install the exhaust outlet connection (17), the lock washers (18), and the capscrews (19) and (20). Torque Value: Exhaust Outlet Connection Capscrews

40 N•m

[ 30 ft-lb ]

Install the parts on the air intake connection (26). 21. Capscrews (two) 22. Bracket 23. Flat washers, heavy 24. Lock washers 25. Nuts. Install the o-ring seal (27) in the groove on the connection (26). Use engine oil or lubriplate to secure the seal in the groove. Install the parts on the low pressure turbocharger (16). 26. Connection 27. Flat washers (four) 28. Lock washers (four) 29. Capscrews (four). Tighten only the capscrews (30). Torque Value: Capscrews

25 N•m

[ 18 ft-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. Use a hoist and lifting strap. Put the turbocharger (16) in position and push the compressor housing on the air pipe.

Install the capscrews (31) through the heavy flat washers (32), and the brackets (22) and (4). Install the heavy flat washers (32), lock washers (33), and the nuts (34).

Apply an anti-seize compound to the threads of the capscrews (35). Install the two capscrews (35) through the exhaust outlet connection (17) and the bracket (4). Install the heavy flat washers (36), the lock washers (37), and the nuts (38).

The gasket must be installed so that the raised bead on the gasket is toward the turbocharger. Install the gasket (39) between the turbocharger turbine housing and the exhaust connection. Apply an anti-seize compound to the threads of the capscrews (40). Install the four capscrews (40) through the holes in the turbine housing, the gasket, and the connection. Install the lock washers (41) and the nuts (42).




NOTE: Some of the compressor housing is shown removed for clarity. Check the angle of the oil drain. Check the alignment of the compressor housing to the air inlet pipe. If the angle or alignment is not correct, see Turbocharger, Oil Drain Angle, Adjust, or Turbocharger, Compressor Housing Alignment, Adjust, described in this section.

Tighten the six capscrews (7) that hold the bracket to the supports. Torque Value: Bracket to Supports

90 N•m

[ 66 ft-lb ]

Tighten the two capscrews (35) and nuts (36) that hold the turbocharger exhaust outlet connection to the bracket. Torque Value: Exhaust Outlet Connection to Bracket

90 N•m

[ 66 ft-lb ]

NOTE: Be sure the bracket (32) is flat against the flange on the air inlet connection. Tighten the two capscrews (43) and the nuts (34) that hold the air intake connection (32) to the bracket (4). Torque Value: Air Intake connection to bracket

40 N•m

[ 30 ft-lb ]


Tighten the two capscrews (31) and the nuts (25) that hold the bracket (32) to the connection (26). Torque Value: Bracket Capscrews

40 N•m

[ 30 ft-lb ]

Tighten the four capscrews (40) and nuts (42) that hold the exhaust connection to the turbine housing. Torque Value: Exhaust Connection Capscrews

90 N•m

[ 66 ft-lb ]

Tighten the vee-band clamp (8). Torque Value: Vee-band Clamp

7 N•m

[ 62 in-lb ]

Use a mallet. Tap around the clamp to be sure it is seated. Torque the clamp nut to the same torque value. Continue tapping and tightening the clamp until the nut does not turn at the specified torque after tapping.

Tighten the two t-bolt clamps (45) on the air inlet pipe. Torque Value: T-bolt clamps

7 N•m

[ 62 in-lb ]




CAUTION Be sure the correct capscrews are installed. If the wrong capscrews are installed, failure of the part can result. NOTE: Newer BBC® RR153 turbochargers have a fitting that is threaded directly into the bearing housing. Older BBC® RR 153 turbochargers require an adapter plate, Part Number 3176567, and a gasket, Part Number 3176568, attached to the bearing housing with two capscrews. NOTE: All BBC® RR 151 turbochargers have an adapter plate and gasket. The adapter plate and gasket are different than on the older BBC® RR 153 turbochargers. Install the parts for the turbocharger oil inlet. 55. Gasket 56. Plate 57. Lock washers 58. Capscrews. Torque Value: Oil Inlet Capscrew

40 N•m

[ 30 ft-lb ]

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 parts for the turbocharger oil drain. 47. Gasket 48. Hose 49. Lock washers 50. Capscrews. Torque Value: Oil Drain Capscrews

40 N•m

[ 30 ft-lb ]

Install the o-ring seal (51) on the hose flange. Use vegetable oil. Lubricate the seal. Install the flange, the lock washer (52), and the capscrews (53) in the proper holes in the cylinder block. Torque Value: Oil Drain Flange Capscrews

40 N•m

[ 30 ft-lb ]


K2000E and K1800E High Pressure Turbochargers The K2000E uses Holset® HC5A high pressure turbochargers (2), the HT100 Low Pressure Turbochargers (1) installation is described later in this section.

The K1800E engine is single stage turbocharged and does not use the turbocharger interstage connections or assembly procedures as does the K2000E. The K1800E engine uses Holset® HX85 turbochargers (1).

NOTE: The high pressure turbochargers (2) are mounted to the exhaust manifold using four capscrews (3) and nuts (4). These capscrews and nuts are manufactured from high strength stainless steel that has high temperature capability. Do not substitute with lower quality parts.

The gasket must be installed with the raised bead (2) toward the turbocharger. Install the gasket (1) on the exhaust manifold.




Coat the threads of the capscrews with anti-seize compound. Install the turbocharger (2), capscrews (3) and nuts (4). Torque Value: Turbocharger Mounting Capscrews

40 N•m

[ 30 ft-lb ]

NOTE: Some of the compressor housing has been removed for clarity. Check the angle of the oil drain and the alignment of the compressor housing to the air crossovers (this can not be checked until the aftercooler assemblies are installed). If the angle is not correct, the bearing housing must be rotated in relation to the turbine housing. Adjust the turbocharger oil drain angle.

If the alignment is correct or after the adjustment, lock the bearing housing to the turbine casing lockplate tabs.

Connect the turbocharger oil inlet hose to the fitting. Install the clamps for the oil inlet hose. The other end of the oil inlet hose must be connected to a fitting in the cylinder block. Refer to Procedure 001-026.


Install the gasket (5), the hose (6), the lock washers (7) and the two capscrews (8) to the turbocharger oil drain.

Install the o-ring seal (9) on the hose flange. Use engine oil to lubricate the seal. Install the flange in the bore of the block. Install the lock washer (10) and the capscrew (11). Torque Value: Oil Inlet Capscrews

40 N•m

[ 30 ft-lb ]

Repeat the procedure to install the other turbocharger and connect the oil supply and the drain hose.

K2000E Low Pressure Turbochargers The K2000E engine contains two low pressure turbochargers. This illustration shows the installation of only one turbocharger. The recommendation is to install both low pressure turbochargers at the same time. The K2000E engine contains six turbocharger supports. Two of each of the supports are mounted on the front of the right bank and rear of the left bank. One of each of the supports is mounted on the front of the left bank and rear of the right bank. Install the turbocharger supports (1), and the lock washers (2), and the socket head capscrews (3). Torque Value: Turbocharger support capscrews

270 N•m

[ 199 ft-lb ]

NOTE: From this point on, do not tighten the clamps or fasteners to their final torque unless the torque value is given. Tighten only enough to allow the parts to move for alignment.




Install the bracket (4), the six lock washers (6), and the six capscrews (7).


Apply anti-seize compound to the threads of the capscrews (12). Install the gasket (10), capscrews (12), lock washers (13), and nuts (14).

Use anti-seize compound to coat the slip joints of the exhaust pipe (11) and the turbocharger connection (16). Install the turbocharger connection (16) on the exhaust pipe (11). After all interstage connections are in place, there must be a minimum of 3.18 mm [0.125 inch] expansion space between connections (11 and 16). The gap can be adjusted by moving the low pressure turbocharger or low pressure turbocharger mounting bracket.


Use anti-seize compound to coat the bore on the low pressure turbocharger (22) for the exhaust outlet connection (17), and the threads of the capscrews (19 and 20). The bracket (21) must be oriented to provide proper turbocharger alignment. NOTE: The two capscrews (19) are longer than the six capscrews (20). Install the exhaust outlet connection (17), the lock washers (18), and the capscrews (19 and 20). Torque Value: Exhaust Outlet Capscrews

40 N•m

[ 30 ft-lb ]

Install the two capscrews (31), the bracket (32), the heavy flat washer (23), the lock washers (24), and the nuts (25) on the air intake connection. Install the o-ring seal (27) in the groove on the connection (26). Use engine oil or Lubriplate® to hold the seal in the groove. Install the connection (26), the four flat washers (28), lock washers (29), and the capscrews (30), on the low pressure turbocharger. Tighten only the four capscrews (30). Torque Value: Air Intake Connection Capscrews

40 N•m

[ 30 ft-lb ]

Use a hoist and lifting strap to position the turbocharger and to align the capscrew holes in the brackets.

Install the capscrews (43) through the heavy flat washer (44) and both brackets (32 and 4). Install the heavy flat washers (44), lock washers (33) and the nuts (34).




Use anti-seize compound to coat the threads of the capscrews (35). Install the two capscrews (35) through the exhaust outlet connection (17) and the bracket (4). Install the heavy flat washers (36), the lock washers (37), and the nuts (38).

The raised bead on the gasket (39) must be toward the turbocharger. Install the gasket (39) between the turbocharger turbine housing and the exhaust connections (16). Use anti-seize compound to coat the threads of the capscrews (40). Install the four capscrews (40) through the holes in the turbine housing, the gasket, and the connection. Install the lock washers (41) and the nuts (42).

Slide one t-bolt clamp (45) and hose (46) over the end of the intake pipe (47). Slide the hose on far enough to install the pipe. Install the second clamp (45) over the compressor outlet. Position the intake pipe (47) between the turbochargers and insert the gasket (48). Secure the flanges with four bolts (49), flat washers (50), lock washers (51), and nuts (52).

NOTE: Some of the compressor housing has been removed for clarity. Check the angle of the oil drain. Check the alignment of the compressor housing to the air inlet pipe. If the angle or alignment is not correct, the bearing housing must be rotated in relation to the turbine housing. See Turbocharger, Compressor Housing Alignment, Adjust and Turbocharger, Oil Drain Angle Alignment, Adjust, described in this section.


Prior to any of the capscrews being tightened, check to be sure there is a minimum of 3.18 mm [0.125 in] expansion space at the slip joints on both exhaust interstage connections.

Tighten the six capscrews (7) that hold the bracket to the supports. Torque Value: Support Bracket Capscrews

95 N•m

[ 70 ft-lb ]

Tighten the two capscrews (35) and nuts (38) that hold the turbocharger exhaust outlet connection to the bracket. Torque Value: Bracket Capscrews

95 N•m

[ 70 ft-lb ]

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 Connection Capscrews

40 N•m

[ 30 ft-lb ]




Tighten the two capscrews (31) and nuts (25) that hold the bracket (32) to the connection (26). Torque Value: Bracket Connection Capscrews

40 N•m

[ 30 ft-lb ]

Tighten the four capscrews (40) and nuts (42) that hold the exhaust connection to the turbine housing. Torque Value: Exhaust Connection Capscrews

95 N•m

[ 70 ft-lb ]

Tighten the three capscrews (19) that hold the bracket (21) to the exhaust outlet connection (17). Torque Value: Exhaust Outlet Connection Capscrews

40 N•m

[ 30 ft-lb ]

Tighten the four capscrews (12) and nuts (14) that hold the two exhaust connections (9 and 11). Torque Value: Exhaust Outlet Connections

95 N•m

[ 70 ft-lb ]

Tighten the vee-band clamp. Torque Value: Vee-Band

9 N•m

[ 80 in-lb ]

Use a mallet. Tap all around the clamp to make sure it is seated. Torque the clamp nut to the same torque value. Continue tapping and tightening the clamp until the nut will not turn at the specified torque after tapping.


Tighten the four capscrews (49) and nuts (52) that hold the air intake pipe (47) to the turbocharger compressor outlet. Torque Value: Intake Pipe Capscrews

40 N•m

[ 30 ft-lb ]

CAUTION The hoses and t-bolt clamps of the air intake system are of heavy duty design to withstand temperatures and pressures to which they are exposed. Only specified parts are to be used. The clamps can be removed and tightened again a maximum of three times. The torque retention on the nut will be beyond reuse after this. At this time, a second nut MUST be added to double lock the nut or a new clamp MUST be used. Center the hose (46) over the high pressure turbocharger compressor inlet and the pipe (47). Secure the two t-bolt clamps (45). 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 Clamps

8 N•m

[ 71 in-lb ]

These clamps need to be tightened again after the engine has operated a few hours. Wrap the interstage air hose with a heat shield (blanket). The blanket is secured by placing the eyelets that are located on each end of the blanket over the hose clamp tbolts. Use flat washers and nuts on the t-bolts to retain the heat shield (blanket).




Install the gasket (55), the plate (56), the lock washers (57), and the capscrews (58) for the low pressure turbocharger oil inlet. Torque Value: Low Pressure Turbocharger Oil Inlet

25 N•m

[ 18 ft-lb ]

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 Drain

25 N•m

[ 18 ft-lb ]

Install the seal (63) on the hose flange. Use engine oil to lubricated the seal. Install the flange, the lock washer (64) and the capscrews (65) in the proper holes in the cylinder block. Torque Value: Hose Flange

40 N•m

[ 30 ft-lb ]

NOTE: The turbocharger oil drain line must run downhill from the turbocharger to the cylinder block. with Electronically Actuated Injector 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 Mounting Capscrews and Nuts

45 N•m

[ 33 ft-lb ]


Install the exhaust outlet and clamp.

Apply anti-seize compound, Part Number 3824397, or equivalent to both ends of the exhaust inter-stage piping flanges. Install both halves of the exhaust inter-stage using new gaskets. Apply anti-seize compound, Part Number 3824397, or equivalent to the mounting capscrews. Tighten the exhaust outlet connection clamp. Torque Value: Hose Clamp

8 N•m

[ 71 in-lb ]

Install the capscrews, washers and nuts finger tight to allow for alignment. Install the hose and clamps (with tightening screws facing downward) to the inlet side of the turbocharger. Tighten the hose clamp closest to the turbocharger inlet. Torque Value: Hose Clamp

8 N•m

[ 71 in-lb ]

Install the intake air piping into the hose and loosely tighten the clamp to allow for alignment.

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.




Install a new steel gaskets between the outer low pressure turbocharger and the outer low turbocharger exhaust connection. Check that the raised beads on the gaskets are facing the outer turbocharger. Install the capscrews, washers and nuts in the same orientation noted prior to removal and hand tighten. Check the alignment and tighten the capscrews. Torque Value: Exhaust Connection Capscrews and Nuts

95 N•m

[ 70 ft-lb ]

Install a new paper gasket between the air intake connection and the turbocharger and install the capscrews, washers and nuts. Hand tighten only to allow for alignment. Add the p-clip to the top right capscrew. Do not tighten this bolt until the oil supply line is installed. Once alignment is checked, tighten the capscrews. Torque Value: Air Intake Connection Capscrews and Nuts

48 N•m

[ 35 ft-lb ]

Check that all air transfer connections are aligned and tighten the interstage hose clamps. Torque Value: Interstage Hose Clamp

8 N•m

[ 71 in-lb ]

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 Capscrews

48 N•m

[ 35 ft-lb ]


Apply anti-seize compound, Part Number 3824394, or equivalent, to the rear turbocharger outlet flange and install the exhaust adapter and bracket onto the low pressure turbocharger and trolly assembly. Apply anti-seize compound, Part Number 3824394, or equivalent, to the eight mounting capscrews and install. Torque Value: Exhaust Adapter Capscrews

48 N•m

[ 36 ft-lb ]

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. with Electronically Actuated Injector 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 Page 10-130


Turbocharger, Water-Cooled (010-037) 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 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.


Remove Remove the turbocharger coolant vent lines.

Left Bank Loosen the hose clamp connecting the flexible hose between the sections of the air crossover tube. Remove the eight capscrews and washers connecting the air crossover tube to the turbocharger. Remove the air crossover tube and discard the gasket.

Remove the Straub coupling from the water transfer tube. Disconnect the water transfer tube from the turbocharger and remove.

Remove the six capscrews, washers, and nuts from the turbocharger to exhaust manifold flange.




WARNING 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.

Remove the Straub coupling from the water transfer tube. Disconnect the water transfer tube from the turbocharger and remove.

Remove the six capscrews, washers, and nuts from the turbocharger to exhaust manifold flange.


WARNING 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.

If the turbocharger requires clocking, set the turbocharger on a bench with the turbine housing against the bench and loosen the V-band clamp.

The turbocharger can be used in different applications and has three clock marks on the turbine housing. 1. 19 casting line 2. Left bank 3. Right bank




The bearing housing has a machined surface on the top, creating an alignment mark.

Rotate the bearing housing, aligning the mark with the 19 casting line on the turbine housing. Apply anti-seize compound to the V-band threads. Tighten the V-band clamp. Torque Value: Step1 Step2 Step3

20 N•m [ 177 in-lb ] Loosen 2 to 3 turns 18 to 20 N•m[ 160 to 177 in-lb ]

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. Install the six capscrews, washers, and nuts. Tighten the nuts Torque Value: Turbocharger Capscrews

136 N•m

[ 100 ft-lb ]


Install the turbocharger to center section mounting capscrews and washers and tighten. Torque Value: Turbocharger to Center Section Mounting Capscrews

102 to 115 [ 75 to 85 ftN•m lb ]

Install the water transfer tube to the turbocharger. Torque Value: 43 to 47 N•m [ 32 to 35 ft-lb ] Install the Straub coupling to the water transfer tube. Torque Value: 20 N•m [ 180 in-lb ]

Use a new gasket and install the air crossover tube between the turbocharger and forward section for the air crossover tube. Install the eight capscrews and washers connecting the air crossover tube to the turbocharger. Torque Value: 22 N•m [ 16 ft-lb ] Tighten the hose clamp on the flexible hose between the sections of the air crossover tube. Torque Value: 11 N•m [ 97 in-lb ]

Install the turbocharger coolant vent lines.




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. Install the six capscrews, washers, and nuts. Tighten the nuts Torque Value: Turbocharger Capscrews

136 N•m

[ 100 ft-lb ]

Install the turbocharger to center section mounting capscrews and washers and tighten. Torque Value: Turbocharger to Center Section Mounting Capscrews

102 to 115 [ 75 to 85 ftN•m lb ]

Install the water transfer tube to the turbocharger. Torque Value: 43 to 47 N•m [ 32 to 35 ft-lb ] Install the Straub coupling to the water transfer tube. Torque Value: 20 N•m [ 180 in-lb ]


Use a new gasket and install the air crossover tube between the turbocharger and forward section of the air crossover tube. Install the eight capscrews and washers connecting the air crossover tube to the turbocharger. Torque Value: 22 N•m [ 16 ft-lb ] Tighten the hose clamp on the flexible hose between the sections of the air crossover tube. Torque Value: 11 N•m [ 97 in-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. 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.

Turbocharger (010-038)

Axial

Clearance

Preparatory Steps • Remove the intake and exhaust piping from the turbocharger.

Turbocharger Axial Clearance Page 10-137



Measure NOTE: Check the model of turbocharger fitted to the engine, this is for: Holset®, Model HC5 To measure axial clearance, use Part Number ST-537 Dial Depth Gauge or a dial indicator. Measure the axial motion. Holset® HX5 - Axial Clearance mm 0.05 0.13

MIN MAX

in 0.002 0.005

If the end clearance exceeds the specifications, the turbocharger must be replaced or rebuilt. See Bulletin Number 3810243, HC5 Series Turbocharger Shop Manual, for rebuild instructions. Use your hand to push the compressor impeller end of the shaft towards the housing. Use a wire - type feeler gauge or a feeler gauge no wider that 13 mm [1/2 inch]. Measure the clearance between the impeller and the housing at the minimum clearance point. Holset® HX5 - Compressor Impeller Radial Clearance mm in 0.15 MIN 0.006 0.46 MAX 0.018

Perform the same measurement procedure for the turbine wheel. Holset® HX5 - Turbine Wheel Radial Clearance mm in 0.20 MIN 0.008 0.53 MAX 0.021 If the clearance exceeds the specification, the part must be replaced or rebuilt. See Bulletin Number 3810243, HC5 or HC5A turbocharger manual for rebuild instructions.


NOTE: Check the model of turbocharger fitted to the engine, this is for: Brown Boveri®, Model RR-153 and RR-151 To measure axial clearance, use Part Number ST-537 Dial Depth Gauge or a dial indicator. Measure the axial motion. BBC (RR-151) and (RR-153) End Clearance mm in 0.09 MIN 0.004 0.13 MAX 0.005 If the end clearance exceeds the specifications, the turbocharger must be replaced or rebuilt. See Bulletin Number 3810235, Exhaust - Gas Turbocharger RR-153, Instructions for Operation and Maintenance or Bulletin Number 3810325, Exhaust - Gas Turbocharger, RR151-12, Instructions for operation and Maintenance. NOTE: The compressor and turbine casings do not require removal to measure the radial clearance. The parts shown are removed for clarity. Use dial indicator. Measure the clearance. BBC (RR-151) and (RR-153) Bearing Radial Clearance mm in RR-153 0.55 MAX 0.021 RR-151 0.75 MAX 0.030 If the clearance exceeds the specification, the part must be replaced or rebuilt. See Bulletin Number 3810235, Exhaust - Gas Turbocharger, RR-153, Instructions for operation and Maintenance or Bulletin Number 3810315, Exhaust - Gas Turbocharger, RR-151-12, Instructions for Operation and Maintenance. NOTE: Check the model of turbocharger fitted to the engine, this is for: AiResearch®, Model T-18A Use a dial indicator . Measure the clearance. AiResearch® T-18A End Clearance mm in 0.10 MIN 0.004 0.23 MAX 0.009 If the end clearance exceeds the specifications, the turbocharger must be replaced or rebuilt. See Bulletin Number 33379091, Turbocharger Component Shop Manual, for rebuild instructions.


Turbocharger Blade Damage Page 10-140


Finishing Steps • Install the intake and exhaust piping to the turbocharger.

Turbocharger Blade Damage (010-039) Inspect for Reuse Remove the intake and exhaust pipes from the turbochargers.

Inspect the turbocharger compressor impeller blades for damage. Remove and rebuild or replace the turbocharger if damage is found. Refer to Procedure 010-033 (Turbocharger) in Section 10.

If the impeller is damaged, inspect the intake air piping and the air filter element for damage and cause of leaks. Inspect the compressor cover for any debris. Repair any damage before operating the engine.


Inspect the turbine wheel for damage. Check for debris stuck in the turbine housing. Remove and rebuild or replace the turbocharger if damage is found. Refer to Procedure 010-033 (Turbocharger) in Section 10.

Turbocharger Compressor Seal Leaks (010-040) Inspect Remove the air intake piping from the turbocharger.

Remove the hose and two clamps between the air crossover and the turbocharger. Remove the clamp between the air crossover and the aftercoolers or intercoolers. Remove the air crossover.

Examine the compressor discharge and air crossover piping for oil.

Turbocharger Compressor Seal Leaks Page 10-141



If oil is in the compressor discharge or crossover piping, check the axial clearance of the turbocharger. Refer to Procedure 010-038 (Turbocharger Axial Clearance) in Section 10. Check the radial clearance of the turbocharger. Refer to Procedure 010-047 (Turbocharger Radial Bearing Clearance) in Section 10.

Check for intake restriction. Refer to Procedure 010-031 (Air Intake Restriction) in Section 10. If the restriction exceeds specifications, replace or clean the air filter element; refer to the OEM's instructions.

Disconnect the oil drain hose from the cylinder block. Remove and discard the o-ring seal (9).

Disconnect the oil drain hose from the turbocharger. Remove any support clamps and the hose. Remove and discard the o-ring gasket (5). Clear any restrictions found in the hose. Discard the hose if it is cracked, frayed, or will not bend without cracking.


Check the angle of the drain tube. NOTE: The angle of the tube must be within 35 degrees of vertical. Adjust the turbocharger, if necessary. Refer to Procedure 010-033 (Turbocharger) in Section 10.

If the drain tube is free of restrictions and at the correct angle, check the crankcase breathers and tubes to make sure they are not plugged or restricted.

If these checks do not reveal the problem, measure the crankcase pressure (blowby). Refer to Procedure 014-005 (Engine Testing (Engine Dynamometer)) in Section 14.


Turbocharger Coolant Hoses Page 10-144


Turbocharger Coolant Hoses (010-041) Preparatory Steps EAI 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.

NOTE: Shown is the Two Stage turbocharger, the Single Stage is similar. Remove the supply union fittings on the turbocharger and water manifold. Discard the o-rings.


Remove the capscrews, washers, cover plate, and water tube brackets supporting the turbocharger drain tube.

Disconnect and remove the coolant return hose from the turbocharger and the thermostat housing connection. Discard the o-rings.

Remove the drain fittings from the thermostat housing and turbocharger. Discard the o-rings.

Marine Applications Disconnect the coolant supply and return hoses from the turbocharger, coolant supply, and return water manifolds.




Remove the fittings from the turbocharger, and from the supply and return manifolds. Discard the o-rings.

Inspect for Reuse EAI Inspect the coolant supply and return hoses for cracks or other damage.

Inspect the unions, elbows, t-fittings, reducer nuts, and drain cocks for stripped threads, cracks, and other damage.

Install 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 Turbocharger Fittings

57 N•m

[ 42 ft-lb ]


Install the turbocharger coolant supply lines to the union fittings on the turbocharger and the water manifold. Tighten the supply line fittings. Torque Value: Turbocharger Supply Line Fittings

54 N•m

[ 40 ft-lb ]

Install new o-rings on the drain union fittings on the turbocharger and thermostat housing. Tighten the fittings. Torque Value: Thermostat Housing and Turbocharger Fittings

57 N•m

[ 42 ft-lb ]

Install the turbocharger coolant drain lines to the union fitting on the turbocharger and thermostat housing. Torque Value: Turbocharger Drain Line Fittings

54 N•m

[ 40 ft-lb ]

Install the water tube bracket, cover plates, washers and capscrews on the turbocharger supply and drain hoses. Torque Value: Bracket Capscrews

9 N•m

[ 80 in-lb ]


Turbocharger Oil Drain Line Page 10-148


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 ]

Install the coolant supply and return hoses on the turbocharger and water manifolds. Tighten the hoses. Torque Value: 54 N•m [ 40 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.

Turbocharger Oil Drain Line (010-045) Preparatory Steps with Electronically Actuated Injector • Remove the turbocharger heat shields (marine applications only).


Remove Single Stage Remove the capscrews, washers, and p-clips securing the turbocharger oil drain lines.

Remove the capscrews and washers connecting the oil drain lines to the turbochargers and to the engine block. Discard gaskets and o-ring.

Two Stage Remove the capscrews, washers and p-clips securing the turbocharger oil drain lines.

Remove the capscrews and washers connecting the oil drain lines to the engine block and to the high pressure turbochargers. Discard the gaskets and o-rings.




Remove the capscrews and washers that secure the oil drain line to the engine block and the capscrews connecting the oil drain line to the front and rear low pressure turbochargers. Discard the gaskets and o-rings.

Marine Applications Remove the turbocharger oil drain line mounting capscrews from the turbocharger mounting base and the flywheel housing. Remove the oil drain and discard the gaskets.

Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING 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.


Inspect the turbocharger oil drain tubes for signs of damage. If damage is found, the tubes must be replaced.

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 ] Install the turbocharger oil drain line p-clips, 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 ] Install the high pressure turbocharger oil drain lines, pclips, 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).


Turbocharger Oil Supply Line 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.

Turbocharger (010-046)

Oil

Supply

Line

Preparatory Steps with Electronically Actuated Injector • Remove the turbocharger heat shield (marine applications). Refer to the OEM manual.



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 orings. Remove the capscrews, washers, and p-clips from the oil supply tubes.

Remove the oil supply tubes from the male unions on the engine. Discard the o-rings.


Two Stage High pressure turbocharger, remove the oil supply tubes from the male unions on the high pressure turbochargers. Discard the o-rings.

Remove the capscrews, washers, p-clips, and mounting spacers securing the turbocharger oil supply tubes for the high pressure turbochargers.

Remove the oil supply tubes from the male unions on the engine. Discard the o-rings.

Low Pressure Turbocharger Remove the turbocharger oil supply tubes from the male unions on the low pressure turbochargers. Discard the orings.




Remove the p-clips, capscrews, mounting spacers and washers, securing the turbocharger oil supply tubes for the low pressure turbochargers.

Remove the turbocharger oil supply tubes from the male unions on the engine for the low pressure turbochargers. 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.

Remove the capscrews, washers, and p-clips securing the turbocharger oil supply tubes. Remove the oil supply tube from the turbocharger. Remove the oil supply line.


Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING 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. Inspect the turbocharger oil supply lines for cracks, other damage, or restrictions. Replace the line if damaged.

Inspect the p-clips. Replace if damage is found.




Install Industrial Applications Install new o-rings on the male unions. Install the turbocharger oil supply tubes to the male unions on the turbochargers. Torque Value: Oil Supply Tube Fitting to Turbocharger

35 N•m

[ 26 ft-lb ]

Install new o-rings on the male unions. Install the turbocharger oil supply tubes to the male unions on the engine. Torque Value: Oil Supply Tube Fitting to Male Union

35 N•m

[ 26 ft-lb ]

Attach the p-clips to the turbocharger oil supply tubes. Attach the p-clips to the engine with the capscrews, washers, and mounting spacers. Torque Value: P-clip to Cylinder Head Capscrews Torque Value: P-clip to Injector Cover Plate Capscrews

20 N•m

[ 15 ft-lb ]

42 N•m

[ 31 ft-lb ]

Two Stage CAUTION Do not use sealant or gasket adhesive on gaskets as this can contaminate the oil system causing engine damage. High Pressure Turbochargers • Install new o-rings on the male unions on the turbocharger. • Install the turbocharger oil supply tubes to the male unions. Torque Value: Oil Supply Tube Fitting to Turbocharger

35 N•m

[ 26 ft-lb ]


Install new o-rings on the male unions on the engine. Install the turbocharger oil supply tubes to the male unions. Torque Value: Oil Supply Tube Fitting to Male Union

35 N•m

[ 26 ft-lb ]

Attach the p-clips to the engine with the capscrews, washers, and mounting spacers. Torque Value: P-clip to Cylinder Head Capscrews Torque Value: P-clip to Injector Cover Plate Capscrews

20 N•m

[ 15 ft-lb ]

42 N•m

[ 31 ft-lb ]

Low Pressure Turbocharger CAUTION Do not use sealant or gasket adhesive on gaskets as this can contaminate the oil system, causing engine damage. Low pressure turbochargers, install new o-rings on the male unions. Install the turbocharger oil supply tubes to the male unions on the turbocharger. Torque Value: Oil Supply Tube Fitting to Turbocharger

35 N•m

[ 26 ft-lb ]

Install new o-rings on the male unions. Install the turbocharger oil supply tubes to the male unions on the engine. Torque Value: Oil Supply Tube Fitting to Male Union

35 N•m

[ 26 ft-lb ]




Attach the p-clips to the engine with the capscrews, washers, and mounting spacers. Torque Value: P-clip to Cylinder Head Capscrews Torque Value: P-clip to Injector Cover Plate Capscrews

20 N•m

[ 15 ft-lb ]

42 N•m

[ 31 ft-lb ]

Marine Applications NOTE: Shown is the right bank oil supply line. The procedure is the same for the left bank. Install the oil supply hose. Install the capscrews, washers, and p-clips securing the turbocharger oil supply tubes. Torque Value: 38 N•m [ 28 ft-lb ]

Use new o-rings and install the turbocharger oil supply tubes to the male unions on the turbochargers. Torque Value: 24 to 27 N•m [ 18 to 20 ft-lb ]

Use new o-rings and install the turbocharger oil supply tubes to the male unions on the engine. Torque Value: 24 to 27 N•m [ 18 to 20 ft-lb ]


Turbocharger Radial Bearing Clearance Page 10-161

Finishing Steps with Electronically Actuated Injector • Install the turbocharger heat shield applications). Refer to the OEM manual. • Operate the engine and check for leaks.

Turbocharger Radial Clearance (010-047)

(marine

Bearing

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 (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. AiResearch® T-18A Impeller and Turbine Wheel Radial Clearance mm in 0.08 MIN 0.003 0.18 MAX 0.007 If the radial bearing clearance is not within specification, the turbocharger must be replaced. See Bulletin Number 3379091, Turbocharger Component Shop Manual, for rebuild instructions.

Aftercooler Housing (Center Mount) Page 10-162


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.

Aftercooler Housing (Center Mount) (010-073) Modify KTA50 This procedure provides the steps required to modify a K50 center mount aftercooler housing to allow the installation of cross bolts. The cross bolts increase the stability of the housing and reduce failures caused by cyclic loading of the parts that have different rates of thermal expansion. This procedure represents the aftercooler housing that contains a rib in the center of the housing. The procedure and specifications are also recommended for the K50 aftercooler housing that does not contain the rib. This modification applies only to the aftercooler housing on K50 engines. The modification is not required for the aftercooler housing on K38 engines. Some K50 engines contain aftercoolers that have the cross bolts installed. Tools Required: • Band saw (with blade-welding attachment), hand-type reciprocating saw, end mill, or hand drill and bits to remove the center rib that is 11 mm [0.43 in] thick • Hand grinder to smooth the surface created when the rib is removed • Radial drill or drill press with sufficient throat clearance to drill the holes for the cross bolts • A 14 mm [17/32-in] drill bit to drill the holes for the cross bolts • A 38 mm [1 1/2-in] diameter spot-face tool or end mill to machine clearance for the flat washers installed on the cross bolts. Parts Required: NOTE: All the parts required, except the sealant, are available in a kit, Part Number 3176123. • 3 each - Part Number 3176117, Stud • 12 each - Part Number S-264, Flat Washer • 12 each - Part Number S-200, Nut [1/2-13 UNC] • 6 each - Part Number S-608, Lock Washer • 1 each - Part Number 3177132, RTV Sealant If the stud, Part Number 3176117, is not available, a part can be fabricated to the dimensions illustrated and specified. Reference No. 1 2 3 4

mm 350 12 114 M12x1.75

in 13-0.75 0.5 4-0.5 1/2-13 UNC



NOTE: The front to the rear hole center dimension can be determined by using the three threaded holes for the cover, marked "+", that are nearest to the center of the housing. Use a center punch and a hammer. Mark the location for the holes on the top (9) of the housing. Reference No. 5 6 7 8

mm 248 250 361 362 474 475 99

MIN MAX MIN MAX MIN MAX MAX

in 9.770 9.830 14.210 14.270 18.650 18.710 3.90

Use a center punch and a hammer. Mark the location for the holes on the bottom (10) of the housing. The specifications are the same as for the top of the housing.

NOTE: This step is not required if the housing contains a rib in the center of the casting. CAUTION The covers must be installed on housings that do not contain a rib to prevent the housing from bending during the drilling operation. Install the aftercooler covers. Install a minimum of six capscrews in the holes illustrated. Torque Value: 27 N•m [ 20 ft-lb ]



Put the housing on the table of the radial drill or drill press. Be sure the housing is secured to the table of the drill to prevent movement during the drilling process. NOTE: If a metric cross bolt is installed, use the correct size drill bit. Use the drill size given for the stud from the kit or a stud fabricated from a [0.5 in] rod. Use a 14 mm [17/32] drill bit. Drill three holes in the bottom or top of the housing. Repeat this step to drill the three holes in the other side of the housing.

NOTE: The spot-face must only be of sufficient depth to be sure the flat washer will have full contact with the housing and will be 90 degrees from the centerline of the drilled hole. Use a 38 mm [1.5 in] spot-face tool or end mill. Spot-face each of the six holes on the top and bottom of the housing. Remove the housing from the drill press.

Remove the covers from the housing that do not have a rib.

CAUTION Do not use a large hammer, or a hammer and chisel to remove the rib. The housing will be damaged. Use a band or a hand saw. Remove the center rib. NOTE: If a saw is not available, drill several holes as near together as possible in the rib near the walls of the housing. Then very carefully break or saw the material to connect the holes.


NOTE: If a saw was used, it is possible that this step is not necessary. Use a hand-type grinder. Remove all sharp edges and burrs that remain on the housing from the rib.

Check the six holes on the inside of the housing. Be sure the washer (9) can be placed flat on the surface of the housing. If the remainder of the rib causes the washer not to be flat on the surface, use the spot-face tool or end mill to remove the material so that the washer can be placed flat on the housing. CAUTION Be sure there is no oil around the holes that were drilled. Any oil will prevent the proper curing of the RTV sealant. Use solvent or steam. Clean the parts. NOTE: Refer to the following steps to install the three studs. NOTE: When installing the stud, Part Number 3176117, the end of the stud with the longest thread length must be inserted first, or there will not be sufficient clearance to install the second stud. Insert one end of the stud through the hole. Install a nut (10). Turn the nut until it is on the last thread, nearest to the center of the stud. Install the flat washer (11).

Insert the stud through the hole in the other side of the housing. Install a nut (10) and a flat washer (11). Turn both nuts until they are approximately 25 mm [1 in] from the surface of the housing.




Apply the RTV sealant to the surface of the housing where the washer will touch, and in the hole around the stud.

CAUTION Do not use a wrench to turn the nuts on the inside of the housing. If the nuts on the inside of the housing are too tight, the housing will bend, causing failure. Use your hand. Turn the nuts until the washers touch the housing. Be sure the stud protrudes the same length at the top and the bottom of the housing.

Apply sealant to the outside of the housing at the top and the bottom where the flat washer touches, and in the hole around the stud.

Install the flat washers (10), lock washers (12), and the nuts (11) on the studs. Turn each nut until the flat washer touches the housing. Tighten the nuts alternately and evenly. Torque Value: 102 N•m [ 75 ft-lb ]


Aftercooler Water Outlet Tube Page 10-167

Aftercooler Water Inlet Tube (010-074) Clean and Inspect for Reuse 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. 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.

Aftercooler (010-075)

Water

Outlet

Tube

Clean and Inspect for Reuse Center-Mount NOTE: Two water outlet tubes are required for each engine. 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 Page 10-168


Check the tube for cracks or damage from corrosion. Check to be sure the tube is not restricted because of mineral deposits. Remove any mineral deposits.

K38, K50, QSK38, and QSK50 Section 11 — Exhaust System — Group 11

Page 11-a

Section 11 — Exhaust System — Group 11 Section Contents Page Bellows ..........................................................................................................................................................11-36 Finishing Steps............................................................................................................................................. 11-37 Install............................................................................................................................................................11-36 Preparatory Steps......................................................................................................................................... 11-36 Remove.........................................................................................................................................................11-36 Exhaust Connection Pipe ................................................................................................................................11-2 Clean and Inspect for Reuse...........................................................................................................................11-2 Finishing Steps...............................................................................................................................................11-3 Install..............................................................................................................................................................11-3 Preparatory Steps...........................................................................................................................................11-2 Remove..........................................................................................................................................................11-2 Exhaust Manifold (Wet) Water Connections .................................................................................................11-33 Clean and Inspect for Reuse......................................................................................................................... 11-34 MAI............................................................................................................................................................11-34 Finishing Steps............................................................................................................................................. 11-35 MAI............................................................................................................................................................11-35 Install............................................................................................................................................................11-34 MAI............................................................................................................................................................11-34 Preparatory Steps......................................................................................................................................... 11-33 Remove.........................................................................................................................................................11-33 MAI............................................................................................................................................................11-33 Exhaust Manifold, Dry .....................................................................................................................................11-4 Assemble........................................................................................................................................................11-9 Clean and Inspect for Reuse...........................................................................................................................11-7 Disassemble...................................................................................................................................................11-7 Finishing Steps............................................................................................................................................. 11-23 General Information.........................................................................................................................................11-4 Install............................................................................................................................................................11-10 KT38 and KTA38 with Dry Exhaust Manifolds.............................................................................................11-10 KTTA38 with Dry Exhaust Manifolds...........................................................................................................11-11 KT38 and KTA38 with Dry Exhaust Manifolds.............................................................................................11-11 KTA50 Dry Exhaust Manifolds....................................................................................................................11-13 KTTA50 Dry Exhaust, Log Type Manifolds..................................................................................................11-14 K50 Dry Exhaust, Pulse Type Manifolds......................................................................................................11-15 K38 and K50 Bellows Manifold....................................................................................................................11-20 Preparatory Steps...........................................................................................................................................11-5 Remove..........................................................................................................................................................11-6 Exhaust Manifold, Wet ..................................................................................................................................11-24 Clean and Inspect for Reuse......................................................................................................................... 11-26 EAI.............................................................................................................................................................11-26 Finishing Steps............................................................................................................................................. 11-31 EAI.............................................................................................................................................................11-31 Install............................................................................................................................................................11-28 EAI.............................................................................................................................................................11-28 Preparatory Steps......................................................................................................................................... 11-24 EAI.............................................................................................................................................................11-24 Remove.........................................................................................................................................................11-25 EAI.............................................................................................................................................................11-25 Exhaust Restriction .......................................................................................................................................11-31 Measure........................................................................................................................................................11-31 Service Tools ...................................................................................................................................................11-1 Exhaust System Dataplate...............................................................................................................................11-1

Page 11-b





Service Tools Exhaust System Dataplate


Tool No.

Tool Description Manometer (Mercury Filled Slack Tube) Used to measure exhaust restriction.

ST-1111-3


Used to speed asembly and disassembly of studs, bolts, capscrews, flanges, and fittings.

Nylon Lifting Strap 2 in by 6 ft Used to aid in the removal and installation of heavy components. 3375958




Tool Illustration

Exhaust Connection Pipe Page 11-2


Exhaust Connection Pipe (011-001) Preparatory Steps • Remove the bolts securing the OEM exhaust connection pipe. Refer to manufacturer's installation instructions.

Remove Remove the eight nuts and bolts from each flange connecting the exhaust connection pipe to the exhaust bellows.

WARNING 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.

Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING 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.


Inspect the exhaust connection pipe for any signs of damage or deterioration. If damage is found that will allow exhaust gas leakage, replace the exhaust connection pipe.

Install WARNING 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 ]

Install the eight nuts and bolts on each flange connecting the exhaust connection pipe to the exhaust bellows. Torque Value: 195 N•m [ 140 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 Connection Pipe Page 11-3

Exhaust Manifold, Dry Page 11-4


Exhaust Manifold, Dry (011-007) General Information The manifold parts and mounting hardware are not the same for all K38 and K50 engines. Because the parts are different, procedures are described for installation of the exhaust manifolds for: • KT38 and KTA38 Dry Exhaust Manifolds • KTTA38 Dry Exhaust Manifolds • KT38 and KTA38 Dry Exhaust Manifolds with Center Mount Turbochargers (Outboard aftercoolers) • KT38, KTA38, and KTA50 Wet Exhaust Manifolds • KTA50 Dry Exhaust Manifolds • KTTA50 Dry Exhaust, Log Type Manifolds • KTA50, KTTA50, K1500E, K1800E and K2000E Dry Exhaust, Pulse Type Manifolds • K38 and K50 Bellows Manifolds. The marine exhaust system is used on the K38 M0/M1/ M2/D(M1) and the K50M2/D(M1) engines. The marine exhaust manifold side profile is shown.

The marine exhaust manifold bellows has a different design than the industrial exhaust manifold bellows. The marine exhaust manifold bellows is shown.


The exhaust manifold bellows gasket, Part Number 3966350, is located in the end of the bellows. The bellows will not seal without the gasket in place.

The illustration shows the marine exhaust manifold bellows with the gasket fitted in place.

Preparatory Steps WARNING 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.




On KTTA engines, remove the low pressure turbocharger support brackets.

Remove Use a drift and hammer to bend the lock plates away from the capscrew heads. NOTE: All engines do not contain this type of lockplate. Some engines contain a lockplate that snaps over the capscrew head. Some engines have locking capscrews that do not require lockplates.

WARNING 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.


Disassemble Use a mallet to separate the manifold sections.

Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING 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.




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. Check for cracks in the areas shown. Check all turbocharger mounting studs for damage.

If a manifold section is to be installed again, measure the inside diameter (1) and the outside diameter (2) of the connecting manifold section. The inside diameter can be a maximum of 0.063 mm [0.0025 in] larger than the outside diameter. The inside diameter and the outside diameter can be the same size.


WARNING 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.




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 antiseize 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] capscrew Torque Value: 76 mm [3 in] capscrew with N stamped on head Torque Value: 76 mm [3 in] capscrew without N stamped on head

60 N•m

[ 44 ft-lb ]

55 N•m

[ 41 ft-lb ]

80 N•m

[ 59 ft-lb ]

NOTE: Capscrews without the N stamped on the head have special threads to lock the capscrew and are not available for service. The torque value is included in case they are used again. NOTE: Lockplates are not required on capscrews with locking threads. Use a 5/8 inch 12 point socket and a mallet to install each lockplate (5) on the heads of two capscrews. Do not break the lockplate.


KTTA38 with Dry Exhaust Manifolds WARNING 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. 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 following information applies to center-mount turbochargers with outboard aftercoolers only. The manifold center section must be installed on the correct engine bank for the engine exhaust piping to fit the application. If the exhaust is to be toward the rear of the engine, the center section (8) with the smallest angle must be installed on the right bank. If the exhaust is to be toward the front of the engine, the center section (8) with the smallest angle must be installed on the left bank.




Install the mounting capscrews (2) that are 114 mm [4.5 in] in length and hardened washers (1) for the center section of the manifold. Install the mounting capscrews (4) that are 76 mm [3 in] in length and the spacers (3) that are 42.4 mm [1.67 in] for the end sections. Install the washers (1) on the capscrews (2). Install the spacers (3) on the capscrews (4). Apply an anti-seize compound on the threads of the capscrews. NOTE: The gasket must be installed so the raised bead on the gasket is toward the manifold. Install the gaskets (5), manifold (6), and 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.


KTA50 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. 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] capscrew with N stamped on head Torque Value: 140 mm [5.5 in] and 38 mm [1.5 in] capscrews without N stamped on head

55 N•m

[ 41 ft-lb ]

80 N•m

[ 59 ft-lb ]

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.




KTTA50 Dry Exhaust, Log Type 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. 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] capscrew with N stamped on head Torque Value: 140 mm [5.5 in] and 38 mm [1.5 in] capscrews without N stamped on head

55 N•m

[ 41 ft-lb ]

80 N•m

[ 59 ft-lb ]

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.


K50 Dry Exhaust, Pulse Type Manifolds This procedure applies to the KTA50, KTTA50, K1500E, K1800E, 2000E manifolds also. KTA50 engines with pulse-type manifolds contain a straight center section (1) on one bank and a curved center section (2) on the other bank. The manifold center sections must be installed on the correct engine bank for the engine exhaust piping to fit the application. If the exhaust is to be toward the rear of the engine, the manifold with the straight center section (1) must be installed on the left bank. If the exhaust is to be toward the front of the engine, the straight center section must be installed on the right bank. KTTA50 engines with pulse-type manifolds contain a straight center section (1) in both banks. These manifolds can be installed on either engine bank. A variety of changes were made to the K50 pulse-type exhaust manifolds (1, 2, and 3) and manifold mounting parts (7, 8, and 9).

A revised straight center section, Part Number 3630241, replaced the previous straight center section, Part Number 3626757 or 3628682. This revised straight center section is to be used on nonuprate K50 engines that require a pulse manifold (example: KTA50C-1600 engine).




This manifold, Part Number 3630241, can be identified by a notch in the exhaust port nearest to the two exhaust inlets or double end. The previous manifold, Part Number 3626757 or 3628682, did not have a notch.

The notch can also be seen in the lower exhaust inlet.

Uprate construction K50 exhaust manifold center sections require a higher thermal fatigue strength material (NiResist). The distance between the two exhaust inlets or the double end has increased.

A dogleg exhaust manifold section, Part Number 3627878, was released for use on uprate K50 construction engines to accommodate this increased distance.


The uprate construction straight center section, Part Number 3629532, is to be used on the K2000E, KTTA50C1800-B version, and on the left bank of the K1800E.

The construction uprate curved center section is to be used on the right bank of the K1800E. The K1800E right-bank center section allows for rear-out exhaust. Engine Serial Number First for Sections Serial Number Section Part Number 33122641 3627877 33122641 3627878 33124817 3630241 * 3629532 * Engine serial number first build date is March 1994. The manifolds have been changed by increasing the size of the dowel hole (A) to the same diameter, 15 mm [0.591 in], as the other seven mounting holes within each section. The smaller dowel hole was used to locate the manifold front to rear to make sure the slip joint was properly positioned.

CAUTION Guide pins or studs must be used or the manifolds will not be positioned properly, causing the manifold cylinder head capscrews to break. Use locating pins to position the new manifolds properly. Use one pin in each section. The diameter of the pin provides the proper manifold position and alignment.




The locating pin dimensions are listed below so they can be locally manufactured. (A) Diameter: 13.8 mm to 14.0 mm [0.543 in to 0.551 in]. (B) Undercut to thread root diameter (C) Thread size 0.438 in x 14 in x 0.50 in long (D) Unthreaded length 99.2 mm [3.91 in]. NOTE: Wrench flats are optional on unthreaded end.

Inadequate clearance between exhaust manifold sections (A and B) will result in failed capscrews, exhaust manifolds, or cylinder heads. Use guide pins or studs to make sure the manifolds have proper clearance (C and D). The typical manifold clearance (C) ranges from 4.0 to 9.5 mm [0.158 to 0.374 in].

Longer exhaust manifold mounting capscrews and spacers provide improved gasket sealing while permitting slippage or movement at the cylinder head and exhaust manifold interface. Part Name Spacer-A Spacer-B

Old Dimension New Dimension 42.4 mm [1.67 in] 105.6 mm [4.16 in] 76.2 mm [3.00 in] 139.7 mm [5.50 in]

NOTE: The longer capscrews and spacers can be used in all positions except the left-bank front without any component changes. Installation of longer capscrews and spacers in the left-bank front position requires a new thermostat housing support and water transfer tube. New capscrews and spacers can be used on any K50 pulsetype manifold part number.


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 ] NOTE: When installing the lockplate over the capscrew head, install the plate to approximately one-half of the head height. Installing the lockplate until it bottoms will cause it to break. In order to obtain clearance (A) for the longer capscrews and spacers, three other component changes have been made. 1. A clearance (A) has been cast into the thermostat housing support to permit wrench and lockplate clearance.

2. The water transfer tube (A) from the front of the Vcavity to the thermostat housing support interferes with the capscrew lockplate (B). A flat has been added to the water transfer tube (A) to help prevent interference with the capscrew lockplate (B) when the longer spacers are used. The dotted line (C) represents the flat added to the tube.




NOTE: Do not install the old lockplate, Part Number 3043912, upside down to clear the water tube. The lockplate will either break or not be retained properly on the capscrew head. 3. To increase the water-tube-to-lockplate clearance even more, a new lockplate was released. The new lockplate has the V-bend pointed downward toward the manifold, rather than upward. These changes were introduced in November 1994 (ESN first 33128992).

K38 and K50 Bellows Manifold Install the bellows to both sides of the bolt-together manifold sections. Securing the bellows with V-band clamps, install the clamps with the tightening screw on the topside of the exhaust facing inboard. NOTE: Bellows must be installed correctly to prevent damage from the gas flow. The arrow in the picture indicates the correct direction of gas flow through the bellows.

Install additional bellows to the single inlet side of the center turbocharger mounting section, securing the bellows V-clamp, as above. Install the exhaust outlet adapter with the gasket.

Starting on the left bank of the engine, install gaskets of the correct thickness and install the bolt-together pulse section to cylinder heads 5 and 6. Leave the clamps loose at this point.


After installing the correct thickness gaskets, install the rear exhaust section while securing it to the bellows of the bolt-together section just installed. If the rocker housings are on the engine, then it will be necessary to loosen the bolt-together pulse section capscrews to allow the V-clamp to be fitted. Leave the capscrews loose at this point.

Install the center turbocharger mounting section while securing it to the two bellows of the bolt-together pulse section. Leave the main securing capscrews loose at this point.

Install the final end section of the exhaust system, leaving the capscrews loose at this point.




Remove two upper capscrews from the center sections of the exhaust system. Make sure the exhaust section is centered with the tapped holes in the cylinder heads. Tighten the main securing capscrews. Torque Value: 54 N•m [ 40 ft-lb ] Move either direction to the next section and remove two capscrews. Center the exhaust manifold over the tapped holes. Tighten the main capscrews. Torque Value: 54 N•m [ 40 ft-lb ] NOTE: It is important that each section of the exhaust system be centralized to the tapped holes in the cylinder head before tightening mounting capscrews and V-band clamps. It is also important that the bellows be installed correctly for the gas flow direction. Position the V-band clamps at approximately 110 degrees to the exhaust mounting face. Torque Value: Tighten the marine application Vband clamp Torque Value: Tighten the industrial application Vband clamp

17 N•m [ 150 in-lb ]

5 N•m

[ 44 in-lb ]

Repeat the above installation instructions on right bank.

CAUTION Installing the lockplate until it bottoms will cause it to break. NOTE: When installing the lockplate over the capscrew head, install the plate to approximately one-half of the head height. Install lockplates on the heads of all exhaust manifold capscrews.


Finishing Steps On KTTA engines, install the low pressure turbocharger support brackets.

WARNING 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 Page 11-24


Exhaust Manifold, Wet (011-008) Preparatory Steps EAI 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 (EngineMounted)) 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.


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.

Remove the elbows from the exhaust manifold. Discard the o-rings.

Remove the hose clamps from the front of the water transfer tubes.

Remove the capscrews, the top halves of the isolators, and the transfer tube. Remove the lower halves of the transfer tube isolators.




WARNING 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.

Remove the capscrews from the bottom two holes of each cylinder head exhaust port; replace with guide studs.

Remove the upper capscrews connecting the exhaust manifold to the cylinder heads. Lift and remove the exhaust manifold. Discard the gaskets.

Clean and Inspect for Reuse EAI Use a wire brush or scraper to clean the cylinder head to exhaust manifold surface. Remove the guide studs, if necessary replace after cleaning.


WARNING Wear safety glasses of a face shield, as well as protective clothing, to prevent personal injury when using a steam cleaner or high-pressure water. Use a steam cleaner or high pressure water to clean the exhaust manifold. Use a wire brush or scraper to remove any scale on the exhaust manifold sealing joint inside and outside diameters.

Inspect the exhaust manifold turbocharger mating flange for cracks. If cracks or other damage is found, replace the exhaust manifold.

Inspect the mounting capscrew holes and water transfer elbow mounting area for damage. If cracks or other damage is found, replace the exhaust manifold.

Inspect the elbows and hoses for signs of damage or wear. If damage is found, replace the elbows and/or hoses.




Inspect the water transfer tubes for leakage or other signs of damage.

Inspect the isolators and capscrews for damage or wear. Inspect the capscrews for damaged threads or corrosion.

Install EAI With the guide studs still in the bottom two holes of each cylinder head exhaust port, install the exhaust gaskets.

Start the exhaust manifold onto the guide studs. Push the exhaust manifold in until it contacts the cylinder head.


Apply anti-seize compound to the exhaust mounting capscrews and install the washers and capscrews into the top row of mounting holes. Hand tighten the capscrews. Remove the lifting straps.

Remove the guide studs, apply anti-seize compound to the exhaust mounting capscrews, and install the washers and capscrews.

Tighten the capscrews in the sequence illustrated. Torque Value: 54 to 61 N•m [ 40 to 45 ft-lb ]

Install the lower half of the transfer tube isolators. Install the transfer tube, top half of the isolators, and the capscrews. Torque Value: 20 N•m [ 177 in-lb ]




Install the Staub clamps on the front of the water transfer tubes. Torque Value: 8 N•m [ 71 in-lb ]

Use new o-rings and install the elbows on the exhaust manifold.

Install the water hoses from the transfer tubes to the inlet elbows. Align the fittings and hose connections. Tighten the fittings and hose connections.


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 (EngineMounted)) 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.

Exhaust Restriction (011-009) Measure Connect a pressure gauge in the exhaust piping. The gauge must have a capacity of 75 mm Hg [3 inch Hg] or 1270 mm H2O [50 inch H2O]

Exhaust Restriction Page 11-31

Exhaust Restriction Page 11-32


The pressure gauge adapter, or fitting, must be installed at a 90-degree angle to the exhaust flow in a straight section of pipe. The adapter location must be a minimum of 254 mm [10 in] after the turbocharger. The adapter must not extend through the wall of the exhaust tubing. If the adapter must be located in a curved section of tubing, locate it on the flat side of the curve, not in the radius, or the measured valve will not be accurate. Connect a 305 mm [12 in] piece of metal tubing between the gauge adapter and the gauge hose. This will prevent damage to the hose from extreme heat. Operate the engine at rated rpm and load; record the manometer reading. NOTE: Exhaust pressure must not exceed 7.5 cm [3.0 Hg].

If the exhaust restriction exceeds the specification, inspect the exhaust piping for damage. Refer to the OEM's instructions. If damage is not visible, check the size and routing of the exhaust piping. Refer to the installation recommendation bulletin.

Remove the test equipment.


Exhaust Manifold (Wet) Connections (011-016)

Exhaust Manifold (Wet) Water Connections Page 11-33

Water

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 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 (CenterMount Aftercooler)) in Section 10. • Remove the center mounted aftercooler. Refer to Procedure 010-003 (Aftercooler Assembly (CenterMount)) 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.



Clean and Inspect for Reuse MAI Clean and check the water connections for reuse.

Install MAI NOTE: The engine has two water connections. The installation procedure is the same for both. NOTE: If the o-rings have not been installed on the water tubes, install them. Use vegetable oil. Lubricate the o-rings. Position the connection (1) between the water tubes. Push the tubes into the bore of the connection. Install the two flat washers, lock washers, and capscrews (2). 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 ]


NOTE: The plug is to be installed only on the exhaust manifold at the left bank rear of the engine. Install the o-ring on the plug. Use vegetable oil. Lubricate the o-ring. Install the plug in the bore in the exhaust manifold. Install the spacer, lock washer, and capscrew. The spacer will hold the plug in the bore. Torque Value: 20 N•m [ 177 in-lb ]

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 (CenterMount)) in Section 10. • Install the water transfer inlet and outlet connections. Refer to Procedure 010-020 (Air Crossover (CenterMount 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 Page 11-36


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 ]


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 Page 11-37

Bellows Page 11-38


Notes

K38, K50, QSK38, and QSK50 Section 12 — Compressed Air System — Group 12

Page 12-a

Section 12 — Compressed Air System — Group 12 Section Contents Page Air Compressor ............................................................................................................................................. 12-13 Finishing Steps............................................................................................................................................. 12-18 with Mechanically Actuated Injector............................................................................................................12-18 Install............................................................................................................................................................12-16 with Mechanically Actuated Injector............................................................................................................12-16 Preparatory Steps......................................................................................................................................... 12-13 with Mechanically Actuated Injector............................................................................................................12-13 Remove.........................................................................................................................................................12-14 with Mechanically Actuated Injector............................................................................................................12-14 Air Compressor (Oil Carryover) .................................................................................................................... 12-22 Inspect for Reuse..........................................................................................................................................12-22 Air Compressor Carbon Buildup .....................................................................................................................12-4 Inspect............................................................................................................................................................12-4 Air Compressor Pin Bore Wear .......................................................................................................................12-6 Initial Check....................................................................................................................................................12-6 Air Compressor Unloader and Valve Assembly .............................................................................................12-9 Assemble......................................................................................................................................................12-11 Holset® QE230, QE296, and QE338 A/C Model.......................................................................................... 12-11 Clean and Inspect for Reuse......................................................................................................................... 12-10 Disassemble..................................................................................................................................................12-10 Holset® QE230, QE296, and QE338 A/C Model.......................................................................................... 12-10 Finishing Steps............................................................................................................................................. 12-13 Initial Check....................................................................................................................................................12-9 Air Governor (Air Compressor Pumps Continuously) ..................................................................................12-19 Initial Check..................................................................................................................................................12-19 Air Governor (Air Compressor Will Not Pump) .............................................................................................12-18 Initial Check..................................................................................................................................................12-18 Air Leaks, Compressed Air System ..............................................................................................................12-21 Initial Check..................................................................................................................................................12-21 Air Starting Motor ..........................................................................................................................................12-23 General Information.......................................................................................................................................12-23 Service Tools ...................................................................................................................................................12-1 Compressed Air System..................................................................................................................................12-1

Page 12-b





Service Tools Compressed Air System


Tool No.

Tool Description Ball Joint Vise Used to hold the air compressor for disassembly or assembly.

ST-302

Standard Puller ST-647

Used to pull the drive gear. Use with puller capscrews that have M8 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

Valve Spring Tester 3375182

Used to check the exhaust valve, intake valve, and unloader valve cap springs.

Coupling Puller Used to remove the spline coupling hub. 3376663

Tool Illustration



Tool No.

Tool Description Air Compressor Seat Installation Tool Used to install exhaust valve seats.

3377415

Air Compressor Seat Removal Tool Used to remove exhaust valve seats. 3377416

Air Compressor Seat Socket 3823528

Used to remove and install exhaust valve seats and the inlet valve cages.

Valve Seat Puller ST-544

Used to remove exhaust valve seats on older compressors, where the head is mounted on the air compressor.

Compressor Exhaust Valve Seat Kit 3822674

Tools used to pull and install the press fit nine hole exhaust seats in single cylinder Cummins air compressors.

Compressor Exhaust Valve Seat Kit 3822681

Kit that converts Compressor Exhaust Valve Seat Kit, Part Number 3822674, into a two cylinder air compressor kit.


Lubricant that speeds assembly and disassembly of studs, bolts, capscrews, flanges, and fittings.

Torque Wrench An inch-pound dial-type torque wrench 3824783

Tool Illustration


Tool No.

Tool Description Torque Wrench Used to tighten capscrews 13 to 136 N•m [10 to 100 ft-lb].

3164794


Tool Illustration

Air Compressor Carbon Buildup Page 12-4


Air Compressor (012-003)

Carbon

Buildup

Inspect 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.

Measure the total carbon deposit thickness inside the air discharge line as shown. The carbon deposit thickness must not exceed 1.6 mm [0.06 in].

WARNING The air discharge line must be capable of withstanding extreme heat and pressure to prevent personal injury and property damage. See to the manufacturer's specifications. If the total carbon deposit thickness exceeds specification, remove and clean, or replace the air discharge line. See to the manufacturer's material specifications.


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. Assemble the air compressor using new gaskets and orings; see to the Master Repair Manual, Holset® Air Compressors, Bulletin 3666121. Install and tighten the air inlet and outlet connections.

Close the wet tank drain cock. Operate the engine and check for air leaks.

Air Compressor Carbon Buildup Page 12-5

Air Compressor Pin Bore Wear Page 12-6


On upright two cylinder air compressors, replace the air compressor.


Pin

Bore

Wear

Initial Check WARNING The unloader valve body is installed with spring tension. Use care when removing to reduce the possibility of personal injury. Always wear protective eye wear. NOTE: This procedure applies to SS and ST models only. Hold the unloader valve body down, and remove the two captive washer capscrews and the two plain washers. Remove the unloader valve body. Remove the o-ring. Remove the rectangular ring seal.

CAUTION To reduce the possibility of damage to the air compressor, do not allow any debris to fall into the air compressor cylinder. NOTE: Disassembly of the center unloader valve on Cummins® Turbo Technologies two-cylinder air compressors is similar to the single-cylinder unloader valve. Remove the unloader valve cap and the unloader valve spring. Remove the intake valve seat and valve. Remove the intake valve spring.


CAUTION Do not use a screwdriver. A screwdriver can gouge the top of the piston. Insert the small end of a 3/8-inch drive socket extension 152 to 254 mm (6- to 10-inches long) through the exhaust valve seat onto the top of the piston.

Bar the crankshaft over until the compressor piston reaches top dead center and the extension starts to move downward approximately 3 to 6 mm [1/8 to 1/4 in].

CAUTION To prevent damage to the top of the piston, do not use a hammer. Give a quick, hard push, downward on the extension, and listen for a metallic click as wear clearance is taken up.

If significant piston motion is felt or a metallic click is heard, the pin bores can be worn, and the compressor must be examined further.




All air compressors will not exhibit pin bore wear. If no motion or sound is heard, the compressor is in satisfactory condition and does not need to be replaced.

Remove the extension.

Install the intake valve spring with the tang down. Install the intake valve. Install the intake valve seat with the flange side up. Install the unloader valve cap spring. Install the unloader valve cap. Use high-temperature grease (Accrolube lubrication Teflon grease, or equivalent) to lubricate the outside diameter of the cap.

Install the rectangular ring seal with the grooved side up. Install the o-ring. Use clean engine oil to lubricate the o-ring seal. Install the unloader valve body. Press the unloader valve body down to be sure the tangs of the unloader valve cap are in the three slots of the intake valve seat.


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 ]

Air Compressor Unloader and Valve Assembly (012-013) Initial Check WARNING Air pressure must be released from system before removing the air governor to reduce the possibility of personal injury. NOTE: The illustrations shown will be of the SS model single-cylinder air compressor. Differences in procedures for SS, QE, and ST model Cummins® Turbo Technologies air compressors will be shown where necessary. Remove the air governor or air governor hose from the air compressor unloader body. Operate the engine to activate the air compressor. If the air compressor is not pumping, the unloader valve is malfunctioning and must be repaired or replaced.

Air Compressor Unloader and Valve Assembly Page 12-9



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. NOTE: Disassembly of the center unloader valve on Cummins® Turbo Technologies two-cylinder air compressors is similar to the single-cylinder unloader valve. Remove the unloader valve cap and the unloader valve spring. Remove the intake valve seat and valve. Remove the intake valve spring.

Holset® QE230, QE296, and QE338 A/C Model WARNING 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.

Clean and Inspect for Reuse CAUTION Do not use caustic cleaners. Caustic cleaners can cause damage to component parts. Remove all carbon and varnish from the unloader valve cap body.


For Cummins® Turbo Technologies two-cylinder air compressors, check both cylinder and center unloader springs. Cummins® Turbo Technologies recommends that new springs be installed during rebuild. Use a valve spring tester to check the unloader spring. See the Compressor Spring Force Specifications chart in the Cummins® Turbo Technologies Air Compressor Master Repair Manual, Bulletin 3666121. Replace the unloader spring if it does not meet the specifications shown, or if the wrong spring has been used.

If the compressor has a flat hat type of unloader cap (1), it must use an unloader spring and valve seat different from that used with the three-prong unloader.

Assemble The following steps are for the Cummins® Turbo Technologies SS, E-Type, and ST models. Apply high-temperature grease (Accrolube lubrication teflon grease or equivalent) to the rectangular ring seal, unloader cap, and unloader body bore. Install the unloader spring, cap, and valve body. Tighten the capscrews. Torque Value: 14 N•m [ 120 in-lb ]

Holset® QE230, QE296, and QE338 A/C Model Install the new rectangular V-seal into the unloader body with the grooved side up. Liberally lubricate the unloader valve bore above and below the rectangular ring seal with high-temperature grease (Accrolube lubrication Teflon grease, or equivalent).




Install a new o-ring on the unloader valve body.

Use clean 15W-40 oil or Accrolube lubrication Teflon grease (or equivalent) to lubricate the seal.

Liberally lubricate the unloader valve body bore and unloader cap with high-temperature grease (Accrolube lubrication Teflon grease, or the equivalent). Install the unloader cap. Install the unloader spring.

Lubricate the unloader capscrew threads and underhead with clean engine oil (SAE 15W-40) before installation. NOTE: The two unloader body screws must not be used to attach any brackets.


The longer capscrews are used to mount the manifold to the air compressor. Assemble the unloader components and attach the unloader assembly to the valve plate with the four capscrews and washers. Torque Value: 27 N•m [ 20 ft-lb ]

Finishing Steps Operate the engine and check for leaks.

Air Compressor (012-014) 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 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 Page 12-13



Remove with Mechanically Actuated Injector Remove the air inlet and outlet connections from the air compressor.

Remove the fuel pump. Refer to Procedure 005-016.

NOTE: Not all engines are equipped with this option. NOTE: A Cummins® Two cylinder air compressor is shown. Remove the air compressor coolant inlet tube. Remove and discard the rectangular seals.

Remove the two capscrews (7) that hold the support bracket to the cylinder block. The heavy washers (5) are special.


WARNING 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.

Inspect the splined coupling for cracks or other damage.

Use a dial indicator and magnetic base, Part Numbers 3376051 and 3377399, to check the crankshaft end clearance. End Clearance mm 0.04 0.24

MIN MAX

in 0.0015 0.0095




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 12point 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 ]


Install the rectangular seals on the air compressor water inlet tube. Install the water inlet tube to the fittings on the front of the air compressor and the side of the engine cylinder block. NOTE: The air compressor water outlet tube is to be installed after the thermostat support is installed. NOTE: The air compressor oil drain tube is to be installed after the oil pan and adapter assembly has been installed.

Install the fuel pump. Refer to Procedure 005-016.

Install the air inlet and outlet connections to the air compressor. Tighten the clamps. Torque Value: 6 N•m [ 50 in-lb ]


Air Governor (Air Compressor Will Not Pump) Page 12-18


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.

Air Governor (Air Compressor Will Not Pump) (012-017) Initial Check Remove the air governor or air governor line from the air compressor unloader body.

CAUTION Without the air signal from the air governor, the air compressor will continue to pump. Do not continue to operate the air compressor at pressures greater than 930 kPa [135 psi] air pressure. If the pressure is exceeded, air hoses or tanks may rupture suddenly, causing damage. 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.


If the air compressor does not pump, remove, clean, and inspect the air compressor unloader valve assembly.

Air Governor (Air Compressor Pumps Continuously) (012-018) Initial Check NOTE: If the air govenor is remote mounted, do not disconnect the line from the air compressor unloader valve. Remove the air accessory air lines from the air compressor governor.

Install pipe plugs in the air governor unloader ports where accessory air lines were removed. Operate the engine to activate the air compressor. If the air compressor stops pumping (air pressure stops rising) at the governed air pressure, there is a leak in an accessory or an accessory air line. See to the equipment manufacturer's instructions for troubleshooting and repair.

If the air compressor does not stop pumping (air pressure continues to rise) at the governed air pressure, connect a regulated shop air pressure line to one of the following: The air compressor unloader valve port One of the air governor unloader valve ports.

Air Governor (Air Compressor Pumps Continuously) Page 12-19

Air Governor (Air Compressor Pumps Continuously) Page 12-20


Make sure the air pressure gauge is accurate, and the supply lines and fittings are in good condition, before performing any air pressure checks. Use a master gauge of known accuracy to check the air pressure gauge.

Apply 690-kPa [100-psi] air pressure to the unloader port. If the air compressor stops pumping (air pressure stops rising), the air governor is malfunctioning and must be repaired or replaced, or the air governor mounting gasket is leaking. See to the OEM's instructions.

If the air compressor continues to pump (air pressure continues to rise), the unloader valve is malfunctioning and must be repaired or replaced.

Remove the pipe plugs from the unloader ports used for accessory air lines. Install and tighten the accessory air lines. Connect the line to the unloader valve.


Operate the engine and check for air leaks.

Air Leaks, Compressed Air System (012-019) Initial Check 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 singlecylinder 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 to activate the air compressor. With the air compressor pumping between 550 to 690 kPa [80 to 100 psi], use a solution of soapy water to check for air leaks in the following areas: • Air compressor cover gasket • Unloader body o-ring • Air compressor head gasket • Air compressor valve plate gasket (QE models only) • Hose and fitting leaks. If air leaks are found, replace the leaking gasket or o-ring. Refer to the Master Repair Manual, Holset® Air Compressors, Bulletin 3666121.

Air Leaks, Compressed Air System Page 12-21

Air Compressor (Oil Carryover) Page 12-22



(Oil

Carryover)

Inspect for Reuse NOTE: The illustrations shown will be of the singlecylinder air compressor. Differences in procedure for oneor two-cylinder Cummins air compressors will be shown where necessary. Cycle the air compressor five times while viewing the discharge from the air dryer. If the discharge appears excessively oily, perform the following check.

Remove the air compressor line from the air compressor. Apply regulated air pressure to the air governor unloader port. Air Pressure: 690 kPa [ 100 psi ]

Operate the engine at low idle for 10 minutes with the air compressor unloaded (shop air applied to the unloader port). Remove the shop air pressure from the unloader port. Operate the engine at low idle for 10 minutes with a white cloth over the air compressor discharge port.

Remove the white cloth, and check the cloth for contamination. If the cloth indicates more than a trace of gray, the air compressor is using an excessive amount of oil and must be replaced. Refer to Procedure 012-014.


Install and tighten the air discharge line. Operate the engine and check for air leaks.

Air Starting Motor (012-022) General Information An engine air starting motor is shown in the illustration. The air starting motor system (tanks, line sizes, and valves) is designed and installed by the OEM and the starting motor suppliers. Refer any questions about the air starting systems to the manufacturer. Do not operate the air starting motor with air pressure lower than 480 kPa [70 psi]. Maintain the air compressor according to the recommendations outlined in the component manufacturer's manual. For maximum efficiency, the hoses, tubes, and lines must not leak. Refer to the OEM and starting motor manufacturer's manuals for specific information regarding the starting motors, valves, and systems.

Air Starting Motor Page 12-23

Air Starting Motor Page 12-24


Notes

K38, K50, QSK38, and QSK50 Section 13 — Electrical Equipment — Group 13

Page 13-a

Section 13 — Electrical Equipment — Group 13 Section Contents Page Alternator .........................................................................................................................................................13-3 Finishing Steps...............................................................................................................................................13-6 Inspect for Reuse............................................................................................................................................13-4 Install..............................................................................................................................................................13-4 Preparatory Steps...........................................................................................................................................13-3 Remove..........................................................................................................................................................13-3 Alternator Adjusting Link ..............................................................................................................................13-22 Adjust............................................................................................................................................................13-23 Clean and Inspect for Reuse......................................................................................................................... 13-22 Inspect for Reuse..........................................................................................................................................13-22 Alternator Pulley ............................................................................................................................................13-10 Finishing Steps............................................................................................................................................. 13-11 Install............................................................................................................................................................13-11 Preparatory Steps......................................................................................................................................... 13-10 Remove.........................................................................................................................................................13-10 Alternator Bracket ...........................................................................................................................................13-7 Clean and Inspect for Reuse...........................................................................................................................13-7 Finishing Steps...............................................................................................................................................13-8 Install..............................................................................................................................................................13-8 Preparatory Steps...........................................................................................................................................13-7 Remove..........................................................................................................................................................13-7 Batteries ........................................................................................................................................................ 13-12 Inspect..........................................................................................................................................................13-12 Battery Cables and Connections .................................................................................................................. 13-13 Initial Check..................................................................................................................................................13-13 Drive Belt, Alternator ......................................................................................................................................13-9 Finishing Steps............................................................................................................................................. 13-10 Inspect for Reuse............................................................................................................................................13-9 Install..............................................................................................................................................................13-9 Preparatory Steps...........................................................................................................................................13-9 Remove..........................................................................................................................................................13-9 Service Tools ...................................................................................................................................................13-1 Electrical Equipment.......................................................................................................................................13-1 Starter Magnetic Switch ................................................................................................................................13-14 Inspect for Reuse..........................................................................................................................................13-14 Starter Solenoid .............................................................................................................................................13-17 Voltage Check...............................................................................................................................................13-17 Starter Switch ................................................................................................................................................13-16 Test...............................................................................................................................................................13-16 Starting Motor ................................................................................................................................................13-20 Clean and Inspect for Reuse......................................................................................................................... 13-20 Finishing Steps............................................................................................................................................. 13-21 Install............................................................................................................................................................13-21 Preparatory Steps......................................................................................................................................... 13-20 Remove.........................................................................................................................................................13-20

Page 13-b





Service Tools Electrical Equipment


Tool No.

Tool Description Belt Tensioner Gauge Used to measure alternator belt tension.

ST-1193

Digital Multimeter 3164488

This is an auto-ranging digital multimeter that includes functions of DC and AC voltage, current, resistance, continuity, and diode test. It comes with test leads and a protective boot that surrounds the meter.

Automotive Meter 3164489

This auto-ranging digital multimeter includes the functions of frequency, capacitance, and temperature (with a built-in temperature module). Also included are the functions: RPM, Dwell, Duty Cycle, and Pulse Width. Inductive Charging - Cranking Systems Analyzer

3377193

Used to test generators, alternators, relays, starters, regulators, and batteries. Contains built- in voltmeter and ammeter.



Tool Illustration



Tool No.

Tool Description Spark Plug Socket

4918793

Removes spark plugs. The CSA application uses a 22 mm [0.875 in] thread size plug. The non-CSA application uses a 21 mm [0.8125 in] thread size plug.

Tool Illustration


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.

NOTE: The three capscrews are SAE Grade 8 and the three spacers are hardened. Keep the parts together to aid the assembly procedure. Remove the parts as shown.

Alternator with a guard. Remove the alternator brace to the front gear cover. Remove the two capscrews, four plain washers, and two lock washers.

Alternator Page 13-3



Inspect for Reuse Remove the nut and pulley from the alternator. Clean and check the pulley for reuse.

Install Alternator without a guard. Lubricate the shaft with engine oil. Install the pulley and nut on the alternator shaft. Tighten the pulley mounting nut. Torque Value: 100 N•m [ 75 ft-lb ] NOTE: New alternators will not operate correctly until the pulley mounting nut is correctly torqued.

NOTE: The belt must be installed and adjusted before the capscrews are tightened. NOTE: The end of the adjusting link with the largest area at the capscrew hole must be nearest to the alternator. Install the alternator and the adjusting link as shown.

CAUTION To avoid damage to the alternator belt, do not pry the belt onto the pulley. Install the belt. Turn the adjusting screw counterclockwise to shorten the link if necessary.


Alternator with a guard. Install the alternator brace to the front gear cover using two capscrews, four plain washers, and two lock washers (9). The plain washers act as spacers and must be installed between the alternator brace and the front gear cover. Use two spacers per capscrew. The lock washers are installed between the capscrew and alternator brace. Torque Value: 90 N•m [ 65 ft-lb ]

The alternator must swing through the same arc as the machined slot in the alternator brace. Fasten the alternator to the alternator brace using the capscrew. Install the belt. Adjust the belt tension. Refer to Procedure 013-022 (Alternator Adjusting Link) in Section 13.

Install the vibration isolators (3 and 4) between the bottom bracket (6) and the main guard. Install the plain washer (2) and nut (1).

Do not overtighten the isolators. The compressed thickness of the vibration isolator must be approximately 13 mm [0.5 in].




Install a vibration isolator between the top bracket and the main guard.

Install the assembled belt guard onto the brace and alternator support bracket with three capscrews. Tighten the capscrews. Torque Value: 45 N•m [ 35 ft-lb ] NOTE: The belt and pulleys must not contact the guard or brackets. Loosen the three capscrews and adjust the guard if an interference is detected. The alternator brace has slotted holes that allow a small amount of vertical movement.

Finishing Steps WARNING 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.


Alternator Bracket (013-003) 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 (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.

Clean and Inspect for Reuse 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 Page 13-7

Alternator Bracket Page 13-8


Check the threads of the capscrews for damage. Check the bracket for cracks. Check the bores for wear. Replace any parts that are damaged or worn.

Install Check to be sure the two sleeves (1) are installed in the bracket. The sleeves move in the bracket as the capscrews are tightened to the front gear cover and housing. NOTE: The capscrews (4) are SAE Grade 8. The heavy flat washers (3) are hardened. The washers have a notch for identification. These parts are used because they must clamp the gear cover and housing properly, while withstanding the torque and vibration of the alternator. Install the bracket (2), the flat washers (3), and the two capscrews (4). 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.


Drive Belt, Alternator (013-005) Preparatory Steps • Loosen the alternator adjusting link. Refer to Procedure 013-022 (Alternator Adjusting Link) in Section 13.

Remove Remove the alternator drive belt.

Inspect for Reuse Check the belt for wear or other damage. If the belt indicates any wear or other damage, it must be replaced.

Install Install the alternator belt.

Drive Belt, Alternator Page 13-9

Alternator Pulley Page 13-10


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.

Alternator Pulley (013-006) 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 (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.


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.

Alternator Pulley Page 13-11

Batteries Page 13-12


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 manufacturer's specifications.

water.

Refer

to

the

Do not attempt to check the specific gravity of a battery immediately after adding water. If it is necessary to add water to allow use of the hydrometer, charge the battery several minutes at a high rate to mix the electrolyte. Use a hydrometer to measure the specific gravity of each cell. Refer to the accompanying table to determine the battery state of charge based on the specific-gravity readings. Battery State of Charge 100 percent 75 percent 50 percent 25 percent Discharged

Specific Gravity @ 27°C [80°F] 1.260 to 1.280 1.230 to 1.250 1.200 to 1.220 1.170 to 1.190 1.110 to 1.130

If the specific gravity of any cell is below 1.200, the battery must be charged.


Battery Cables (013-009)

and

Connections

Initial Check There are two possible heavy-duty battery connections: • Battery terminal and clamp (1) • Threaded battery terminal and nut (2).

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.

If the connections are corroded, use a battery brush or wire brush to clean the connections until shiny. Make sure all debris is removed from the connecting surfaces.

WARNING 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.

Battery Cables and Connections Page 13-13

Starter Magnetic Switch Page 13-14


Starter Magnetic Switch (013-017) Inspect for Reuse Before inspecting specific starting system components with the multimeter: • Inspect terminals for loose, broken, or corroded connections. • Replace or repair wiring and components as necessary.

WARNING Be sure the starter switch is in the OFF position to reduce the possibility of electrical shock and personal injury. Remove the cable connecting the magnetic switch to the starter solenoid from the magnetic switch terminal. Connect the leads of digital multimeter, Part Number 3377161, to the two large switch terminals.

Set the multimeter to measure resistance. With the starter switch in the OFF position, the multimeter must indicate resistance at infinity. • If the multimeter indicates zero or very little resistance, replace the magnetic switch. • If the multimeter indicates resistance at infinity, proceed with the following instructions.

Turn the starter switch to the START position. The multimeter must indicate zero or very little resistance. A click will be heard when the starting switch is turned to the START position.


If the multimeter indicates resistance at infinity with the starter switch in the START position and a click is not heard: • Turn the starter switch to the OFF position. • Set the multimeter scale to indicate DC voltage.

Connect the positive (+) lead of the multimeter to the magnetic switch ground wire terminal and the other lead to the small magnetic switch terminal. Turn the starter switch to the START position. The multimeter will indicate some voltage across the magnetic switch terminals. If the multimeter indicates Full System Voltage, the magnetic switch is malfunctioning and must be replaced.

If the multimeter indicates no voltage, the magnetic switch is not the cause of the complaint. Refer to Procedure 013-018.

Turn the starter switch to the OFF position. Remove the multimeter leads and connect the magnetic switch to the starter solenoid wire.

Starter Magnetic Switch Page 13-15

Starter Switch Page 13-16


Starter Switch (013-018) Test WARNING Be sure the starter switch is in the OFF position to reduce the possibility of electrical shock and personal injury. Remove the wire connecting the starter switch to the magnetic switch from the starter switch terminal. Connect the positive (+) lead of the digital multimeter, Part Number 3377161, to the starter switch terminal and the negative (-) lead to a chassis or engine ground location. With the starter switch in the OFF position, there must not be voltage at the starter switch terminal. If the multimeter indicates voltage, the starter switch is malfunctioning and must be replaced.

Turn the starter switch to the START position. The multimeter must indicate system voltage.

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.


If the multimeter indicates system voltage, the starter switch is defective and must be replaced.

If the multimeter indicates no voltage, the switch is not the cause of the complaint.

Inspect the wiring from the starter switch to the starter solenoid and from the starter solenoid to the battery. Replace any broken or damaged wires.

Starter Solenoid (013-019) Voltage Check Use the multimeter, Part Number 3377161, and set it to measure VDC. Connect the multimeter positive (+) lead to the starter solenoid positive (+) cable terminal and the negative (• ) lead to the battery cable connection at the starting motor. The multimeter must show system voltage.

Starter Solenoid Page 13-17



If the multimeter does not indicate system voltage, check the battery to starting motor cable for broken, loose, or corroded connections.

If the multimeter indicates system voltage, but the starting motor will not operate, check the wire connecting the starter solenoid to the starter switch for broken, loose, or corroded connections.

If the wire connecting the starter solenoid and starter switch is not loose or damaged and the starter will not operate: • Remove the cable connecting the starting motor and starter solenoid from the solenoid terminal. • Connect the multimeter positive (+) lead to the solenoid positive (+) terminal and the negative (• ) lead to a chassis or engine ground.

Turn the starter switch to the START position. If the multimeter indicates system voltage, the starter solenoid is malfunctioning and must be replaced.


If the multimeter does not indicate system voltage, check the wire connecting the starter solenoid to the magnetic switch for broken, loose, or corroded connections.

If the wire connecting the starter solenoid to the magnetic switch is not loose or damaged and the starting motor will not operate, check the cable connecting the starter solenoid to the starting motor for broken, loose, or corroded connections.

Check the cable connecting the starter to the battery for broken, loose, or corroded connections.

If the cables are not loose or damaged, the starting motor is defective and must be replaced.


Starting Motor Page 13-20


Starting Motor (013-020) 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 battery. Refer to Procedure 013-009 (Battery and Cable Connections) in Section 13.

Remove Remove the electrical connections from the starter motor.

Remove the starter motor capscrews, starter, spacers, and gaskets. Discard the gaskets.

Clean and Inspect for Reuse 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.


Install CAUTION Make sure to use the same thickness of starter motor spacer (1), (if used), as the one removed to install the starter motor to prevent engine or starter motor damage. NOTE: Installation of the top electric starter motor first on K38 and K50 series engines will simplify the installation of both starter motors.

Install the starter motor and capscrews. Tighten the capscrews. Torque Value: Cast Iron Flywheel Housing

215 N•m

[ 160 ft-lb ]

Torque Value: Aluminium Flywheel Housing

195 N•m

[ 145 ft-lb ]

Install the electrical connections to the starter motor.

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.

Starting Motor Page 13-21

Alternator Adjusting Link Page 13-22


Alternator Adjusting Link (013-022) Clean and Inspect for Reuse 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. Check the adjusting link threads for damage. Replace any parts that are damaged or worn.

Inspect for Reuse Use the belt tension gauge. Check the belt tension. Alternator belt tension Gauge Part Number. Tension ST-1293 (Burrough) 165 lb ST-1274 (Kriket) 88 lb


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.

Turn the adjusting screw clockwise to tighten the belt tension.

Tighten the jam nuts on the adjusting screw to 55 N•m [40 ft-lb]. Tighten the adjusting link and alternator mounting capscrews. Torque Value: Nut 1

95 N•m

[ 70 ft-lb ]

Torque Value: Nut 2

70 N•m

[ 55 ft-lb ]

Torque Value: Nut 3

95 N•m

[ 70 ft-lb ]

Check the belt tension again to make sure it is correct.




Notes

K38, K50, QSK38, and QSK50 Section 14 — Engine Testing — Group 14

Page 14-a

Section 14 — Engine Testing — Group 14 Section Contents Page Dynamometer Worksheet ................................................................................................................................14-4 Worksheet.......................................................................................................................................................14-4 Engine Compression .....................................................................................................................................14-52 Finishing Steps............................................................................................................................................. 14-56 Preparatory Steps......................................................................................................................................... 14-52 Pressure Differential Test..............................................................................................................................14-54 Setup............................................................................................................................................................14-53 Engine Run-in (Engine Dynamometer) ..........................................................................................................14-25 General Information.......................................................................................................................................14-25 Run-In Instructions........................................................................................................................................14-25 with Mechanically Actuated Injector............................................................................................................14-25 with Electronically Actuated Injector............................................................................................................14-43 Engine Run-in (Without Dynamometer) ........................................................................................................14-11 Run-In Instructions........................................................................................................................................14-11 Engine Testing (Chassis Dynamometer) ........................................................................................................14-5 Test................................................................................................................................................................14-5 Engine Speed (rpm)......................................................................................................................................14-5 Fuel Pressure...............................................................................................................................................14-6 Fuel Rate.....................................................................................................................................................14-6 Fuel Inlet Restriction.....................................................................................................................................14-6 Fuel Drain Line Restriction...........................................................................................................................14-6 Intake Manifold Pressure..............................................................................................................................14-7 Intake Manifold Air Temperature Control - Chassis Dynamometer test..........................................................14-7 Intake Air Restriction....................................................................................................................................14-8 Intake Manifold Air Temperature Control - Chassis Dynamometer test..........................................................14-8 Engine Blowby.............................................................................................................................................14-8 Lubricating Oil Pressure.............................................................................................................................14-10 Air Compressor.......................................................................................................................................... 14-11 Starting Motor............................................................................................................................................ 14-11 Engine Testing (Engine Dynamometer) ........................................................................................................14-12 General Information.......................................................................................................................................14-12 Install............................................................................................................................................................14-12 Coolant Plumbing.......................................................................................................................................14-12 Intake Air Temperature Control...................................................................................................................14-13 LTA............................................................................................................................................................14-13 Test............................................................................................................................................................14-13 Engine Throttle Control...............................................................................................................................14-15 Test...............................................................................................................................................................14-19 Engine Speed (rpm)....................................................................................................................................14-20 Fuel Drain Line Restriction......................................................................................................................... 14-20 Intake Air Restriction..................................................................................................................................14-20 Exhaust Air Restriction...............................................................................................................................14-21 Engine Blowby........................................................................................................................................... 14-21 Lubricating Oil Pressure.............................................................................................................................14-23 Engine Coolant Pressure............................................................................................................................14-23 Air Compressor.......................................................................................................................................... 14-24 Starting Motor............................................................................................................................................ 14-24 Service Tools ...................................................................................................................................................14-1 Engine Testing................................................................................................................................................14-1

Page 14-b





Service Tools Engine Testing


Tool No.

Tool Description Manometer Used with blowby orifice for measuring engine crankcase pressure.

3164875

Blowby Check Tool (0.354 inch Orifice) 3822567

Used with manometer Part Number ST-1111-3 to measure engine crankcase pressure.

Blowby Check Tool (0.406 inch Orifice) 3822568

Used with manometer Part Number ST-1111-3 to measure engine crankcase pressure. Cummins recommends this orifice be used on the KTA38GC engine for blowby measure.

Bottle Stopper Blowby Tool (0.302 inch Orifice) 3375150

Used with manometer Part Number ST-1111-3 to measure engine crankcase pressure.

Differential Pressure Tester 3824223

This tester with appropriate leak test adapter checks individual cylinders to locate sources of leaks or excessive blowby. Use adapter, Part number 4918177, with this tester for use on the 14 mm spark plugs. Filter Wench Used to remove spin on filters.

3400157

Tool Illustration



Tool No.

Tool Description Filter Wrench Strap Type up to 152 mm [6 inch] Used to remove spin on filters.

3400158

Engine Lift Fixture Kit Used to lift the engine during installation or removal. 3163264

Engine Lift Fixture Kit Used to lift the engine during installation or removal. 3375109

Pressure Gauge [0 to 75 in-Hg] Used to measure intake manifold pressure turbo boost. ST-1273

Pressure Gauge [0 to 100 psi] Used to measure lubricating oil pressure. 3375275

Pressure Gauge [0 to 600 psi] 3375932

Used to measure fuel pressure. Includes necessary hoses and hardware attached to a fuel pump.

Fuel Flow Measuring Instrument 3376375

Used to measure the fuel rate consumption of a Cummins® diesel engine.

Digital Optical Tachometer Used to measure engine speed (rpm). 3377462

Tool Illustration


Tool No.


Tool Description Vacuum Gauge Used to check fuel filter or intake air restriction.

ST-434

Engine Control 3163890

Used to operator the engine out-of-chassis on the QSK50 engines. Used with the Engine Control Harness, Part Number 4918643.

Engine Control Harness 4918643

Used to operate the engine out-of-chassis on the QSK50 with electronically actuated injectors.

INLINE™5 Adapter Kit 4918416

Used with the Engine Control, Part Number 3163890 and the Engine Control harness, Part Number 4918643. Used with the SAE J1939 standard protocol. Used with INSITE™ electronic service tool 6.3 or later versions.

Tool Illustration

Dynamometer Worksheet Page 14-4


Dynamometer Worksheet (014-001) Worksheet Date: ESN: Complaint:

Repair Order No: CPL:

PARAMETER Fuel Pressure (psi @ rpm) Fuel Pressure (psi @ rpm) Fuel Pressure (psi @ rpm) Fuel Rate (lb/hr) Intake Mfd. Pressure (in.Hg) Intake Mfd. Temperature *Intake Air Restriction

Operator: Fuel Pump Code: SC Code:

CODE SPECIFICATIONS 150 to 180 psi at Idle 225 to 250 psi at 1800 rpm 250 to 300 psi at 2100 rpm

ACTUAL READING

See Fuel Pump Code 25 in. H 2 O, Maximum

*Exhaust Air Restriction 3 in. Hg, Maximum *Fuel Inlet Restriction 8 in. Hg (Dirty Filter), Maximum *Fuel Drain Line Restriction 3 psi, Maximum Engine Blowby See Tables * Recorded at maximum horsepower speed and full load Road Speed Limit Check Oil Level Engine Speed

Low

Fuel *Rate/Press Fuel Temp

Engine High Speed Limit OK Fuel Quality

High

Turbo Inlet Intake Manifold Air Temp Temp/Press

Coolant Temp/ Press

* Be sure that the fuel rate is corrected for temperature. Fuel Temperature Less than 7°C [45°F] 7 to 13°C [45 to 55°F] 13.0 to 20.0°C [55 to 68°F] 20.0 to 29°C [68 to 85°F] 29 to 42°C [85 to 108°F] 42 to 56°C [108 to 132°F] 56°C above [132°F] Pressure Conversions 1 in. H 2 0 = 0.074 in. Hg = 0.036 psi 1 in. Hg = 13.514 in. H 2 0 = 0.491 psi 1 psi = 2.036 in. Hg = 27.7 in. H 2 0 This Page Can Be Copied For Your Convenience.

Correction for Flow Rate Flow meter not accurate Subtract 2% from flow rate reading Subtract 1% from flow rate reading No Correction Add 1% to flow rate reading Add 2% to flow rate reading Flow meter not accurate.

OK

Not OK

Engine Lube Oil HP or Blowby Press Torque


Engine Testing Dynamometer) (014-002)

Engine Testing (Chassis Dynamometer) Page 14-5

(Chassis

Test To monitor engine performance properly, record the following parameters. To limit dynamometer operating time, instrument the engine to perform as many checks as possible. The INSITE™ tool will provide most if not all of the following: • Engine speed rpm with a verified tachometer • Fuel pressure • Fuel rate • Fuel temperature (if needed to correct fuel rate) • Fuel inlet restriction • Fuel drain line restriction • Intake manifold pressure (per bank). • • • • • • • •

Intake air restriction (per bank) Exhaust air restriction (per bank) Coolant temperature Engine blowby Lubricating oil pressure Coolant pressure Inlet manifold air temperature Turbocharger inlet air temperature.

Engine Speed (rpm) Use digital optical tachometer, Part Number 3377462, to check and verify engine speed.



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.

Fuel Inlet Restriction Use the INSITE™ electronic service tool or pressure gauge ST-434 to measure the fuel restriction between the fuel filter and the gear pump inlet. Refer to Procedure 006-020.

Fuel Drain Line Restriction Use pressure gauge, Part Number ST-1273, to measure fuel drain line restriction. Refer to Procedure 006-012.


Intake Manifold Pressure Measure the intake manifold pressure (turbocharger boost). This test can be done using the INSITE™ electronic service tool or manually, or the appropriate electronic service tool manual.

Intake Manifold Air Temperature Control - Chassis Dynamometer test When operating an engine on a dynamometer, follow these steps for best results and safe operation. If the engine is equipped with an automatic fan, lock the cooling fan in the ON mode. This can be done by installing a jumper across the temperature switch, or by supplying shop air to the control valve. Refer to the fan drive manufacturer for the recommended procedure.

Monitor the intake manifold air temperature using INSITE™ electronic service tool in the monitor mode, or install Fluke digital thermometer, Part Number 3822666, and thermocouple wire kit, Part Number 3822988, into the intake manifold. The intake manifold air temperature must not exceed 77° C [171°F]. Maintain intake manifold air temperature to 66°C [110°F] or below during chassis dynamometer operation.

If the intake manifold temperature exceeds 77°C [171°F], shut off the engine. Allow the engine to cool. Check the fan drive. Be sure the fan is locked in the ON mode. Remove any obstructions such as a winterfront or debris. Manually lock the shutters in the OPEN position if equipped. Inspect the dynamometer room for adequate supply of suitably cool or outside air. Make sure that dynamometer room recirculation is not an issue. Resume the test.




Intake Air Restriction Measure the inlet air restriction. Install a manometer, Part Number ST-1111-3, in the intake air piping. The gauge adapter must be installed at a 90-degree angle to the airflow in a straight section of pipe at a minimum of one pipe diameter before the turbocharger. Refer to Procedure 010-031..

Intake Manifold Air Temperature Control - Chassis Dynamometer test Measure the exhaust air restriction. Install the pressure gauge, Part Number ST-1273, or a manometer Part Number ST-1111-3, in the exhaust air piping. The gauge adapter must be installed near the turbocharger in a straight section of pipe at the turbine outlet. Refer to Procedure 011-009.

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].

Use a length of hose (1) to attach the blowby tool to one of the crankcase breathers. Attach a manometer to the location shown (2).


Operate the engine at rated rpm and full load (wide-open throttle) until a steady reading is obtained. Compare the blowby readings to previous readings on the engine. If previous readings for the engine are not available, compare the blowby reading to new engine specifications. Engine Blowby 10-mm [0.406-in] Orifice rpm = All ratings mm H2O in H2O New/Rebuilt Engine 127 MAX 5 Used Engine 330 MAX 13 A sudden increase in blowby indicates a problem. A gradual increase over a period of time is normal (due to wear of internal engine components). If the blowby is higher than normal, check the crankcase breathers and breather tubes to see whether they are plugged.

Check the engine oil level. If the level is too high, it can cause a higher than normal crankcase pressure.

Operate the engine at rated speed. Record the blowby value.




Isolate the air compressor to determine whether it is malfunctioning and causing the high blowby pressure. Relieve the air pressure on the first air tank in the system after the air compressor (wet tank). Disconnect the air inlet and outlet connections. Plug the intake manifold or air piping where the inlet connection was removed.

Operate the engine at rated speed and full load (wideopen throttle) until a steady blowby reading is obtained. Compare the blowby readings to the previous value. If the blowby is now acceptable, replace the air compressor. Refer to Procedure 012-014.

A sudden increase in blowby or a high reading that is not steady indicates that there is internal damage in the engine. To determine which cylinder is at fault, refer to the Troubleshooting Trees, Section TS.

Lubricating Oil Pressure Use pressure gauge, Part Number. 3375275, or the INSITE™ tool to measure lubricating oil pressure. . Install the pressure gauge to the main oil rifle (1) or oil filter head (2). Lubricating Oil Pressure kPa Low Idle (Minimum 138 MAX Allowable) At 1200 rpm (Minimum 207 MAX Allowable)

psi 20 30


Engine Run-in (Without Dynamometer) Page 14-11

Air Compressor All air compressors manufactured by Cummins Inc. must be operating during the engine run-in. During the performance check, all air compressors must be in the unload or nonoperating mode. Connect a source of compressed air capable of providing 665 kPa [97 psi] to the air compressor unloader (1). This air line must contain a valve between the source and the unloader. The compressed air load in the accompanying illustration must be attached to the air compressor outlet (2).

Use an air tank (2). Install an air regulator (3) capable of maintaining 345- to 517-kPa [50- to 75-psi] air pressure at both minimum and maximum engine rpm. Install a steel tube or high-temperature hose (1). Hose Temperature (Minimum): 260 °C [ 500 °F ] Connect the tube or hose (1) to the air compressor outlet.

Starting Motor Inspect the voltage rating on the starting motor before installing the electrical wiring. Install the electrical wiring to the starting motor and batteries, if used. If another method of starting the engine is used, follow the OEM instructions to make the necessary connections.

Engine Run-in (Without Dynamometer) (014-004) Run-In Instructions CAUTION Do not operate the engine at rated speed for the initial 1 to 2 hours, or 100 to 150 kilometers [50 to 100 miles]. CAUTION Do not allow the engine to "IDLE" for more than 5 minutes during the initial 2 hours, or 150 kilometers [100 miles]. Operate the engine as near as possible to the run-in-period schedule described in procedure 014-006, Engine Runin-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) Page 14-12


Engine Testing (Engine Dynamometer) (014-005) General Information This document provides procedures for the use of an engine control, Part Number 3163890. The engine control is a portable, handheld electronic control, used to start and control engine speed on the Cummins® electronic engines. It replaces the throttle pedal, driver interface panel, and fault code monitoring circuits. The engine control has a datalink provision to connect to an electronic service tool to monitor engine operation and fault codes. The engine control harnesses required for the engines are purchased separately. The engine control and engine control harnesses are designed to be used with both (+) 12-VDC and (+) 24-VDC battery systems. NOTE: The engine control can be used on engines with frequency throttle calibrations by first downloading a linear throttle calibration to the electronic control module (ECM). After the testing/repair is complete, reload the correct frequency throttle calibration.

Install NOTE: Make certain that the dynamometer capacity is sufficient to permit testing at 100 percent of the engine's rated horsepower. If the capacity is not enough, the testing procedure must be modified to the restrictions of the dynamometer. Use engine lifting fixture, Part Number 3163264, 3375109, or equivalent, to install the engine to the test stand. Align and connect the dynamometer. See the manufacturer's instructions for aligning and testing the engine.

Coolant Plumbing Connect the coolant supply to the water inlet connection. Connect the coolant return to the water outlet connection. Install the drain plugs, and close all of the water drain cocks. NOTE: Low temperature aftercooler engines require connecting the low temperature aftercooler water lines to a remote heat exchanger.


Intake Air Temperature Control The use of a remote heat exchanger is mandatory whenever a Cummins low temperature aftercooler engine is attached to an engine dynamometer for the purpose of engine run-in, performance testing, and engine diagnostics. Do not attempt to run a Cummins low temperature aftercooler engine without any means of controlling the intake manifold air temperature. A. Aftercooler water out B. Aftercooler water in C. Cooling water out to drain D. Cooling water in.

LTA All industrial engines require low temperature aftercooler and, therefore, have unique radiator requirements. The heat exchanger must be sized to maintain 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.




For engines without an automatic prelube device, use a pump capable of supplying 205-kPa [30-psi] continuous pressure. Remove the pipe plug at the front rear underside of the one-piece lubricating oil filter head. Install an extended elbow (1) into the rear port the pipe plug was removed from. The final position of this elbow is facing the rear of the engine and slightly inboard to make certain that the check valve clears the front filter on the one-piece lubricating filter head. Tighten the elbow. Torque Value: 60 N•m [ 44 ft-lb ] Apply a small amount of Loctite 641 to the tapered threads of the male adapter (3) and install it into the flow end of the check valve (2). Apply a small amount of Loctite 641 to the tapered threads of the extended elbow (1) and install the check valve with the arrow pointing the elbow in the lubricating oil filter head. Tighten the check valve. Torque Value: 48 N•m [ 35 ft-lb ] Connect the pump to the male adapter. Use a supply of clean oil. Turn the pump to the ON position. Check the engine oil pressure gauge. When the gauge indicates oil pressure, begin monitoring the oil level in the oil pan. Remove the pump. Remove the extended elbow (1), check valve (2), and adapter (3) from the lubricating oil filter head. Install the pipe plug.

Check the engine lubricating oil level to make sure it is filled to the proper level. Use a known source of good-quality number 2 diesel fuel. Number 1 diesel fuels, along with most other alternate fuels, are lighter (lower specific gravity, higher API gravity) than number 2 diesel fuel. The lighter the fuel, the lower the energy content per gallon (liter).


WARNING 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.

Engine Throttle Control Electrically Actuated Injectors 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). Disconnect the OEM harness 16-pin and 31-pin Deutsch connectors from the engine wiring harness. Connect the engine control harness, Part Number 4918643. Connect the engine control harness 16-pin and 31-pin Deutsch connectors to the engine wiring harness. Remove the 3-pin Deutsch terminating resistor cap (cap will have a blue insert) from the wiring harness. Connect the engine control harness 3-pin Deutsch connector to the J1939 connector of the engine wiring harness. The 3-pin Deutsch terminating resistor cap must be installed after the engine control harness is removed. If the cap is broken or has been misplaced, replace with resistor cap, Part Number 3163051.




NOTE: If additional cable length is needed to connect the engine control, use electrical cable, Part Number 3163895. Connect the engine control harness (2) to the engine control. An INSITE™ electronic service tool equipped personal computer can be used to monitor circuits for proper operation. Connect the INLINE™5 datalink adapter kit (3), Part Number 4918416, and a personal computer to the datalink connector of the engine control.

Engines that are run on an engine dynamometer require the engine harness be installed and connected to the engine. Additionally, the engine control, Part Number 3163890, must be used to properly control the engine during the dynamometer run.

Ground Connection Connect the black-wire alligator clip of the engine control harness to the engine block to achieve electrical ground.

CAUTION Do not connect the alligator clip to the starter motor solenoid “S” terminal. Doing so can cause equipment damage. Starter Connection If not already equipped, install and wire a magnetic starter switch. Clip the alligator connector to the positive (+) coil terminal of the magnetic starter switch.


Air Starter If an air starter is being used, coil the red wire into a loop and secure the loop to the engine control harness to protect it from an electrical short.

WARNING Batteries can emit explosive gases. To avoid personal injury, always ventilate the compartment before servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Connect battery power to the starter. Connect the dynamometer test OEM wiring harness starter solenoid lead (yellow) to the starter solenoid. Connect the ground lead (black) to the starter solenoid. Connect the ground lead (black) to the starter or battery negative (-) or ground side. Connect the (+) 12 VDC power lead (red) to either the starter or battery positive (+) 12 VDC side. Rotate the throttle knob fully counterclockwise. Push down on the throttle knob to return the throttle to the idle position. Repeat this step three times. Turn the keyswitch to the OFF position for 30 seconds.

CAUTION Check coolant and lubricating oil levels before starting and operating engine. If coolant and lubricating oil are not at the proper level engine damage can result. Turn the keyswitch to the START position until the engine starts and release the keyswitch.




CAUTION Verify the red wire is connected to the positive (+) battery terminal and the black wire is connected to the negative (-) battery terminal. Equipment or engine damage can result if not connected properly. The power light will illuminate when power is supplied and the keyswitch is turned to the accessory or ON position. If the power light does not illuminate, return the keyswitch to the OFF position. Verify the red wire is connected to the positive (+) battery terminal and the black wire is connected to the negative (-) battery terminal. Turn the keyswitch to the ON position. Light indicators on the engine control, STOP, WARN, MAINT, WIF, and WAIT TO START, will illuminate, if applicable. The light indicators will illuminate for approximately 30 seconds. If no fault codes are found, the light indicators will extinguish. If the STOP light indicator (red) or WARN light indicator (yellow) continues to illuminate, use INSITE™ electronic service tool and the OEM service literature to diagnose the engine fault code.


NOTE: The engine can be returned to idle at any time by pushing in on the throttle knob. Slowly rotate the throttle knob counterclockwise to increase the engine rpm. Slowly rotate the throttle knob clockwise to decrease the engine rpm.


Turn the keyswitch to the OFF position to stop the engine.

Return parameters to their original values when the test or run-in is complete. Connect the keyswitch panel datalink cable to the Cummins electronic service tool. Use INSITE™ electronic service tool to set the engine up for the dynamometer. The setup is now complete, and the auto/manual throttle can be used to control engine speed.

Engine operating specifications are available from Cummins authorized repair locations.

Test To properly monitor engine performance, record the following parameters. To limit dynamometer operating time, instrument the engine to make as many checks as possible. The INSITE™ electronic service tool will provide most, if not all, of the following: • Engine speed rpm with a verified tachometer • Fuel pressure • Fuel rate • Fuel temperature (if needed to correct fuel rate) • Fuel inlet restriction • Fuel drain line restriction • Intake manifold pressure (per bank).




• • • • • • • •

Intake air restriction (per bank) Exhaust air restriction (per bank) Coolant temperature Engine blowby Lubricating oil pressure Coolant pressure Inlet manifold air temperature Turbocharger inlet air temperature.

Engine Speed (rpm) Use digital optical tachometer, Part Number 3377462, to check the engine speed.

Fuel Drain Line Restriction NOTE: Do not measure fuel drain line restriction with the fuel measuring device installed. This will not measure the drain line restriction of the vehicle's return plumbing. Use pressure gauge, Part Number ST-1273, to measure fuel drain line restriction. Refer to Procedure 006-012.

Intake Air Restriction Install the gauge adapter at a 90-degree angle to the airflow in a straight section of pipe at a minimum of one pipe diameter before the turbocharger. Install the vacuum gauge, Part Number ST-434, or a manometer, Part Number ST-1111-3, in the intake air piping. Measure the inlet air restriction. Refer to Procedure 010-031.


Exhaust Air Restriction Install the gauge adapter near the turbocharger, in a straight section of pipe at the turbine outlet. Install the pressure gauge, Part Number ST-1273, or a manometer in the exhaust air piping. Measure the exhaust air restriction. Refer to Procedure 011-009.

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]. Blowby Tool Part Number 3822570 3822571

Orifice Size 9.00 mm [0.354 in] 10.30 mm [0.406 in]

Use a length of hose (1) to attach the blowby tool to one of the crankcase breathers. Attach a manometer to the location shown (2).




Operate the engine at rated rpm and full load (wide open throttle) until a steady reading is obtained. Compare the blowby readings to previous readings on the engine. If previous readings for the engine are not available, compare the blowby reading to new engine specifications. A sudden increase in blowby indicates a problem. A gradual increase over time is normal (due to wear of internal engine components).

If the blowby is higher than normal, check the crankcase breathers and breather tubes to see whether they are plugged.

Check the engine oil level. If the level is too high, it can cause a higher than normal crankcase pressure.

Isolate the air compressor to determine whether it is malfunctioning and causing the high blowby pressure. Relieve the air pressure on the first air tank in the system after the air compressor (wet tank). Disconnect the air inlet and outlet connections. Plug the intake manifold or air piping where the inlet connection was removed.



Operate the engine at rated speed and full load (wideopen throttle) until a steady blowby reading is obtained. Compare the blowby readings to the previous value. If the blowby is acceptable, replace the air compressor. Refer to Procedure 012-014.

A sudden increase in blowby or a high reading that is not steady indicates that there is internal damage in the engine.

Lubricating Oil Pressure Use pressure gauge, Part Number 3375275, to measure lubricating oil pressure. Install the pressure gauge to the main oil rifle (1) or air filter head (2). Lubricating Oil Pressure kPa Low Idle 138 MIN Rated rpm 413 MIN

psi 20 60

Engine Coolant Pressure Measure the coolant pressure at the water manifold (1). Coolant Pressure kPa 241

MAX

psi 35



Air Compressor All air compressors manufactured by Cummins Inc. must be operating during the engine run-in. During the performance check, all air compressors must be in the unloaded or non-operating mode. Connect a source of compressed air capable of producing 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).

Use an air tank (2). Install an air regulator (3) capable of maintaining 345- to 517-kPa [50- to 75-psi] air pressure at both minimum and maximum engine rpm. Install a steel tube or high-temperature flexible hose (1) capable of 260°C [500°F]. Connect the tube or hose (1) to the air compressor outlet.

Starting Motor Inspect the voltage rating on the starting motor before installing the electrical wiring. Install the electrical wiring to the starting motor and batteries, if used. NOTE: If another method of starting the engine is used, follow the manufacturer's instructions to make the necessary connections.


Engine Run-in (Engine Dynamometer) (014-006) General Information This document provides procedures for the use of an engine control, Part Number 3163890. The engine control is a portable, handheld electronic control, used to start and control engine speed on the Cummins® electronic engine families. It replaces the throttle pedal, driver interface panel, and fault code monitoring circuits. The engine control has a datalink provision to connect to an electronic service tool to monitor engine operation and fault codes. The engine control harnesses required for the engines are purchased separately. The engine control and engine control harnesses are designed to be used with both (+) 12-VDC and (+) 24-VDC battery systems. NOTE: The engine control can be used on engines with frequency throttle calibrations by first downloading a linear throttle calibration to the electronic control module (ECM). After the testing/repair is complete, reload the correct frequency throttle calibration.

Run-In Instructions with Mechanically Actuated Injector The performance of an engine installed in a vehicle can be tested on a chassis dynamometer.

Engine Speed (rpm) - Measure At the tachometer drive Measure the engine RPM at the tachometer drive location (1). This RPM is the same as the crankshaft RPM. Minimum Gauge Capacity: 2500 RPM

Engine Run-in (Engine Dynamometer) Page 14-25



With a verified tachometer Use digital optical tachometer, Part Number 3377462, to check and verify speed.

Oil Pressure - Measure Measure the engine oil pressure at location (1). Minimum Gauge Capacity: 1034 kPa [150 psi]

Oil Temperature - Measure Measure the oil temperature at the oil pan sump. Minimum Gauge Capacity: 149°C [300°F]

Coolant Temperature - Measure Measure the coolant temperature at the thermostat housing support. The measurement of the coolant outlet temperature for both banks of the engine can aid during troubleshooting. Minimum Gauge Capacity: 107°C [225°F]



Engine Blowby - Measure Measure the engine blowby (crankcase pressure). Use one of the two blowby service tool kits and a manometer. Minimum Gauge Capacity: 1270 mm-H 20 [50 in-H 20]

CAUTION The engine blowby tools are designed similar. The difference between the tools is the size of the orifice. Use a length of hose (1) to attach a blowby tool to each of the two crankcase breathers. Attach a manometer to the location shown (2). The other tool must be plugged (3). NOTE: Make certain that the blowby tool with the correct orifice size is used. Blow-By Tool Kit Part Number 3822570 3822571

mm

in

9.00 10.31

0.354 0.406

NOTE: Each tool kit contains two orifices. Fuel Rail Pressure - Measure Measure the fuel rail pressure at the fitting at the fuel pump outlet. Minimum Gauge Capacity: 2070 kPa [300 psi]



Air Manifold Pressure - Measure Measure the intake manifold pressure (boost) at the location shown. NOTE: Any of the plugs in the air crossover can be used. Minimum Gauge Capacity: 2286 mm-Hg [90 in-Hg]

Measure the intake manifold pressure (boost) at the location shown for KTA engines and KTTA engines with outboard aftercoolers. Use two manometers and measure the pressure for each bank of the engine.

Fuel Vacuum and Temperature - Measure Use a gauge. Do not use a manometer filled with liquid. The liquid will mix with the fuel and the measurement will not be accurate. Use one of the adapters listed below. Install the adapter as near to the fuel pump inlet as possible. Attach a vacuum gauge to the adapter. Hose Size 12 12 16

Adapter

Thread

Fitting Angle

3375845 3376719 3376922

1-1/16 - 14 1-1/16 - 12 1-5/16 - 12

45 Degrees 37 Degrees 37 Degrees

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.



Exhaust Pipes - Connect The I.D. of the exhaust pipe must be the correct size.

Minimum Exhaust Pipe Size mm 127 127 152 152 203

KT38 KTA38 KTTA38 KTA50, K1500E KTTA50, K2000E, K1800E

in 5.0 5.0 6.0 6.0 8.0

* Note:An engine with outboard aftercoolers and two center mount turbochargers.

Exhaust Back-Pressure and Temperature - Measure CAUTION The exhaust back-pressure sensor must be installed a minimum of 254 mm [10 in] from the turbocharger (2). The excessive heat will damage the sensor. Measure the exhaust temperature and the exhaust back pressure from the fittings in the exhaust pipe. Install the temperature sensor as near to the turbocharger as possible (1). Minimum Gauge Capacity: 649°C [1200°F] Minimum Gauge Capacity: 254 mm-Hg [10 in-Hg] Air Inlet Pipes - Connect NOTE: The inlet piping must contain a filter. Connect an air inlet restriction sensor (1) between the air filter and the turbocharger. Minimum Gauge Capacity: 1270 mm-H 20 [50 in-H 20].



Fuel Return Line Pressure - Measure Use a gauge. Do not use a manometer filled with liquid. The liquid will mix with the fuel and the measurement will not be accurate. Use one of the adapters listed below. Install the adapter between the check valve (1) and the fuel tank. Install a pressure gauge to the adapter. Minimum Gauge Capacity: 254 mm-Hg [10 in-Hg].

Hose Size 10 12 12

Adapter ST-434-2 3376719 3375845

Thread

Fitting Angle

7/8 - 14 1-1/16 - 12 1-1/16 - 14

37 Degrees 37 Degrees 45 Degrees

Oil Contamination - Monitor Use a lubricating oil sampling filter, Part Number ST-1135 (1) or equivalent. Connect the filter oil inlet hose to the location on the lubricating oil filter head as shown (2). The oil is not filtered at this location. Connect the sampling filter oil outlet hose to the sightglass hole in the oil pan adapter. See the filter manufacturer's instructions to perform the test. NOTE: If this tool is not available, inspect the full-flow oil filters after the engine test.

If the port on the lubricating oil filter head is in use, the sampling filter inlet can be connected at the pipe plug hole on the oil jumper cover on the block.


Piston Cooling Pressure - Measure (outboard piston cooling) NOTE: Measure the piston cooling oil pressure on both banks because there are two piston cooling pressure regulators. Measure the piston cooling oil rifle pressure in the location shown (1). NOTE: Some of the newer engines have rivet type plugs (AVSEALS) instead of threaded pipe plugs in the piston cooling nozzles. It will be necessary to fabricate test nozzles if the piston cooling pressure is to be measured. Remove the AVSEAL by drilling the center. Drill the nozzle to the proper size for the threads to accommodate a pipe fitting. Do not damage the nozzle spray nose or hole. Piston Cooling Pressure - Measure (inboard piston cooling) Minimum Gauge Capacity: 830 kPa [120 psi] NOTE: When the main oil rifle pressure exceeds 172 kPa [25 psi], the oil will begin to flow to the piston cooling rifle. When the main oil rifle pressure indicates 303 kPa [44 psi], the oil pressure in the piston cooling rifle must be within 69 kPa [10 psi] of the main oil rifle pressure.

Fuel Flow - Measure Because of excessive heat, do not connect the fuel flow measuring instrument until the engine run-in-period procedure is complete. Use a fuel flow measuring instrument, Part Number 3376375, to measure the fuel flow. See the manufacturer's instructions for installation and testing procedures.

Coolant Pressure - Measure On KT or KTA engines with the center mount aftercoolers, measure the coolant pressure at the water manifold (1). Minimum Gauge Capacity: 414 kPa [60 psi]




On KTA and KTTA engines with outboard aftercoolers, measure the coolant pressure at the cylinder block (2). Remove the draincock. Minimum Gauge Capacity: 414 kPa [60 psi]

Cooling System - Connect Install the coolant supply to the water pump (1). Install the coolant return to both of the connections on the thermostat housing (2). Install four Diesel Coolant Additive (DCA)/Supplemental Coolant Additive (SCA) water filters (3). Be sure the two Diesel Coolant Additive/Supplemental Coolant Additive (SCA) filter valves are in the "OUT" position. Add the correct amount of Diesel Coolant Additive/ Supplemental Coolant Additive (SCA) powder or liquid to charge the system properly. NOTE: Connect deaeration hoses to both of the fittings on top of the aftercooler water outlet connections (4), or open the petcocks on the aftercooler water outlet connections (4) during the coolant filling procedure. All air must be eliminated to allow a complete fill of coolant. Fill the engine with a coolant of 50 percent antifreeze and 50 percent water. Check for leaks. Repair any leaks immediately. Air Compressors - Unload All air compressors manufactured by Cummins Inc. must be operated during the engine run-in-period. During the performance check, all air compressors must be in the unloaded or non-operating mode. Connect a source of compressed air capable of producing 655 kPa [95 psi] to the air compressor unloader (1). This air line must contain a valve between the source and the unloader. The load shown in the next illustration must be attached to the air compressor outlet (2).


Use an air tank (2). Install a regulator (3) capable of maintaining 345 kPa to 517 kPa [50 psi to 75 psi] at both minimum and maximum engine RPM. Use a steel tube or a high temperature flexible hose (1) capable of 260°C [500°F]. Connect the air compressor outlet (1) to the air tank.

Lubricating System - Prime Cummins Inc. recommends an external pressure pump to prime the lubricating system. If an external pressure pump is not available, see the Cranking Engine-Fuel "OFF" Method.

External Pressure Pump Method Use a pump capable of supplying 207 kPa [30 psi] continuous pressure. Connect the pump to the port on the oil filter head as shown. Use a supply of clean oil. Turn the pump to the "ON" position. Check the engine oil pressure gauge. When the gauge indicates oil pressure, begin monitoring the oil level in the oil pan. NOTE: This method will fill the full-flow filters and lubricate the turbochargers.

Use the engine oil dipstick. Monitor the oil level. Turn the external pump to the "OFF" position when the oil touches the "LOW" mark on the dipstick. Disconnect the pump. Install the pipe plug in the filter head. Torque Value: 54 N•m [ 40 ft-lb ]




Allow 10 minutes for the oil to drain into the oil pan. Use the oil dipstick. Check the oil level. Add oil until the oil touches the "HIGH" mark. NOTE: The engine lubrication system is now primed. Omit the next six illustrations. Proceed with Prime the Fuel System.

Cranking Engine-Fuel "OFF" Method Use the oil dipstick to measure the oil level. Add oil until it touches the "HIGH" mark on the dipstick.

NOTE: All turbochargers on the KTTA engine must be lubricated. Use 60 to 90 milliliters [2 to 3 fluid ounces] of engine oil. Disconnect the turbocharger oil inlet hose. Lubricate the turbochargers. Connect the hose.

Use 3.5 liters [0.93 U.S. gallon] of oil for each full-flow filter. Fill all of the filters with oil.


NOTE: The manual override screw must be turned Counterclockwise until it stops. CAUTION Disconnect the two wires that supply power to the solenoid.

CAUTION When starting motors are used, do not crank the starting motor for more than 30 seconds. Excessive heat will damage the starting motor. Use the starting motor. Crank the engine until the oil pressure gauge indicates 207 kPa [30 psi]. If the oil pressure is less than specification after 30 seconds, allow 2 minutes for the starting motor to cool.

Allow 10 minutes for the oil to drain into the oil pan. Use the oil dipstick. Measure the oil level. Add oil until the oil touches the "HIGH" mark on the dipstick. Connect the two wires to the fuel pump solenoid.

Fuel System - Prime Use clean filtered fuel. Fill the fuel filters with fuel. Install the fuel filters. Connect the facility fuel supply to the inlet of the fuel filter head (1).




Use clean, filtered fuel. Fill the fuel pump suction hose or the fuel pump housing with fuel.

Connect a throttle control device to the throttle arm on the fuel pump.

NOTE: The solenoid power requirement is cast-molded in the housing near the terminals. Use a power supply that has an in-line switch. Connect the electrical power to the solenoid terminal (1). NOTE: The manual override screw must be turned counterclockwise until it stops. This will allow the solenoid to "OPEN" and "CLOSE" when the electrical supply is turned to the "ON" and "OFF" positions.

See the appropriate fuel pump calibration manual to determine the test values. Test Horsepower: Line 3. Rated RPM: Line 3. Torque Rise: Line 5. Torque Peak RPM: Line 18. CPL: Line 2. Engine Fuel Rail Pressure: Line 4. Fuel Rate: Line 7. Intake Manifold Pressure (Boost): Line 15.



NOTE: If the dynamometer is equipped to measure in metric units, the values from the fuel pump manual must be converted. Use these conversion factors: English Symbol ft-lb hp

Multiply by, to Obtain 1.356 0.746

Metric Symbol N•m kw



Use this tabulation to determine the test load. The run-in-period test must be performed with the engine operating at torque peak RPM. Operate a generator set engine at rated RPM. Example: The test load for a 2000 hp engine rated at 2000 RPM with a 15 percent torque rise is 1661 N•m [1225 ftlb]. NOTE: This tabulation assumes the dynamometer constant is 5252. If the dynamometer constant is not 5252, use the following formula to determine the correct test load: Correct Test Load = (Dynamometer Constant) x (Test Load) divided by 5252 Example: The dynamometer constant for testing the engine in the above example is 4000. Correct Test Load = (4000 x 1225) divided by 5252 = 933 ft-lb Rated RPM 1500 1800 1800 1800 1800 1900 1900 1900 1900 1900 1950 2000 2000 2000 2100 2100 2100 2100 2100 2100

Rated Horsepower All 0 to 999 1000 to 1050 1051 to 1100 Above 1100 0 to 999 1000 to 1050 1051 to 1200 1201 to 1600 Above 1600 0 to 800 0 to 999 1600 1800 0 to 999 1000 to 1100 1200 1350 1600 1800

Torque Rise All All All All All All All All All All All All All All All All All All All All

Test Load 1015 N•m [750 ft-lb] 745 N•m [550 ft-lb] 1015 N•m [750 ft-lb] 1120 N•m [825 ft-lb] 1390 N•m [1025 ft-lb] 880 N•m [650 ft-lb] 1015 N•m [750 ft-lb] 1120 N•m [825 ft-lb] 1490 N•m [1100 ft-lb] 1695 N•m [1250 ft-lb] 745 N•m [550 ft-lb] 1015 N•m [750 ft-lb] 1490 N•m [1100 ft-lb] 1660 N•m [1225 ft-lb] 880 N•m [650 ft-lb] 1015 N•m [750 ft-lb] 1120 N•m [825 ft-lb] 1290 N•m [950 ft-lb] 1490 N•m [1100 ft-lb] 1625 N•m [1200 ft-lb]

Engine - "START" CAUTION Do not crank the electric starting motor for more than 30 seconds. Excessive heat will damage the starting motor. "START" the engine. If the engine does not begin operating after 30 seconds, allow 2 minutes for the electric starting motor to cool. CAUTION If the oil pressure is not within specifications, turn the engine "OFF" immediately. Both low and high oil pressure will cause engine damage. Main Oil Rifle Pressure (at Idle) kPa 138

MIN

psi 20


Operate the engine at the "IDLE" position. Check for leaks and unusual noises. If the engine appears acceptable, proceed with the break in procedure. If the engine appears unacceptable, (i.e. major oil coolant leak or engine noise) stop the engine. CAUTION Do not operate the engine at "IDLE" longer than specified. Excessive carbon formation will cause engine damage.

Adjust the engine RPM to 1200 RPM. Adjust the dynamometer load to the test load as determined previously. Operate the engine at this setting until the coolant temperature indicates 71°C [160°F]. Check for leaks. Fix any leaks. Check all gauges and record the readings. NOTE: Do not proceed to the next step until the blowby becomes stable within specifications.

Adjust the engine RPM to the torque peak RPM. Adjust the dynamometer load to equal the test load multiplied by 2. Operate the engine for 2 minutes. Check all the gauges and record the readings. NOTE: Do not proceed to the next step until the blowby becomes stable within specifications.

Maintain the engine RPM at torque peak RPM. Increase the dynamometer load to equal the test load multiplied by 3. Operate the engine at this load for 2 minutes. Check all the gauges and record the readings. NOTE: Do not proceed to the next step until the blowby becomes stable within specifications.




Move the throttle lever to the "FULL OPEN" position. Increase the load until the engine RPM is at torque peak RPM. Operate the engine at this setting for 10 minutes or until the blowby becomes stable within specifications. Check all the gauges and record the readings.

Decrease the dynamometer load until the engine RPM increases to the rated RPM. Operate the engine at this load for 5 minutes. Check all the gauges and record the readings.

Decrease the dynamometer load completely. Do not turn the engine "OFF" immediately. The engine must be allowed to cool. Move the throttle lever to the "LOW IDLE" position. Operate the engine at this setting for 3 to 5 minutes. This will allow the turbocharger and the other engine components to cool. CAUTION Do not operate the engine at "IDLE" longer than specified. Excessive carbon formation can cause engine damage.

Turn the engine "OFF".



Engine Performance - Check Connect the fuel flow measuring instrument, Part Number 3376375, or equivalent. Measure the fuel consumption during the performance check. Follow the manufacturer's instructions that accompany this instrument.

All air compressors must be unloaded during the performance check. Apply 655 kPa [95 psi] air pressure to the air compressor unloader valve (1).

CAUTION 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. Main Oil Rifle Pressure (at Idle) kPa 138

MIN

psi 20

Move the throttle lever to the "FULL OPEN" position. Adjust the dynamometer load until the engine maintains the rated RPM. Allow the readings to stabilize. Read the horsepower. Check all the gauges and record the readings. The oil temperature must be a minimum of 88°C [190°F]. The fuel temperature must not exceed 32°C [90°F]. The horsepower reading will not be accurate if the oil or fuel temperature is not within specification.





If the engine has, or will have throttle air cylinders, adjust them now.

Disconnect all the connections and instruments. Remove the engine from the dynamometer. Prepare the engine for Painting, refer to procedure 000-009. For Long Term Storage information, refer to procedure 000-005.


with Electronically Actuated Injector For engines without automatic prelube, use a pump, Part Number 07600483, capable of supplying 205-kPa [30-psi] continuous pressure. Connect the pump to the front of the engine oil cooler as shown. Use a supply of clean oil. Turn the pump to the ON position. Check the engine oil pressure gauge. When the gauge indicates oil pressure, begin monitoring the oil level in the oil pan.

Check the engine lubricating oil level to be sure it is filled to the proper level.

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 Throttle Control 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). Disconnect the OEM harness 16-pin and 31-pin Deutsch connectors from the engine wiring harness. Connect the engine control harness, Part Number 4918643. Connect the engine control harness 16-pin and 31-pin Deutsch connectors to the engine wiring harness. Remove the 3-pin Deutsch terminating resistor cap (cap will have a blue insert) from the wiring harness. Connect the engine control harness 3-pin Deutsch connector to the J1939 connector of the engine wiring harness. The 3-pin Deutsch terminating resistor cap must be installed after the engine control harness is removed. If the cap is broken or has been misplaced, replace with resistor cap, Part Number 3163051. NOTE: If additional cable length is needed to connect the engine control, use electrical cable, Part Number 3163895. Connect the engine control harness (2) to the engine control. An INSITE™ electronic service tool equipped personal computer can be used to monitor circuits for proper operation. Connect the INLINE™5 datalink adapter kit (3), Part Number 4918416, and a personal computer to the datalink connector of the engine control.


Engines that are run on an engine dynamometer require the engine harness be installed and connected to the engine. Additionally, the engine control, Part Number 3163890, must be used to properly control the engine during the dynamometer run.

Ground Connection Connect the black-wire alligator clip of the engine control harness to the engine block to achieve electrical ground.

CAUTION Do not connect the alligator clip to the starter motor solenoid “S” terminal. Doing so can cause equipment damage. Starter Connection If not already equipped, install and wire a magnetic starter switch. Clip the alligator connector to the positive (+) coil terminal of the magnetic starter switch.

Air Starter If an air starter is being used, coil the red wire into a loop and secure the loop to the engine control harness to protect it from an electrical short.




WARNING Batteries can emit explosive gases. To avoid personal injury, always ventilate the compartment before servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Connect battery power to the starter. Connect the dynamometer test OEM wiring harness starter solenoid lead (yellow) to the starter solenoid. Connect the ground lead (black) to the starter solenoid. Connect the ground lead (black) to the starter or battery negative (-) or ground side. Connect the (+) 12 VDC power lead (red) to either the starter or battery positive (+) 12 VDC side. Rotate the throttle knob fully counterclockwise. Push down on the throttle knob to return the throttle to the idle position. Repeat this step three times. Turn the keyswitch to the OFF position for 30 seconds.


CAUTION Verify the red wire is connected to the positive (+) battery terminal and the black wire is connected to the negative (-) battery terminal. Equipment or engine damage can result if not connected properly. The power light will illuminate when power is supplied and the keyswitch is turned to the accessory or ON position. If the power light does not illuminate, return the keyswitch to the OFF position. Verify the red wire is connected to the positive (+) battery terminal and the black wire is connected to the negative (-) battery terminal. Turn the keyswitch to the ON position.


Light indicators on the engine control, STOP, WARN, MAINT, WIF, and WAIT TO START, will illuminate if applicable. The light indicators will illuminate for approximately 30 seconds. If no fault codes are found, the light indicators will extinguish. If the STOP light indicator (red) or WARN light indicator (yellow) continues to illuminate, use INSITE™ electronic service tool and the OEM service literature to diagnose the engine fault code.


NOTE: The engine can be returned to idle at any time by pushing in on the throttle knob. Slowly rotate the throttle knob counterclockwise to increase the engine rpm. Slowly rotate the throttle knob clockwise to decrease the engine rpm.

Turn the keyswitch to the OFF position to stop the engine.




Return parameters to their original value when the test or run-in is complete. Connect the keyswitch panel datalink cable to the Cummins electronic service tool. Use INSITE™ electronic service tool to set the engine up for the dynamometer. The setup is now complete, and the auto/manual throttle can be used to control engine speed.

Engine operating specifications are available from Cummins authorized repair locations.

Refer to Engine Testing - Engine Dynamometer, Procedure 014-005, for the engine operating procedures and safety precautions. The run-in test must be preformed with the engine operating at torque peak rpm. Operate a generator set at the rated rpm. See the performance charts available through Cummins Inc. Rated RPM 1800 1900

Torque Peak 1500 1500



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. Main Oil Rifle Pressure (at Idle) kPa 138 483

MIN MAX

psi 20 70

If the oil pressure is not within specifications, the engine must be shut down. Operate the engine at the "IDLE" position. Check for leaks and unusual noises. If the engine appears acceptable, proceed with the break in procedure. If the engine appears unacceptable, (i.e. major oil coolant leak or engine noise) stop the engine. CAUTION Do not operate the engine at "IDLE" longer than specified. Excessive carbon formation will cause engine damage.

Adjust the engine RPM to 1200 RPM. Adjust the dynamometer load to the test load as determined previously. Operate the engine at this setting until the coolant temperature indicates 71°C [160°F]. Check for leaks. Fix any leaks. Check all gauges and record the readings. NOTE: Do not proceed to the next step until the blowby becomes stable within specifications.



Adjust the engine RPM to the torque peak RPM. Adjust the dynamometer load to equal the test load multiplied by 2. Operate the engine for 2 minutes. Check all the gauges and record the readings. NOTE: Do not proceed to the next step until the blowby becomes stable within specifications.

Maintain the engine RPM at torque peak RPM. Increase the dynamometer load to equal the test load multiplied by 3. Operate the engine at this load for 2 minutes. Check all the gauges and record the readings. NOTE: Do not proceed to the next step until the blowby becomes stable within specifications.

Move the throttle lever to the "FULL OPEN" position. Increase the load until the engine RPM is at torque peak RPM. Operate the engine at this setting for 10 minutes or until the blowby becomes stable within specifications. Check all the gauges and record the readings.

Decrease the dynamometer load until the engine RPM increases to the rated RPM. Operate the engine at this load for 5 minutes. Check all the gauges and record the readings.





Engine Compression Page 14-52


Engine Compression (014-012) Preparatory Steps • Remove the rocker lever cover. Refer to Procedure 07-04 in the Troubleshooting and Repair Manual K19, Bulletin 3810307. Refer to Procedure 003-011 in the Troubleshooting and Repair Manual QSK19 Series Engines, Bulletin 3666098. Refer to Procedure 07-04 in the K38 and K50 Troubleshooting and Repair Manual, Bulletin 3810432. Refer to Procedure 003-011 in the QSK45 and QSK60 Base Engine Troubleshooting and Repair Manual, Bulletin 3666261. Refer to Procedure 003-011 in the Troubleshooting and Repair Manual QSK78 Series Engines Bulletin 3666727. Refer to Procedure 003-011 in the Troubleshooting and Repair Manual QSK23 Series Engines, Bulletin 4021375. • Remove the rocker lever assembly. Refer to Procedure 07-09 Troubleshooting and Repair Manual K19, Bulletin 3810307. Refer to Procedure 003-009 Troubleshooting and Repair Manual QSK19 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. • Remove 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.


• Establish top dead center (TDC) on the compression stroke. Refer to Procedure 07-20 in the Troubleshooting and Repair Manual K19, Bulletin 3810307. Refer to Procedure 006-025 in the Troubleshooting and Repair Manual QSK19 Series Engines , Bulletin 3666098. Refer to Procedure 07-18 in the K38 and K50 Troubleshooting and Repair Manual, Bulletin 3810432. Refer to Procedure 006-025 in the QSK45 and QSK60 Base Engine Troubleshooting and Repair Manual , Bulletin 3666261. Refer to Procedure 006-025 in the Troubleshooting and Repair Manual QSK78 Series Engines , Bulletin 3666727. Refer to Procedure 006-025 in the Troubleshooting and Repair Manual QSK23 Series Engines , Bulletin 4021375. Continue to rotate the crankshaft until the piston passes TDC and is 12.7 mm [0.50 inch] after top dead center (ATDC). Rotate the crankshaft in the opposite direction to raise the piston 6.35 mm [0.250 inch] below TDC.

Setup Install the appropriate air fitting (supplied with the differential pressure tester, Part Number 3824223) into the top of the leak test adapter with thread sealing tape. Check all o-rings for cracks or damage prior to each cylinder test and replace if necessary. Lubricate the o-rings and leak test adapter with 15W-40 lubricating oil.

NOTE: If the injector installation tool, Part Number 3824830, is not available, use a 40 mm [1 9/16-inch] socket with an extension and a rubber mallet to install the leak test adapter. Install the leak test adapter and hold-down clamp into the cylinder head. Use injector installation tool, Part Number 3824830, to seat the leak test adapter in the bore. The slide hammer will make a dull sound when the leak test adapter is seated properly.




Install the injector hold-down clamp and capscrew. Torque Value: 54 N•m [ 40 ft-lb ]

NOTE: The crankshaft breather is not to be obstructed during this test, do not install plugs or orifices as used in traditional blowby tests. Close the ball valve on the differential cylinder pressure tester, Part Number 3824223. Connect the differential cylinder pressure tester outlet hose to the fitting on the leak test adapter.

Pressure Differential Test WARNING 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.


Pressurize the cylinder and adjust the regulator on the differential pressure tester until gauge (1) indicates 100 psi [689 kPa]. When the reading on gauge (2) has stabilized, record the pressure reading of both gauges and record the cylinder number and bank. If at any time during the test the reading on gauge (2) is not stable, lightly tap the tops of the engine valves with a rubber mallet to make certain that they are closed. If the reading on gauge (2) remains unstable, repeat positioning procedure described earlier. Position each remaining cylinder and test.

The leakdown test can be used to determine the relative condition of a cylinder when compared to other cylinders in the engine. The leakdown test can also help diagnose the source of the leak or blowby. This includes, but is not limited to, air flow from the breather (worn cylinder), air flow in the intake or exhaust manifold (leaking valves) or air bubbles in the coolant (leaking cylinder head gasket, cylinder head crack or cylinder block crack). Before taking any action based on leakdown test results, repeat the leakdown test for the suspect cylinder and compare to the original results. Factory leakdown limits will not be established, cautious judgment must be used before replacing parts or taking any action due to results from the leakdown test. Additionally, the test results subject to comparison need to be obtained within a relatively short time frame. Leakdown test results are expected to vary depending on engine temperature. Because of this, comparing leakdown results from different engines is not recommended. Remove the differential pressure tester and leak test adapter.




Finishing Steps • Install the injector. Refer to Procedure 05-09 in the 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

Section 16 — Mounting Adaptations — Group 16 Section Contents Page Engine Lifting Brackets ...................................................................................................................................16-3 Clean and Inspect for Reuse...........................................................................................................................16-3 Install..............................................................................................................................................................16-3 Remove..........................................................................................................................................................16-3 Engine Mounts ...............................................................................................................................................16-33 Clean and Inspect for Reuse......................................................................................................................... 16-33 Engine Support Bracket, Front .......................................................................................................................16-5 Finishing Steps...............................................................................................................................................16-9 Inspect for Reuse............................................................................................................................................16-7 Install..............................................................................................................................................................16-8 Preparatory Steps...........................................................................................................................................16-5 Remove..........................................................................................................................................................16-5 Flexplate ........................................................................................................................................................16-10 Clean and Inspect for Reuse......................................................................................................................... 16-10 Finishing Steps............................................................................................................................................. 16-13 Install............................................................................................................................................................16-12 Measure........................................................................................................................................................16-12 Face Runout...............................................................................................................................................16-12 Preparatory Steps......................................................................................................................................... 16-10 Remove.........................................................................................................................................................16-10 Flywheel .........................................................................................................................................................16-14 Clean and Inspect for Reuse......................................................................................................................... 16-15 Finishing Steps............................................................................................................................................. 16-18 Install............................................................................................................................................................16-16 Preparatory Steps......................................................................................................................................... 16-14 Remove.........................................................................................................................................................16-14 Flywheel Housing ..........................................................................................................................................16-19 Clean and Inspect for Reuse......................................................................................................................... 16-21 Finishing Steps............................................................................................................................................. 16-31 Install............................................................................................................................................................16-27 Measure........................................................................................................................................................16-28 Alignment...................................................................................................................................................16-28 Preparatory Steps......................................................................................................................................... 16-19 Redowel........................................................................................................................................................16-21 Remove.........................................................................................................................................................16-20 Flywheel Ring Gear .......................................................................................................................................16-32 Assemble......................................................................................................................................................16-32 Service Tools ...................................................................................................................................................16-1 Mounting Adaptations......................................................................................................................................16-1

Page 16-b





Service Tools Mounting Adaptations


Tool No.

Tool Description Dowel Pin Puller

3163720

Kit contains various size collets used to remove dowel pins throughout the engine.

Drill/Ream Fixture ST-1232

Used to drill and ream dowel holes. Bushings are not included and must be ordered separately.

Engine Lifting Fixture Used with a hoist to lift the engine. 3375109

Engine Lift Fixture Kit Used to lift the engine during installation of removal. 3163264

Engine Speed Sensor Socket Used to remove the engine speed sensor on QSK50 engines. 4918623


Tool Illustration



Tool No.

Tool Description Torque Wrench Used to tighten capscrews 136 to 813 N•m [100 to 600 ft-lb].

3164798



Tool Illustration


Engine Lifting Brackets (016-001) Remove NOTE: The K38 and K50 engines have four lifting brackets, two on each bank. The lifting brackets for the K38 are installed between cylinder numbers 1 and 2, and 5 and 6. The lifting brackets for the K50 are installed between cylinder numbers 2 and 3, and 6 and 7. Remove the capscrews, flat washer, and lifting bracket.

Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. 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 Page 16-3

Engine Lifting Brackets Page 16-4


Add a bead of sealant to the bottom of the capscrew head. Install the flat washer. Apply a bead of sealant to the flat washer.

Install the lifting bracket, flat washer, and capscrew. Torque Value: 270 N•m [ 200 ft-lb ]


Engine Support (016-002)

Bracket,

Engine Support Bracket, Front Page 16-5

Front

Preparatory 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 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.



Support the engine in strict accordance with correct safety considerations and precautions. Refer to Procedure 000-001.

If the front of the engine must be supported from underneath while work is performed on the front end, drain the oil and remove the oil pan adapter assembly first. Refer to Procedure 007-027.

The engine can then be supported by a heavy wooden timber placed under the block pan rails. Use suitable means to take the weight off the front support.

K38 and K50 engines have four lifting brackets that are bolted to the cylinder block. Lifting brackets are designed to lift the engine only.


Remove the capscrews that mount the front support to the chassis or frame. Remove the front support from the gear housing cover trunnion.

Inspect for Reuse WARNING 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. Measure the front support bore. Torque Value: 300 N•m [ 220 ft-lb ] Front Support Bore Diameter mm 210.03 210.08

MIN MAX

in 8.269 8.271

If the front support bore is not within specifications, the front engine support bracket must be replaced.




Check the trunnion sleeve for damage. The sleeve must be replaced if it is worn or cracked.

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.

If the two-piece front support is used, tighten the capscrews to the specified torque. Torque Value: 300 N•m [ 200 ft-lb ]

Raise the engine to take the weight off the supports used under the engine block. Remove the supports and install the oil pan. Refer to Procedure 007-027.


Lower the engine until the front engine support is in position. Remove the engine lifting fixture.

Finishing Steps WARNING 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 Page 16-10


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.

Clean and Inspect for Reuse WARNING When using solvents, acids or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the 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.


WARNING Cummins Inc, does not recommend resurfacing of the flexplate. Resurfacing of the flexplate can cause possible personal injury, property damage, or cause it to be too thin and result in breakage. Use the dye penetrant method to check the area of the mounting holes for cracks. There must not be any cracks in the flexplate mounting area. Check the mounting pilot for damage. If the pilot is damaged, the flexplate must be replaced.

Check the tightness of the twenty five capscrews. Torque Value: 290 N•m [ 215 ft-lb ] Use SAE Grade 8 capscrews if replacement is required.

The flexplate can consist of as many as nine separate steel plates. Check closely for cracks. If any of the steel plates are cracked or damaged, the engine flexplate must be replaced.

Check the two tapered dowels for damage. If the dowels are bent or broken, they must be replaced.




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.


WARNING The flexplate mounting capscrews must be SAE Grade 8 minimum with rolled threads. The flexplate mounting plain washers are special hardened . Do not substitute the parts or a failure can result that can cause personal injury. The use of a guide bolt will aid the assembly procedure. Do not lubricate the threads of the crankshaft. Use engine oil. Lubricate the capscrews and the washers. Allow the excess oil to drip from the parts. Check to be sure the mating surfaces of the crankshaft and flexplate are clean, dry, and free of nicks or burrs. Align the hole in the flexplate for the roll pin with the roll pin in the crankshaft. Install the flexplate, washers, and the capscrews. The flexplate must fit firmly against the crankshaft. Use the following steps to tighten the capscrews in the sequence shown. Torque Value: Step1 Step2 Step3

150 N•m 285 N•m 515 N•m

[ 110 ft-lb ] [ 210 ft-lb ] [ 380 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. • 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 Page 16-14


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.


Clean and Inspect for Reuse 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. Inspect the teeth of the ring gear for wear or damage. If the teeth of the ring gear are worn or damaged, the ring gear must be replaced.

Use the dye penetrant, Part Number 3375452, to check the area of the mounting capscrew holes for cracks. There must not be any cracks in the flywheel mounting area. Inspect the mounting pilot hole for damage. If the pilot hole is damaged, the flywheel must be replaced.

Flywheel Page 16-15

Flywheel Page 16-16


WARNING Cummins Inc., does not recommend resurfacing the flywheel. Resurfacing the flywheel can cause it to be too thin and cause personal injury, property damage, or result in breakage. Inspect the face of the flywheel for cracks or other damage. The flywheel must be replaced if cracked or otherwise damaged.

Install Install the roll pin (1) in the crankshaft. The pin is required to align the timing marks that are on the flywheel. NOTE: The flywheel and flexplate are not the same for K38 and K50 engines. The valve and injector adjustment marks that are stamped on the parts are different.

Lubricate the flywheel mounting capscrew threads and flange head surfaces with clean engine oil. Install the washer onto the capscrew and lubricate the washer (1).

WARNING 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.


Tighten the flywheel mounting capscrews in the sequence shown. Torque Value: Step1 Step2 Step3

150 N•m 285 N•m 515 N•m

[ 110 ft-lb ] [ 210 ft-lb ] [ 380 ft-lb ]

Measure the flywheel total indicator runout. NOTE: The crankshaft end clearance must be pushed or pulled in the same direction each time a point is measured. Attach an indicator as shown. Continue to look at the indicator while rotating the engine. Maximum radial runout is 0.13 mm [0.005 inch]. If the runout is not within specification, the pilot on the flywheel is not positioned correctly on the crankshaft. If the pilot is damaged, the flywheel must be replaced.

Attach an indicator as shown. Measure the flywheel alignment at four equally spaced points by rotating the flywheel. Measure the distance from the center of the crankshaft to the indicator tip. Multiply (x) the distance by 0.025 mm [0.001 inch] to obtain the maximum run out. If the flywheel alignment is not within specifications, check for interference between the flywheel and the crankshaft.

Flywheel Page 16-17

Flywheel Page 16-18


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.


Flywheel Housing (016-006) Preparatory 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 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 Page 16-19



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.


Clean and Inspect for Reuse WARNING When using solvents, acids or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the 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. Inspect all threaded capscrew holes for damage. Inspect the engine speed sensor threaded hole for damage. Repair or replace the housing if the threaded holes are damaged.

Redowel The tools needed to perform this procedure are: Part Number ST-1232, Drill Ream Fixture that contains: 1. Plate, Part Number ST-1232-1 2. Locator pin, Part Number 3375052 3. Drill/Ream actual sizes. Bushing set depends on the dowel size 4. Drill adapter locally obtained; use to adapt openshank reamers to drill-chuck 5. Reamer locally obtained 6. Drill bit locally obtained.




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.

Use a dowel pin extractor, Part Number 3163720, or equivalent. Remove the two dowels (9) from the block. Measure a dowel pin that is removed so that an oversize dowel pin size can be determined.

WARNING 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.

Align the flywheel housing to the crankshaft. Move the housing with a mallet until the bore is within specifications. Make sure that the bore and face of the housing are in alignment. Flywheel Housing - Radial Run Out Inside Diameter SAE Maximum Runout Number mm in mm in 787 31.0 00 0.30 0.012 648 25.5 0 0.25 0.010


Flywheel Housing - Face Run Out Inside Diameter SAE Maximum Runout Number mm in mm in 787 31.0 00 0.30 0.012 648 25.5 0 0.25 0.010

When the housing is in alignment, tighten the capscrews in the sequence shown. Flywheel Housing - Torque Sequence Torque Value: Step1 Step2 Step3

102 N•m 203 N•m 366 N•m

[ 75 ft-lb ] [ 150 ft-lb ] [ 270 ft-lb ]

After the capscrews are tightened, check the alignment again.

This illustration shows the location of the dowel holes on the flywheel housing.

Use appropriate size capscrews. Attach Part Number ST-1232-1, Plate, that is contained in Part Number ST-1232 Drill Ream Fixture, to the crankshaft. Do not tighten the capscrews so much that the plate does not move.




CAUTION The crankshaft must be "locked" in position. It can turn during reaming. Use the locator pin to align the plate with the hole for the dowel pin. Tighten the capscrews. The taper on the pin must engage the dowel pin hole. The locator pin must rotate easily after the capscrews are tightened. "Lock" the crankshaft in position. Be sure the locator pin is still in alignment and that the locator pin can be rotated easily.

Measure the dowel pins to be installed. Obtain a reamer (5) that is 0.013 mm to 0.025 mm [0.0005 inch to 0.001 inch] smaller than the dowel. The dowel length must protrude from the block one-half of the flywheel housing wall thickness. There are three oversize dowel pins available from Cummins Inc. Oversize Dowel Pin Outside Diameter mm in Oversize 13.08 0.515 [0.015 in] 13.46 0.530 [0.030 in] 13.84 0.545 [0.045 in]


Install the appropriate drill bushings (4). The following bushings are available from Cummins Inc. Drill/Ream Bushing Sets - 25.4 mm [1.0 inch] Oversize Oversize Bushing Bushing mm [Inch] Size mm Size [Inch] 3376495 Special 12.304 [0.4844] Standard 12.700 [0.5000] 0.38 [0.015] 13.096 [0.5156] 0.76 [0.030] 13.492 [0.5312] 1.14 [0.045] 13.879 [0.5464] ST-1234 Standard 14.288 [0.5625] 0.38 [0.015] 14.684 [0.5781] 0.76 [0.030] 15.080 [0.5937] 1.14 [0.045] 15.479 [0.6094] ST-1235 Standard 15.875 [0.6250] 0.38 [0.015] 16.271 [0.6406] 0.76 [0.030] 16.667 [0.6562] 1.14 [0.045] 17.066 [0.6719] ST-1236 Standard 17.463 [0.6875] 0.38 [0.015] 17.859 [0.7031] 0.76 [0.030] 18.255 [0.7187] 1.14 [0.045] 18.654 [0.7344] ST-1237 Standard 19.050 [0.7500] 0.38 [0.015] 19.446 [0.7656] 0.76 [0.030] 19.842 [0.7812] ST-1238 22.621 [0.8906] 23.813 [0.9375] The drill bushing that is used must be the same size as the reamer (or the drill) that is used.




WARNING 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.


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. Install the twelve lock washers (3) on the ten capscrews (4) and the two capscrews (5). Remove any guide bolts.

Follow the sequence shown to tighten the capscrews. Torque Value: 366 N•m [ 270 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. On flywheel housings with the rear seal, make sure the two dowel pins are installed in the cylinder block. Check to make sure the mating surfaces of the block and the housing are clean, dry, and free from nicks and burrs. Install the gasket (1). Install the flywheel housing (2). Push the housing over the dowel pins and to the cylinder block. The capscrews (5) and (6) must be SAE Grade 8. The two capscrews (5) have 7/16-14 inch threads. The other capscrews (6) have 3/4-10 in threads. Install the two lock washers (3) and twelve lock washers (4). Install the two capscrews (5) and twelve capscrews (6). Follow the sequence shown to tighten the capscrews. Torque Value: 7/16-14 in Capscrews 3/4-10 in Capscrews

90 N•m

[ 66 ft-lb ]

366 N•m

[ 270 ft-lb ]

Measure Alignment The bore and the face of the housing must be in alignment with the crankshaft. The indicator arm must be rigid for an accurate reading. It must not sag. Attach an indicator to the crankshaft as shown to check the radial run out.


Position the indicator at the 12 o'clock position. Adjust the dial until the needle points to “0”. Rotate the crankshaft 1 complete revolution (360 degrees). Record the total indicator runout.

The maximum allowable total indicator runout depends on the diameter of the bore. Bore Diameter MIN/MAX MIN/MAX mm in 787.4/810.5 [31.00/31.91] 647.7/648.0 [25.50/25.51]

SAE Number 00 0

Maximum Total Indicator Runout mm in 0.30 0.012 0.25 0.010

If the alignment is not within specifications and the bore is round, the housing can be shifted. If the alignment is not within specifications and the bore is not round, the housing must be replaced.

CAUTION The crankshaft must be pushed or pulled in the same direction each time it is measured. Face Runout Attach an indicator at the 12 o'clock position. Adjust the dial until the needle points at “0”.




Record the indicator reading at 3 different points: 3 o'clock, 6 o'clock, and 9 o'clock. Turn to the original 12 o'clock position. Make sure the needle still points to “0”. Determine the total indicator runout. Total Indicator Runout Example mm 12 o'clock 0.00 3 o'clock +0.08 6 o'clock -0.05 9 o'clock +0.08 Equal Total Indicator Runout 0.13

in [0.00] [+0.003] [-0.002] [+0.003] [0.005]

The maximum allowable total indicator runout depends on the diameter of the bore. Bore Diameter MIN/MAX MIN/MAX mm 787.4/810.5 647.7/648.0

in [31.00/31.91] [25.50/25.51]

Maximum SAE Total Indicator Number Runout mm in 00 0.30 0.012 0 0.25 0.010

If the alignment is not within specifications, remove the housing. Check for nicks, burrs, or foreign material between the block and the housing. Check the alignment again. If the alignment is not within specifications, the block or the housing is not machined correctly.


Finishing Steps WARNING 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 Page 16-32


Flywheel Ring Gear (016-008) 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 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.


Engine Mounts (016-010) Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Two different front support assemblies have been supplied on K38 and K50 engines. Previous engines were supplied with a support comprised of two pieces. Present engines are supplied with a support that is one piece. Use solvent to clean the support. Dry with compressed air Check the part for cracks or other damage. If the support is cracked or damaged, it must be replaced. Follow the procedure below to check for wear. If wear is apparent the mounts must be replaced

When applicable, assemble the front support. Tighten the capscrews. Torque Value: Front Support Capscrews

298 N•m

[ 220 ft-lb ]

NOTE: The bore specification is identical for both supports. Front Support Bore mm 210.03 210.08

MIN MAX

in 8.269 8.271

NOTE: Modify the older support that has two pieces for the installation of a grease fitting during engine rebuild. Drill and tap the cap of the support for a grease fitting.

Engine Mounts Page 16-33

Engine Mounts Page 16-34


Notes

K38, K50, QSK38, and QSK50 Section 17 — Miscellaneous — Group 17

Page 17-a

Section 17 — Miscellaneous — Group 17 Section Contents Page Capscrew .........................................................................................................................................................17-1 Magnetic Crack Inspect...................................................................................................................................17-1 Cup Plug ..........................................................................................................................................................17-2 Clean and Inspect for Reuse...........................................................................................................................17-2 Install..............................................................................................................................................................17-3 Remove..........................................................................................................................................................17-2 Flexible Hose ...................................................................................................................................................17-3 Inspect for Reuse............................................................................................................................................17-3 Pipe Plug .........................................................................................................................................................17-4 Clean and Inspect for Reuse...........................................................................................................................17-4 Install..............................................................................................................................................................17-4 Remove..........................................................................................................................................................17-4 Straight Thread Plug .......................................................................................................................................17-5 Clean and Inspect for Reuse...........................................................................................................................17-5 Install..............................................................................................................................................................17-6 Remove..........................................................................................................................................................17-5

Page 17-b




Capscrew Page 17-1

Capscrew (017-001) Magnetic Crack Inspect This procedure describes the visual and magnetic particle inspection of special and high strength capscrews for the: 1. Cylinder head 2. Main bearing cap 3. Flywheel 4. Connecting rod 5. Crankshaft pulley or adapter 6. Lifting bracket 7. Crankshaft counterweights 1. the threads are damaged. 2. rust or corrosion has caused pitting in the body. 3. the body is nicked, galled, bent, or stretched. NOTE: Refer to Procedure 001-014 (Connecting Rod) in Section 1 contains additional information about the connecting rod capscrews. CAUTION Prevent damage to the capscrews. Nicks in the body of the capscrew can cause an area of stress that can fail during engine operation. Damage to the threads will cause torque values to be wrong and will damage the mating parts. If necessary, use a wire wheel to remove all rust, corrosion, and dirt from the capscrews. WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Use solvent. Clean the part. Dry with compressed air. Check the capscrew. The capscrew must be replaced if: NOTE: Some capscrews (cylinder head, main bearing cap, connecting rods) have threads that have been formed by a rolling operation during manufacture. Repair of rolled threads by the use of a thread die is not recommended. The thread die can create a sharp corner on the minor diameter (root) of the threads. This sharp corner can cause an area of increased stress. Use a magnetic particle testing machine such as Magnaflux. Use the residual method. Apply a head shot of 300 to 400 ampere-turns direct current or rectified alternating current. Use an ultraviolet light. Check for indications of cracks. NOTE: The magnetic particles tend to accumulate on sharp corners and edges. Do not mistake these accumulations for cracks. No indications are acceptable (OK). Prepare the machine for a coil shot. Be sure the capscrew is near one side of the coil and not in the center. Apply 1000 to 1250 ampere-turns. Use an ultraviolet light. Check for indications of cracks. No indications are acceptable (OK). Demagnetize the capscrew thoroughly. WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Cup Plug Page 17-2


Use solvent. Clean the part. Dry with compressed air.

Cup Plug (017-002) Remove CAUTION Do not allow metal shavings to fall inside the engine when drilling a hole in the cup plug. Damage to engine components can occur. Use a center punch to mark the cup plugs for drilling. Drill a 3.20 mm [0.125 in] hole in the cup plug.

Use a dent puller to remove the cup plug. Discard all used cup plugs.

Clean and Inspect for Reuse Thoroughly clean the cup plug bore using Scotch-Brite™, or equivalent. Use spray cleaner, Part Number 3375433 or equivalent, to clean the bore.

Inspect the cup plug bores for damage. Repair any damaged cup plug bores.


Install CAUTION Excessive sealant can run back into the engine and cause damage to other components. Allow the sealant to dry for a minimum of two hours before operating the engine. The plug can come out of the bore if the sealant is not dry. Apply a 2 mm [1/6 in] bead of cup plug sealant, Part Number 3375068 or equivalent, to the outside circumference of the cup plug and the inside circumference of the cup plug bore. Do not install a used cup plug. Install the cup plug with the appropriate cup plug driver.

CAUTION Do not install the cup plug too deeply. If the cup plug is not installed straight and flat, it must be replaced with a new cup plug. The cup plug must be installed with the edge of the cup plug 0.5 to 1.0 mm [0.020 to 0.040 in] deeper than the leading chamfer of the bore.

Flexible Hose (017-005) Inspect for Reuse Inspect all flexible hoses and their connections for leaks or deterioration. Repair or replace the hose if damaged.

Flexible Hose Page 17-3

Pipe Plug Page 17-4


Pipe Plug (017-007) Remove Remove the pipe plug.

Clean and Inspect for Reuse Use spray cleaner, Part Number 3375433 or equivalent, to clean the threads of the pipe plugs and threaded bores.

Inspect the threads of the pipe plug for damage. Replace the pipe plug if damaged. Inspect the threaded bore for damage. Repair the threaded bore if damaged.

Install Apply a film of pipe plug sealant, Part Number 3375066 or equivalent, to the pipe plug threads. Install the pipe plug.


Tighten the pipe plug. Refer to Procedure 018-005 for pipe plug torque specifications.

Straight Thread Plug (017-011) Remove Select the appropriate size allen wrench or socket and remove the straight thread plug.

Clean and Inspect for Reuse Use spray cleaner, Part Number 3375433 or equivalent, to clean the threads of the straight thread plug and threaded bore.

Inspect the threads of the straight thread plug for damage. Replace the straight thread plug if damaged. Inspect the threaded bore for damage. Repair the bore if damaged.

Straight Thread Plug 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.



Tighten the straight thread plug. Refer to the chart in the graphic for torque values.

Thread Size in inches 1/4 3/8 1/2 9/16 5/8 3/4 7/8 1 1-1/16 1-3/16

Straight Thread O-Ring Plugs N•m in-lb 4 35 6 50 8 70 12 105 16 145 20 180

N•m

ft-lb

35 40 45 55

26 30 33 41



Notes

K38, K50, QSK38, and QSK50 Section 21 — Main Power Generator — Group 21

Page 21-a

Section 21 — Main Power Generator — Group 21 Section Contents Page Bearing, Generator ..........................................................................................................................................21-8 Clean............................................................................................................................................................21-18 Internal.......................................................................................................................................................21-18 External......................................................................................................................................................21-18 Clean and Inspect for Reuse......................................................................................................................... 21-12 Finishing Steps............................................................................................................................................. 21-16 Install............................................................................................................................................................21-13 Lubrication for the Power Components..........................................................................................................21-17 Preparatory Steps...........................................................................................................................................21-8 Remove..........................................................................................................................................................21-9 Generator (Alternator) Exciter Rotating Diodes ...........................................................................................21-18 Finishing Steps............................................................................................................................................. 21-22 Install............................................................................................................................................................21-21 Preparatory Steps......................................................................................................................................... 21-18 Remove.........................................................................................................................................................21-19 Generator (Alternator) Windings ...................................................................................................................21-23 Clean............................................................................................................................................................21-23 Finishing Steps............................................................................................................................................. 21-24 Preparatory Steps......................................................................................................................................... 21-23 Generator Fuse Holder ....................................................................................................................................21-1 Generator Rotor .............................................................................................................................................21-30 Finishing Steps............................................................................................................................................. 21-36 Install............................................................................................................................................................21-33 Preparatory Steps......................................................................................................................................... 21-30 Remove.........................................................................................................................................................21-30 Generator, Main ...............................................................................................................................................21-1 General Information.........................................................................................................................................21-1 Instrument Panel..........................................................................................................................................21-2 Permanent Magnet Generator .......................................................................................................................21-25 Finishing Steps............................................................................................................................................. 21-29 Install............................................................................................................................................................21-27 Preparatory Steps......................................................................................................................................... 21-25 Remove.........................................................................................................................................................21-25

Page 21-b




Generator, Main Page 21-1

Generator Fuse Holder (021-005) Inspect NOTE: The Generator Fuse Holder is located in the DC or Generator Interface Box (GIB) box. Check that the fuse is installed in the fuse holder correctly. Refer to the engine wiring diagram to make sure the fuse is the correct amperage.

If the fuse is installed correctly, check for a blown fuse. Remove the fuse(s) to be checked. Touch each one of the multimeter leads to each fuse terminal. Measure the resistance. The multimeter must show less than 10 ohms, which is a closed circuit. If the circuit is closed, then put the fuse back into the holder and install the fuse cover. NOTE: Whenever a fuse is replaced, it must always be replaced with the correct amperage fuse. Installing a higher amperage fuse can cause damage to the engine or generator set.

Generator, Main (021-009) General Information Alternator • Newage® Stamford™, four pole, three phase, 60 Hz design • brushless rotating field design and is built to meet BS5000 Part 3 and international standards • self-excited with excitation power from a permanent magnet generator (PMG) powered excitation system. The manufacturer's installation service and maintenance manual is available on the manufacturer's website at: http://www.newage-avkseg.com/engish/content/download/newage/manuals/p7/p7_gb_10_04_02.pdf To access this document, copy the URL above and paste it into your web browser address bar. Service assembly drawings can be viewed on page 37 of the installation service and maintenance manual listed above. For service parts and contacts, information can be viewed at the following address: http://www.newage-avkseg.com/select_language.html To access this document, copy the URL above and paste it into your web browser address bar. Generator Control Panels • GP 6001 • GP 6002 • GP 6003 • GP 6004 • GP 6005 • GP 6006 • GP 6007 The following is a breakdown of the generator control panel options. K38 C Power


Control Panel Options Option Number GP 6004 GP 6005 GP 6006 GP 6007


Panels Used None 4930117 4930117 3972970 4930117 3972970

Quantity 0 1 1 1 1 2

Description No controls Base panel Base panel Remote panel Base panel Remote panel

Panels Used None 4930117 4930117 3972970 4930117 3972970

Quantity 0 1 1 1 1 2

Description No controls Base panel Base panel Remote panel Base panel Remote panel

K50 C Power Control Panel Options Option Number GP 6004 GP 6001 GP 6002 GP 6003

User's manuals for the panels are available for download at the Cummins Marine website. http://marine.cummins.com/public_cummins/content.jhtml?tlaId +5&anchorId=contentId=43&marketId=13&menuId=1 To access this document, copy the URL above and paste it into your web browser address bar. Instrument Panel

Base Panel Cabinet (into which the base panel mounts) Panel Description 1. Control panel 2. Block heater indicator button 3. Cable connection 4. Emergency stop button



Base Control Panel Panel Description 1. Digital display 2. LED indicator lights 3. Button A: toggles between instrument view and alarm list view 4. Button B: toggles between two instrument views 5. Alarm silence 6. Backlight on/off 7. Alarm acknowledge 8. Start button 9. Stop button. The base panel is an electronic control unit for controlling and monitoring diesel engines used as propulsion engines or generator sets. The base panel monitors the following data: • Oil pressure • Oil temperature • Turbocharger pressure • Coolant temperature • Battery voltage • Engine speed • Exhaust temperature • Total engine hours • Trip engine hours • Number of starts. The panel is also equipped with an event log which records a history of the last 500 events such as alarms, start ups, and shut downs. The base panel has several built in alarms, as shown in the table below. Base Panel Built-in Alarms Alarm Low battery voltage Secondary battery low voltage Overspeed Engine stopped Engine failed to stop

Description Low voltage at the start battery Low voltage at the secondary battery source Engine running faster than the overspeed setpoint Engine stopped for unknown reason 60 seconds after issuing the stop command, the engine has still not stopped


Base Panel Built-in Alarms Alarm Start failure Pickup failure Output circuit overload Analog sensor failure Broken wire


Description Engine failed to start after the last start attempt Unable to read the pickup signal while engine is running Short circuit in one of the (+)24-VDC terminals Detailed information on which analog channel has failed Detailed information on which terminal experiences the broken wire

Operation of the Base Panel - The base panel has several different screens or views. These views include: • Two instrument views • Alarm list view • Information view • Event log view To toggle between instrument view and alarm list view press button A. (See Figure 2) To toggle between the two instrument views press button B. (See Figure 2) To go to information view press and hold button A for approximately 1 second. To go to event log view press and hold button B for approximately 1 second. When connected to the remote panel, both the remote panel and the base panel can control the engine. However it is possible to lock out the remote panel and allow control only from the base panel. To lock out the remote panel: 1. Go to INFO view 2. Press and hold BUZZER OFF for 2 seconds until a beep is heard. The screen will change to toggle Local Mode ON/OFF. When ON, this disables the remote panel commands. Stop Button - To stop the unit, press and hold the red button labeled STOP until the unit has stopped. If the STOP button is held for less than one half a second the engine will not stop. The control unit stops the generator set by pulling the stop solenoid. When the red LED in the stop button is lit, this indicates that the control unit is pulling the stop solenoid. Start Button - Manual start is done with the green button labeled Start. Press and hold the button until the engine has started. A running engine indicated by the green LED in the Start button and the text Running in the left most status field on the digital display. The rpm meter will indicate the engine speed. Standby and Manual Mode Button - The standby button is a toggle button, meaning that for every other keypress, the unit is set to Standby or Manual. A green LED in the Standby button indicates that the unit is set to Standby. The right most status field also indicates the chosen mode by displaying either Standby or Manual. Acknowledge (Reset) Button - In case of alarms, a press on the acknowledge button, labeled ACKN, will reset the alarm(s). At the same time, the buzzer will be silenced. In the Alarm List view ACKN will reset all alarms, whereas, in the instrument view, ACKN will reset the alarm in the top of the screen only. Buzzer Off Button - Press the buzzer OFF button to silence the built in buzzer signal that is activated when an alarm occurs. The alarm that activated the buzzer remains active until acknowledged.



Instrument Panel

Remote Panel Digital Display Remote Panel Digital Display The remote panel is a touch screen display that shows most of the data available from the base control panel. It can also execute many of the same commands as the base panel. It connects to the supplied terminals on the engine cabinet with six wires. Four wires are for communication and two are for power supply 1. Oil pressure gauge 2. Oil temperature gauge 3. Indicator light Grey - ready to start Green - starting/running Red - stopping/stopped 4. Button to access the alarm list 5. Engine rpm 6. Navigate between pages

7. 8. 9. 10. 11.

Battery voltage gauge Start button Stop button Reset button Coolant temperature gauge.

Analog Values Available From the Remote Panel Value Description Range and Units Oil pressure 0.0 to 6.0 bar [0 to 87 psi] Oil temperature 0 to 150°C [32 to 302°F] Coolant temperature 0 to 130°C [32 to 266°F] Battery voltage 20 to 30 VDC Engine speed 0 to 2000 rpm Exhaust stack temperature 0 to 600°C [32 to 1112°F] Total engine hours 0 to 99999 hours Trip engine hours 0 to 999 hours Start counter 0 to 99999 starts



Instrument Panel Screen Overviews NOTE: The alarm list is not displayed. It can be accessed from all the pages.

Start up screen and the applications main view. Main View This is the Start-up screen and the applications main view. 1. Oil pressure 2. Oil temperature 3. Indicator light Grey - ready to start Green - starting/running Red - stopping/stopped 4. Button to access the alarms list 5. Engine rpm 6. Navigate between pages

7. 8. 9. 10. 11.

Battery voltage Start button Stop button Reset button Coolant temperature.



Each press on this button (1) toggles between Standby and Manual setting Exhaust Temperatures This screen displays the exhaust temperatures and the counters. The Standby/Manual setting is changed through this screen as well. The following table lists the commands that can be executed with the remote panel. Remote Panel Commands Command Engine Start Engine Stop Acknowledge Alarms Set to Standby Set to Manual Remote Panel Alarm Descriptions Alarm Description Low oil pressure High coolant temperature Emergency stop/start disabled Low coolant pressure Power failure Overspeed Oil pressure Oil temperature Coolant temperature Start failure

Description Brings up a dialog to confirm engine start Brings up a dialog to confirm engine stop. An ongoing start attempt can be cancelled by pressing stop. Will acknowledge all pending alarms in the Base Panel The base panel will do automatic start attempts. The base panel will not do automatic start attempts.

Comment 1.7 bar [25 psi] 106°C [223°F] Manual emergency stop is operated. Start is disabled. 0.7 bar [10 psi] Either the primary or the secondary (backup) voltage supply to the DCU 305 R2 is too low. 50 Hz overspeed = 1725 rpm 60 Hz overspeed = 2070 rpm 2.4 bar [35 psi] 120°C [248°F] 104°C [219°F] When set to standby only.

Bearing, Generator Page 21-8


Subbase Because the engine and alternator are being offered as a complete set, another new option is the subbase. The subbase option includes all the vibration damping and fastening hardware necessary to mount the engine and alternator onto the base rail.

Bearing, Generator (021-027) Preparatory Steps WARNING To reduce the possibility of property damage and personal injury from electrical shock, make certain the unit is isolated from all voltage sources. WARNING 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.


Remove The non-drive end bracket must be removed in order to replace the bearing on all frame sizes.

Remove the non-drive end access cover, the terminal box sides, lid, and support brackets.

Remove the permanent magnet exciter stator and rotor.

Do not pry on the generator fan to rotate the engine. The fan blades can be easily bent and broken. The entire generator rotor must be disassembled to replace the generator fan, if damaged.




WARNING 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.

Loosen the four inner capscrews that hold the bearing housing cap to the bearing cartridge first. It is difficult to keep the bearing cartridge from rotating if the four outer capscrews have been removed.

Remove the four outer capscrews that hold the bearing cartridge or inner bearing cap to the end bracket.

WARNING 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.


Tap the end bracket lightly while turning the jacking screws in. Check to make sure the bearing cartridge is not stuck in the end bracket.

CAUTION The main exciter stator is attached to the end bracket and comes out when the end bracket is removed. Use extreme care not to damage the main exciter stator as the end bracket is removed. WARNING 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.

Remove the capscrews that hold the bearing cap to the bearing cartridge.

Remove the bearing cap.




Remove the large snap ring from the generator shaft.

CAUTION Use two or more flat washers or a spacer between the puller and the end of the shaft to avoid damaging the threads in the end of the shaft. Use a puller to remove the bearing.

Press the old bearing from the bearing cartridge. The outer race of the bearing is lightly pressed into the bearing cartridge. Remove the bearing outer race.

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 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.


Inspect the bearing cartridge and bearing caps for cracks, fretting, or other signs of damage. If damage is present, replace the bearing cartridge caps.

Install Pack 27 ml [1 fluid oz] of the recommended lubricant into the bearing and put the same amount of lubricant into the bearing cartridge and end cap.

Sealed bearings are also an option.

CAUTION When installing the bearing in the cartridge, press on the outer race of the bearing to avoid damaging the bearing. WARNING To reduce the possibility of personal injury, use insulated gloves to handle the hot bearing cartridge. Heat the bearing cartridge in an oven to 100°C [212°F] for 1 hour. Press the bearing into the bearing cartridge.




NOTE: The maximum oven temperature should not exceed 120°C [248°F] Heat the bearing cartridge, with bearings installed, in an oven to 100°C [212°F] for 2 hours. Apply a thin coating of clean engine oil to the generator shaft.

WARNING To reduce the possibility of personal injury, use insulated gloves to handle the hot bearing cartridge. Use insulated gloves to install the bearing onto the shaft. Quickly push the bearing onto the shaft until it seats against the shaft shoulder. The bearing must slide on the shaft and be seated without excessive force.

CAUTION Apply pressure to only the inside race of the bearing. Applying pressure to the outer bearing race will damage the bearing. If the bearing binds on the shaft before being fully seated, use a length of pipe with an inside diameter slightly larger that the shaft diameter to drive the bearing against the shaft seat. Apply pressure to the inner race of the bearing only.

Install the snap ring onto the shaft next to the inner bearing race. Make sure the snap ring is seated in the groove.


Install the bearing cap.

NOTE: Make sure that the end plug of the three wire harness which is attached to the permanent magnet exciter stator, and is through the end bracket and the harness is retained by the internal wire clamp. The harness is difficult to install when the end bracket is on the generator. Install the end bracket onto the bearing cartridge.

WARNING 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.

Install the end bracket capscrews. Tap the end bracket with a dead-blow hammer as the capscrews are tightened Torque Value: 60 N•m [ 45 ft-lb ]




Align the bearing cartridge threaded capscrew holes with the holes in the end bracket by turning the bearing cap. The bearing cartridge will rotate in the end bracket. Install and tighten the bearing cartridge capscrews. Torque Value: 45 N•m [ 35 ft-lb ]

Pull the main exciter leads (X and XX) and the permanent magnetic exciter stator leads (P2, P3, and P4) through the hole in the frame terminal box. Connect the leads to the corresponding terminals on the auxiliary terminal block.

Install the permanent magnetic exciter. Install the non-drive end access cover, the terminal box sides, lid, and support brackets.

Finishing Steps WARNING 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.


Lubrication for the Power Components CAUTION Greasing of the alternator bearings must only take place when the generator set is in operation. Greasing the bearings on a static (non-running) alternator can damage the bearing cartridge seals. The bearing grease type and supplier must always be confirmed by checking the alternator dataplate, before the bearings are serviced.

CAUTION Check that the grease gun nozzle and bearing lubrication fittings are free from contaminants before beginning the lubrication process. Failure to do so can allow contaminants to be injected into the bearing, which can cause premature bearing failure. With the generator set operating, pump the specified amount of grease into the bearings. NOTE: The average grease gun expels approximately 1 gram per stroke. Grease Volume Specifications — Maintenance Alternator Model Drive End Non-Drive End Frame 7 - All 89 grams 75 grams Frame 8 - All 140 grams 100 grams DIG130 - All 80 grams 80 grams P-80 - 6232 Bearing 121 grams 121 grams P-80 - 6324 Bearing 151 grams 151 grams P-80 - 6236 Bearing 173 grams 173 grams NOTE: An increase in alternator bearing operating temperature can be observed following the lubrication process. Bearing temperature will return to normal after approximately 10 hours of operation.


Generator (Alternator) Exciter Rotating Diodes Page 21-18


Clean Internal CAUTION To reduce the possibility of personal injury, the generator set must be shut down and the alternator isolated from any voltage source before opening any alternator access doors. NOTE: Greasing the bearings with the generator set operating allows the old grease and excess grease to purge from the bearing cartridge through internal vents. The termination of the internal vents can differ by alternator manufacturer and model. The non-drive end bearing internal vent location is shown in the illustration. The drive-end internal vent is similar. Remove any old or excess grease purged from the bearing during the lubrication process by opening the alternator side panels and wiping the collected grease from the affected internal vent areas. Additional grease can purge after cleaning the internal vent areas, if the alternator had not achieved normal operating temperature during the lubrication process. External NOTE: Greasing the bearings with the generator set operating allows the old grease and excess grease to purge from the bearing cartridge through external vents. The termination of the external vents can differ by alternator manufacturer and model. Alternators with external bearing vents do not need to have the generator set shut down for the removal of purged grease. Remove any old or excess grease purged from the bearing during the lubrication process from the affected external vent areas. Additional grease can purge after cleaning the external vent areas, if the alternator had not achieved normal operating temperature during the lubrication process.

Generator (Alternator) Rotating Diodes (021-028)

Exciter

Preparatory Steps WARNING To reduce the possibility of property damage and personal injury from electrical shock, make certain the unit is isolated from all voltage sources. Remove the non-drive end access cover and the two side covers from the terminal box.


Remove There are three diodes on each of the two plates attached to the hub. These plates are on the drive end side of the main exciter rotor. The diodes are easier to check if the crankshaft is rotated.

NOTE: During assembly, the diode lead (3) is installed at the bottom of the connection stud (2). To make later service easier, put the diode lead (3) on the connection stud (2) last (under the nut). A lead from a diode (3) and a lead from the main exciter rotor (1) are both attached to the adjacent connector stud (2). Remove the diode lead (3) from the connection stud (2).

Use a multimeter, Part Number 3376898, set to ohms. Connect one lead of the meter to the diode lead and the other meter lead to the diode plate. record the reading. Reverse the meter leads and record the readings again.

A good diode will give a high resistance reading in one direction and a lower resistance reading in the opposite direction. The high reading must be at least ten times the low reading. A faulty diode will give a high resistance reading (open) in both directions or a low resistance reading (shorted) in both directions.




Before installing a new diode, check the appearance of the varistor (surge suppressor). The varistor is located on the opposite side of the shaft from the main generator rotor leads. A faulty generator varistor will be burned or have a lead wire burned off.

The diodes (1) are held in place by captive inserts (2) within the molded base (3). Remove the diode (1) by turning it counterclockwise.

To replace the varistor: 1. Disconnect the main generator rotor leads. 2. Remove all six diodes. 3. Move the ends of the two plates away from the main exciter rotor. 4. Remove the nut from the varistor stud. 5. Remove the varistor wire lead from the stud. 6. Replace the varistor assembly.


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.

Red Lead Black Lead

International Diodes International Rectifier 40HF100 40HFR100

Marconi M41-1000 M41R1000

A diode obtained from an electrical supply company will not have a lead soldered to the terminal. If a lead must be soldered to the terminal, use 60-40 rosin core solder. Hold the diode terminal with a long nose pliers during the soldering to prevent excessive heat transfer though the terminal to the diode junction.

CAUTION This compound must not be applied to the diode stud threads. It will act as a lubricant and allow the diode to loosen. The area if the diode that will be in contact with the plate must be coated with Midland Silicone Heat Sink Compound, Type MS 2623, or equivalent.




NOTE: All of the diode (1) installed on one plate must have the same polarity, and all the diodes (2) on the other plate must have the opposite polarity. Do not mix the polarity of the diodes on the plate. NOTE: On generators with permanent magnet exciter, it makes no difference which plate has the “R” polarity diodes. Install the diodes on the plates.

Finishing Steps • Install the access panels to the terminal box. • Operate the engine and check for proper operation.


Generator (021-029)

(Alternator)

Windings

Preparatory Steps WARNING To reduce the possibility of property damage and personal injury from electrical shock, make certain the unit is isolated from all voltage sources. WARNING 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 Page 21-23

Generator (Alternator) Windings Page 21-24


Thoroughly wash the windings with clean water to remove all traces of detergents. Dry the generator stator windings. Refer to the Blown Air Dehumidify step in Procedure 021-009.

NOTE: The anti-tracking resin or varnish must be: • of the same insulation thermal rating as the generators working duty cycle • checked to make sure the resin or varnish will adhere to the original insulation material. Overcoat the stator windings with an appropriate electrical anti-tracking resin or varnish. Overcoating protects the windings from immediate contamination of the winding surface.

Finishing Steps WARNING 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.


Permanent (021-030)

Magnet

Generator

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. 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.

Mark the permanent magnet exciter stator housing on the non-drive end bracket so it can be returned to the same location during assembly.

Permanent Magnet Generator Page 21-25



Disconnect the plug inside the permanent magnet exciter access cover. This plug connects the stator to the leads going into the generator rear end bracket.

Remove the four capscrews and clamps that hold the permanent magnet exciter stator to the end bracket.

CAUTION The rotor is highly magnetic and attracts the stator housing. Use care not to damage the stator windings as the stator is removed. Pull the permanent magnet exciter stator housing out of the recess in the end bracket. Lightly tap on the housing to loosen it. Light pulling force will be required.

Remove the shaft centerline capscrew from the end of the rotor shaft.


CAUTION Do not attempt to take the permanent magnet rotor apart. The magnetic proprieties of the rotor will be destroyed.

Pull the complete permanent magnet exciter rotor assembly from the shaft. The shaft is located with a dowel pin. A firm pull will be required to remove the rotor.

Wrap the permanent magnet exciter rotor in a protective cover to keep it clean and to prevent metallic particles from collecting on the magnets.

Install Place the permanent magnet exciter rotor on the generator shaft aligning the dowel pin in the shaft with the locating hole in the rotor. Push the rotor into position.




Install the center rotor retaining capscrew and tighten. Torque Value: 20 to 27 N•m [ 15 to 20 ft-lb ]

CAUTION The rotor is highly magnetic and attracts the stator housing. Use care not to damage the stator windings during installation. Use care not to get your fingers pinched in the installation process. Install the permanent magnet exciter stator housing in the end bracket recess with the stator leads at the top. Lightly tap the housing to seat it into the recess.

Align the location mark on the permanent magnet exciter stator housing with the location mark on the end bracket made during removal.

Install the four capscrews and clamps that hold the permanent magnet exciter stator housing to the end bracket. Tighten the capscrews. Torque Value: 20 to 27 N•m [ 15 to 20 ft-lb ]


Pull the plug attached to the leads extending from the generator rear end bracket through the stator opening. Connect the lead to the connector on the stator windings.

Install the access cover.

Finishing Steps WARNING 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 Page 21-30


Generator Rotor (021-031) Preparatory Steps WARNING To reduce the possibility of property damage and personal injury from electrical shock, make certain the unit is isolated from all voltage sources. WARNING 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.


Remove the four outer capscrews that hold the non-drive end bearing cartridge to the end bracket. NOTE: Do not loosen the four inner capscrews unless the bearing is to be replaced.

Remove all the capscrews that hold the non-drive end bracket to the frame. Thread two of the capscrews into the jacking holes on the end bracket horizontal center line. Screw these capscrews in to pull the end bracket pilot from the locating recess in the main generator frame.

Lightly tap the end bracket while turning the jacking screws in. Check to make certain the bearing cartridge is not stuck in the end bracket.

WARNING 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.




Remove the eight capscrews holding the drive end bracket to the frame.

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.

Support the drive end bracket while tapping the end bracket to release it from the recess in the generator frame.

CAUTION Do not pry on the fan ring between the fan blades. The fan blades can be easily bent or broken. The entire generator rotor must be disassembled (normally at the factory) to replace the generator fan. Move the rotor out from the stator by prying on the fan ring at the fan blade.


WARNING 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.

Continue to pull and rotate the rotor assembly as it is removed from the stator. Move the sling closer to the center balance point of the rotor as it is removed

Position the sling around the main generator rotor where only a slight down force on the fan is required to balance the assembly. Set the rotor in a formed support as shown to reduce the possibility of damage to the main exciter rotor windings.

Install WARNING 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.




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.


NOTE: Check that the permanent magnet exciter harness attached to the stator is through the end bracket and the harness is retained by the internal wire clamp. The harness is difficult to install when the end bracket is on the generator. The main exciter stator leads must be on the top of the generator. Install the end bracket on the bearing cartridge.

WARNING 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.

Install the end bracket capscrews. Tap the end bracket with a dead-blow hammer as the capscrews are tightened Torque Value: 60 N•m [ 45 ft-lb ]

Pull the main exciter leads (X and XX) and the permanent magnetic exciter stator leads (P2, P3, and P4) through the hole in the frame terminal box. Connect the leads to the corresponding terminals on the auxiliary terminal block.




Align the bearing cartridge threaded capscrew holes with the holes in the end bracket by turning the bearing cap. The bearing cartridge will rotate in the end bracket. Install the bearing cartridge capscrews. Torque Value: 45 N•m [ 35 ft-lb ]

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.

Cummins Service Publications Electronic Books on CD-ROM Enclosed, we’ve included on CD-ROM, an electronic copy of this publication in Adobe® Acrobat® format (PDF) for your personal use and reference. Before you begin to use the CD-ROM, please read the “Cummins Service Publications Electronic Books on CD-ROM Information” printed section, beginning on the next page. This section includes information about this CD-ROM including System Requirements, Local Administrative Rights requirements, How to Use, Helpful Support Tips and other information.

Cummins Service Publications Electronic Books on CD-ROM Information The enclosed CD-ROM provides you with the capability to view this publication electronically as well as perform searches. This CD-ROM is copy protected and will not allow Printing, Changing of Content, Extracting Content or Commenting / Annotating of the PDF file. This CD-ROM is read only, and you will not be able to copy files from the CD-ROM and have them open or function in any manner. The only method to view the electronic publication is from the original CD-ROM. This CD-ROM is intended for use by the owner of the printed publication only. Copying or distribution of content from this CD-ROM is expressly prohibited. This CD-ROM will not function from a network server CD-ROM drive. It will function only in a CD-ROM drive directly connected to your computer. For Microsoft Windows NT 4.0, Microsoft Windows 2000 or Microsoft Windows XP, this CD-ROM requires that you have Local Administrative rights in order to use. See the System requirements section for additional details.

System Requirements: Use of the Cummins Service Publications Electronic Books on CD-ROM requires Adobe Acrobat, Adobe Acrobat Reader, or Adobe Reader software to be pre-installed on your computer. This product has been tested for compatibility with Adobe Acrobat software versions 5.0, 6.0 and 7.0. It may function properly with versions later than Adobe Acrobat 7.0, but testing has not been performed. Acrobat Reader is available as a free download from www.adobe.com. The Cummins Service Publications Electronic Books on CD-ROM product requires the following system components: • Microsoft Windows Auto-Play must be enabled on your computer (it is enabled by default when Windows is installed) • CD-ROM Drive • Color Monitor with at least 800x600 resolution graphics • Microsoft Windows XP Professional or Microsoft Windows 2000 Professional. This CD-ROM may be compatible with Microsoft Windows 98 SE, Microsoft Windows NT 4.0, or Microsoft Windows XP Home Edition, but testing has not been performed. • Recommended memory, processor speed and available hard-disk space is in accordance with respective Microsoft Operating System Guidelines, as well as Adobe Acrobat system requirements listed later in these instructions. Note: The Cummins Service Publications Electronic Books on CD-ROM product is not Macintosh compatible. About required Local Administrative Rights: The copy protection system used on this product requires direct access to CD-ROM drives in order to authenticate copy protected discs. In order to allow the software to enable direct access to CD-ROM drives rights under Microsoft Windows, if you are using Microsoft Windows NT 4.0, Microsoft Windows 2000 or Microsoft Windows XP, your logon account/profile must have Local Administrative Rights on the computer you will be using your Cummins Service Publications Electronic Book on CDROM with. If this computer is set up in Restricted Mode, and your logon account/profile does not have Local Administrative Rights, then, with approval of your I.T. department or the owner of your computer, you can choose from the following options to allow the Cummins Service Publications Electronic Book on CD-ROM to function properly: • •

Have your computer account enabled to have Local Administrative rights and then you can run the Cummins Service Publications Electronic Book on CD-ROM - OR Have a user with Local Administrative Rights logon to your computer and run the CD-ROM one time. By doing this, the necessary files will be loaded to your computer and your computer will be enabled to have direct access to CDROM drives. Then restart this computer. It is very important to restart the computer after you have done this. For all future needs, you can run the Cummins Service Publications Electronic Book on CD-ROM under your own account, without requiring your logon account/profile to have Local Administrative Rights. (Note: This needs to be done only once for any Cummins Service Publications Electronic Book on CD-ROM and then does not need to be done again for other Cummins Service Publications Electronic Book on CD-ROM titles you may own.)

Cummins Service Publications Electronic Books on CD-ROM Information (continued) About the Copy Protection Software: • This product may upgrade the proprietary copy protection software files it uses that are placed on your computer system to a new version, if an older version exists on your computer. If you have CD-ROM copy protected items from other companies and they use older versions of the same HexaLock copy protection software that the Cummins Service Publications Electronic Books on CD-ROM uses, it may render them incompatible for use on your computer. Adobe Acrobat Reader 5.0 system requirements: • PC Compatible computer w/ Intel® Pentium® processor • One of the following Microsoft® Windows Operating Systems: Microsoft Windows 98 SE Microsoft Windows Millennium Edition Microsoft Windows NT® 4.0 with Service Pack 5 Microsoft Windows 2000 Microsoft Windows XP • 64MB of RAM • 24MB of available hard-disk space • Additional 70MB of hard-disk space for Asian fonts (optional) (Asian fonts are not required for Cummins Service Publications Electronic Books on CD-ROM product.) Adobe Reader 6.0.1 system requirements: • PC Compatible computer w/ Intel Pentium processor • One of the following Microsoft Windows Operating Systems: Microsoft Windows 98 SE Microsoft Windows Millennium Edition Microsoft Windows NT 4.0 with Service Pack 6 Microsoft Windows 2000 with Service Pack 2 Microsoft Windows XP Professional or Home Edition Microsoft Windows XP Tablet PC Edition • 32MB of RAM (64MB recommended) • 60MB of available hard-disk space • Microsoft Internet Explorer 5.0.1, 5.5, 6.0, or 6.1 Adobe Reader 7.0 system requirements: • PC Compatible computer w/ Intel Pentium processor • One of the following Microsoft Windows Operating Systems: Microsoft Windows 2000 with Service Pack 2 Microsoft Windows XP Professional or Home Edition Microsoft Windows XP Tablet PC Edition • 128MB of RAM • Up to 90MB of available hard-disk space • Microsoft Internet Explorer 5.5 or higher

How to Use the Cummins Service Publications Electronic Book on CD-ROM: To use the CD-ROM, simply insert the CD-ROM into your computer and it should automatically run, open Adobe Acrobat and open the Electronic Book. (This happens with Microsoft Windows Auto-Play functionality, and Adobe Acrobat preloaded by you on your computer).

Cummins Service Publications Electronic Books on CD-ROM Information (continued) Helpful Support Tips: • •

•

If Windows Auto-Play is not enabled, try re-enabling it, or navigate with Windows Explorer to your CD-ROM drive and double click on the CD-ROM drive letter to open it. Then double-click on the program named “clickhere”. (Do not attempt to directly open the PDF file by clicking on the PDF document.) In rare occasions, after inserting the CD-ROM you may receive a notice from Adobe Acrobat that it “could not open the PDF because it is either not a supported file type or the file has been corrupted”. This can occur in rare occasions due to application timing issues. If this occurs there are several options to remedy the situation: 1) Simply click OK on the notice, eject the CD-ROM and re-insert it to have it restart the program, or 2) Click OK on the notice and navigate with Windows Explorer to your CD-ROM drive and double click on the CD-ROM drive letter to open it. Then doubleclick on the program named “clickhere”. (Do not attempt to directly open the PDF file by clicking on the PDF document) or 3) Click OK on the notice, eject the CD-ROM, restart your computer and after the system has restarted, re-insert the CD-ROM and have it automatically run. If the Cummins Service Publications Electronic Books on CD-ROM does not function, see the prior section on “About required Local Administrative Rights:” in this documentation and verify you have Local Administrative Rights on your computer in order to run the CD-ROM.

Special Instructions for Cummins PowerSweep PC Users: (This only applies to Cummins Inc. & Distributor Employees): Cummins PowerSweep PC users that DO NOT have Local Administrative rights to their PC will require a HexaLock patch software installation. If you are a Cummins Inc. or Distributor Employee who wants to use these CD-ROM’s, and you have a PowerSweep PC – please order the ‘HexaLock’ software from the Cummins Software Shelf. The Software Shelf personnel will contact you to arrange installation. Software will be installed remotely by Software Shelf personnel. Once software is installed, first reboot your PC, then attempt to read your encrypted CD-ROM manual while Cummins Software Shelf personnel are still on the telephone.

Electronic Book Technical Support: Support for this product is available from Monday through Friday weekly, excluding Holidays, from 8 a.m. to 5 p.m. You may call (502) 540-4981 for telephone support. For e-mail support, please e-mail [email protected].

CD-ROM Media Replacement Options: Up to 90 days from date of purchase: Within the first 90 days from your date of purchase, if your copy of an Electronic Book on CD-ROM does not function, and after a Cummins Electronic Book Technical Support Technician has confirmed the situation and authorized its replacement by providing you an RMA#, you may send back the CD-ROM for a free replacement. To do so, you must package the CD-ROM and ship/mail, with postage pre-paid by you, to the below address. You must also include a photocopy of the original invoice for proof of purchase of the publication clearly indicating the bulletin # and the purchase date. The RMA# must be on the address information of the package. If the proof of purchase copy of the invoice is not enclosed, your request will not be able to be processed and will not be returned. Delivery of the replacement will be shipped to you at no charge. Allow 3 to 4 weeks for your receipt of replacement copy. Note: Return only the nonfunctional CD-ROM, do not return the entire printed publication. The replacement CD-ROM maintains the original purchase/invoice date for the purposes of this replacement policy. This policy is subject to change at any time, without notice. For a copy of the most current replacement options policy, please e-mail [email protected] with your request. Media Replacement Ship to Address: Attn: Cummins Service Publications Electronic Books Technical Support RMA#: XXXXXX (where XXXXXX is the RMA#) 808 E. Liberty Street Louisville, KY 40204 U.S.A. Cummins Service Publications Electronic Books on CD-ROM are Copyright © Cummins Inc. Adobe Acrobat Reader is a registered trademark of Adobe Systems Incorporated. Microsoft, Windows, and Windows NT are registered trademarks of Microsoft Corporation. Intel and Pentium are trademarks of Intel Corporation. HexaLock is Copyright © HexaLock, Ltd. All other names and products used herein are trademarks for their respective owner.

K38, K50, QSK38, and QSK50 Section L — Service Literature

Page L-a

Section L — Service Literature Section Contents Page Additional Service Literature ............................................................................................................................L-1 General Information..........................................................................................................................................L-1 Cummins Customized Parts Catalog ................................................................................................................L-3 General Information..........................................................................................................................................L-3 Ordering the Customized Parts Catalog.............................................................................................................L-3 Ordering by Telephone...................................................................................................................................L-3 Ordering On-Line...........................................................................................................................................L-3 Service Literature Ordering Location ...............................................................................................................L-2 Contact Information...........................................................................................................................................L-2


Page L-b



Additional Service Literature Page L-1

Additional Service Literature General Information The following publications are available on QuickServe® or can be purchased by contacting a Cummins® Distributor. Bulletin 3810313 3810344 3810243 3666040 3810257 3379035 4021520 4021537 3379052 3666069 3810497 3667180 3666231 3666085 3377710 3379000 3379001 3379068 3379071 3379084 3379091 3379177 3379179 3379182 3379231 3379352 3387622 3379664 3666085 3666106 3666132 3666191 3810235 3810251 3810340 3810334 3810335 3379133 3810250

Title of Publication PT (Type D) STC Injector Shop Manual PT (Type D) Top Stop Injector Shop Manual Holset® HC-5 or HC-5A Turbocharger Shop Manual Shop and Installation Manual Rear Engine Power Take-Off (REPTO) Cummins® ST 677 Two Cylinder Air Compressor Shop Manual Alternative Repair Manual QSK50 CM850 Industrial Modular Common Rail Wiring Diagram QSK50 CM850 Power Generation Modular Common Rail Wiring Diagram Construction/Industrial Diesel Engines Operation and Maintenance Manual CENTRY™ System (PT) Operation and Maintenance Manual Operation and Maintenance Manual K38, K50, QSK38 and QSK50 K38 and K50 Owners Manual Centinel™ Master Repair Manual CENTRY™ Fault Code Manual Service Products Catalog Air for Your Engines Fuels for Cummins® Engines Fuel Pump PT (Type G) Calibration Values (1970-1975) Injectors PT Rebuild Manual Fuel Pump PT (Type G) Rebuild and Calibration Instructions Turbochargers Rebuild Manual American Bosch® Governors Woodward® Governors Fuel Pump PT (Type G) Calibration Values (1976-1980) Electric Fuel Control Governor (EFC) Fuel Pump PT (Type G) Calibration Values (1981-Present) Cold Weather Operations Injector Parts Flow and Cross Reference CENTRY™ Fault Code Manual Hydro-mechanical Step Timing Control Valve Coolant Requirements and Maintenance Cummins® Branded Starters and Alternators Brown Boveri® Exhaust-Gas Turbocharger, RR 153 Rockford® Clutch Overhaul Procedure Cummins® Engine Oil Recommendations K38 Standard Repair Times K50 Standard Repair Times Control Parts List (CPL) Rockford® Fan Clutch Service Manual and Parts List

Service Literature Ordering Location Page L-2


Service Literature Ordering Location Contact Information Region United States and Canada

All Other Countries

Ordering Location Cummins Distributors or Credit Cards at 1-800-646-5609 or Order online at www.powerstore.cummins.com Cummins Distributors or Dealers


Cummins Customized Parts Catalog Page L-3

Cummins Customized Parts Catalog General Information Cummins is pleased to announce the availability of a parts catalog compiled specifically for you. Unlike the generic versions of parts catalogs that support general high volume parts content; Cummins Customized catalogs contains only the new factory parts that were used to build your engine. The catalog cover, as well as the content, is customized with you in mind. You can use it in your shop, at your worksite, or as a coffee table book in your RV or boat. The cover contains your name, company name, address, and telephone number. Your name and engine model identification even appears on the catalog spine. Everybody will know that Cummins created a catalog specifically for you. This new catalog was designed to provide you with the exact information you need to order parts for your engine. This will be valuable for customers that do not have easy access to the Cummins Electronic Parts Catalog or the Cummins Parts Microfilm System. Additional Features of the Customized Catalog include: • Engine Configuration Data • Table of Contents • Separate Option and Parts Indexes • Service Kits (when applicable) • ReCon Part Numbers (when applicable)

Ordering the Customized Parts Catalog Ordering by Telephone North American customers can contact their Cummins Distributor or call Gannett Direct Marketing Services at 1-800-646-5609 and order by credit card. Outside North America order on-line or make an International call to Gannett at (++)502-454-6660. Ordering On-Line The Customized Parts Catalog can be ordered On-Line from the Cummins Powerstore by credit card. Contact the Powerstore at WWW.POWERSTORE.CUMMINS.COM Contact GDMS or the CUMMINS POWERSTORE for the current price; Freight may be an additional expense. Information we need to take your Customized Parts Catalog Order. This information drives the cover content of the CPC. • Customer Name • Street Address • Company Name (optional) • Telephone no. • Credit Card No. • Cummins Engine Serial Number (located on the engine data plate) • Please identify the required media: Printed Catalog, CD-ROM, or PDF File Unfortunately not all Cummins Engines can be supported by this parts catalog. Engines older than 1984 or newer than 3 months may not have the necessary parts information to compile a catalog. We will contact you if this occurs and explain why we are unable to fill your order. Customized Parts Catalogs are produced specifically for a single customer. This means they are not returnable for a refund. If we make an error and your catalog is not useable, we will correct that error by sending you a new catalog.

Cummins Customized Parts Catalog Page L-4


Notes

K38, K50, QSK38, and QSK50 Section M — Component Manufacturers

Page M-a

Section M — Component Manufacturers Section Contents Page Component Manufacturers' Addresses ...........................................................................................................M-1 Air Compressors..............................................................................................................................................M-1 Air Cylinders....................................................................................................................................................M-1 Air Heaters.......................................................................................................................................................M-1 Air Starting Motors...........................................................................................................................................M-1 Alternators.......................................................................................................................................................M-1 Auxiliary Brakes...............................................................................................................................................M-1 Belts................................................................................................................................................................M-1 Catalytic Converters.........................................................................................................................................M-1 Coolant Level Switches....................................................................................................................................M-1 Clutches..........................................................................................................................................................M-1 Coolant Heaters...............................................................................................................................................M-2 Drive Plates.....................................................................................................................................................M-2 Electric Starting Motors....................................................................................................................................M-2 Electronic Switches..........................................................................................................................................M-2 Engine Protection Controls...............................................................................................................................M-2 Fan Clutches....................................................................................................................................................M-2 Fans................................................................................................................................................................M-2 Fault Lamps.....................................................................................................................................................M-2 Filters...............................................................................................................................................................M-2 Flexplates........................................................................................................................................................M-2 Fuel Coolers....................................................................................................................................................M-2 Fuel Pumps......................................................................................................................................................M-2 Fuel Warmers..................................................................................................................................................M-2 Gauges............................................................................................................................................................M-3 Governors........................................................................................................................................................M-3 Heat Sleeves....................................................................................................................................................M-3 Hydraulic and Power Steering Pumps..............................................................................................................M-3 In-Line Connectors...........................................................................................................................................M-3 Oil Heaters.......................................................................................................................................................M-3 Prelubrication Systems.....................................................................................................................................M-3 Radiators.........................................................................................................................................................M-3 Throttle Assemblies..........................................................................................................................................M-3 Torque Converters...........................................................................................................................................M-3

Page M-b




Component Manufacturers' Addresses Page M-1

Component Manufacturers' Addresses (203-001) NOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins engines. Suppliers can be contacted directly for any specifications not covered in this manual. Belts Air Compressors Ingersoll-Rand Engine Starting Systems T.B.A. Belting Ltd. Bendix Heavy Vehicles Systems 888 Industrial Drive P.O. Box 77 Div. of Allied Automotive Elmhurst, IL 60126 Wigan 901 Cleveland Street Telephone: (708) 530-3875 Lancashire Elyria, OH 44036 WN2 4XQ StartMaster Telephone: (216) 329-9000 England Air Starting Systems Holset Engineering Co., Inc. Telephone: (0)1942-259221 A Division of Sycon Corporation 1320 Kemper Meadow Drive 9595 Cheney Avenue Dayco Mfg. Suite 500 P. O. Box 491 Belt Technical Center Cincinnati, OH 45240 Marion, OH 43302 1955 Enterprize Telephone: (513) 825-9600 Telephone: (614) 382-5771 Rochester Hills, MI 48309 Midland-Grau Alternators Telephone: (810) 853-8300 Heavy Duty Systems Gates Rubber Company Robert Bosch Ltd. Heavy Duty Group Headquarters 900 S. Broadway P.O. Box 98 10930 N. Pamona Avenue Denver, CO 80217 Broadwater Park Kansas City, MO 64153 North Orbital Road Telephone: (816) 891-2470 Goodyear Tire and Denham Air Cylinders Rubber Company Uxbridge Industrial Products Div. Bendix Ltd. Middlesex UD9 5HG 2601 Fortune Circle East Douglas Road England Indianapolis, IN 46241 Kingswood Telephone: (0)1895-838383 Telephone: (317) 898-4170 Bristol Prestolite Electrics Catalytic Converters England Cleveland Road Telephone: 0117-671881 Donaldson Company, Inc. Leyland 1400 West 94th Street Catching Engineering PR5 1XB P.O. Box 1299 1733 North 25th Avenue England Minneapolis, MN 55440 Melrose Park, IL 60160 Telephone: (0)1772-421663 Telephone: (612) 887-3835 Telephone: (708) 344-2334 C. E. Niehoff & Co. Nelson Division TEC - Hackett Inc. 2021 Lee Street Exhaust and Filtration Systems 8909 Rawles Avenue Evanston, IL 60202 1801 U.S. Highway 51 P.O. Box 428 Indianapolis, IN 46219 Telephone: (708) 866-6030 Telephone: (317) 895-3670 Stoughton, WI 53589 Delco-Remy America Telephone: (608) 873-4200 Air Heaters 2401 Columbus Avenue Walker Manufacturing P.O. Box 2439 Fleetguard, Inc. 3901 Willis Road Anderson, IN 46018 1200 Fleetguard Road P.O. Box 157 Telephone: (317) 646-3528 Cookeville, TN 38502 Grass Lake, MI 49240 Telephone: (615) 526-9551 Leece-Neville Corp. Telephone: (517) 522-5500 400 Main Street Kim Hotstart Co. Coolant Level Switches Arcade, NY 14009 P.O. Box 11245 Telephone: (716) 492-1700 Spokane, WA 99211-0245 Robertshaw Controls Company Telephone: (509) 534-6171 P.O. Box 400 Auxiliary Brakes Knoxville, TN 37901 Air Starting Motors The Jacobs Manufacturing Company Telephone: (216) 885-1773 Vehicle Equipment Division Ingersoll Rand Clutches 22 East Dudley Town Road Chorley New Road Bloomfield, CT 06002 Horwich Twin Disc International S.A. Telephone: (203) 243-1441 Bolton Chaussee de Namur Lancashire Nivelles England Belguim BL6 6JN Telephone: 067-224941 Telephone: 01204-65544 Twin Disc Incorporated 1328 Racine Street Racine, WI 53403 Telephone: (414) 634-1981



Coolant Heaters

Fan Clutches

Fault Lamps

Fleetguard, Inc. 1200 Fleetguard Road Cookeville, TN 38502 Telephone: (615) 526-9551

Kysor Cooling Systems N.A. 6040 West 62nd Street Indianapolis, IN 46278 Telephone: (317) 328-3330

Drive Plates

Holset Engineering Co. Ltd. ST Andrews Road Huddersfield, West Yorkshire England HD1 6RA Telephone: (0)1484-22244

Cutler-Hammer Products Eaton Corporation 4201 N. 27th Street Milwaukee, WI 53216 Telephone: (414) 449-6600

Detroit Diesel Allison Division of General Motors Corporation P.O. Box 894 Indianapolis, IN 46206-0894 Telephone: (317) 242-5000 Electric Starting Motors Prestolite Electrics Cleveland Road Leyland PR5 1XB England Telephone: 01772-421663 Delco-Remy America 2401 Columbus Avenue P.O. Box 2439 Anderson, IN 46018 Telephone: (317) 646-3528 Leece-Neville Corp. 400 Main Street Arcade, NY 14009 Telephone: (716) 492-1700 Nippondenso Inc. 2477 Denso Drive P.O. Box 5133 Southfield, MI 48086 Telephone: (313) 350-7500 Electronic Switches Cutler-Hammer Products Eaton Corporation 4201 N. 27th Street Milwaukee, WI 53216 Telephone: (414) 449-6600 Engine Protection Controls Flight Systems Headquarters Hempt Road P.O. Box 25 Mechanicsburg, PA 17055 Telephone: (717) 697-0333 The Nason Company 2810 Blue Ridge Blvd. West Union, SC 29696 Telephone: (803) 638-9521 Teddington Industrial Equipment Windmill Road Sunbury on Thames Middlesex TW16 7HF England Telephone: (0)9327-85500

Horton Industries, Inc. P.O. Box 9455 Minneapolis, MN 55440 Telephone: (612) 378-6410 Rockford Clutch Company 1200 Windsor Road P.O. Box 2908 Rockford, IL 61132-2908 Telephone: (815) 633-7460 Fans Truflo Ltd. Westwood Road Birmingham B6 7JF England Telephone: (0)121-3283041

Filters Fleetguard International Corp. Cavalry Hill Industrial Park Weedon Northampton NN7 4TD England Telephone: 01327-341313 Fleetguard, Inc. 1200 Fleetguard Road Cookeville, TN 38502 Telephone: 1-800-22-Filters (1-800-223-4583) Flexplates Corrugated Packing and Sheet Metal Hamsterley Newcastle Upon Tyne England Telephone: (0)1207-560-505

Hayes-Albion Corporation Jackson Manufacturing Plant 1999 Wildwood Avenue Jackson, MI 49202 Telephone: (517) 782-9421

Allison Transmission Division of General Motors Corporation P.O. Box 894 Indianapolis, IN 46206-0894 Telephone: (317) 242-5000

Engineered Cooling Systems, Inc. 201 W. Carmel Drive Carmel, IN 46032 Telephone: (317) 846-3438

Midwest Mfg. Co. 29500 Southfield Road, Suite 122 Southfield, MI 48076 Telephone: (313) 642-5355

Brookside Corporation P.O. Box 30 McCordsville, IN 46055 Telephone: (317) 335-2014

Wohlert Corporation 708 East Grand River Avenue P.O. Box 20217 Lansing, MI 48901 Telephone: (517) 485-3750

TCF Aerovent Company 9100 Purdue Rd., Suite 101 Indianapolis, IN 46268-1190 Telephone: (317) 872-0030 Kysor-Cadillac 1100 Wright Street Cadillac, MI 49601 Telephone: (616) 775-4681 Schwitzer 6040 West 62nd Street P.O. Box 80-B Indianapolis, IN 46206 Telephone: (317) 328-3010

Fuel Coolers Hayden, Inc. 1531 Pomona Road P.O. Box 848 Corona, CA 91718-0848 Telephone: (909) 736-2665 Fuel Pumps Robert Bosch Corp. Automotive Group 2800 South 25th Ave. Broadview, IL 60153 Fuel Warmers Fleetguard, Inc. 1200 Fleetguard Road Cookeville, TN 38502 Telephone: (615) 526-9551


Gauges Grasslin U.K. Ltd. Vale Rise Tonbridge Kent TN9 1TB England Telephone: (0)1732-359888 Datcon Instruments P.O. Box 128 East Petersburg, PA 17520 Telephone: (717) 569-5713 Rochester Gauges, Inc. 11616 Harry Hines Blvd. P.O. Box 29242 Dallas, TX 75229 Telephone: (214) 241-2161 Governors Woodward Governor Co. P.O. Box 1519 Fort Collins, CO 80522 Telephone: (303) 482-5811 (800) 523-2831 Barber Colman Co. 1354 Clifford Avenue Loves Park, IL 61132 Telephone: (815) 637-3000 United Technologies Diesel Systems 1000 Jorie Blvd. Suite 111 Oak Brook, IL 69521 Telephone: (312) 325-2020 Heat Sleeves Bentley Harris Manufacturing Co. 100 Bentley Harris Way Gordonville, TN 38563 Telephone: (313) 348-5779 Hydraulic and Power Steering Pumps Honeywell Control Systems Ltd. Honeywell House Arlington Business Place Bracknell Berks RG12 1EB Telephone: (0)1344-656000


Sperry Vickers P.O. Box 302 Troy, MI 48084 Telephone: (313) 280-3000 Z.F. P.O. Box 1340 Grafvonsoden Strasse 5-9 D7070 Schwaebisch Gmuend Germany Telephone: 7070-7171-31510 In-Line Connectors Pioneer-Standard Electronics, Inc. 5440 Neiman Parkway Solon, OH 44139 Telephone: (216) 349-1300 Deutsch Industrial Products Division 37140 Industrial Avenue Hemet, CA 92343 Telephone: (714) 929-1200 Oil Heaters Fleetguard, Inc. 1200 Fleetguard Road Cookeville, TN 38502 Telephone: (615) 526-9551 Kim Hotstart Co. P.O. Box 11245 Spokane, WA 99211-0245 Telephone: (509) 534-6171 Prelubrication Systems RPM Industries, Inc. Suite 109 55 Hickory Street Washington, PA 15301 Telephone: (412) 228-5130 Radiators JB Radiator Specialties, Inc. P.O. Box 292087 Sacramento, CA 95829-2087 Telephone: (916) 381-4791

The G&O Manufacturing Company 100 Gando Drive P.O. Box 1204 New Haven, CT 06505-1204 Telephone: (203) 562-5121 Young Radiator Company 2825 Four Mile Road Racine, WI 53404 Telephone: (910) 271-2397 L and M Radiator, Inc. 1414 East 37th Street Hibbing, MN 55746 Telephone: (218) 263-8993 Throttle Assemblies Williams Controls, Inc. 14100 SW 72nd Avenue Portland, OR 97224 Telephone: (503) 684-8600 Torque Converters Twin Disc International S.A. Chaussee de Namur Nivelles Belgium Telephone: 067-224941 Twin Disc Incorporated 1328 Racine Street Racine, WI 53403-1758 Telephone: (414) 634-1981 Rockford Powertrain, Inc. Off-Highway Systems 1200 Windsor Road P.O. Box 2908 Rockford, IL 61132-2908 Telephone: (815) 633-7460 Modine Mfg. Co. 1500 DeKoven Avenue Racine, WI 53401 Telephone: (414) 636-1640



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

Page V-b


ECM Cooling Plate...................................................................................................................................................V-74 ECM Cooling Plate Lines......................................................................................................................................... V-74 Expansion Tank........................................................................................................................................................V-64 Fan Drive Idler Arm Assembly..................................................................................................................................V-63 Fan Hub Bracket...................................................................................................................................................... V-63 Fan Hub, Belt Driven................................................................................................................................................V-63 Fan, Cooling.............................................................................................................................................................V-64 Heat Exchanger........................................................................................................................................................V-64 Sea Water Pump......................................................................................................................................................V-70 Sea Water Pump Support........................................................................................................................................ V-71 Water Manifold.........................................................................................................................................................V-72 Water Pump............................................................................................................................................................. V-72 Cummins/Fleetguard® Filter Specifications .................................................................................................V-133 Specifications...............................................................................................................................................V-133 Cylinder Block — Group 01 - Specifications ....................................................................................................V-1 Bearings, Connecting Rod.........................................................................................................................................V-1 Bearings, Main...........................................................................................................................................................V-1 Bearings, Thrust.........................................................................................................................................................V-2 Camshaft....................................................................................................................................................................V-2 Camshaft Bushings....................................................................................................................................................V-3 Camshaft Gear (Camshaft Installed)..........................................................................................................................V-3 Camshaft Gear (Camshaft Removed)........................................................................................................................V-3 Camshaft Thrust Bearing......................................................................................................................................... V-11 Connecting Rod..........................................................................................................................................................V-4 Crankshaft..................................................................................................................................................................V-5 Crankshaft Gear, Front (Crankshaft Removed).........................................................................................................V-5 Cylinder Block............................................................................................................................................................V-6 Cylinder Block and Liner Seats..................................................................................................................................V-7 Cylinder Block Counterbore..................................................................................................................................... V-11 Cylinder Liner.............................................................................................................................................................V-7 Cylinder Liner Protrusion..........................................................................................................................................V-12 Gear Cover Accessory Drive Bushing......................................................................................................................V-13 Gear Cover, Front......................................................................................................................................................V-8 Gear Train Backlash, Front......................................................................................................................................V-11 Idler Gear, Camshaft..................................................................................................................................................V-8 Idler Shaft, Camshaft Idler Gear...............................................................................................................................V-11 Idler Shaft, Water Pump Idler Gear..........................................................................................................................V-12 Piston....................................................................................................................................................................... V-10 Piston and Connecting Rod Assembly.....................................................................................................................V-11 Piston Rings.............................................................................................................................................................V-10 Vibration Damper, Viscous.......................................................................................................................................V-10 Cylinder Block — Group 01 - Torque Values .................................................................................................V-14 Bearings, Connecting Rod....................................................................................................................................... V-14 Bearings, Main......................................................................................................................................................... V-14 Bearings, Thrust.......................................................................................................................................................V-15 Camshaft..................................................................................................................................................................V-15 Camshaft Cover Plate..............................................................................................................................................V-15 Camshaft Gear (Camshaft Installed)........................................................................................................................V-15 Crankshaft................................................................................................................................................................V-15 Crankshaft Adapter.................................................................................................................................................. V-16 Crankshaft Pulley.....................................................................................................................................................V-16 Crankshaft Seal, Rear..............................................................................................................................................V-16 Cylinder Block.......................................................................................................................................................... V-16 Cylinder Block Counterbore..................................................................................................................................... V-18 Cylinder Liner...........................................................................................................................................................V-16 Cylinder Liner Protrusion..........................................................................................................................................V-19 Gear Cover, Front.................................................................................................................................................... V-16 Gear Housing, Front.................................................................................................................................................V-17 Hand Hole Cover......................................................................................................................................................V-17 Idler Gear, Camshaft................................................................................................................................................V-17 Piston Cooling Nozzle..............................................................................................................................................V-17 Vibration Damper, Double........................................................................................................................................V-18 Vibration Damper, Viscous.......................................................................................................................................V-18


Page V-c

Water Header Plate, Cylinder Block.........................................................................................................................V-18 Cylinder Head — Group 02 - Specifications ..................................................................................................V-20 Crosshead................................................................................................................................................................V-20 Cylinder Head...........................................................................................................................................................V-20 Cylinder Head — Group 02 - Torque Values ..................................................................................................V-23 Crosshead................................................................................................................................................................V-23 Cylinder Head...........................................................................................................................................................V-23 Drive Belt Tension ........................................................................................................................................V-140 Tension Chart...............................................................................................................................................V-140 Drive Units — Group 09 - Specifications ...........................................................................................................V-76 Accessory Drive.......................................................................................................................................................V-76 Accessory Drive Bushing.........................................................................................................................................V-77 Accessory Drive Gear and Shaft..............................................................................................................................V-77 Accessory Drive Pulley.............................................................................................................................................V-78 Fuel Pump Drive.......................................................................................................................................................V-78 Hydraulic Pump Drive...............................................................................................................................................V-80 Hydraulic Pump Drive Gear and Shaft.....................................................................................................................V-81 Rear Gear Drive (Lower Assembly).........................................................................................................................V-81 Rear Gear Drive (Upper Assembly).........................................................................................................................V-82 Rear Gear Drive Gear and Shaft (Upper Assembly)................................................................................................V-83 Water Pump Drive Bushing......................................................................................................................................V-84 Water Pump Drive Gear and Shaft...........................................................................................................................V-84 Woodward Governor Drive.......................................................................................................................................V-84 Drive Units — Group 09 - Torque Values .......................................................................................................V-86 Accessory Drive.......................................................................................................................................................V-86 Fuel Pump Drive.......................................................................................................................................................V-86 Hydraulic Pump Drive...............................................................................................................................................V-87 Rear Gear Drive (Lower Assembly).........................................................................................................................V-87 Rear Gear Drive (Upper Assembly).........................................................................................................................V-87 Woodward Governor Drive.......................................................................................................................................V-88 Electrical Equipment — Group 13 - Torque Values .....................................................................................V-116 Alternator................................................................................................................................................................V-116 Alternator Adjusting Link........................................................................................................................................V-116 Alternator Bracket...................................................................................................................................................V-116 Starting Motor.........................................................................................................................................................V-116 Electrical System ..........................................................................................................................................V-131 Batteries (Specific Gravity)............................................................................................................................V-131 Specifications...............................................................................................................................................V-131 Engine Testing — Group 14 - Specifications ...............................................................................................V-117 Engine Run-in (Engine Dynamometer)..................................................................................................................V-117 Engine Testing (Chassis Dynamometer)................................................................................................................V-117 Engine Testing (Engine Dynamometer).................................................................................................................V-117 Engine Testing — Group 14 - Torque Values ..............................................................................................V-118 Engine Compression..............................................................................................................................................V-118 Engine Run-in (Engine Dynamometer)..................................................................................................................V-118 Engine Testing (Engine Dynamometer).................................................................................................................V-118 Exhaust System ............................................................................................................................................V-130 Specifications...............................................................................................................................................V-130 Exhaust System — Group 11 - Torque Values .............................................................................................V-111 Bellows...................................................................................................................................................................V-113 Exhaust Connection Pipe.......................................................................................................................................V-111 Exhaust Manifold (Wet) Water Connections..........................................................................................................V-112 Exhaust Manifold, Dry............................................................................................................................................V-111 Exhaust Manifold, Wet...........................................................................................................................................V-112 Fraction, Decimal, Millimeter Conversions ..................................................................................................V-143 Conversion Chart..........................................................................................................................................V-143 Fuel Recommendations and Specifications .................................................................................................V-135 General Information......................................................................................................................................V-135 Fuel System ..................................................................................................................................................V-125 Specifications...............................................................................................................................................V-125 with Electronically Actuated Injector...........................................................................................................V-125 with Mechanically Actuated Injector............................................................................................................V-125 Fuel System — Group 05 - Specifications .....................................................................................................V-31

Page V-d


Fuel Lift Pump..........................................................................................................................................................V-31 Fuel System — Group 05 - Torque Values .....................................................................................................V-32 .................................................................................................................................................................................V-34 Fuel Lift Pump..........................................................................................................................................................V-33 Fuel Pump................................................................................................................................................................V-32 Fuel Pump Gear Pump Check Valve.......................................................................................................................V-33 General Engine ..............................................................................................................................................V-123 General Specifications..................................................................................................................................V-123 Injectors and Fuel Lines — Group 06 - Specifications ..................................................................................V-35 Fuel Drain Line Restriction.......................................................................................................................................V-35 Fuel Inlet Restriction.................................................................................................................................................V-35 Static Injection Timing..............................................................................................................................................V-35 Injectors and Fuel Lines — Group 06 - Torque Values .................................................................................V-36 Air in Fuel.................................................................................................................................................................V-36 Fuel Block.................................................................................................................................................................V-36 Fuel Connection Block (Manifold-Mounted).............................................................................................................V-36 Fuel Drain Lines.......................................................................................................................................................V-37 Fuel Filter Head........................................................................................................................................................V-38 Fuel Filter Head Bracket...........................................................................................................................................V-39 Fuel Inlet Restriction.................................................................................................................................................V-39 Fuel Manifold (Combined)........................................................................................................................................V-39 Fuel Manifold (Drain)................................................................................................................................................V-40 Fuel Manifold (Supply).............................................................................................................................................V-41 Fuel Pressure Relief Valve.......................................................................................................................................V-46 Fuel Supply Lines.....................................................................................................................................................V-41 Injector......................................................................................................................................................................V-44 Injector Supply Lines (High Pressure)......................................................................................................................V-46 Single Bank Idle Valve.............................................................................................................................................V-44 Static Injection Timing..............................................................................................................................................V-44 STC Oil Control Valve (Electrical)............................................................................................................................V-45 STC Oil Control Valve (Mechanical).........................................................................................................................V-45 STC Oil Manifold......................................................................................................................................................V-45 STC Wiring Harness.................................................................................................................................................V-46 Timing Mark Pointer.................................................................................................................................................V-46 Lubricating Oil Recommendations and Specifications ................................................................................V-136 General Information......................................................................................................................................V-136 Lubricating Oil System .................................................................................................................................V-126 Specifications...............................................................................................................................................V-126 Lubricating Oil System — Group 07 - Specifications ....................................................................................V-47 Lubricating Oil Filter Head........................................................................................................................................V-47 Lubricating Oil Filter Head, Aluminum......................................................................................................................V-47 Lubricating Oil High Pressure Relief Valve..............................................................................................................V-47 Lubricating Oil Pump................................................................................................................................................V-48 Lubricating Oil System — Group 07 - Torque Values ...................................................................................V-50 Eliminator Filter........................................................................................................................................................V-55 Lubricating Oil Cooler Cover....................................................................................................................................V-54 Lubricating Oil Filter Head........................................................................................................................................V-50 Lubricating Oil Filter Head (Remote-Mounted).........................................................................................................V-51 Lubricating Oil Filter Head, Aluminum......................................................................................................................V-51 Lubricating Oil Pan...................................................................................................................................................V-52 Lubricating Oil Pan Adapter.....................................................................................................................................V-52 Lubricating Oil Pressure Regulator (Main Rifle).......................................................................................................V-52 Lubricating Oil Pump................................................................................................................................................V-52 Lubricating Oil Suction Tube (Block-Mounted).........................................................................................................V-53 Lubricating Oil Temperature Gauge.........................................................................................................................V-54 Pre-Lubricating Oil Pump.........................................................................................................................................V-54 Main Power Generator — Group 21 - Torque Values ..................................................................................V-122 Bearing, Generator.................................................................................................................................................V-122 Generator Rotor.....................................................................................................................................................V-122 Permanent Magnet Generator................................................................................................................................V-122 Mounting Adaptations — Group 16 - Specifications ....................................................................................V-119 Engine Mounts.......................................................................................................................................................V-119 Engine Support Bracket, Front...............................................................................................................................V-119


Page V-e

Mounting Adaptations — Group 16 - Torque Values ...................................................................................V-120 Engine Lifting Brackets...........................................................................................................................................V-120 Engine Mounts.......................................................................................................................................................V-121 Engine Support Bracket, Front...............................................................................................................................V-120 Flexplate.................................................................................................................................................................V-120 Flywheel.................................................................................................................................................................V-120 Flywheel Housing...................................................................................................................................................V-120 Newton-Meter to Foot-Pound Conversions ..................................................................................................V-144 Conversion Chart..........................................................................................................................................V-144 Pipe Plug Torque Values ..............................................................................................................................V-145 Torque Table................................................................................................................................................V-145 Rocker Levers — Group 03 - Specifications ..................................................................................................V-24 Overhead Set (OBC)................................................................................................................................................V-24 Overhead Set (Travel Method).................................................................................................................................V-24 Rocker Lever Assembly........................................................................................................................................... V-24 Rocker Levers — Group 03 - Torque Values ................................................................................................. V-25 Crankcase Breather (External).................................................................................................................................V-25 Overhead Set (OBC)................................................................................................................................................V-25 Overhead Set (Travel Method).................................................................................................................................V-26 Rocker Lever Assembly........................................................................................................................................... V-26 Rocker Lever Cover................................................................................................................................................. V-27 Rocker Lever Housing..............................................................................................................................................V-27 Tap-Drill Chart - U.S. Customary and Metric ................................................................................................V-146 General Information......................................................................................................................................V-146 Weights and Measures - Conversion Factors ..............................................................................................V-147 Conversion Chart..........................................................................................................................................V-147


Page V-f


K38, K50, QSK38, and QSK50 Section V — Specifications Component or Assembly (Procedure)

Cylinder Block — Group 01 - Specifications Page V-1 Ref.No./ Steps

Metric

U.S. .

Cylinder Block — Group 01 - Specifications Bearings, Connecting Rod (001-005) Connecting Rod Bearing Thickness Standard or Oversize (OS) Standard

3.106 3.157 3.233 3.284 3.360 3.411 3.487 3.538 3.614 3.665

MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX

0.1223 0.1243 0.1273 0.1293 0.1323 0.1343 0.1373 0.1393 0.1423 0.1443

Rod Capscrew Stretch Specification

0.343 mm 0.470 mm

MIN MAX

0.0135 in 0.0185 in

Rod to Crankshaft Side Clearance

0.30 mm 0.51 mm

MIN MAX

0.012 in 0.020 in

4.280 4.336 4.407 4.463 4.534 4.590 4.661 4.717 4.788 4.844


0.1685 0.1707 0.1735 0.1757 0.1785 0.1807 0.1835 0.1857 0.1885 0.1907

0.13 mm 0.51 mm

MIN MAX

0.005 in 0.020 in

0.010 (OS) 0.020 (OS) 0.030 (OS) 0.040 (OS)

Bearings, Main (001-006) Main Bearing Thickness Standard or Oversize (OS) Standard 0.010 (OS) 0.020 (OS) 0.030 (OS) 0.040 (OS) Crankshaft End Clearance

Cylinder Block — Group 01 Page V-2


Ref.No./ Steps

Metric

U.S.

.

Bearings, Thrust (001-007) Thrust Bearing Thickness Standard or Oversize Standard

4.826 4.940 5.080 5.194 5.334 5.448 5.588 5.702 5.842 5.956


0.1900 0.1945 0.2000 0.2045 0.2100 0.2145 0.2200 0.2245 0.2300 0.2345

0.13 mm 0.51 mm

MIN MAX

0.005 in 0.020 in

0.15 mm 0.33 mm

MIN MAX

0.006 in 0.013 in

Camshaft Bushing Journal Diameter

76.07 mm 76.12 mm

MIN MAX

2.995 in 2.997 in

Camshaft End Clearance

0.15 mm 0.33 mm

MIN MAX

0.006 in 0.013 in

Front Gear Train Gear Backlash

0.07 mm 0.51 mm

MIN MAX

0.003 in 0.020 in

Cam Follower Capscrew Torque Value

39 N•m 42 N•m

MIN MAX

29 ft-lb 31 ft-lb

0.010 (OS) 0.020 (OS) 0.030 (OS) 0.040 (OS) Crankshaft End Clearance

Camshaft (001-008) Camshaft Thrust End Clearance


Cylinder Block — Group 01 Page V-3 Ref.No./ Steps

Metric

U.S. .

Camshaft Bushings (001-010) Camshaft Bushing Bore in the Block

80.963 mm 80.988 mm

MIN MAX

3.1875 in 3.1885 in

57.125 mm 57.150 mm

MIN MAX

2.2490 in 2.2500 in

57.201 mm

MIN

2.2520 in

57.211 mm

MAX

2.2524 in

Camshaft Thrust Bearing Thickness

9.14 mm 9.45 mm

MIN MAX

0.360 in 0.372 in

Camshaft end clearance

0.15 mm 0.33 mm

MIN MAX

0.006 in 0.013 in

57.201 mm 57.211 mm

MIN MAX

2.2520 in 2.2524 in

57.125 mm 57.150 mm

MIN MAX

2.2490 in 2.2500 in

Camshaft Gear (Camshaft Installed) (001-012) Camshaft Gear Inside Diameter

Camshaft Gear Mounting Surface (Outside Diameter)

Camshaft Gear (Camshaft Removed) (001-013) Camshaft Outside Diameter (Gear Location)

Camshaft Gear Inside Diameter


K38, K50, QSK38, and QSK50 Section V — Specifications Ref.No./ Steps

Component or Assembly (Procedure)

Metric

U.S.

.

Camshaft Thrust Bearing Thickness

9.14 mm 9.45 mm

MIN MAX

0.360 in 0.372 in

136.14 mm 136.91 mm

MIN MAX

5.360 in 5.390 in

Capscrew outside diameter (2)

15.27 mm 15.37 mm

MIN MAX

0.601 in 0.605 in

Capscrew outside diameter (3)

17.35 mm 17.45 mm

MIN MAX

0.683 in 0.687 in

Connecting Rod Bushing inside diameter

60.985 mm 61.024 mm

MIN MAX

2.4010 in 2.4025 in

114.330 mm 114.382 mm

MIN

4.5012 in

MAX

4.5032 in

289.69 mm 289.74 mm

MIN MAX

11.405 in 11.407 in

Maximum Connecting Rod Bend Bushing Installed Bushing Removed

0.10 0.20

MAX MAX

0.004 0.008

Maximum Connecting Rod Twist Bushing Installed Bushing Removed

0.25 0.51

MAX MAX

0.010 0.020

Connecting Rod (001-014) Capscrew Length (1)

Connecting diameter

Rod

Bearing

Bore

Connecting Rod Length

inside



Metric

U.S. .

Crankshaft (001-016) Crankshaft Outside Diameter Location (1)

110.74 110.77 111.07 111.13 184.10 184.15

MIN MAX MIN MAX MIN MAX

4.360 4.361 4.373 4.375 7.248 7.250

Rod Bearing Journal Outside Diameter (5)

107.87 mm 107.95 mm

MIN MAX

4.247 in 4.250 in

Main Bearing Outside Diameter (6)

165.05 mm 165.10 mm

MIN MAX

6.498 in 6.500 in

Thrust Flange (7)

12.52 mm 12.75 mm

MIN MAX

0.493 in 0.502 in

Crankshaft Bow at Top Indicator Reading K38 Engine K50 Engine

0.267 0.356

MAX MAX

0.0105 0.0140

Adjacent Journal Run Out Fully Fillet Hardened Non-Fully Fillet Hardened

0.089 0.089

MAX MAX

0.0035 0.0035

MIN

4.380 in

MAX

4.381 in

MIN MAX

4.3768 in 4.3775 in

Location (2) Location (3)

Crankshaft Gear, Front (Crankshaft Removed) (001-019) Crankshaft Outside Diameter (Gear 111.25 mm Location) 111.28 mm

Front Crankshaft Gear Inside Diameter

111.71 mm 111.89 mm



Ref.No./ Steps

Metric

U.S.

.

Cylinder Block (001-026) Correct Press

181.80 mm 181.81 mm

MIN MAX

7.157 in 7.158 in

Correct Press

181.74 mm 181.79 mm

MIN MAX

7.155 in 7.157 in

190.284 190.335 190.538 190.589 190.792 190.843 191.046 191.097 191.300 191.351 190.284 190.335

MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX

7.4915 7.4935 7.5015 7.5035 7.5115 7.5135 7.5215 7.5235 7.5315 7.5335 7.4915 7.4935

Correct Press

181.80 mm 181.81 mm

MIN MAX

7.157 in 7.158 in

(4) Packing Ring Bore

177.34 mm 177.39 mm

MIN MAX

6.982 in 6.984 in

Camshaft Idler Shaft Bore Inside Diameter

25.37 mm 25.40 mm

MIN MAX

0.999 in 1.000 in

Oversized [Inch] Standard 0.010 0.020 0.030 0.040 Standard



Metric

U.S. .

Water Pump Idler Shaft Counter Bore - New (13)

43.18 mm

MIN

1.700 in

43.21 mm

MAX

1.701 in

4.57 mm

MIN

0.180 in

5.08 mm

MAX

0.200 in

Water Pump Idler Shaft Bore - New (15)

21.97 mm 22.23 mm

MIN MAX

0.865 in 0.875 in

Water Pump Idler Shaft Bore - Old (16)

25.37 mm 25.40 mm

MIN MAX

0.999 in 1.000 in

(18) Cylinder Block Height

481.94 mm 482.78 mm

MIN MAX

18.974* in 19.007 in

(19) Cylinder Block Height - Main Bearing Saddle

395.00 mm

MIN

15.551* in

395.81 mm

MAX

15.583 in

Camshaft Bushing Inside Diameter

76.200 mm 76.289 mm

MIN MAX

3.0000 in 3.0035 in

Main Bearing Bore Inside Diameter (Capscrews Torqued to Specification)

173.86 mm

MIN

6.845 in

173.89 mm

MAX

6.846 in

177.34 mm 177.39 mm

MIN MAX

6.982 in 6.984 in

158.737 mm 158.877 mm

MIN

6.2495 in

MAX

6.2550 in

Water Pump Idler Shaft Counter Bore Depth - New (14)

Cylinder Block and Liner Seats (001-027) Packing Ring Bore diameter

Cylinder Liner (001-028) Cylinder Liner Inside Diameter



Ref.No./ Steps

Metric

U.S.

.

Cylinder Liner Flange Thickness Standard

13.36 13.39 13.61 13.64 13.87 13.89 14.12 14.15 14.38 14.40


0.526 0.527 0.536 0.537 0.546 0.547 0.556 0.557 0.566 0.567

5.055 5.067 5.105 5.118 5.156 5.169


0.1990 0.1995 0.2010 0.2015 0.2030 0.2035

181.81 mm 181.86 mm

MIN MAX

7.158 in 7.160 in

1.1 mm 1.6 mm

MIN MAX

0.0468 in 0.0625 in

39.75 39.790 38.13 38.25

MIN MAX MIN MAX

1.565 1.571 1.501 1.506

47.638 mm 47.714 mm

MIN MAX

1.8755 in 1.8785 in

Camshaft Idler Shaft Outside Diameter - (1)

25.397 mm 25.400 mm

MIN MAX

0.9995 in 1.0000 in

Camshaft Idler Shaft Outside Diameter - (2)

47.549 mm 47.600 mm

MIN MAX

1.8720 in 1.8740 in

0.25 mm [0.010 inch] 0.51 mm [0.020 inch] 0.76 mm [0.030 inch] 1.02 mm [0.040 inch] Counterbore Ring Thickness Standard 0.05 mm [0.002 inch] 0.10 mm [0.004 inch]

Cylinder Liner Outside Diameter (2)

RTV™ Sealant Bead Size

Gear Cover, Front (001-031) Bushing Inside Diameter (15) Accessory Drive and Water Pump Drive: (16) Hydraulic Pump Drive:

Idler Gear, Camshaft (001-036) Idler Gear Bushing Inside Diameter



Metric

U.S. .

(1) - Engine Serial Number Higher than 33110701

43.167 mm

MIN

1.6995 in

43.180 mm

MAX

1. 7000 in

47.549 mm

MIN

1.8720 in

47.600 mm

MAX

1.8740 in

25.397 mm

MIN

0.9995 in

25.400 mm

MAX

1.0000 in

47.549 mm

MIN

1.8720 in

47.600 mm

MAX

1.8740 in

Thrust Bearing thickness

2.34 mm 2.39 mm

MIN MAX

0.092 in 0.094 in

Camshaft Idler Shaft Bore Inside Diameter

25.38 mm 25.40 mm

MIN MAX

0.999 in 1.000 in

Camshaft Idler Shaft Bore Inside Diameter (13)

43.18 mm

MIN

1.700 in

43.22 mm

MAX

1.701 in

4.57 mm

MIN

0.180 in

5.08 mm

MAX

0.200 in

21.97 mm

MIN

0.865 in

22.23 mm

MAX

0.875 in

Diameter (16)

25.38 mm 25.4 mm

MIN MAX

0.999 in 1.000 in

Idler Gear End Clearance

0.13 mm 0.46 mm

MIN MAX

0.005 in 0.018 in

(2) - Engine Serial Number Higher than 33110701 (1) - Engine Serial Number Lower than 33110701 (2) - Engine Serial Number Lower than 33110701

Camshaft Idler Shaft Bore Inside Diameter (14) Camshaft Idler Shaft Bore Inside Diameter (15)



Ref.No./ Steps

Metric

U.S.

.

Front Gear Train Gear Backlash

0.07 mm 0.51 mm

MIN MAX

0.003 in 0.020 in

4.788 mm 4.851 mm

MIN MAX

0.1885 in 0.1910 in

60.942 mm 60.952 mm

MIN MAX

2.3993 in 2.3997 in

158.445 158.471 158.466 158.542 158.440 158.501


6.2380 6.2390 6.2388 6.2418 6.2378 6.2402

0.64 1.02 0.64 1.02 0.30 0.76


0.025 0.040 0.025 0.040 0.015 0.030

Vibration Damper, Viscous (001-052) Houdaille™

65.38 mm

MAX

2.574 in

Made in England F-82 and After

65.51 mm

MAX

2.579 in

Made in England Before F-82

65.66 mm

MAX

2.585 in

Vibration Damper Eccentricity (Total Indictor Reading)

0.51 mm

MAX

0.020 in

Piston (001-043) Piston Oil Ring Groove Width

Piston Pin Bore Inside Diameter

Piston Skirt Outside Diameter (1) (2a) (2b) Piston Rings (001-047) Piston Ring Gap Top Intermediate Oil




Metric

U.S. .

Vibration Damper Indicator Reading)

Face

Runout

(Total

Piston and Connecting Rod Assembly (001-054) Connecting Rod and Crankshaft Side Clearance

Gear Train Backlash, Front (001-055) Front Gear Train Gear backlash

Camshaft Thrust Bearing (001-056) Camshaft thrust bearing thickness

Cylinder Block Counterbore (001-058) WITH Double Undercut Radius WITHOUT Double Undercut Radius

Cylinder Liner Protrusion (A)

Idler Shaft, Camshaft Idler Gear (001-061) Idler Gear Bushing Inside Diameter

0.58 mm

MAX

0.023 in

0.30 mm

MIN

0.012 in

0.52 mm

MAX

0.020 in

0.07 mm 0.51 mm

MIN MAX

0.003 in 0.020 in

9.14 mm 9.45 mm

MIN MAX

0.360 in 0.372 in

189.79 mm 190.04 mm

MIN MAX

7.472 in 7.482 in

187.20 mm 187.45 mm

MIN MAX

7.370 in 7.380 in

0.15 mm 0.20 mm

MIN MAX

0.006 in 0.008 in

47.638 mm 47.714 mm

MIN MAX

1.8755 in 1.8785 in



Ref.No./ Steps

Metric

U.S.

.

Camshaft Idler Shaft Outside Diameter (1)

25.387 mm 25.400 mm

MIN MAX

0.9995 in 1.0000 in

Camshaft Idler Shaft Outside Diameter (2)

47.549 mm 47.600 mm

MIN MAX

1.8720 in 1.8740 in

Thrust Bearing Thickness

0.235 mm 0.245 mm

MIN MAX

0.092 in 0.096 in

47.638 mm 47.714 mm

MIN MAX

1.8755 in 1.8785 in

43.167 mm

MIN

1.6995 in

43.180 mm

MAX

1.7000 in

47.549 mm

MIN

1.8720 in

47.600 mm

MAX

1.8740 in

23.397 mm

MIN

0.9995 in

25.400 mm

MAX

1.0000 in

47.549 mm

MIN

1.8720 in

47.600 mm

MAX

1.8740 in

2.34 mm 2.39 mm

MIN MAX

0.092 in 0.094 in

0.15 mm 0.20 mm

MIN MAX

0.006 in 0.008 in

Idler Shaft, Water Pump Idler Gear (001-063) Idler Gear Bushing Inside Diameter

Water Pump Idler Shaft Outside Diameter — Engine Serial Number Higher than 33110701 (1) Water Pump Idler Shaft Outside Diameter — Engine Serial Number Higher than 33110701 (2) Water Pump Idler Shaft Outside Diameter — Engine Serial Number Lower than 33110701 (1) Water Pump Idler Shaft Outside Diameter — Engine Serial Number Lower than 33110701 (2) Thrust Bearing Thickness

Cylinder Liner Protrusion (001-064) K38 and K50 Cylinder Liner Protrusion



Metric

U.S. .

Gear Cover Accessory Drive Bushing (001-066) Front Cover Bushing Bore inside diameter (15) Accessory Drive and Water Pump Drive: (16) Hydraulic Pump Drive:

43.08 43.10 41.28 41.30

MIN MAX MIN MAX

1.696 1.697 1.625 1.626

Cylinder Block — Group 01 - Torque Values Page V-14



Metric

U.S.

.

Cylinder Block — Group 01 - Torque Values Bearings, Connecting Rod (001-005) Connecting Rod Capscews

Bearings, Main (001-006) K38 And Qsk38 Main Capscrew

K50 And Capscrew

Qsk50

Main

K38 And Qsk38 Main Mounting Capscrews

K50 And Qsk50 Main Mounting Capscrews

Bearing

Bearing

Bearing

Bearing

1 2 3 4 5 1 2 3 4 5 6 7

Cap

Cap

Cap

Cap

102 N•m [ 75 ft-lb ] Rotate 90 degrees. Loosen both capscrews. 102 N•m [ 75 ft-lb ] Rotate 90 degrees. 108 N•m [ 80 ft-lb ] 217 N•m [ 160 ft-lb ] 325 N•m [ 240 ft-lb ] Loosen both capscrews. 108 N•m [ 80 ft-lb ] 217 N•m [ 160 ft-lb ] 325 N•m [ 240 ft-lb ] 365 N•m

[ 270 ft-lb ]

1 2 3 4 5 6 7

176 N•m 285 N•m 610 N•m Loosen 176 N•m 285 N•m 610 N•m

[ 130 ft-lb ] [ 210 ft-lb ] [ 450 ft-lb ]

1 2 3 4 5 6 7

176 N•m 285 N•m 610 N•m Loosen 176 N•m 285 N•m 610 N•m

[ 130 ft-lb ] [ 210 ft-lb ] [ 450 ft-lb ]

1 2 3 4 5

176 N•m 339 N•m Loosen 339 N•m +90 degrees

[ 130 ft-lb ] [ 250 ft-lb ]

1 2 3 4 5

176 N•m 339 N•m Loosen 339 N•m +90 degrees

[ 130 ft-lb ] [ 250 ft-lb ]

[ 130 ft-lb ] [ 210 ft-lb ] [ 450 ft-lb ]

[ 130 ft-lb ] [ 210 ft-lb ] [ 450 ft-lb ]

[ 250 ft-lb ]

[ 250 ft-lb ]



Metric

U.S. .

K38 And Qsk38 Main Bearing Capscrews Side Bolt

1 2 3

68 N•m 217 N•m 454 N•m

[ 50 ft-lb ] [ 160 ft-lb ] [ 335 ft-lb ]

40 N•m

[ 30 ft-lb ]

45 N•m

[ 35 ft-lb ]

40 N•m

[ 30 ft-lb ]

45 N•m

[ 35 ft-lb ]

Crankshaft (001-016) Crankshaft Counterweight Capscrews

285 N•m

[ 210 ft-lb ]

Connecting Rod Capscrews

285 N•m

[ 210 ft-lb ]

Bearings, Thrust (001-007)

Camshaft (001-008)

Camshaft Cover Plate (001-011)

Camshaft Gear (Camshaft Installed) (001-012)



Ref.No./ Steps

Metric

U.S.

.

Crankshaft Adapter (001-017) Crankshaft Adapter Capscrews

Crankshaft Pulley (001-022) Crankshaft Pulley Capscrews

1 2 3

220 N•m 395 N•m 555 N•m

[ 160 ft-lb ] [ 290 ft-lb ] [ 410 ft-lb ]

1 2 3

220 N•m 395 N•m 555 N•m

[ 160 ft-lb ] [ 290 ft-lb ] [ 410 ft-lb ]

35 N•m 35 N•m

[ 25 ft-lb ] [ 25 ft-lb ]

Crankshaft Seal, Rear (001-024)

Cylinder Block (001-026) Main Bearing Capscrews 176 N•m Side Bolts Main Bearing Capscrews (Performing Two Steps) Side Bolts (Performing Two Steps)

Main Bearing Capscrews 176 N•m Side Bolts Main Bearing Capscrews (Performing Two Steps) Side Bolts (Performing Two Steps)

[ 130 ft-lb ] 14 N•m

[ 10 ftlb ]

[ 130 ft-lb ] 14 N•m

[ 10 ftlb ]

Cylinder Liner (001-028)

Gear Cover, Front (001-031) [0.125 Inch] [0.250 Inch] [0.375 Inch]

47 N•m

[ 35 ft-lb ]

20 N•m 27 N•m 34 N•m

[ 15 ft-lb ] [ 20 ft-lb ] [ 25 ft-lb ]



Metric

U.S. .

61 N•m

[ 45 ft-lb ]

60 N•m

[ 45 ft-lb ]

60 N•m

[ 45 ft-lb ]

40 N•m

[ 30 ft-lb ]

1 2 3

205 N•m Loosen 290 N•m 250 N•m

[ 150 ft-lb ]

1 2 3 4

205 N•m Loosen 88 N•m Rotate 90 degrees 250 N•m

[ 185 ft-lb ]

10 N•m 15 N•m

[ 96 in-lb ] [ 120 in-lb ]

Gear Housing, Front (001-033)

Hand Hole Cover (001-035)

Idler Gear, Camshaft (001-036) Capscrews With Flange Head: Capscrew Without Flange Head:

Capscrews With Flanged Head: Capscrew Without Flange Head:

[ 215 ft-lb ] [ 185 ft-lb ]

[ 150 ft-lb ] [ 65 ft-lb ]

Piston Cooling Nozzle (001-046)



Ref.No./ Steps

Metric

U.S.

.

Gallery Cooled Piston Cooling Nozzle

23 N•m 23 N•m

[ 17 ft-lb ] [ 17 ft-lb ]

190 N•m

[ 140 ft-lb ]

190 N•m

[ 140 ft-lb ]

41 N•m 34 N•m 95 N•m

[ 30 ft-lb ] [ 25 ft-lb ] [ 70 ft-lb ]

41 N•m

[ 30 ft-lb ]

41 N•m

[ 30 ft-lb ]

41 N•m 41 N•m

[ 30 ft-lb ] [ 30 ft-lb ]

Vibration Damper, Double (001-050)

Vibration Damper, Viscous (001-052) Damper Washers And Capscrews

Water Header Plate, Cylinder Block (001-053) Steel Lock Washers: Copper Flat Washers:

Cylinder Block Counterbore (001-058)



Metric

U.S. .

Cylinder Liner Protrusion (001-064) Liner Clamp Capscrews

68 N•m

[ 50 ft-lb ]

41 N•m 41 N•m

[ 30 ft-lb ] [ 30 ft-lb ]

47 N•m

[ 35 ft-lb ]

68 N•m

[ 50 ft-lb ]

Cylinder Head — Group 02 - Specifications Page V-20 Component or Assembly (Procedure)


Metric

U.S.

.

Cylinder Head — Group 02 - Specifications Crosshead (002-001) Crosshead Guide Bore Inside Diameter

Crosshead Guide Bore Inside Diameter

Cylinder Head (002-004) Maximum Allowable Crack Length

Maximum Allowable Valve Depth from the Combustion Face

Maximum Allowable Crack Length

Maximum Allowable Valve Depth from the Combustion Face

Cylinder Head Thickness Used Cylinder Head Minimum Thickness (1) New Cylinder Head Thickness (1)

11.02 mm 11.18 mm

MIN MAX

0.434 in 0.440 in

11.02 mm 11.18 mm

MIN MAX

0.434 in 0.440 in

6 mm

MAX

0.25 in

0.51 mm

MAX

0.020 in

6 mm

MAX

0.25 in

0.00 mm

MIN

0.000 in

0.51 mm

MAX

0.020 in

119.76 120.52 120.78

MIN MIN MAX

4.715 4.745 4.755


Cylinder Head — Group 02 Page V-21 Ref.No./ Steps

Metric

U.S. .

Air Pressure

552 kPa

MAX

80 psi

Valve Guide Inside Diameter (Installed)

12.600 mm 12.667 mm

MIN MAX

0.496 in 0.499 in

Valve Guide Bore Inside Diameter

21.425 mm 21.450 mm

MIN MAX

0.844 in 0.845 in

60.37 60.40

MIN MAX

2.377 2.378

12.50 12.62

MIN MAX

0.492 0.497

3.00 2.16

MIN MIN

0.120 0.085

12.535 mm 12.576 mm

MIN MAX

0.494 in 0.495 in

1053 1237 1134 1318

MIN MAX MIN MAX

237 278 255 296

3.05 3.55 1.52 2.54

MIN MAX MIN MAX

0.120 0.140 0.060 0.100

Valve Seat Insert Bore Inside Diameter (6) Exhaust and Intake Valve Seat Insert Bore Depth (7) and (8) Exhaust and Intake

Minimum Valve Head Thickness (at the outside diameter) Exhaust Intake

Valve Stem Outside Diameter

Valve Spring Force Long Spring (Without Rotator) Short Spring (With Rotator)

Valve Seat Insert Width Intake Exhaust

Cylinder Head — Group 02 Page V-22


Ref.No./ Steps

Metric

U.S.

.

Valve Guide Height (Installed) Taper-Top (3) Flat-Top (5)

Injector Protrusion

Valve Guide Height (Installed)

33.665 34.163 29.210 29.178

MIN MAX MIN MAX

1.325 1.345 1.150 1.170

2.29 mm 2.79 mm

MIN MAX

0.090 in 0.110 in

27.737 mm 28.245 mm

MIN MAX

1.092 in 1.112 in


Cylinder Head — Group 02 - Torque Values Page V-23 Ref.No./ Steps

Metric

U.S. .

Cylinder Head — Group 02 - Torque Values Crosshead (002-001) With Adapter Without Adapter

35 N•m 40 N•m

[ 25 ft-lb ] [ 30 ft-lb ]

Cylinder Head (002-004) Cylinder Head Pressure Test Clamp

20 N•m

[ 177 in-lb ]

Cylinder Head Test Adapter Clamp

54 N•m

[ 40 ft-lb ]

270 N•m 407 N•m 555 N•m

[ 200 ft-lb ] [ 300 ft-lb ] [ 410 ft-lb ]

1 2 3

Rocker Levers — Group 03 - Specifications Page V-24 Component or Assembly (Procedure)


Metric

U.S.

.

Rocker Levers — Group 03 - Specifications Overhead Set (OBC) (003-006) Valve Clearances - Initial Set Exhaust Valves (A) Intake Valves (B) Valve Clearances - Second Check Exhaust Valves (A) Intake Valves (B) Overhead Set (Travel Method) (003-007) Injector Travel Verification Specification (Non-STC and CENTRY™)

Rocker Lever Assembly (003-009) Shaft Outside Diameter

Bushing Bore Inside Diameter

0.69 0.36

MAX MAX

0.027 0.014

0.61 0.76 0.28 0.43

MIN MAX MIN MAX

0.024 0.030 0.011 0.017

7.80 mm

MIN

0.307 in

7.82 mm

MAX

0.308 in

34.823 mm 34.862 mm

MIN MAX

1.3710 in 1.3725 in

34.887 mm 34.991 mm

MIN MAX

1.3735 in 1.3776 in


Rocker Levers — Group 03 - Torque Values Page V-25 Ref.No./ Steps

Metric

U.S. .

Rocker Levers — Group 03 - Torque Values Crankcase Breather (External) (003-001) 40 N•m 6 N•m

[ 30 ft-lb ] [ 50 in-lb ]

Overhead Set (OBC) (003-006) Crosshead Adjusting Screws With Adapter Crosshead Adjusting Screws Without Adapter

35 N•m 40 N•m

[ 25 ft-lb ] [ 30 ft-lb ]

Adjusting Screw

0.68 N•m

[ 6 in-lb ]

Adjusting Locknut With Adapter Adjusting Locknut Without Adapter

45 N•m 60 N•m

[ 35 ft-lb ] [ 45 ft-lb ]

Adjusting Screw

11 N•m 10 N•m

[ 100 in-lb ] [ 90 in-lb ]

Valve And Injector Adjusting Screw With Adapter Valve And Injector Adjusting Screw Without Adapter

45 N•m 60 N•m

[ 35 ft-lb ] [ 45 ft-lb ]

Valve Adjusting Screw

0.7 N•m

[ 6 in-lb ]

Rocker Levers — Group 03 Page V-26


Ref.No./ Steps

Metric

U.S.

.

Valve Set - Torque Wrench Method With Adapter Valve Set - Torque Wrench Method Without Adapter

48 N•m 60 N•m

[ 35 ft-lb ] [ 44 ft-lb ]

Valve Set - Torque Wrench Method With Adapter Valve Set - Torque Wrench Method Without Adapter

48 N•m 60 N•m

[ 35 ft-lb ] [ 44 ft-lb ]

0.68 N•m

[ 6 in-lb ]

Locknut With Adapter

45 N•m 60 N•m

[ 35 ft-lb ] [ 45 ft-lb ]

Locknut With Adapter

45 N•m 60 N•m

[ 35 ft-lb ] [ 45 ft-lb ]

Rocker Lever Assembly (003-009) Rocker Lever Mounting Capscrews

95 N•m

[ 70 ft-lb ]

Rocker Lever Mounting Capscrews

95 N•m

[ 70 ft-lb ]

Overhead Set (Travel Method) (003-007) Valve Adjusting Screw


Rocker Levers — Group 03 Page V-27 Ref.No./ Steps

Metric

U.S. .

Rocker Lever Cover (003-011) 20 N•m

[ 180 in-lb ]

Rocker Lever Capscrews

45 N•m

[ 30 ft-lb ]

Rocker Lever Cover Capscrews

40 N•m

[ 30 ft-lb ]

40 N•m

[ 30 ft-lb ]

90 N•m

[ 66 ft-lb ]

25 N•m

[ 18 ft-lb ]

95 N•m

[ 70 ft-lb ]

Rocker Lever Housing (003-013)

Rocker Lever Housing Capscrews

Cam Followers/Tappets — Group 04 - Specifications Page V-28 Component or Assembly (Procedure)


Metric

U.S.

.

Cam Followers/Tappets — Group 04 - Specifications Cam Follower Assembly (004-001) Roller Clearance (1)

0.23 0.61 0.076 0.178

MIN MAX MIN MAX

0.009 0.024 0.003 0.007

Lever Bore Inside Diameter

22.225 mm 22.276 mm

MIN MAX

0.875 in 0.877 in

Shaft Outside Diameter

22.174 mm 22.200 mm

MIN MAX

0.8730 in 0.8740 in

0.23 0.61 0.076 0.178

MIN MAX MIN MAX

0.009 0.024 0.003 0.007

Lever Bore Inside Diameter

22.225 mm 22.276 mm

MIN MAX

0.875 in 0.877 in


22.174 mm 22.200 mm

MIN MAX

0.8730 in 0.8740 in

39 N•m

MIN

29 ft-lb

42 N•m

MAX

31 ft-lb

54 N•m

MAX

40 ft-lb

(2)

Roller Clearance (1) (2)

Grooved (Old) Cam Follower Capscrew Torque Value New Cam Follower Capscrew Torque Value


Cam Followers/Tappets — Group 04 Page V-29 Ref.No./ Steps

Metric

U.S. .

Cam Follower Roller and Pin (004-005) Roller Identification Outside Diameter: Inside Diameter: Valve Injector 1Injector (K2000E, K1800E and K1500E)

41.28 19.18 17.07 25.22 28.07

MAX MAX MAX MAX MAX

1.625 0.755 0.672 0.993 1.105

Lever Pin Bore Inside Diameter (1)

19.037 mm 19.057 mm

MIN MAX

0.7495 in 0.7503 in

Pin Outside Diameter (2)

19.063 mm 19.075 mm

MIN MAX

0.7505 in 0.7510 in

Press Fit Between Pin and Lever

0.005 mm 0.038 mm

MIN MAX

0.0002 in 0.0015 in

0.23 0.61 0.076 0.178

MIN MAX MIN MAX

0.009 0.024 0.003 0.007

Roller Clearance (1) (2)

Cam Followers/Tappets — Group 04 - Torque Values Page V-30 Component or Assembly (Procedure)


Metric

U.S.

.

Cam Followers/Tappets — Group 04 - Torque Values Cam Follower Assembly (004-001) Cam Follower Capscrews

70 N•m

[ 52 ft-lb ]

Cam Follower Cover (004-002) Cam Follower Capscrews

40 N•m

[ 30 ft-lb ]

Cam Follower Cover Capscrews

40 N•m

[ 30 ft-lb ]

Lower Bracket Capscrews

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

Bracket Capscrews

45 N•m

[ 33 ft-lb ]


Fuel System — Group 05 - Specifications Page V-31 Ref.No./ Steps

Metric

U.S. .

Fuel System — Group 05 - Specifications Fuel Lift Pump (005-045) Minimum Fuel Lift Pressure

300 kPa

MIN

43.5 psi

Fuel System — Group 05 - Torque Values Page V-32 Component or Assembly (Procedure)


Metric

U.S.

.

Fuel System — Group 05 - Torque Values Fuel Pump (005-016) Fuel Pump Capscrews

68 N•m

[ 50 ft-lb ]

Fuel Pump Capscrews

68 N•m

[ 50 ft-lb ]

Fuel Pump Capscrews

45 N•m

[ 33 ft-lb ]

Gerotor Capscrews

19 N•m 100 N•m

[ 168 in-lb ] [ 74 ft-lb ]

Fuel Pump Support Bracket

113 N•m

[ 83 ft-lb ]

Fuel Pump Capscrews

48 N•m

[ 35 ft-lb ]

Fuel Pump Capscrews

45 N•m

[ 33 ft-lb ]


Fuel System — Group 05 Page V-33 Ref.No./ Steps

Metric

U.S. .

Fuel Pump Mounting Capscrews

117 N•m

[ 86 ft-lb ]

Intake Manifold Capscrews

58 N•m

[ 40 ft-lb ]

Bracket To Bracket Capscrews (2) Bracket To Engine Block Capscrews (4)

45 N•m 45 N•m

[ 33 ft-lb ] [ 33 ft-lb ]

Capscrew To Camshaft Cover

45 N•m 45 N•m

[ 33 ft-lb ] [ 33 ft-lb ]

Fuel Pump Gear Pump Check Valve (005-026) Fuel Pump Check Valve Elbow Jam Nut

5 to N•m

6

[ 45 to 50 in-lb ]

Fuel Lift Pump (005-045) Fuel Lift Pump Mounting Capscrews

15 N•m

[ 133 in-lb ]

Supply And Discharge Hoses

54 N•m

[ 40 ft-lb ]

Fuel System — Group 05 Page V-34


Ref.No./ Steps

Metric

U.S.

.

(005-232) Fuel Pump Pressurizing Capscrews Fuel Pump Pressurizing Capscrews

8 N•m

[ 71 in-lb ]


Injectors and Fuel Lines — Group 06 - Specifications Page V-35 Ref.No./ Steps

Metric

U.S. .

Injectors and Fuel Lines — Group 06 - Specifications Fuel Drain Line Restriction (006-012) Fuel drain line Restriction With check valve Without check valve

165 65

MAX MAX

6.5 2.5

100 mm Hg

MAX

4 in Hg

200 mm Hg

MAX

8 in Hg

Stage 1 Filter Restriction (Clean)

76 mm Hg

MAX

3 in Hg

Stage 1 Filter Restriction (Dirty)

152 mm Hg

MAX

6 in Hg

Stage 2 Filter Restriction (Clean Filter)

14 kPa

MAX

2.03 psi

Stage 2 Filter Restriction (Dirty Filter)

138 kPa

MAX

20 psi

Stage 1 Filter Restriction (Clean)

76 mm Hg

MAX

3 in Hg

Stage 1 Filter Restriction (Dirty)

152 mm Hg

MAX

6 in Hg

Stage 2 Filter Restriction (Clean Filter)

28 kPa

MAX

4 psi

Stage 1 Filter Restriction (Dirty Filter)

138 kPa

MAX

20 psi

Static Injection Timing (006-025) Cam Follower Capscrew Torque Value (Excluding K2000E and K1800E)

39 N•m

MIN

29 ft-lb

42 N•m

MAX

31 ft-lb

Fuel Inlet Restriction (006-020) Filter Restriction (Clean) Filter Restriction (Dirty)

Injectors and Fuel Lines — Group 06 - Torque Values Page V-36 Component or Assembly (Procedure)


Metric

U.S.

.

Injectors and Fuel Lines — Group 06 - Torque Values Air in Fuel (006-003) Fuel Inlet Hose

120 N•m

[ 89 ft-lb ]

Fuel Block (006-007) Valve Seats

55 N•m

[ 40 ft-lb ]

Fuel Block Capscrews

40 N•m

[ 30 ft-lb ]

Fuel Connection Block (Manifold-Mounted) (006-010) Revised Type Fuel Connection Block 5 N•m Mounting Capscrews

Fuel Hoses To Fuel Connection Block

Old Type Fuel Block To Bracket Capscrews

[ 45 in-lb ]

25 N•m 14 N•m

[ 20 ft-lb ] [ 125 in-lb ]

5 N•m

[ 45 in-lb ]

25 N•m 40 N•m

[ 20 ft-lb ] [ 30 ft-lb ]


Injectors and Fuel Lines — Group 06 Page V-37 Ref.No./ Steps

Metric

U.S. .

Fuel Drain Lines (006-013) Drain Line Manifold Banjo Capscrews

22 N•m

[ 16 ft-lb ]

Fuel Drain Manifold Unions

25 N•m

[ 18 ft-lb ]

Drain Manifold Banjo Capscrews

22 N•m

[ 16 ft-lb ]

Fuel Drain Manifold Fittings

25 N•m

[ 18 ft-lb ]

Fuel Drain Manifold Bracket Capscrews

5 N•m

[ 44 in-lb ]

Fuel Drain Line Fittings

45 N•m

[ 33 ft-lb ]

Air Bleed Line Banjo Capscrew

30 N•m 45 N•m

[ 22 ft-lb ] [ 33 ft-lb ]

Injectors and Fuel Lines — Group 06 Page V-38



Metric

U.S.

.

Fuel Drain Line Banjo Capscrews

48 N•m

[ 35 ft-lb ]

102 N•m 102 N•m

[ 75 ft-lb ] [ 75 ft-lb ]

Sensor And Fitting Adapters

102 N•m

[ 75 ft-lb ]

Fuel Inlet And Outlet

62 N•m

[ 46 ft-lb ]

Filter Spuds

87 N•m 87 N•m

[ 65 ft-lb ] [ 65 ft-lb ]

Fuel Hose Fittings Fuel Hose Fittings

55 N•m 55 N•m

[ 41 ft-lb ] [ 41 ft-lb ]

45 N•m

[ 33 ft-lb ]

Fuel Filter Head (006-017) Fuel Filter Adapter

Fuel Filter Capscrews

Head

Mounting

Nut

And



Metric

U.S. .

Fuel Filter Head Bracket (006-018) 38 N•m

[ 28 ft-lb ]

325 N•m

[ 240 ft-lb ]

38 N•m

[ 28 ft-lb ]

7 N•m

[ 60 in-lb ]

10 N•m

[ 85 in-lb ]

Fuel Inlet Restriction (006-020) Threaded O-Ring Plug Threaded O-Ring Plug

29 N•m

[ 21 ft-lb ]

Fuel System Tester Fuel System Tester Air Bleed Hose

55 N•m 45 N•m

[ 41 ft-lb ] [ 33 ft-lb ]

Fuel Manifold (Combined) (006-019)

Injectors and Fuel Lines — Group 06 Page V-40



Metric

U.S.

.

Threaded Hex Head O-Ring Threaded Hex Head O-Ring Plugs

Plugs

27 N•m

[ 20 ft-lb ]

Fuel System Tester Fuel System Tester Air Bleed Hose

55 N•m 45 N•m

[ 40 ft-lb ] [ 33 ft-lb ]

Threaded Hex Head O-Ring Plugs

27 N•m

[ 20 ft-lb ]

Air Bleed Check Valve Air Bleed Hose

55 N•m 45 N•m

[ 41 ft-lb ] [ 33 ft-lb ]

Fuel Manifold (Drain) (006-021) Drain Manifold Block Capscrews

45 N•m

[ 33 ft-lb ]

Fuel Drain Union

70 N•m

[ 52 ft-lb ]

Drain Manifold Block Capscrews

20 N•m

[ 177 in-lb ]



Metric

U.S. .

Check Valve/Union

55 N•m

[ 41 ft-lb ]

Fuel Drain Unions

170 N•m

[ 125 ft-lb ]

Fuel Manifold (Supply) (006-022) M27 Stor Plug M14 Stor Plug Fuel Inlet Fitting Outlet Elbow

45 N•m 35 N•m 95 N•m 95 N•m

[ 33 ft-lb ] [ 25 ft-lb ] [ 70 ft-lb ] [ 70 ft-lb ]

Fuel Manifold Capscrew

10 N•m

[ 85 in-lb ]

Fuel Pump Capscrew

35 N•m

[ 26 ft-lb ]

Fuel Supply Lines (006-024) Gerotor Pump Actuator Union

100 N•m

[ 74 ft-lb ]

Fuel Supply Line

65 N•m

[ 48 ft-lb ]

Injectors and Fuel Lines — Group 06 Page V-42 Component or Assembly (Procedure)


Metric

U.S.

.

Gerotor Pump Outlet Union

100 N•m

[ 74 ft-lb ]

Fuel Supply Line

65 N•m 9 N•m

[ 48 ft-lb ] [ 80 in-lb ]

Tee Fitting Locknut

100 N•m

[ 74 ft-lb ]

Fuel Pump Inlet To Actuator Union

170 N•m

[ 125 ft-lb ]

Gerotor Fuel Supply Line

91 N•m

[ 67 ft-lb ]

Fuel Line From Filter To Gerotor Pump Inlet

91 N•m

[ 67 ft-lb ]

Fuel Supply Line

65 N•m

[ 48 ft-lb ]

Line Clamp Capscrews

9 N•m

[ 80 in-lb ]



Metric

U.S. .

Flexible Fuel Line

91 N•m

[ 67 ft-lb ]

Fuel Supply Lines

91 N•m

[ 67 ft-lb ]

Stage Two Capscrews

9 N•m

[ 81 in-lb ]

Gerotor Pump Outlet Union

100 N•m

[ 74 ft-lb ]

Tee Fitting Locknut

100 N•m

[ 74 ft-lb ]

Fuel Pump Inlet To Actuator Union

170 N•m

[ 125 ft-lb ]

Gerotor Fuel Supply Line

91 N•m

[ 67 ft-lb ]

Fuel Line From Manifold To Gerotor Pump Tee Fitting

91 N•m

[ 67 ft-lb ]



Metric

U.S.

.

Static Injection Timing (006-025) K2000e And K1800e Cam Follower Shaft Capscrews

65 N•m

[ 50 ft-lb ]

45 N•m

[ 33 ft-lb ]

75 N•m

[ 55 ft-lb ]

Injector (006-026)

Injector Hold Down Capscrew

Injector Hold-Down Clamp Capscrew

1 2 3 4

68 N•m [ 50 ft-lb ] Loosen capscrew completely. 30 N•m [ 22 ft-lb ] Rotate the capscrew 60 degrees.

Single Bank Idle Valve (006-031) 9 N•m

[ 80 in-lb ]

9 N•m

[ 80 in-lb ]

40 N•m

[ 30 ft-lb ]



Metric

U.S. .

STC Oil Control Valve (Electrical) (006-036)

STC Oil Control Valve (Mechanical) (006-037) Stc Bracket Capscrews

Sensing, Return, Oil Drain Line

9 N•m

[ 80 in-lb ]

40 N•m

[ 30 ft-lb ]

27 N•m

[ 20 ft-lb ]

7 N•m 27 N•m

[ 60 in-lb ] [ 20 ft-lb ]

7 N•m 20 N•m

[ 60 in-lb ] [ 15 ft-lb ]

10 N•m

[ 85 ft-lb ]

10 N•m

[ 85 ft-lb ]

STC Oil Manifold (006-038)



Metric

U.S.

.

STC Wiring Harness (006-042)

Injector Supply Lines (High Pressure) (006-051) Injector Plug

40 N•m

[ 30 ft-lb ]

40 N•m

[ 30 ft-lb ]

45 N•m

[ 33 ft-lb ]

45 N•m 45 N•m

[ 33 ft-lb ] [ 33 ft-lb ]

20 N•m

[ 180 in-lb ]

135 N•m

[ 100 ft-lb ]

Timing Mark Pointer (006-053)

Fuel Pressure Relief Valve (006-061) Mechanical Dump Valve


Lubricating Oil System — Group 07 - Specifications Page V-47 Ref.No./ Steps

Metric

U.S. .

Lubricating Oil System — Group 07 - Specifications Lubricating Oil Filter Head (007-015) Load (7)

249 N 286 N

MIN MAX

56.0 lbf 64.4 lbf

Load (7)

51 N 57 N

MIN MAX

11.5 lbf 12.8 lbf

124 128 60.96

MIN MAX NOM

4.88 5.02 2.40

189 222

MIN MAX

42.5 49.9

102 106 63.5

MIN MAX NOM

4.03 4.18 2.50

249 286

MIN MAX

56.0 64.4

60.7 64.5 44.4

MIN MAX NOM

2.39 2.54 1.75

51 57

MIN MAX

11.5 12.8

178.8 182.6 117.09

MIN MAX NOM

7.04 7.19 4.61

729 164

MIN MAX

164 192

92.2 94.7 49.3 391 463

MIN MAX NOM MIN MAX

3.63 3.73 1.94 88 104

Lubricating Oil Filter Head, Aluminum (007-020) Pressure Regulator Spring (27) Part Number 206187 Free Length: Working Height (6): Pressure Regulator Spring (27) Part Number 206187 Load (7): Filter Bypass Valve Spring (15) Part Number 205659 Free Length: Working height (6): Filter Bypass Valve Spring (15) Part Number 205659 Load (7): Piston Cooling Regulator Valve Spring (10) Part Number 205349 Free Length: Working height (6): Piston Cooling Regulator Valve Spring (10) Part Number 205349 Load (7): Lubricating Oil High Pressure Relief Valve (007-021) K38 High Pressure Relief Valve Spring Free Length: Working Height (6): K38 High Pressure Relief Valve Spring Load (7): K50 High Pressure Relief Valve Spring Free Length: Working Height (6): Load (7):

Lubricating Oil System — Group 07 Page V-48 Component or Assembly (Procedure)


Metric

U.S.

.

Lubricating Oil Pump (007-031) K38 Oil Pump Drive Gear End Clearance

0.10 mm 0.18 mm

MIN MAX

0.004 in 0.007 in

0.10 mm

MIN

0.004 in

0.18 mm

MAX

0.007 in

0.20 mm

MIN

0.008 in

0.81 mm

MAX

0.032 in

0.15 mm

MIN

0.006 in

0.25 mm

MAX

0.010 in

0.114 mm

MIN

0.0045 in

0.216 mm

MAX

0.0085 in

Oil Pump Bushing Inside Diameter

38.164 mm 38.227 mm

MIN MAX

1.5025 in 1.5050 in

Oil Pump Shaft Outside Diameter

38.082 mm 38.100 mm

MIN MAX

1.4993 in 1.5000 in

K50 High Speed Oil Pump Drive Gear End Clearance

K50 and QSK50 Low Speed Oil Pump Compound Gear End Clearance

K50 and QSK50 Low Speed Oil Pump Compound Gear to Drive Gear Backlash

K50 and QSK50 Low Speed Oil Pump Drive Shaft End Clearance


Lubricating Oil System — Group 07 Page V-49 Ref.No./ Steps

Metric

U.S. .

Oil Pump Drive Gear Inside Diameter

38.031 mm 38.057 mm

MIN MAX

1.4973 in 1.4983 in

K38 Oil Pump Drive Gear End Clearance

0.10 mm 0.18 mm

MIN MAX

0.004 in 0.007 in

K50 High Speed Oil Pump Drive Gear End Clearance

0.10 mm

MIN

0.004 in

0.18 mm

MAX

0.007 in

0.20 mm

MIN

0.008 in

0.81 mm

MAX

0.032 in

0.15 mm

MIN

0.006 in

0.25 mm

MAX

0.010 in

0.114 mm

MIN

0.0045 in

0.216 mm

MAX

0.0085 in

0.08 mm

MIN

0.003 in

0.30 mm

MAX

0.012 in

K50 and QSK50 Low Speed Oil Pump Compound Gear End Clearance K50 and QSK50 Low Speed Oil Pump Compound Gear to Drive Gear Backlash K50 and QSK50 Low Speed Oil Pump Drive Shaft End Clearance Lubricating Pump-to-Rear Crankshaft Gear Backlash

Lubricating Oil System — Group 07 - Torque Values Page V-50 Component or Assembly (Procedure)


Metric

U.S.

.

Lubricating Oil System — Group 07 - Torque Values Lubricating Oil Filter Head (007-015) Filter Adapter

95 N•m 200 N•m

[ 70 ft-lb ] [ 148 ft-lb ]

Pipe Or Restrictor Plug

20 N•m

[ 15 ft-lb ]

Spring Stop Capscrew

47 N•m

[ 35 ft-lb ]

Cover Plate Capscrews

41 N•m

[ 30 ft-lb ]

Retainer Capscrew

47 N•m

[ 35 ft-lb ]

Cover Plate Capscrews

47 N•m 20 N•m

[ 35 ft-lb ] [ 177 in-lb ]

Threaded Plug

122 N•m

[ 90 ft-lb ]




Metric

U.S. .

Straight Thread Plugs

20 N•m

[ 177 in-lb ]

Lubrication Capscrews

Oil

Filter

Head

Mounting

40 N•m

[ 30 ft-lb ]

Lubrication Capscrews

Oil

Filter

Head

Mounting

47 N•m

[ 35 ft-lb ]

Lubricating Oil Filter Head (Remote-Mounted) (007-017) 200 N•m

[ 150 ft-lb ]

45 N•m

[ 35 ft-lb ]

27 N•m

[ 20 ft-lb ]

27 N•m

[ 20 ft-lb ]

Lubricating Oil Filter Head, Aluminum (007-020)



Metric

U.S.

.

27 N•m 34 N•m

[ 20 ft-lb ] [ 25 ft-lb ]

Rectangular Ring Seal Capscrew

47 N•m

[ 35 ft-lb ]

Lubricating Oil Pan (007-025) Adapter Plate Capscrews Oil Pan Drain Plugs

45 N•m 45 N•m

[ 33 ft-lb ] [ 33 ft-lb ]

60 N•m

[ 45 ft-lb ]

Lubricating Oil Pressure Regulator (Main Rifle) (007-029) 25 N•m

[ 18 ft-lb ]

40 N•m

[ 30 ft-lb ]

68 N•m

[ 50 ft-lb ]

Lubricating Oil Pan Adapter (007-027)

Lubricating Oil Pump (007-031)



Metric

U.S. .

Compound Idler Gear Capscrew

169 N•m

[ 125 ft-lb ]

40 N•m

[ 30 ft-lb ]

47 N•m

[ 35 ft-lb ]

95 N•m

[ 70 ft-lb ]

Lubricating Oil Suction Tube (Block-Mounted) (007-035) 41 N•m

[ 30 ft-lb ]

41 N•m

[ 30 ft-lb ]

61 N•m

[ 45 ft-lb ]

Lubricating Oil Pump Capscrews

Lubricating Oil System — Group 07 Page V-54



Metric

U.S.

.

41 N•m 41 N•m

[ 30 ft-lb ] [ 30 ft-lb ]

Lubricating Oil Temperature Gauge (007-038) Oil Pan Plug

47 N•m

[ 35 ft-lb ]

Lubricating Oil Cooler Cover (007-045) Steel Lock Washers Copper Flat Washers Oil Cooler Lock Nuts

40 N•m 35 N•m 95 N•m

[ 30 ft-lb ] [ 25 ft-lb ] [ 70 ft-lb ]

80 N•m 78 N•m

[ 59 ft-lb ] [ 58 ft-lb ]

30 N•m

[ 22 ft-lb ]

74 N•m

[ 55 ft-lb ]

163 N•m 45 N•m

[ 120 ft-lb ] [ 33 ft-lb ]

Pre-Lubricating Oil Pump (007-063) Prelub High-Volume Pump Bracket Capscrews M12 Prelub High-Volume Pump Bracket Capscrews M10

Prelub High-Volume Bracket Capscrews

Pump

U-Shaped



Metric

U.S. .

190 N•m 45 N•m

[ 140 ft-lb ] [ 33 ft-lb ]

35 N•m

[ 26 ft-lb ]

25 N•m

[ 18 ft-lb ]

Eliminator Filter Head Capscrews

35 N•m

[ 26 ft-lb ]

Eliminator Internal And External Flange Assembly Plugs

20 N•m

[ 177 in-lb ]

25 N•m

[ 18 ft-lb ]

5 N•m

[ 44 in-lb ]

Eliminator Filter (007-067) Eliminator Filtering Unit Distributor Cover Capscrews



Metric

U.S.

.

Hydraulic Motor Capscrews

25 N•m

[ 18 ft-lb ]

Hydraulic Motor Return Pipe Banjo Screw

40 N•m

[ 30 ft-lb ]

Eliminator Cover Capscrews

25 N•m

[ 18 ft-lb ]

Eliminator Filter Bracket Capscrews

67 N•m

[ 50 ft-lb ]

Eliminator Hand Hole Cover Capscrews

40 N•m

[ 30 ft-lb ]

Eliminator Mounting Capscrews

40 N•m 40 N•m

[ 30 ft-lb ] [ 30 ft-lb ]

Eliminator Pipe Plugs

10 N•m

[ 96 in-lb ]


Cooling System — Group 08 - Specifications Page V-57 Ref.No./ Steps


Metric

U.S. .

Cooling System — Group 08 - Specifications Coolant Thermostat (008-013) Engine Thermostat Initial Temperature

Opening

82.2 °C

MIN

180 °F

94.4 °C

MAX

202 °F

73.8 °C 86.1 °C

MIN MAX

165 °F 187 °F

38.087 mm 38.113 mm

MIN MAX

1.4995 in 1.5005 in

0.03 mm 0.15 mm

MIN MAX

0.001 in 0.006 in

0.025 mm 0.150 mm

MIN MAX

0.001 in 0.006 in

0.18 mm 0.23 mm

MIN MAX

0.007 in 0.009 in

30.010 mm

MIN

1.1816 in

30.020 mm

MAX

1.1820 in

24.999 mm

MIN

0.9842 in

25.009 mm

MAX

0.9846 in

Water Pump Impeller Inside Diameter (17)

24.919 mm 24.945 mm

MIN MAX

0.9811 in 0.9821 in

Water Pump Impeller Bore Inside Diameter (17)

24.932 mm

MIN

0.9816 in

24.958 mm

MAX

0.9826 in

LTA Thermostat Initial Opening Temperature

Fan Drive Idler Arm Assembly (008-029) Shaft Outside Diameter

Fan Hub, Belt Driven (008-036) Bearing End Clearance

Bearing End Clearance

Sea Water Pump (008-057) Sea Water Pump Impeller Side Clearance

Water Pump (008-062) Water Pump Shaft Outside (Bearing Area) Water Pump (Impeller End)

Shaft

Outside

Diameter

Diameter

Cooling System — Group 08 Page V-58


Ref.No./ Steps

Metric

U.S.

.

K38 and K50 Water Pump Body Bore Inside Diameter Water Seal (21) Oil Seal (22) Water Seal (23) Oil Seal (24)

53.60 54.10 38.05 38.10 61.997 62.009 71.996 72.012

MIN MAX MIN MAX MIN MAX MIN MAX

2.110 2.130 1.498 1.500 2.4408 2.4412 2.8345 2.8351


Cooling System — Group 08 - Torque Values Page V-59 Ref.No./ Steps

Metric

U.S. .

Cooling System — Group 08 - Torque Values Belt Guard (008-001) Vibration Guard Capscrews

25 N•m

[ 18 ft-lb ]

Rear Guard Housing Capscrews Auxiliary Drive Guard Capscrews

40 N•m 15 N•m

[ 30 ft-lb ] [ 133 in-lb ]

Drive Belt, Cooling Fan (008-002) Fan Idler Capscrew

45 N•m

[ 35 ft-lb ]

Upper And Lower Control Rod Capscrew

90 N•m

[ 65 ft-lb ]

Upper Control Rod Capscrew

60 N•m 60 N•m

[ 45 ft-lb ] [ 45 ft-lb ]

Shock Absorber Capscrews

60 N•m

[ 45 ft-lb ]

Adjusting Capscrew

285 N•m

[ 210 ft-lb ]



Ref.No./ Steps

Metric

U.S.

.

Coolant Bypass Tube (008-005) Thermostat Support Capscrews

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

Upper Flange Capscrews Upper Flange Capscrews

38 N•m

[ 28 ft-lb ]

Lower Flange Capscrews Lower Flange Capscrews

28 N•m

[ 20 ft-lb ]

U-Bolts U-Bolts

21 N•m

[ 186 in-lb ]

Straub Coupling Straub Coupling

30 N•m

[ 22 ft-lb ]

Coolant Thermostat (008-013) Thermostat Housing

45 N•m

[ 33 ft-lb ]

Radiator Hose Clamps

6 N•m

[ 50 in-lb ]


Cooling System — Group 08 Page V-61 Ref.No./ Steps

Metric

U.S. .

Lta Thermostat Housing

45 N•m 6 N•m

[ 33 ft-lb ] [ 50 in-lb ]

Lta Capscrews

45 N•m

[ 33 ft-lb ]

Lta Thermostat Housing

45 N•m

[ 33 ft-lb ]

Straub Couplings

28 N•m 6 N•m

[ 21 ft-lb ] [ 50 in-lb ]

Thermostat Housing Capscrews

40 N•m

[ 30 ft-lb ]

38 N•m 11 N•m

[ 28 ft-lb ] [ 97 in-lb ]

38 N•m

[ 28 ft-lb ]

Coolant Thermostat Housing Support (008-015) Water Outlet Capscrews Water Outlet Capscrews Transfer Tube Capscrews Transfer Tube Capscrews

Lta Thermostat Housing Capscrews Lta Thermostat Housing Capscrews



Ref.No./ Steps

Metric

U.S.

.

Lta Thermostat Cover Capscrews Lta Thermostat Cover Capscrews

60 N•m

[ 44 ft-lb ]

Left Bank Transfer Tube Capscrews Left Bank Transfer Tube Capscrews

22 N•m

[ 16 ft-lb ]

Right Bank Transfer Tube Capscrews Right Bank Transfer Tube Capscrews

22 N•m

[ 16 ft-lb ]

Hose Clamps Hose Clamps

8 N•m

[ 71 in-lb ]

Upper Half Transfer Tube Capscrews Upper Half Transfer Tube Capscrews

11 N•m

[ 97 in-lb ]

Retaining Clamps Retaining Clamps

38 N•m

[ 28 ft-lb ]

Upper Flange Capscrews Upper Flange Capscrews

38 N•m

[ 28 ft-lb ]

Bypass Tube U-Bolts Bypass Tube U-Bolts

22 N•m

[ 16 ft-lb ]



Metric

U.S. .

Straub Coupling Straub Coupling

30 N•m

[ 22 ft-lb ]

203 N•m

[ 150 ft-lb ]

Pulley Assembly Capscrews

47 N•m

[ 35 ft-lb ]

Fan Belt Idler Assembly Capscrew

60 N•m

[ 45 ft-lb ]

366 N•m

[ 270 ft-lb ]

365 N•m

[ 270 ft-lb ]

15 N•m

[ 133 in-lb ]

Fan Drive Idler Arm Assembly (008-029)

Fan Hub Bracket (008-035)

Fan Hub, Belt Driven (008-036) Fan Hub Pipe Plugs



Ref.No./ Steps

Metric

U.S.

.

Fan Hub Locknut

610 N•m

[ 450 ft-lb ]

Fan Hub Capscrews

20 N•m

[ 177 in-lb ]

Fan Hub Capscrews

280 N•m

[ 207 ft-lb ]

135 N•m

[ 100 ft-lb ]

Expansion Tank (008-052) Expansion Tank Capscrews

40 N•m

[ 30 ft-lb ]

Expansion Tank Capscrews

40 N•m

[ 30 ft-lb ]

61 N•m

[ 45 ft-lb ]

Fan, Cooling (008-040)

Heat Exchanger (008-053)



Metric

U.S. .

61 N•m

[ 45 ft-lb ]

54 N•m

[ 40 ft-lb ]

Guide Pin Bolts

256 N•m

[ 190 ft-lb ]

Shield Capscrews

9 N•m

[ 80 in-lb ]

Tighten All 8 Top Bolts

256 N•m

[ 190 ft-lb ]

Bracket Capscrew

31 N•m

[ 23 ft-lb ]

16 N•m

[ 144 in-lb ]

75 N•m

[ 55 ft-lb ]



Ref.No./ Steps

Metric

U.S.

.

16 N•m

[ 144 in-lb ]

25 N•m

[ 20 ft-lb ]

55 N•m

[ 40 ft-lb ]

55 N•m

[ 40 ft-lb ]

27 N•m

[ 20 ft-lb ]

135 N•m

[ 100 ft-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 50 in-lb ]



Metric

U.S. .

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

40 N•m

[ 30 ft-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

40 N•m 5 N•m 20 N•m

[ 30 ft-lb ] [ 44 in-lb ] [ 15 ft-lb ]

40 N•m

[ 30 ft-lb ]



Ref.No./ Steps

Metric

U.S.

.

Bolts, Lower Bracket

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 50 in-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

40 N•m 5 N•m

[ 30 ft-lb ] [ 44 in-lb ]

35 N•m

[ 25 ft-lb ]



Metric

U.S. .

Bolts Clips

78 N•m 17 N•m

[ 57 ft-lb ] [ 144 in-lb ]

Bolts, Jacket Water Manifold

31 N•m

[ 23 ft-lb ]

31 N•m

[ 23 ft-lb ]

31 N•m

[ 23 ft-lb ]

365 N•m

[ 270 ft-lb ]

16 N•m

[ 144 in-lb ]

16 N•m

[ 144 in-lb ]

25 N•m

[ 20 ft-lb ]



Ref.No./ Steps

Metric

U.S.

.

55 N•m

[ 40 ft-lb ]

55 N•m

[ 40 ft-lb ]

25 N•m

[ 20 ft-lb ]

30 N•m

[ 22 ft-lb ]

Sea Water Pump (008-057) Lockplates And Nuts

34 N•m

[ 25 ft-lb ]

Pump Impeller Nut Requiring 1.250 Inch Wrench

160 N•m 110 N•m

[ 120 ft-lb ] [ 80 ft-lb ]

Vee Band Clamp

20 N•m

[ 15 ft-lb ]



Metric

U.S. .

Seal Collar Locknut

50 N•m

[ 37 ft-lb ]

Impeller And Distance Ring Retaining Screws

5 N•m

[ 44 in-lb ]

Sea Water Pump Impeller

175 N•m

[ 129 ft-lb ]

Suction Bend And Pump Assembly Screws

25 N•m

[ 221 in-lb ]

Sea Water Pump Mounting Capscrews

75 N•m

[ 55 ft-lb ]

30 N•m

[ 20 ft-lb ]

60 N•m

[ 45 ft-lb ]

Sea Water Pump Support (008-058)



Ref.No./ Steps

Metric

U.S.

.

Tube Nuts

35 N•m

[ 25 ft-lb ]

Support Bracket Capscrews

60 N•m

[ 45 ft-lb ]

34 N•m

[ 25 ft-lb ]

Water Pump (008-062) Drive Key And Self-Locking Capscsrew

20 N•m

[ 177 in-lb ]

Water Pump Capscrews

47 N•m

[ 35 ft-lb ]

Water Pump Support Bracket Capscrews

41 N•m 15 N•m

[ 30 ft-lb ] [ 135 in-lb ]

Fuel Pump To Pump Drive Capscrews

60 N•m 40 N•m

[ 45 ft-lb ] [ 30 ft-lb ]

Water Manifold (008-061)



Metric

U.S. .

Water Pump Inlet Housing Capscrews

40 N•m 60 N•m

[ 30 ft-lb ] [ 45 ft-lb ]

Bypass Connection Capsrews

40 N•m 45 N•m 5.6 N•m

[ 30 ft-lb ] [ 35 ft-lb ] [ 50 in-lb ]

Water Pump Mounting Capscrews

80 N•m

[ 59 ft-lb ]


45 N•m

[ 33 ft-lb ]

Jacket Water Inlet Capscrews

45 N•m

[ 33 ft-lb ]

Jacket Water Radiator Inlet Capscrews

45 N•m

[ 33 ft-lb ]

Low Temperature Aftercooler Bypass Pipe Clamp Capscrews

45 N•m

[ 33 ft-lb ]

Bypass Pipe Capscrews

45 N•m 28 N•m

[ 33 ft-lb ] [ 21 ft-lb ]



Ref.No./ Steps

Metric

U.S.

.

U Clamps Nuts

45 N•m

[ 33 ft-lb ]

ECM Cooling Plate (008-128) Coolant Return Tee

25 N•m

[ 18 ft-lb ]

Coolant Supply Elbow

25 N•m

[ 18 ft-lb ]

Ecm Mounting Studs

80 N•m

[ 59 ft-lb ]

Ecm Cooling Plate Nuts

23 N•m

[ 17 ft-lb ]

ECM Cooling Plate Lines (008-130) Coolant Adapters

15 N•m

[ 133 in-lb ]

Male Connectors

15 N•m

[ 133 in-lb ]



Metric

U.S. .

Supply And Return Colant Line Nuts

15 N•m

[ 133 in-lb ]

Coolant Line Brackets

45 N•m

[ 33 ft-lb ]

Bracket Capacrews

45 N•m

[ 33 ft-lb ]

Drive Units — Group 09 - Specifications Page V-76



Metric

U.S.

.

Drive Units — Group 09 - Specifications Accessory Drive (009-001) Accessory Shaft End Clearance

0.05 mm 0.30 mm

MIN MAX

0.002 in 0.012 in

Accessory Drive Bushing Inside Diameter

49.95 mm 50.03 mm

MIN MAX

1.967 in 1.970 in

Accessory Distance

45.370 mm

MIN

1.786 in

45.450 mm

MAX

1.789 in

25.377 mm

MIN

0.999 in

25.407 mm

MAX

1.000 in

25.255 mm

MIN

0.994 in

25.278 mm

MAX

0.996 in

60.00 mm

MIN

2.362 in

60.05 mm

MAX

2.364 in

34.964 34.976 43.928 43.940 44.370 44.630 45.070 45.082 49.820 49.832 25.424 25.436

MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX

1.376 1.377 1.729 1.730 1.747 1.757 1.774 1.775 1.961 1.962 1.001 1.001

Drive

Busing

Thrust

Face

Accessory Drive Lovejoy Coupling Inside Diameter Accessory Drive Spline Coupling Inside Diameter Accessory Diameter

Drive

Bushing

Bore

Inside

Accessory Drive Shaft Outside Diameter Measurements (1) (2) (3) (4) (5) (6)


Drive Units — Group 09 Page V-77 Ref.No./ Steps

Metric

U.S. .

Accessory Drive Gear Inside Diameter

44.98 mm 45.02 mm

MIN MAX

1.771 in 1.772 in

Accessory Drive Gear to Shaft Distance

0.05 mm

MAX

0.002 in

Accessory Drive Shaft End Clearance

0.05 mm 0.30 mm

MIN MAX

0.002 in 0.012 in

Accessory Drive End Clearance

0.13 mm 0.29 mm

MIN MAX

0.005 in 0.011 in

36.73 mm 36.75 mm

MIN MAX

1.446 in 1.447 in

39.61 mm 39.64 mm

MIN MAX

1.559 in 1.561 in

39.73 mm 39.75 mm

MIN MAX

1.564 in 1.565 in

Accessory Drive Bushing (009-002) Housing Inside Diameter

Housing Inside Diameter

Accessory Drive Gear and Shaft (009-003) Gear Inside Diameter

Drive Units — Group 09 Page V-78


Ref.No./ Steps

Metric

U.S.

.


39.789 mm 39.802 mm

MIN MAX

1.5665 in 1.5670 in

34.912 mm 34.938 mm

MIN MAX

1.3745 in 1.3755 in

35.00 mm 35.03 mm

MIN MAX

1.378 in 1.379 in

0.14 mm 0.27 mm

MIN MAX

0.006 in 0.011 in

Fuel Pump Drive Bushing Inside Diameter

49.95 mm 50.03 mm

MIN MAX

1.967 in 1.970 in

Fuel Pump Drive Busing Thrust Face Distance

45.370 mm

MIN

1.786 in

45.450 mm

MAX

1.789 in

0.05 mm 0.30 mm

MIN MAX

0.002 in 0.012 in

Accessory Drive Pulley (009-004) Accessory Drive Pulley Inside Diameter

Alternator Drive Pulley Inside Diameter

Fuel Pump Drive (009-011) Fuel Pump Shaft End Clearance

Fuel Pump Drive End Clearance.



Metric

U.S. .

Fuel Pump Drive Spline Coupling Inside Diameter

25.255 mm

MIN

0.994 in

25.278 mm

MAX

0.996 in

60.00 mm

MIN

2.362 in

60.05 mm

MAX

2.364 in

34.964 34.976 39.662 39.740 39.789 39.801 49.820 49.832

MIN MAX MIN MAX MIN MAX MIN MAX

1.376 1.377 1.561 1.564 1.566 1.567 1.961 1.962

39.725 mm 39.751 mm

MIN MAX

1.564 in 1.565 in

Fuel Pump Drive Gear to Shaft Distance

0.05 mm

MAX

0.002 in

Fuel Pump Drive Shaft End Clearance

0.05 mm 0.30 mm

MIN MAX

0.002 in 0.012 in

Accessory Drive Gear to Shaft Distance

0.05 mm

MAX

0.002 in

Fuel Pump Drive Bushing Bore Inside Diameter

Fuel Pump Drive Shaft Outside Diameter Measurements (1) (2) (3) (4) Fuel Pump Drive Gear Inside Diameter




Metric

U.S.

.

Fuel Pump Drive Shaft End Clearance

0.14 mm 0.27 mm

MIN MAX

0.006 in 0.011 in

Fuel Pump Drive End Clearance

0.14 mm 0.27 mm

MIN MAX

0.006 in 0.011 in

38.13 mm

MIN

1.501 in

38.25 mm

MAX

1.506 in


2.273 mm 2.299 mm

MIN MAX

0.0895 in 0.0905 in

Shaft Outside Diameter (1)

38.062 mm 38.075 mm

MIN MAX

1.4985 in 1.4990 in


50.749 mm 50.762 mm

MIN MAX

1.9980 in 1.9985 in

Hydraulic Pump Bushing Inside Diameter

50.813 mm 50.902 mm

MIN MAX

2.0005 in 2.0040 in

0.10 mm 0.48 mm

MIN MAX

0.004 in 0.019 in

Hydraulic Pump Drive (009-016) Hydraulic Pump Drive Bushing Diameter

End Clearance

Inside




Metric

U.S. .

Hydraulic Pump Drive Gear and Shaft (009-019) Hydraulic Pump Drive Gear Inside Diameter

44.399 mm 44.425 mm

MIN MAX

1.7480 in 1.7490 in

44.450 mm

MIN

1.7500 in

44.463 mm

MAX

1.7505 in

0.08 mm 0.30 mm

MIN MAX

0.003 in 0.012 in

0.10 mm 0.25 mm

MIN MAX

0.004 in 0.010 in


63.500 mm 63.513 mm

MIN MAX

2.5000 in 2.5005 in

Gear Bushing Inside Diameter

63.564 mm 63.627 mm

MIN MAX

2.5025 in 2.5050 in

2.36 mm 2.41 mm

MIN MAX

0.093 in 0.095 in

Hydraulic Diameter

Pump

Drive

Shaft

Outside

Rear Gear Drive (Lower Assembly) (009-023) Gear Backlash

Gear End Clearance




Ref.No./ Steps

Metric

U.S.

.

Cylinder Block Side Bore Inside Diameter

63.411 mm 63.449 mm

MIN MAX

2.4965 in 2.4980 in

Rear Seal Side Bore Inside Diameter

63.513 mm 63.538 mm

MIN MAX

2.5005 in 2.5015 in

Gear End Clearance

0.10 mm 0.25 mm

MIN MAX

0.004 in 0.010 in

Gear Lash

0.08 mm 0.30 mm

MIN MAX

0.003 in 0.012 in

0.08 mm 0.30 mm

MIN MAX

0.003 in 0.012 in

Gear End Clearance

0.10 mm 0.25 mm

MIN MAX

0.004 in 0.010 in

Bushing Inside Diameter

63.55 mm 63.63 mm

MIN MAX

2.502 in 2.505 in

Rear Gear Drive (Upper Assembly) (009-024) Gear Lash



Metric

U.S. .

Support Bushing Inside Diameter

63.55 mm 63.63 mm

MIN MAX

2.502 in 2.505 in


63.500 mm 63.513 mm

MIN MAX

2.5000 in 2.5005 in

Shaft Protrusion

85.47 mm 85.98 mm

MIN MAX

3.365 in 3.385 in


2.36 mm 2.41 mm

MIN MAX

0.093 in 0.095 in

Gear Lash

0.08 mm 0.30 mm

MIN MAX

0.003 in 0.012 in

Shaft End Clearance

0.10 mm 0.25 mm

MIN MAX

0.004 in 0.010 in

MIN MAX

2.5050 in 2.5055 in

Rear Gear Drive Gear and Shaft (Upper Assembly) (009-028) Gear Step Outside Diameter 63.627 mm 63.640 mm



Ref.No./ Steps

Metric

U.S.

.

Gear or Adapter Bore Inside Diameter

63.53 mm 63.55 mm

MIN MAX

2.501 in 2.502 in

Shaft Protrusion

85.47 mm 85.98 mm

MIN MAX

3.365 in 3.385 in

47.63 mm 47.65 mm

MIN MAX

1.875 in 1.876 in

44.48 mm 44.58 mm

MIN MAX

1.751 in 1.755 in

39.776 mm 39.802 mm

MIN MAX

1.5660 in 1.5670 in

39.726 mm 39.751 mm

MIN MAX

1.5640 in 1.5650 in

0.05 mm 0.10 mm

MIN MAX

0.002 in 0.004 in

Water Pump Drive Bushing (009-030) Housing Bore Inside Diameter

Bushing Inside Diameter

Water Pump Drive Gear and Shaft (009-031) Shaft Outside Diameter

Gear Inside Diameter

Woodward Governor Drive (009-034) Bearing End Clearance



Metric

U.S. .

Seal Bore Inside Diameter (14)

57.12 mm 57.18 mm

MIN MAX

2.249 in 2.251 in

Bearing Bore Inside Diameter (15)

61.991 mm 62.017 mm

MIN MAX

2.4406 in 2.4416 in


34.963 mm 34.976 mm

MIN MAX

1.3765 in 1.3770 in


25.257 mm 25.540 mm

MIN MAX

1.0050 in 1.0055 in


24.999 mm 25.009 mm

MIN MAX

0.9842 in 0.9846 in


20.663 mm 20.676 mm

MIN MAX

0.8135 in 0.8140 in

Governor Drive Gear Inside Diameter

24.971 mm 24.986 mm

MIN MAX

0.9831 in 0.9837 in

Jaw Coupling Hub Bore Inside Diameter

20.625 mm 20.638 mm

MIN MAX

0.8120 in 0.8125 in

0.05 mm 0.10 mm

MIN MAX

0.002 in 0.004 in

End Clearance

Drive Units — Group 09 - Torque Values Page V-86 Component or Assembly (Procedure)


Metric

U.S.

.

Drive Units — Group 09 - Torque Values Accessory Drive (009-001) Accessory Drive Housing Pipe Plug

8 N•m

[ 75 in-lb ]

Accessory Drive Coupling Capscrew 9.525 Mm [0.375 In] Capscrew Length Accessory Drive Coupling Capscrew 12.7 Mm [0.50 In] Capscrew Length

45 N•m 100 N•m

[ 35 ft-lb ] [ 75 ft-lb ]

Accessory Drive Mounting Capscrews

45 N•m

[ 33 ft-lb ]

Fuel Pump Drive (009-011) Fuel Pump Drive Housing Pipe Plug

8 N•m

[ 75 in-lb ]

Fuel Pump Drive Coupling Capscrew 9.525 Mm [0.375 In] Capscrew Length Fuel Pump Drive Coupling Capscrew 12.7 Mm [0.50 In] Capscrew Length

45 N•m 100 N•m

[ 35 ft-lb ] [ 75 ft-lb ]

Straight Thread Plug

6 N•m

[ 55 in-lb ]

60 N•m

[ 40 ft-lb ]



Metric

U.S. .

Fuel Pump Drive Mounting Capscrews

45 N•m

[ 33 ft-lb ]

27 N•m

[ 20 ft-lb ]

Hydraulic Pump Drive Capscrews

60 N•m

[ 44 ft-lb ]

Rear Gear Drive (Lower Assembly) (009-023) Rear Gear Drive Lower Assembly Capscrews

90 N•m

[ 65 ft-lb ]

60 N•m

[ 45 ft-lb ]

20 N•m 41 N•m

[ 15 ft-lb ] [ 30 ft-lb ]

163 N•m

[ 120 ft-lb ]

Hydraulic Pump Drive (009-016)

Rear Gear Drive Lower Unit Cover Plate Capscrews

Rear Gear Drive (Upper Assembly) (009-024)



Ref.No./ Steps

Metric

U.S.

.

68 N•m

[ 50 ft-lb ]

68 N•m

[ 50 ft-lb ]

47 N•m

[ 35 ft-lb ]

47 N•m 47 N•m

[ 35 ft-lb ] [ 35 ft-lb ]

90 N•m

[ 65 ft-lb ]

90 N•m

[ 60 ft-lb ]

41 N•m

[ 30 ft-lb ]

Woodward Governor Drive (009-034)


Air Intake System — Group 10 - Specifications Page V-89 Ref.No./ Steps


Metric

U.S. .

Air Intake System — Group 10 - Specifications Air Intake Restriction (010-031) Vacuum Gauge or Water Manometer Restrictions

635 mm H2O

MAX

25 in H2O

0.05 mm

MIN

0.002 in

0.13 mm

MAX

0.005 in

0.15 mm

MIN

0.006 in

0.46 mm

MAX

0.018 in

0.20 mm

MIN

0.008 in

0.53 mm

MAX

0.021 in

Holset® HT100 End Clearance

0.05 mm 0.15 mm

MIN MAX

0.002 in 0.006 in

Holset® HT100 Compressor Impeller Radial Clearance

0.25 mm

MIN

0.010 in

0.46 mm

MAX

0.018 in

0.38 mm

MIN

0.015 in

0.53 mm

MAX

0.021 in

0.08 mm

MIN

0.003 in

0.18 mm

MAX

0.007 in

0.20 mm

MIN

0.008 in

0.46 mm

MAX

0.018 in

0.05 mm 0.13 mm

MIN MAX

0.002 in 0.005 in

Turbocharger (010-033) Holset® HC5, HC5A, HX80 or HX85 End Clearance

Holset® HC5, HC5A, HX80 or HX85 Compressor Impeller Radial Clearance Holset® HC5, HC5A, HX80 or HX85 Turbine Wheel Radial Clearance

Holset® HT100 Clearance

Turbine

Wheel

Radial

AiResearch® T-18A Impeller and Turbine Wheel Radial Clearance AiResearch® Clearance

T-18A

Bearing

Radial

Turbocharger Axial Clearance (010-038) Holset® HX5 - Axial Clearance

Air Intake System — Group 10 Page V-90



Metric

U.S.

.

Holset® HX5 - Compressor Impeller Radial Clearance

Holset® HX5 Clearance

-

Turbine

Wheel

Radial

BBC (RR-151) and (RR-153) End Clearance

BBC (RR-151) and (RR-153) Bearing Radial Clearance RR-153 RR-151

AiResearch® T-18A End Clearance

Turbocharger Radial Bearing Clearance (010-047) AiResearch® T-18A Impeller and Turbine Wheel Radial Clearance

0.15 mm

MIN

0.006 in

0.46 mm

MAX

0.018 in

0.20 mm

MIN

0.008 in

0.53 mm

MAX

0.021 in

0.09 mm 0.13 mm

MIN MAX

0.004 in 0.005 in

0.55 0.75

MAX MAX

0.021 0.030

0.10 mm 0.23 mm

MIN MAX

0.004 in 0.009 in

0.08 mm

MIN

0.003 in

0.18 mm

MAX

0.007 in


Air Intake System — Group 10 - Torque Values Page V-91 Ref.No./ Steps

Metric

U.S. .

Air Intake System — Group 10 - Torque Values Aftercooler Assembly (010-002) 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 ]

25 N•m

[ 20 ft-lb ]

Air Intake System — Group 10 Page V-92 Component or Assembly (Procedure)


Metric

U.S.

.

Air Intake Manifold Capscrews

16 N•m

[ 145 in-lb ]

45 N•m

[ 35 ft-lb ]

45 N•m

[ 33 ft-lb ]

30 N•m

[ 22 ft-lb ]

60 N•m

[ 45 ft-lb ]

25 N•m 40 N•m

[ 20 ft-lb ] [ 30 ft-lb ]

9 N•m 40 N•m

[ 80 in-lb ] [ 30 ft-lb ]

25 N•m

[ 20 ft-lb ]


Air Intake System — Group 10 Page V-93 Ref.No./ Steps

Metric

U.S. .

Aftercooler Assembly Capscrew

1 2

25 N•m 45 N•m

[ 20 ft-lb ] [ 35 ft-lb ]

25 N•m

[ 20 ft-lb ]

9 N•m 9 N•m

[ 80 in-lb ] [ 80 in-lb ]

6 N•m

[ 140 in-lb ]

25 N•m 9 N•m

[ 20 ft-lb ] [ 80 in-lb ]

9 N•m 9 N•m 8 N•m

[ 80 in-lb ] [ 80 in-lb ] [ 70 in-lb ]

5 N•m

[ 50 in-lb ]

25 N•m

[ 20 ft-lb ]



Metric

U.S.

.

45 N•m

[ 35 ft-lb ]

25 N•m 8 N•m

[ 20 ft-lb ] [ 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 ]



Metric

U.S. .

45 N•m

[ 35 ft-lb ]

Cast Iron Housing Capscrews Cast Iron Housing Capscrews Aluminum Housing Capscrews Aluminum Housing Capscrews Coolant Connection Clamps Coolant Connection Clamps

65 N•m 53 N•m 5 N•m

[ 48 ft-lb ] [ 39 ft-lb ] [ 44 in-lb ]

Turbocharger Outlet And Air Crossover Hose Clamps

9 N•m 45 N•m

[ 80 in-lb ] [ 35 ft-lb ]

142 N•m

[ 105 ft-lb ]

11 N•m

[ 96 in-lb ]

25 N•m

[ 20 ft-lb ]

25 N•m

[ 20 ft-lb ]

Transfer Tube Hose Clamps

Aftercooler Assembly (Center-Mount) (010-003)



Metric

U.S.

.

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 40 N•m

[ 20 ft-lb ] [ 30 ft-lb ]

9 N•m 40 N•m

[ 80 in-lb ] [ 30 ft-lb ]

25 N•m

[ 20 ft-lb ]



Metric

U.S. .

Aftercooler Assembly (Outboard) (010-004) 45 N•m

[ 35 ft-lb ]

25 N•m

[ 20 ft-lb ]

25 N•m

[ 20 ft-lb ]

45 N•m

[ 35 ft-lb ]

25 N•m

[ 20 ft-lb ]

Air Cleaner Assembly (Engine-Mounted) (010-013) Main Support Bracket 40 N•m

[ 30 ft-lb ]

Vibration Isolator Nuts

[ 177 in-lb ]

Aftercooler Element (010-008)

20 N•m



Metric

U.S.


41 to 47 N•m

[ 30 to 35 ft-lb ]

Air Cleaner Straps

40 N•m

[ 30 ft-lb ]

Air Inlet Tubing

10 N•m

[ 96 in-lb ]

.

Air Leaks, Air Intake and Exhaust Systems (010-024) Intake Air System Hose Clamps 8 N•m

[ 71 in-lb ]

Intake Air System Capscrews

20 N•m

[ 15 ft-lb ]

Turbocharger V-Band Clamps

8 N•m

[ 71 in-lb ]

Turbocharger (010-033) Turbocharger Lock Plate

20.3 N•m

[ 180 in-lb ]



Metric

U.S. .

Turbocharger Vee-Band Clamp

12 N•m

[ 106 in-lb ]

Capscrews

40 N•m

[ 30 ft-lb ]

K38 K50

9 N•m 15 N•m

[ 80 in-lb ] [ 133 in-lb ]

Capscrews

16 N•m

[ 142 in-lb ]

Oil Inlet Fitting

35 N•m

[ 26 ft-lb ]

Capscrews

40 N•m

[ 30 ft-lb ]

Flange Capscrews

40 N•m

[ 30 ft-lb ]

Turbocharger Capscrews

40 N•m

[ 30 ft-lb ]



Metric

U.S.

.

Oil Inlet Fitting

35 N•m

[ 26 ft-lb ]

Capscrews

40 N•m

[ 30 ft-lb ]

Flange Capscrews

40 N•m

[ 30 ft-lb ]

Turbocharger Support Capscrews

270 N•m

[ 199 ft-lb ]

Bracket To Supports

90 N•m

[ 66 ft-lb ]

Connection To Bracket

90 N•m

[ 66 ft-lb ]

Turbocharger Connection

40 N•m

[ 30 ft-lb ]

Vee-Band Clamp

7 N•m

[ 62 in-lb ]



Metric

U.S. .

T-Bolt Clamps

9 N•m

[ 80 in-lb ]

Oil Inlet Fitting

35 N•m

[ 26 ft-lb ]

Capscrews Flange Capscrews

40 N•m 40 N•m

[ 30 ft-lb ] [ 30 ft-lb ]


270 N•m

[ 199 ft-lb ]

Exhaust Outlet Connection Capscrews

40 N•m

[ 30 ft-lb ]

Capscrews

25 N•m

[ 18 ft-lb ]

Bracket To Supports

90 N•m

[ 66 ft-lb ]

Exhaust Outlet Connection To Bracket

90 N•m

[ 66 ft-lb ]



Metric

U.S.

.

Air Intake Connection To Bracket

40 N•m

[ 30 ft-lb ]

Bracket Capscrews

40 N•m

[ 30 ft-lb ]

Exhaust Connection Capscrews

90 N•m

[ 66 ft-lb ]

Vee-Band Clamp

7 N•m

[ 62 in-lb ]

T-Bolt Clamps

7 N•m

[ 62 in-lb ]

Oil Inlet Capscrew Fitting Torque

40 N•m 35 N•m

[ 30 ft-lb ] [ 26 ft-lb ]

Oil Drain Capscrews Oil Drain Flange Capscrews

40 N•m 40 N•m

[ 30 ft-lb ] [ 30 ft-lb ]

Turbocharger Mounting Capscrews

40 N•m

[ 30 ft-lb ]



Metric

U.S. .

Oil Inlet Capscrews

40 N•m

[ 30 ft-lb ]


270 N•m

[ 199 ft-lb ]

Exhaust Outlet Capscrews

40 N•m

[ 30 ft-lb ]

Air Intake Connection Capscrews

40 N•m

[ 30 ft-lb ]


95 N•m

[ 70 ft-lb ]

Bracket Capscrews

95 N•m

[ 70 ft-lb ]

Air Inlet Connection Capscrews

40 N•m

[ 30 ft-lb ]

Bracket Connection Capscrews

40 N•m

[ 30 ft-lb ]



Metric

U.S.

.

Exhaust Connection Capscrews Exhaust Outlet Connection Capscrews

95 N•m 40 N•m

[ 70 ft-lb ] [ 30 ft-lb ]

Exhaust Outlet Connections

95 N•m

[ 70 ft-lb ]

Vee-Band

9 N•m

[ 80 in-lb ]

Intake Pipe Capscrews

40 N•m

[ 30 ft-lb ]

Intake Pipe Clamps

8 N•m

[ 71 in-lb ]

Low Pressure Turbocharger Oil Inlet Oil Inlet Fitting

25 N•m 35 N•m

[ 18 ft-lb ] [ 26 ft-lb ]

Turbocharger Oil Drain Hose Flange

25 N•m 40 N•m

[ 18 ft-lb ] [ 30 ft-lb ]

Turbocharger Mounting Capscrews And Nuts

45 N•m

[ 33 ft-lb ]



Metric

U.S. .

Hose Clamp

8 N•m

[ 71 in-lb ]

Hose Clamp

8 N•m

[ 71 in-lb ]

Exhaust Connection Capscrews And Nuts

95 N•m

[ 70 ft-lb ]

Air Intake Connection Capscrews And Nuts Interstage Hose Clamp

48 N•m 8 N•m

[ 35 ft-lb ] [ 71 in-lb ]

Air Intake Capscrews

48 N•m

[ 35 ft-lb ]

Exhaust Adapter Capscrews

48 N•m

[ 36 ft-lb ]

20 N•m Loosen 2 to 3 turns 18 to 20 N•m

[ 177 in-lb ]

Turbocharger, Water-Cooled (010-037) V-Band Clamp

1 2 3

[ 160 to 177 in-lb ]

Air Intake System — Group 10 Page V-106



Ref.No./ Steps

Metric

U.S.

.


Capscrews

Turbocharger

Turbocharger To Center Section Mounting Capscrews Turbocharger To Center Section Mounting Capscrews


Capscrews

Turbocharger

Turbocharger To Center Section Mounting Capscrews Turbocharger To Center Section Mounting Capscrews

136 N•m

[ 100 ft-lb ]

102 to 115 N•m

[ 75 to 85 ft-lb ]

43 to 47 N•m 20 N•m

[ 32 to 35 ft-lb ] [ 180 in-lb ]

22 N•m 11 N•m

[ 16 ft-lb ] [ 97 in-lb ]

136 N•m

[ 100 ft-lb ]

102 to 115 N•m

[ 75 to 85 ft-lb ]

43 to 47 N•m 20 N•m

[ 32 to 35 ft-lb ] [ 180 in-lb ]

22 N•m 11 N•m

[ 16 ft-lb ] [ 97 in-lb ]



Metric

U.S. .

Turbocharger Coolant Hoses (010-041) Water And Turbocharger Fittings

57 N•m

[ 42 ft-lb ]

Turbocharger Supply Line Fittings

54 N•m

[ 40 ft-lb ]

Thermostat Housing And Turbocharger Fittings

57 N•m

[ 42 ft-lb ]

Turbocharger Drain Line Fittings

54 N•m

[ 40 ft-lb ]

Bracket Capscrews

9 N•m

[ 80 in-lb ]

Elbow Fittings

57 N•m

[ 42 ft-lb ]

Coolant Supply And Return Hoses

54 N•m

[ 40 ft-lb ]



Metric

U.S.

.

Turbocharger Oil Drain Line (010-045) Turbocharger Drain Tube Capscrews

45 N•m 40 N•m

[ 33 ft-lb ] [ 30 ft-lb ]

Turbocharger Drain Tube P-Clips

40 N•m

[ 30 ft-lb ]

High Pressureturbocharger Drain Tube Capscrews

45 N•m 40 N•m

[ 33 ft-lb ] [ 30 ft-lb ]

Turbocharger Drain Tube P-Clips

40 N•m

[ 30 ft-lb ]

Low Pressureturbocharger Drain Tube Capscrews

45 N•m 40 N•m

[ 33 ft-lb ] [ 30 ft-lb ]

Turbocharger Oil Supply Line (010-046) Oil Supply Tube Fitting To Turbocharger Oil Supply Tube Fitting To Turbocharger

35 N•m

[ 26 ft-lb ]

35 N•m

[ 26 ft-lb ]

Oil Supply Tube Fitting To Male Union Oil Supply Tube Fitting To Male Union



Metric

U.S. .

P-Clip To Cylinder Head Capscrews P-Clip To Cylinder Head Capscrews P-Clip To Injector Cover Plate Capscrews PClip To Injector Cover Plate Capscrews

20 N•m 42 N•m

[ 15 ft-lb ] [ 31 ft-lb ]

Oil Supply Tube Fitting To Turbocharger Oil Supply Tube Fitting To Turbocharger

35 N•m

[ 26 ft-lb ]


35 N•m

[ 26 ft-lb ]

P-Clip To Cylinder Head Capscrews P-Clip To Cylinder Head Capscrews P-Clip To Injector Cover Plate Capscrews PClip To Injector Cover Plate Capscrews

20 N•m 42 N•m

[ 15 ft-lb ] [ 31 ft-lb ]

Oil Supply Tube Fitting To Turbocharger Oil Supply Tube Fitting To Turbocharger

35 N•m

[ 26 ft-lb ]


35 N•m

[ 26 ft-lb ]

P-Clip To Cylinder Head Capscrews P-Clip To Injector Cover Plate Capscrews

20 N•m 42 N•m

[ 15 ft-lb ] [ 31 ft-lb ]

Turbocharger Oil Supply Tubes

38 N•m

[ 28 ft-lb ]



Metric

U.S.

Oil Supply Tubes Male Union Turbocharger

24 to 27 N•m

[ 18 to 20 ft-lb ]

Male Union Oil Supply Tubes

24 to 27 N•m

[ 18 to 20 ft-lb ]

27 N•m

[ 20 ft-lb ]

102 N•m

[ 75 ft-lb ]

.

Aftercooler Housing (Center Mount) (010-073)


Exhaust System — Group 11 - Torque Values Page V-111 Ref.No./ Steps

Metric

U.S. .

Exhaust System — Group 11 - Torque Values Exhaust Connection Pipe (011-001) Exhaust Connection Pipe To Support Bracket Capscrews

45 N•m

[ 33 ft-lb ]

195 N•m

[ 140 ft-lb ]

60 N•m 55 N•m 80 N•m

[ 44 ft-lb ] [ 41 ft-lb ] [ 59 ft-lb ]

Ktta38 Dry Exhaust Manifold Capscrews

55 N•m

[ 41 ft-lb ]

Kt38 And Kta38 Dry Exhaust Manifold (With Center Mount Turbochargers) Capscrews

55 N•m

[ 41 ft-lb ]

Kta50 Dry Exhaust Manifold 140 Mm [5.5 In] (With 140 Mm [5.5 In] Capscrew With N Stamped On Head Kta50 Dry Exhaust Manifold 140 Mm [5.5 In] (Without 140 Mm [5.5 In] And 38 Mm [1.5 In] Capscrews Without N Stamped On Head

55 N•m 80 N•m

[ 41 ft-lb ] [ 59 ft-lb ]

Kta50 Dry Exhaust Manifold 140 Mm [5.5 In] (With 140 Mm [5.5 In] Capscrew With N Stamped On Head Kta50 Dry Exhaust Manifold 140 Mm [5.5 In] (Without 140 Mm [5.5 In] And 38 Mm [1.5 In] Capscrews Without N Stamped On Head

55 N•m 80 N•m

[ 41 ft-lb ] [ 59 ft-lb ]

Exhaust Connection Pipe To Exhaust Bellows Capscrews

Exhaust Manifold, Dry (011-007) Kt38 And Kta38 Dry Exhaust Manifold 38 Mm [1.5 In] Capscrews 38 Mm [1.5 In] Capscrew Kt38 And Kta38 Dry Exhaust Manifold 76 Mm [3.0 In] Capscrews 76 Mm [3 In] Capscrew With N Stamped On Head 76 Mm [3 In] Capscrew Without N Stamped On Head

Exhaust System — Group 11 Page V-112


Ref.No./ Steps

Metric

U.S.

.

Tighten The Marine Application V-Band Clamp Tighten The Industrial Application V-Band Clamp

55 N•m

[ 41 ft-lb ]

54 N•m 54 N•m

[ 40 ft-lb ] [ 40 ft-lb ]

17 N•m 5 N•m

[ 150 in-lb ] [ 44 in-lb ]

54 to 61 N•m

[ 40 to 45 ft-lb ]

20 N•m

[ 177 in-lb ]

8 N•m

[ 71 in-lb ]

Exhaust Manifold, Wet (011-008)

Exhaust Manifold (Wet) Water Connections (011-016) 20 N•m 40 N•m 20 N•m 20 N•m

[ 177 in-lb ] [ 30 ft-lb ] [ 177 in-lb ] [ 177 in-lb ]


Exhaust System — Group 11 Page V-113 Ref.No./ Steps

Metric

U.S. .

20 N•m

[ 177 in-lb ]

136 N•m

[ 100 ft-lb ]

Bellows (011-018)

Compressed Air System — Group 12 - Specifications Page V-114 Component or Assembly (Procedure)


Metric

U.S.

.

Compressed Air System — Group 12 - Specifications Air Compressor (012-014) End Clearance

0.04 mm 0.24 mm

MIN MAX

0.0015 in 0.0095 in


Compressed Air System — Group 12 - Torque Values Page V-115 Ref.No./ Steps

Metric

U.S. .

Compressed Air System — Group 12 - Torque Values Air Compressor Unloader and Valve Assembly (012-013) Holset Ss, E-Type, And St Unloader 14 N•m Capscrews

[ 120 in-lb ]

Holset Qe Unloader Capscrew

27 N•m

[ 20 ft-lb ]

60 N•m

[ 45 ft-lb ]

40 N•m 60 N•m

[ 30 ft-lb ] [ 45 ft-lb ]

6 N•m

[ 50 in-lb ]


Electrical Equipment — Group 13 - Torque Values Page V-116 Component or Assembly (Procedure)


Metric

U.S.

.

Electrical Equipment — Group 13 - Torque Values Alternator (013-001) Alternator Pully Mounting Nut

100 N•m

[ 75 ft-lb ]

Alternator Brace Capscrews

90 N•m

[ 65 ft-lb ]

Belt Guard Capscrews

45 N•m

[ 35 ft-lb ]

90 N•m

[ 66 ft-lb ]

215 N•m 195 N•m

[ 160 ft-lb ] [ 145 ft-lb ]

95 N•m 70 N•m 95 N•m

[ 70 ft-lb ] [ 55 ft-lb ] [ 70 ft-lb ]

Alternator Bracket (013-003)

Starting Motor (013-020) Cast Iron Flywheel Housing Cast Iron Flywheel Housing Aluminium Flywheel Housing Aluminium Flywheel Housing

Alternator Adjusting Link (013-022) Nut 1 Nut 1 Nut 2 Nut 2 Nut 3 Nut 3


Engine Testing — Group 14 - Specifications Page V-117 Ref.No./ Steps

Metric

U.S. .

Engine Testing — Group 14 - Specifications Engine Testing (Chassis Dynamometer) (014-002) Engine Blowby 10-mm [0.406-in] Orifice rpm = All ratings New/Rebuilt Engine Used Engine

127 330

MAX MAX

5 13

Lubricating Oil Pressure Low Idle (Minimum Allowable) At 1200 rpm (Minimum Allowable)

138 207

MAX MAX

20 30

Engine Testing (Engine Dynamometer) (014-005) Lubricating Oil Pressure Low Idle Rated rpm

138 413

MIN MIN

20 60

Coolant Pressure

241 kPa

MAX

35 psi

Engine Run-in (Engine Dynamometer) (014-006) Main Oil Rifle Pressure (at Idle)

138 kPa

MIN

20 psi

Main Oil Rifle Pressure (at Idle)

138 kPa

MIN

20 psi

Main Oil Rifle Pressure (at Idle)

138 kPa 483 kPa

MIN MAX

20 psi 70 psi

Engine Testing — Group 14 - Torque Values Page V-118 Component or Assembly (Procedure)


Metric

U.S.

.

Engine Testing — Group 14 - Torque Values Engine Testing (Engine Dynamometer) (014-005) 60 N•m 48 N•m

[ 44 ft-lb ] [ 35 ft-lb ]

54 N•m

[ 40 ft-lb ]

54 N•m

[ 40 ft-lb ]

Engine Run-in (Engine Dynamometer) (014-006)

Engine Compression (014-012) Injector Hold Down


Mounting Adaptations — Group 16 - Specifications Page V-119 Ref.No./ Steps

Metric

U.S. .

Mounting Adaptations — Group 16 - Specifications Engine Support Bracket, Front (016-002) Front Support Bore Diameter

Engine Mounts (016-010) Front Support Bore

210.03 mm 210.08 mm

MIN MAX

8.269 in 8.271 in

210.03 mm 210.08 mm

MIN MAX

8.269 in 8.271 in

Mounting Adaptations — Group 16 - Torque Values Page V-120 Component or Assembly (Procedure)


Metric

U.S.

.

Mounting Adaptations — Group 16 - Torque Values Engine Lifting Brackets (016-001) Lifting Bracket Capscrew

270 N•m

[ 200 ft-lb ]

300 N•m

[ 220 ft-lb ]

300 N•m

[ 200 ft-lb ]

290 N•m

[ 215 ft-lb ]

1 2 3

150 N•m 285 N•m 515 N•m

[ 110 ft-lb ] [ 210 ft-lb ] [ 380 ft-lb ]

1 2 3

150 N•m 285 N•m 515 N•m

[ 110 ft-lb ] [ 210 ft-lb ] [ 380 ft-lb ]

1 2 3

102 N•m 203 N•m 366 N•m

[ 75 ft-lb ] [ 150 ft-lb ] [ 270 ft-lb ]

Engine Support Bracket, Front (016-002)

Flexplate (016-004) Flexplate Assembly Capscrews

Flexplate Mounting Capscrews

Flywheel (016-005) Flywheel Mounting Capscrews

Flywheel Housing (016-006) Flywheel Housing Capscrew


Mounting Adaptations — Group 16 Page V-121 Ref.No./ Steps

Metric

U.S. .

Flywheel Housing Capscrews

366 N•m

[ 270 ft-lb ]

Flywheel Housing Capscrews 7/16-14 In Capscrews Flywheel Housing Capscrews 3/4-10 In Capscrews

90 N•m 366 N•m

[ 66 ft-lb ] [ 270 ft-lb ]

298 N•m

[ 220 ft-lb ]

Engine Mounts (016-010) Front Support Capscrews

Main Power Generator — Group 21 - Torque Values Page V-122



Metric

U.S.

.

Main Power Generator — Group 21 - Torque Values Bearing, Generator (021-027) End Bracket Capscrews

60 N•m

[ 45 ft-lb ]

Bearing Cartridge Capscrews

45 N•m

[ 35 ft-lb ]

20 to 27 N•m

[ 15 to 20 ft-lb ]

20 to 27 N•m

[ 15 to 20 ft-lb ]

Generator Rotor (021-031) End Bracket Capscrews

60 N•m

[ 45 ft-lb ]

Bearing Cartridge Capscrews

45 N•m

[ 35 ft-lb ]

Permanent Magnet Generator (021-030) Center Rotor Retaining Capscrew

Permanent Capscrews

Magnet

Exciter

Stator


General Engine Page V-123

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 Page V-124


This illustration illustrates the cylinder numbering sequence for the KTA38 and QSK38 engines. • RB = Right-bank of cylinders • LB = Left-bank of cylinders. To determine the right and left bank on the KTA38 and QSK38 engines, stand at the rear of the engine and face the front. When referencing system electronics, a standard cylinder numbering system has been adopted. This is only used for the electronic system components on engines with electronically actuated injectors.

This graphic illustrates the intake and exhaust valve locations for the KTA38 engine.

This graphic illustrates the cylinder numbering sequence for the KTA50 engine. • RB = Right-bank of cylinders • LB = Left-bank of cylinders.

This graphic illustrates the intake and exhaust valve locations for the KTA50 engine.


Fuel System Page V-125

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 Page V-126


Lubricating Oil System Specifications Lubricating Oil Pressure, Main Oil Rifle (15W-40 oil at 107°C [225°F]): Maximum at rated rpm................................................................................................................483 kPa [70 psi] Minimum at rated rpm.................................................................................................................310 kPa [40 psi] Minimum at idle rpm...................................................................................................................138 kPa [20 psi] Maximum oil pressure spike on a cold engine..........................................................................1655 kPa [240 psi] Maximum lubricating oil flow to all accessories...................................................................57 liters/min [15 gpm] Lubricating Oil Temperature - Maximum in Sump...............................................................................121°C [250°F] K38 Lubricating Oil Pan Capacity Center (one piece casting) Sump Low Level................................................................................................................................87 liter [23 gal] High Level.............................................................................................................................114 liter [30 gal] K38 Lubricating Oil Pan Capacity Subbase Sump Low Level..............................................................................................................................129 liter [34 gal] High Level.............................................................................................................................185 liter [49 gal] K38 Lubricating Oil Pan Capacity Front, Center, Rear Sump Low Level..............................................................................................................................114 liter [30 gal] High Level.............................................................................................................................140 liter [37 gal] K38 Lubricating Oil Pan Capacity Front, Center, Rear (deep) Sump Low Level..............................................................................................................................140 liter [37 gal] High Level.............................................................................................................................167 liter [44 gal] K50 Lubricating Oil Pan Capacity Subbase Low Level..............................................................................................................................170 liter [45 gal] High Level.............................................................................................................................246 liter [65 gal] K50 Lubricating Oil Pan Capacity Front and Front-Center, Rear and Rear-Center (deep) Sump Low Level..............................................................................................................................174 liter [46 gal] High Level.............................................................................................................................204 liter [54 gal] K50 Lubricating Oil Pan Capacity Rear-Center and Front-Center Sump Low Level..............................................................................................................................121 liter [32 gal] High Level.............................................................................................................................151 liter [40 gal] K50 Lubricating Oil Pan Capacity Front and Front-Center, Rear and Rear-Center Sump Low Level..............................................................................................................................148 liter [39 gal] High Level.............................................................................................................................178 liter [47 gal] Maximum Oil Consumption....................................................................................................0.47 liter/hr [0.50 qt/hr] Lubricating Oil Temperature - Maximum in Sump...............................................................................110°C [230°F] Lubricating Oil Pan Capacity High Level..................................................................................................................................185 liter [49 gal] Low Level...................................................................................................................................129 liter [34 gal]


Cooling System Page V-127

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 Page V-128


Low Temperature Aftercooler Circuit Thermostat Opening Temperature..........................................46°C [115°F] Low Temperature Aftercooler Circuit Thermostat Fully Open Temperature......................................57°C [135°F] Maximum Recommended External Coolant Restriction in LTA Circuit (1P-2L or 2P-2L)...............82.7 kPa [12 psi]


Air Intake System Page V-129

Air Intake System Specifications Maximum Intake Air Restriction (heavy duty air cleaner) Dirty Filter....................................................................................................................63.5 cm-H 2O [25 in-H 2O] Maximum Intake Air Restriction (heavy duty air cleaner) Clean Filter................................................................................................................30.48 cm-H 2O [12 in-H 2O] Minimum Dirt Holding Capacity With Heavy Duty Air Cleaner......................................................................25 g/cfm Recommended Intake Piping Size (inside diameter) - QSK50 With Electronically Actuated Injectors.....15.2 cm [6 in]

Exhaust System Page V-130


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]


Electrical System 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. Reserve Capacity Minimum Cranking Speed Without Starting Aids Starting Circuit Resistance (maximum)

640 minutes 150 rpm 0.002 ohms

Batteries (Specific Gravity) Battery State of Charge 100 % 75% 50% 25% DISCHARGED

Specific Gravity (at 27°C [80°F]) 1.260 to 1.280 1.230 to 1.250 1.200 to 1.220 1.170 to 1.190 1.110 to 1.130

Compressed Air System Page V-132


Compressed Air System Specifications The following specifications are for a upright two-cylinder air compressor. Cylinders................................................................................................................................................................2 Compressor Capacity (at 1250 rpm).........................................................................14.2 liter [30.00 cfm] per second Piston Displacement...................................................................................................................676 cc [41.3 C.I.D.] Bore...........................................................................................................................................92.08 mm [3.625 in] Stroke.................................................................................................................................................50.8 mm [2 in] Speed..................................................................................................................................................Engine speed Cooling..............................................................................................................................................Engine coolant Lubrication...............................................................................................................................Engine lubricating oil Plumbing Line Sizes: Coolant Inlet and Outlet (pipe fitting)..........................................................................................[0.3750 in NPTF] Air Inlet (inside diameter).......................................................................................................22.22 mm [0.875 in] Air Outlet (minimum inside diameter).....................................................................................15.88 mm [0.625 in] Height, Overall (approximate)..........................................................................................................34.3 cm [13.5 in] Width, Overall (approximate)............................................................................................................... 17.8 cm [7 in] Length, Overall (approximate).......................................................................................................28.7 cm [11.30 in] Weight (approximate)...................................................................................................................... 33.5 kg [74.5 lb] The following specifications are for a tilted two-cylinder air compressor. Cylinders................................................................................................................................................................2 Compressor Capacity (at 1250 rpm).........................................................................16.1 liter [34.00 cfm] per second Piston Displacement...................................................................................................................773 cc [47.2 C.I.D.] Bore.......................................................................................................................................... 98.43 mm [3.875 in] Stroke................................................................................................................................................ 50.8 mm [2 in] Speed................................................................................................................................................. Engine speed Cooling............................................................................................................................................. Engine coolant Lubrication.............................................................................................................................. Engine lubricating oil Plumbing Line Sizes: Coolant Inlet and Outlet (pipe fitting)..........................................................................................[0.3750 in NPTF] Air Inlet (inside diameter).......................................................................................................22.22 mm [0.875 in] Air Outlet (minimum inside diameter).........................................................................................12.7 mm [0.50 in] Height, Overall (approximate)........................................................................................................40.1 cm [15.80 in] Width, Overall (approximate)........................................................................................................ 27.3 cm [10.75 in] Length, Overall (approximate).......................................................................................................28.7 cm [11.30 in] Weight (approximate).......................................................................................................................36.3 kg [80.0 lb]


Cummins/Fleetguard® Filter Specifications Page V-133

Cummins/Fleetguard® Filter Specifications Specifications Fleetguard®/Nelson is a subsidiary of Cummins Inc. Fleetguard®/Nelson filters are developed through joint testing at Cummins Inc. and Fleetguard®/Nelson. Fleetguard®/Nelson filters are standard on new Cummins® engines. Cummins Inc. recommends their use. Fleetguard®/Nelson products meet all Cummins® Source Approval Test standards to provide the quality filtration necessary to achieve the engine's design life. If other brands are substituted, the purchaser should insist on products that the supplier has tested to meet Cummins Inc. high-quality standards. Cummins Inc. can not be responsible for problems caused by non-genuine filters that do not meet Cummins Inc. performance or durability requirements. Filter Type Lubricating Oil (full-flow)

Lubricating Oil (bypass) Lubricating Oil (venturi combo without Centinel) Lubricating Oil (venturi combo for use with Centinel) Fuel Filter (20 micron, water separation) Fuel Filter (10 micron, water separation) Fuel Filter, Stage 2 (3 micron) with electronically Actuated Injector Fuel and Water Seperator, Statge 1 (7 micron) with electronically Actuated Injector Coolant Filter Coolant Filter Coolant Filter

Cummins® Part Number 3889310 3310169 3313305 3313305 3889311 3101870

Fleetguard® Part Number LF670 LF3325 LF3363 LF3363 LF777 LF9024

4197219

LF9034

3313306

FF202

3089916

FS1006

4964100

FF5634 FS19763

4058964 3100308 4058965

WF2073 WF2075 WF2076

The following table(s) contain information about Fleetguard® coolant filters service intervals and liquid precharge: Standard Service Interval Fleetguard® Filter Part Numbers SCA Units Diesel Coolant Additive2 Diesel Coolant Additive4 (Fleetcool) 2 WF2050 WF2070 4 WF2051 WF2071 6 WF2052 WF2072 8 WF2053 WF2073 12 None WF2074 15 WF2054 WF2075 23 WF2055 WF2076 Chemical Free WF2077 WF2077

SCA Units 5

Standard Service Interval Fleetguard® Liquid Additive Part Numbers Amount Diesel Coolant Additive2 Diesel Coolant Additive4 (Fleetcool) 0.47 liter [1 pt] DCA30L DCA60L

Cummins/Fleetguard® Filter Specifications Page V-134


Standard Service Interval Fleetguard® Liquid Additive Part Numbers SCA Units Amount Diesel Coolant Additive2 Diesel Coolant Additive4 (Fleetcool) 20 1.89 liter [2 qt] DCA35L DCA65L 40 3.78 liter [1 gal] DCA40L DCA70L 200 18.9 liter [5 gal] DCA45L DCA75L 2200 208 liter [55 gal] DCA50L DCA80L Extended Service Fleetguard® Filter Part Numbers SCA Units Extended Service Filter Notes 15 WF2121 Slow Release Chemical Free WF2122 Normal duty Chemical Free WF2123 Severe Duty (40-percent more media than WF2122) Note: Extended Service Filters are designed for use with Extended Service Compleat. Extended Service Fleetguard® Liquid Additive Part Numbers SCA Units Amount Extended Service Extender Liquid 8.4 0.47 liter [1 pt] CC2843 16.8 0.95 liter [1 qt] CC2840 3696 208 liter [55 gal] CC2841


Fuel Recommendations and Specifications Page V-135

Fuel Recommendations and Specifications General Information WARNING Do not mix gasoline, alcohol, or gasohol with diesel fuel. This mixture can cause an explosion. Cummins Inc. recommends the use of ASTM number 2 diesel fuel. The use of number 2 diesel fuel will result in optimum engine performance. At operating temperatures below 0°C [32°F], acceptable performance can be obtained by using blends of number 2D and number 1D. The use of lighter fuels can reduce fuel economy. The viscosity of the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication. For a more detailed description of fuel properties, refer to Fuel for Cummins Engines, Bulletin 3379001. See Procedure 205-001 (Additional Service Literature) in Section L for ordering information.

Lubricating Oil Recommendations and Specifications Page V-136


Lubricating Oil Recommendations and Specifications General Information The use of quality engine lubricating oils combined with appropriate oil drain and filter change intervals are a critical factor in maintaining engine performance and durability. Cummins Inc., recommends the use of a high quality SAE 15W-40, low ash engine oil for natural gas engines. The specifications for oils meeting Cummins recommended SAE 15W-40 oil blends are as follows: Cummins Inc., Oil Recommendations Viscosity 15W-40 API CG Quality Neutralization No (TBN) Calcium (ppm) Phosphorus (ppm) Zinc (ppm) Sulfated Ash (%W) TAN (ASTM D664)

5/5.5 1200 250-350 ppm 250-350 ppm 0.4/0.5 0.5/0.7

CAUTION A sulfated ash limit of 0.5 percent has been placed on all stationary engine lubricating oil recommended for use in Cummins® natural gas engines. Higher ash oil can cause valve and/or piston damage and lead to excessive oil consumption and degradation of the catalyst. For further details and discussion of engine lubricating oils for Cummins® engines, refer to a Cummins Authorized Repair Facility.


Coolant Recommendations and Specifications Page V-137

Coolant Recommendations Specifications

and

Fully Formulated Coolant/Antifreeze Use low-silicate antifreeze that (GM6038M specification) criteria.

meets

ASTM4985

Fully formulated coolant must meet ASTM D-6210/ D-6211. Cummins Inc. recommends using either a 50/50 mixture of good-quality water and fully formulated antifreeze, or fully formulated coolant when filling the cooling system. Good-quality water is important for cooling system performance. Excessive levels of calcium and magnesium contribute to scaling problems, and excessive levels of chlorides and sulfates cause cooling system corrosion. Water Quality Calcium Magnesium Maximum 170 ppm as (hardness) (CaCO3 + MgCO3) Chloride Sulfur

40 ppm as (CI) 100 ppm as (SO4)



Cummins Inc. recommends Fleetguard® antifreeze coolants including ES Compleat containing DCA4 Plus, Fleetcool EX containing DCA2 Plus, and ES Optimax Organic Acid Technology (OAT), which meet the requirements of Cummins Engineering Standard 14603. However, Cummins Inc., Chevron Texaco and Shell have agreed that Chevron Texaco, Shell Rotella® and their private label counterpart Extended Life OAT coolants, which do not meet the elastomer compatibility section of Cummins Engineering Standard 14603 are acceptable for extended service interval use, assuming the initial coolant fill requirements were met from the vehicles' original equipment manufacturer (OEM). Mid-Range, Heavy-Duty and High Horsepower engine overhauls, or repairs involving the replacement of the following components, using this Extended Life OAT coolant must discard the coolant and replace it with new coolant. • Rocker lever housing gasket • Lubricating oil cooler housing gasket • Cylinder head gasket • Thermostat housing gasket If the replacement coolant is Chevron Texaco, Shell Rotella® or their private label counterpart Extended Life OAT coolants, which do not meet the elastomer compatibility section of Cummins Engineering Standard 14603, then the coolant must be treated by adding 0.24 liters [8 oz] of liquid silicate fluid for every 45.5 liters [12 gal] of total coolant system volume. It is critical to not overtreat the coolant with silicate fluid. To obtain order forms or ask questions relative to ordering the silicate fluid, contact: Silicate Fluid Order Program P.O. Box 27388 Houston, TX 77277-7388 Phone: 800-346-9041 Fax: 800-876-5317 For further details and discussion of engine coolant for Cummins engines, refer to Cummins Coolant Requirements and Maintenance, Bulletin 3666132. Fully formulated antifreeze must be mixed with goodquality water at a 50/50 ratio (40- to 60-percent working range). A 50/50 mixture of antifreeze and water gives a -36°C [-33°F] freezing point and a 108°C [226°F] boiling point, which is adequate for locations in North America. The actual lowest freezing point of ethylene glycol antifreeze is at 68 percent. Using higher concentrations of antifreeze will raise the freezing point of the solution and increase the possibility of a silica gel problem.


A refractometer must be used to measure the freezing point of the coolant accurately. Use Fleetguard® refractometer, Part Number CC2800 or CC2806.

Do not use a floating ball hydrometer. Using floating ball hydrometers can give an incorrect reading.

Cooling System Sealing Additives Do not use sealing additives in the cooling system. The use of sealing additives will: • Build up in coolant low-flow areas • Plug the radiator and oil cooler • Possibly damage the water pump seal.

Cooling System Soluble Oils Do not use soluble oils in the cooling system. The use of soluble oils will: • Corrode brass and copper • Damage heat transfer surfaces • Damage seals and hoses.


Drive Belt Tension Page V-140


Drive Belt Tension Tension Chart SAE Belt Size 0.380 in 0.440 in 1/2 in 11/16 in 3/4 in 7/8 in 4 rib 5 rib 6 rib 8 rib 10 rib 12 rib 12 rib K section

Belt Tension Gauge Part No. Click-type Burroughs 3822524 3822524 3822524 ST-1138 3822524 ST-1138 3822524 ST-1138 3822524 ST-1138 3822524 ST-1138 3822524 ST-1138 3822525 ST-1293 3822525 ST-1293 3822525 3823138 3822525 3823138 3822525 3823138

Belt Tension New N lbf 620 140 620 140 620 140 620 140 620 140 620 140 620 140 670 150 710 160 890 200 1110 250 1330 300 1330 300

Belt Tension Range Used* N lbf 270 to 490 60 to 110 270 to 490 60 to 110 270 to 490 60 to 110 270 to 490 60 to 110 270 to 490 60 to 110 270 to 490 60 to 110 270 to 490 60 to 110 270 to 530 60 to 120 290 to 580 65 to 130 360 to 710 80 to 160 440 to 890 100 to 200 530 to 1070 120 to 240 890 to 1070 200 to 240

NOTE: This chart does not apply to automatic belt tensioners. * A belt is considered used if it has been in service for ten minutes or longer. * If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.


Capscrew Markings and Torque Values Page V-141

Capscrew Markings and Torque Values General Information CAUTION When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using the wrong capscrews can result in engine damage. Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew. The following examples indicate how capscrews are identified:

NOTES: 1. Always use the torque values listed in the following tables when specific torque values are not available. 2. Do not use the torque values in place of those specified in other sections of this manual. 3. The torque values in the table are based on the use of lubricated threads. 4. When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb.

Capscrew Markings and Torque Values - Metric

Body Size Diameter mm 6 7 8 10 12 14 16 18 20

Torque Cast Iron Aluminum N•m ft-lb N•m ft-lb 9 5 7 4 14 9 11 7 23 17 18 14 45 33 30 25 80 60 55 40 125 90 90 65 195 140 140 100 280 200 180 135 400 290 — —

Torque Cast Iron Aluminum N•m ft-lb N•m ft-lb 13 10 7 4 18 14 11 7 33 25 18 14 65 50 30 25 115 85 55 40 180 133 90 65 280 200 140 100 390 285 180 135 550 400 — —

Capscrew Markings and Torque Values - U.S. Customary

Torque Cast Iron Aluminum N•m ft-lb N•m ft-lb 14 9 7 4 23 18 11 7 40 29 18 14 70 50 30 25 125 95 55 40 195 145 90 65 290 210 140 100 400 290 180 135 — — — —

Capscrew Markings and Torque Values Page V-142

Capscrew Body Size 1/4 - 20 1/4 - 28 5/16 - 18 5/16 - 24 3/8 - 16 3/8 - 24 7/16 - 14 7/16 - 20 1/2 - 13 1/2 - 20 9/16 - 12 9/16 - 18 5/8 - 11 5/8 - 18 3/4 - 10 3/4 - 16 7/8 - 9 7/8 - 14 1-8 1 - 14

Cast Iron N•m ft-lb 9 7 12 9 20 15 23 17 40 30 40 30 60 45 65 50 95 70 100 75 135 100 150 110 180 135 210 155 325 240 365 270 490 360 530 390 720 530 800 590


Aluminum N•m ft-lb 8 6 9 7 16 12 19 14 25 20 35 25 45 35 55 40 75 55 80 60 110 80 115 85 150 110 160 120 255 190 285 210 380 280 420 310 570 420 650 480

Cast Iron N•m ft-lb 15 11 18 13 30 22 33 24 55 40 60 45 90 65 95 70 130 95 150 110 190 140 210 155 255 190 290 215 460 340 515 380 745 550 825 610 1100 820 1200 890

Aluminum N•m ft-lb 8 6 9 7 16 12 19 14 25 20 35 25 45 35 55 40 75 55 80 60 110 80 115 85 150 110 160 120 255 190 285 210 380 280 420 310 570 420 650 480


Fraction, Decimal, Millimeter Conversions Page V-143

Fraction, Decimal, Millimeter Conversions Conversion Chart Fraction 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2

inch 0.0156 0.0313 0.0469 0.0625 0.0781 0.0938 0.1094 0.1250 0.1406 0.1563 0.1719 0.1875 0.2031 0.2188 0.2344 0.2500 0.2656 0.2813 0.2969 0.3125 0.3281 0.3438 0.3594 0.3750 0.3906 0.4063 0.4219 0.4375 0.4531 0.4688 0.4844 0.5000

Conversion Factor: 1 inch = 25.4 mm

mm 0.397 0.794 1.191 1.588 1.984 2.381 2.778 3.175 3.572 3.969 4.366 4.763 5.159 5.556 5.953 6.350 6.747 7.144 7.541 7.938 8.334 8.731 9.128 9.525 9.922 10.319 10.716 11.113 11.509 11.906 12.303 12.700

Fraction 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1

inch 0.5156 0.5313 0.5469 0.5625 0.5781 0.5938 0.6094 0.6250 0.6406 0.6563 0.6719 0.6875 0.7031 0.7188 0.7344 0.7500 0.7656 0.7813 0.7969 0.8125 0.8281 0.8438 0.8594 0.8750 0.8906 0.9063 0.9219 0.9375 0.9531 0.9688 0.9844 1.0000

mm 13.097 13.494 13.891 14.288 14.684 15.081 15.478 15.875 16.272 16.669 17.066 17.463 17.859 18.256 18.653 19.050 19.447 19.844 20.241 20.638 21.034 21.431 21.828 22.225 22.622 23.019 23.416 23.813 24.209 24.606 25.003 25.400

Newton-Meter to Foot-Pound Conversions Page V-144


Newton-Meter to Foot-Pound Conversions Conversion Chart N•m ft-lb N•m ft-lb N•m 1 9 in-lb 55 41 155 5 44 in-lb 60 44 160 6 53 in-lb 65 48 165 7 62 in-lb 70 52 170 8 71 in-lb 75 55 175 9 80 in-lb 80 59 180 10 89 in-lb 85 63 185 11 97 in-lb 90 66 190 12 106 in-lb 95 70 195 14 124 in-lb 100 74 200 15 133 in-lb 105 77 205 16 142 in-lb 110 81 210 18 159 in-lb 115 85 215 20 15 ft-lb 120 89 220 25 18 125 92 225 30 22 130 96 230 35 26 135 100 235 40 30 140 103 240 45 33 145 107 245 50 37 150 111 250 NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.

ft-lb 114 118 122 125 129 133 136 140 144 148 151 155 159 162 165 170 173 177 180 184


Pipe Plug Torque Values Page V-145

Pipe Plug Torque Values Torque Table Thread

Size Actual Thread O.D.

in 1/16 1/8 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2

in 0.32 0.41 0.54 0.68 0.85 1.05 1.32 1.66 1.90

Torque In Aluminum Components N•m 5 15 20 25 35 45 60 75 85

ft-lb 45 in-lb 10 15 20 25 35 45 55 65

Torque In Cast Iron or Steel Components N•m ft-lb 15 10 20 15 25 20 35 25 55 40 75 55 95 70 115 85 135 100

Tap-Drill Chart - U.S. Customary and Metric Page V-146


Tap-Drill Chart - U.S. Customary and Metric General Information NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size for approximately 60% and 75% of full thread depth. Generally, it is recommended that drill sizes be selected in the 60% range as these sizes will provide about 90% of the potential holding power. Drill sizes in the 75% range are recommended for shallow hole tapping (less than 1 1/2 times the hole diameter) in soft metals and mild steel.


Weights and Measures - Conversion Factors Page V-147

Weights and Measures - Conversion Factors Conversion Chart

Quantity

U.S. Customary Unit Name sq. inch

Abbreviation in2

Fuel Performance Force Length Power

Velocity Volume: liquid displacement

Abbreviation mm2

645.16

0.001550

sq. centimeters

6.452

0.155

sq. foot

sq. meter

m2

0.0929

10.764

pounds per horsepower hour miles per gallon gallons per mile pounds force inch foot horsepower pounds force per sq. inch inches of mercury inches of water

lb/hp-hr

g/kW-hr

608.277

0.001645

mpg gpm lbf in ft hp psi

grams per kilowatt hour kilometers per liter liters per kilometer Newton millimeters millimeters kilowatt kilopascal

km/l l/km N mm mm kW kPa

0.4251 2.352 4.4482 25.40 304.801 0.746 6.8948

2.352 0.4251 0.224809 0.039370 0.00328 1.341 0.145037

in Hg in H2O

kilopascal kilopascal

kPa kPa

3.3769 0.2488

0.29613 4.019299

mm Hg

25.40

0.039370

mm H2O

25.40

0.039370

kPa mm Hg

100.001 750.06

0.00999 0.001333

°C N•m

(°F-32) ÷1.8 (1.8 x °C) +32 1.35582 0.737562

inches of mercury in Hg

Torque

Unit Name sq. millimeters

ft2

inches of water

in H2O

bars bars

bars bars

fahrenheit pound force per foot pound force per inch miles/hour gallon (U.S.) gallon (Imp*) cubic inch

°F ft-lb

millimeters of mercury millimeters of water kilopascals millimeters of mercury centigrade Newton-meter

in-lb

Newton-meter

N•m

0.113

8.850756

mph gal. gal.

kilometers/hour liter liter liter

kph l l l

1.6093 3.7853 4.546 0.01639

0.6214 0.264179 0.219976 61.02545

cubic inch

in3 lb BTU

cubic centimeter

16.387

0.06102

kilograms joules

cm3 kg J

0.4536 1054.5

2.204623 0.000948

kilowatt-hour

kW-hr

0.000293

3414

kilowatt-hour

kW-hr

0.746

1.341

Pressure

Temperature

Metric

From Metric To U.S. Customary Multiply By

cm2

Area Fuel Consumption

From U.S. Customary To Metric Multiply By

in3

Weight (mass) pounds (avoir.) British Thermal Unit British Thermal BTU Work Unit horsepower hours hp-hr

Weights and Measures - Conversion Factors Page V-148


Notes

Index Page X-1 Accessory Drive ...........................................................................................9-3 Assemble....................................................................................................9-8 with Mechanically Actuated Injector........................................................9-8 Disassemble...............................................................................................9-4 with Mechanically Actuated Injector........................................................9-4 Finishing Steps.........................................................................................9-11 with Mechanically Actuated Injector......................................................9-11 Initial Check................................................................................................9-3 with Mechanically Actuated Injector........................................................9-3 Inspect for Reuse........................................................................................9-6 with Mechanically Actuated Injector........................................................9-6 Install........................................................................................................9-10 with Mechanically Actuated Injector......................................................9-10 Preparatory Steps.......................................................................................9-3 with Mechanically Actuated Injector........................................................9-3 Remove......................................................................................................9-3 with Mechanically Actuated Injector........................................................9-3 Accessory Drive Bushing ...........................................................................9-11 Inspect for Reuse......................................................................................9-12 Mechanically Actuated Injector..............................................................9-12 Install........................................................................................................9-13 Mechanically Actuated Injector..............................................................9-13 Remove....................................................................................................9-11 Mechanically Actuated Injector..............................................................9-11 Accessory Drive Cover ...............................................................................9-79 Install........................................................................................................9-79 Accessory Drive Gear and Shaft ................................................................9-14 Assemble..................................................................................................9-15 with Mechanically Actuated Injector......................................................9-15 Disassemble.............................................................................................9-14 with Mechanically Actuated Injector......................................................9-14 Inspect for Reuse......................................................................................9-14 with Mechanically Actuated Injector......................................................9-14 Accessory Drive Pulley ..............................................................................9-16 Clean and Inspect for Reuse.....................................................................9-17 Install........................................................................................................9-18 POSE...................................................................................................9-19 Remove....................................................................................................9-16 Accessory Drive Pulley Wear Sleeve .........................................................9-19 Clean and Inspect for Reuse.....................................................................9-20 Install........................................................................................................9-21 Remove....................................................................................................9-19 Additional Service Literature .......................................................................L-1 General Information....................................................................................L-1 Aftercooler ..................................................................................................10-3 Exploded View..........................................................................................10-4 General Information..................................................................................10-3 Aftercooler Assembly ...............................................................................10-12 Assemble................................................................................................10-25 with Mechanically Actuated Injector.....................................................10-25 with Electronically Actuated Injector....................................................10-32 Clean and Inspect for Reuse...................................................................10-24 Disassemble...........................................................................................10-19 with Mechanically Actuated Injector.....................................................10-19 with Electronically Actuated Injector....................................................10-22 Finishing Steps.......................................................................................10-43 MAI.....................................................................................................10-43 with Electronically Actuated Injector....................................................10-44 Install......................................................................................................10-33 with Mechanically Actuated Injector.....................................................10-33 with Electronically Actuated Injector....................................................10-41 Preparatory Steps...................................................................................10-12 MAI.....................................................................................................10-12 with Electronically Actuated Injector....................................................10-13 Pressure Test..........................................................................................10-23 with Mechanically Actuated Injector.....................................................10-23 Remove..................................................................................................10-13 with Mechanically Actuated Injector.....................................................10-13 with Electronically Actuated Injector....................................................10-18 Aftercooler Assembly (Center-Mount) .....................................................10-45 Assemble................................................................................................10-49 with Mechanically Actuated Injector.....................................................10-49 Clean and Inspect for Reuse...................................................................10-48 with Mechanically Actuated Injector.....................................................10-48 Disassemble...........................................................................................10-46 with Mechanically Actuated Injector.....................................................10-46 Finishing Steps.......................................................................................10-53 with Mechanically Actuated Injector.....................................................10-53 Install......................................................................................................10-51 with Mechanically Actuated Injector.....................................................10-51 Preparatory Steps...................................................................................10-45 with Mechanically Actuated Injector.....................................................10-45 Pressure Test..........................................................................................10-48 Remove..................................................................................................10-45 with Mechanically Actuated Injector.....................................................10-45 Aftercooler Assembly (Outboard) ............................................................10-53 Inspect for Reuse....................................................................................10-53

Install......................................................................................................10-54 Remove..................................................................................................10-53 Aftercooler Element .................................................................................10-56 Finishing Steps.......................................................................................10-61 Inspect for Reuse....................................................................................10-58 Standard.............................................................................................10-58 LTA.....................................................................................................10-58 Center-Mount......................................................................................10-59 Install......................................................................................................10-59 Standard.............................................................................................10-59 LTA.....................................................................................................10-60 Center-Mount......................................................................................10-61 Preparatory Steps...................................................................................10-56 Remove..................................................................................................10-56 Standard.............................................................................................10-56 LTA.....................................................................................................10-57 Center-Mount......................................................................................10-58 Aftercooler Housing (Center Mount) ......................................................10-162 Modify...................................................................................................10-162 KTA50...............................................................................................10-162 Aftercooler Water Inlet Tube ..................................................................10-167 Clean and Inspect for Reuse.................................................................10-167 Center-Mount....................................................................................10-167 Aftercooler Water Outlet Tube ...............................................................10-167 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 Compressor ........................................................................................12-13 Finishing Steps.......................................................................................12-18 with Mechanically Actuated Injector.....................................................12-18 Install......................................................................................................12-16 with Mechanically Actuated Injector.....................................................12-16 Preparatory Steps...................................................................................12-13 with Mechanically Actuated Injector.....................................................12-13 Remove..................................................................................................12-14 with Mechanically Actuated Injector.....................................................12-14 Air Compressor (Oil Carryover) ...............................................................12-22 Inspect for Reuse....................................................................................12-22 Air Compressor Carbon Buildup ................................................................12-4 Inspect......................................................................................................12-4 Air Compressor Pin Bore Wear ..................................................................12-6 Initial Check..............................................................................................12-6 Air Compressor Unloader and Valve Assembly ........................................12-9 Assemble................................................................................................12-11 Holset® QE230, QE296, and QE338 A/C Model...................................12-11 Clean and Inspect for Reuse...................................................................12-10 Disassemble...........................................................................................12-10 Holset® QE230, QE296, and QE338 A/C Model...................................12-10 Finishing Steps.......................................................................................12-13 Initial Check..............................................................................................12-9 Air Connection Pipe (Turbocharger to Turbocharger) ............................10-67 Clean......................................................................................................10-67 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 Governor (Air Compressor Pumps Continuously) .............................12-19 Initial Check............................................................................................12-19 Air Governor (Air Compressor Will Not Pump) ........................................12-18 Initial Check............................................................................................12-18 Air Intake Restriction ...............................................................................10-71 Measure..................................................................................................10-71 Air Intake System .....................................................................................V-129 Specifications.........................................................................................V-129 Air Leaks, Air Intake and Exhaust Systems ............................................10-69 Inspect for Reuse....................................................................................10-69 Air Leaks, Compressed Air System .........................................................12-21 Initial Check............................................................................................12-21 Air Starting Motor .....................................................................................12-23 General Information................................................................................12-23 Alternator ....................................................................................................13-3 Finishing Steps.........................................................................................13-6 Inspect for Reuse......................................................................................13-4 Install........................................................................................................13-4

Index Page X-2 Preparatory Steps.....................................................................................13-3 Remove....................................................................................................13-3 Alternator Adjusting Link .........................................................................13-22 Adjust.....................................................................................................13-23 Clean and Inspect for Reuse...................................................................13-22 Inspect for Reuse....................................................................................13-22 Alternator Drive Pulley ...............................................................................9-21 Clean and Inspect for Reuse.....................................................................9-22 Finishing Steps.........................................................................................9-23 Install........................................................................................................9-22 Preparatory Steps.....................................................................................9-21 Remove....................................................................................................9-21 Alternator Pulley .......................................................................................13-10 Finishing Steps.......................................................................................13-11 Install......................................................................................................13-11 Preparatory Steps...................................................................................13-10 Remove..................................................................................................13-10 Alternator Bracket ......................................................................................13-7 Clean and Inspect for Reuse.....................................................................13-7 Finishing Steps.........................................................................................13-8 Install........................................................................................................13-8 Preparatory Steps.....................................................................................13-7 Remove....................................................................................................13-7 Batteries ...................................................................................................13-12 Inspect....................................................................................................13-12 Battery Cables and Connections .............................................................13-13 Initial Check............................................................................................13-13 Bearing, Generator .....................................................................................21-8 Clean......................................................................................................21-18 Internal...............................................................................................21-18 External..............................................................................................21-18 Clean and Inspect for Reuse...................................................................21-12 Finishing Steps.......................................................................................21-16 Install......................................................................................................21-13 Lubrication for the Power Components....................................................21-17 Preparatory Steps.....................................................................................21-8 Remove....................................................................................................21-9 Bellows .....................................................................................................11-36 Finishing Steps.......................................................................................11-37 Install......................................................................................................11-36 Preparatory Steps...................................................................................11-36 Remove..................................................................................................11-36 Belt Guard ....................................................................................................8-3 Clean and Inspect for Reuse.......................................................................8-4 Install..........................................................................................................8-4 Remove......................................................................................................8-3 Capscrew ....................................................................................................17-1 Magnetic Crack Inspect.............................................................................17-1 Capscrew Markings and Torque Values ..................................................V-141 Capscrew Markings and Torque Values - Metric......................................V-141 Capscrew Markings and Torque Values - U.S. Customary.......................V-141 General Information................................................................................V-141 Component Manufacturers' Addresses ......................................................M-1 Air Compressors........................................................................................M-1 Air Cylinders..............................................................................................M-1 Air Heaters................................................................................................M-1 Air Starting Motors.....................................................................................M-1 Alternators.................................................................................................M-1 Auxiliary Brakes.........................................................................................M-1 Belts..........................................................................................................M-1 Catalytic Converters...................................................................................M-1 Coolant Level Switches..............................................................................M-1 Clutches....................................................................................................M-1 Coolant Heaters.........................................................................................M-2 Drive Plates...............................................................................................M-2 Electric Starting Motors..............................................................................M-2 Electronic Switches....................................................................................M-2 Engine Protection Controls.........................................................................M-2 Fan Clutches.............................................................................................M-2 Fans..........................................................................................................M-2 Fault Lamps...............................................................................................M-2 Filters........................................................................................................M-2 Flexplates..................................................................................................M-2 Fuel Coolers..............................................................................................M-2 Fuel Pumps...............................................................................................M-2 Fuel Warmers............................................................................................M-2 Gauges......................................................................................................M-3 Governors..................................................................................................M-3 Heat Sleeves.............................................................................................M-3 Hydraulic and Power Steering Pumps........................................................M-3 In-Line Connectors.....................................................................................M-3 Oil Heaters................................................................................................M-3 Prelubrication Systems..............................................................................M-3 Radiators...................................................................................................M-3 Throttle Assemblies...................................................................................M-3 Torque Converters.....................................................................................M-3 Compressed Air System ..........................................................................V-132

Specifications.........................................................................................V-132 Coolant Bypass Tube .................................................................................8-12 Clean and Inspect for Reuse.....................................................................8-14 Industrial...............................................................................................8-14 Marine Applications..............................................................................8-14 Finishing Steps.........................................................................................8-16 Install........................................................................................................8-15 Industrial...............................................................................................8-15 Marine Applications..............................................................................8-15 Preparatory Steps.....................................................................................8-12 Remove....................................................................................................8-12 Industrial...............................................................................................8-12 Marine Applications..............................................................................8-13 Coolant Filter ..............................................................................................8-17 Install........................................................................................................8-17 Remove....................................................................................................8-17 Coolant Recommendations and Specifications ......................................V-137 Cooling System Sealing Additives...........................................................V-139 Cooling System Soluble Oils...................................................................V-139 Fully Formulated Coolant/Antifreeze.......................................................V-137 Coolant Temperature Gauge ......................................................................8-11 Inspect for Reuse......................................................................................8-11 Coolant Thermostat ....................................................................................8-18 Finishing Steps.........................................................................................8-32 General Information..................................................................................8-18 Inspect for Reuse......................................................................................8-23 Install........................................................................................................8-27 Conventional Aftercooling.....................................................................8-27 LTA......................................................................................................8-28 with Electronically Actuated Injector......................................................8-29 Gas Compression.................................................................................8-30 Leak Test..................................................................................................8-24 Conventional Aftercooling.....................................................................8-25 LTA......................................................................................................8-26 Preparatory Steps.....................................................................................8-19 Remove....................................................................................................8-19 Conventional Aftercooling.....................................................................8-19 LTA......................................................................................................8-20 with Electronically Actuated Injector......................................................8-22 Test..........................................................................................................8-23 Coolant Thermostat Housing Support .......................................................8-32 Clean and Inspect for Reuse.....................................................................8-37 LTA......................................................................................................8-37 Finishing Steps.........................................................................................8-41 General Information..................................................................................8-32 Install........................................................................................................8-37 LTA......................................................................................................8-37 Preparatory Steps.....................................................................................8-33 Remove....................................................................................................8-33 Cooling System ..........................................................................................8-42 Drain.........................................................................................................8-42 Fill............................................................................................................8-44 Flush........................................................................................................8-42 Cooling System ........................................................................................V-127 Specifications.........................................................................................V-127 with Mechanically Actuated Injector....................................................V-127 with Electronically Actuated Injector....................................................V-127 Cooling System Diagnostics ......................................................................8-54 Inspect......................................................................................................8-54 Cooling System - Air or Combustion Gas Test .........................................8-46 Test..........................................................................................................8-46 Overflow Method...................................................................................8-46 Sight Glass Method...............................................................................8-47 Air Compressor.....................................................................................8-48 Combustion Gas Leak...........................................................................8-49 Cylinder Head and Cylinder Liner..........................................................8-52 Cummins Customized Parts Catalog ...........................................................L-3 General Information....................................................................................L-3 Ordering the Customized Parts Catalog......................................................L-3 Ordering by Telephone...........................................................................L-3 Ordering On-Line....................................................................................L-3 Cummins/Fleetguard® Filter Specifications ............................................V-133 Specifications.........................................................................................V-133 Cup Plug .....................................................................................................17-2 Clean and Inspect for Reuse.....................................................................17-2 Install........................................................................................................17-3 Remove....................................................................................................17-2 Drive Belt Tension ...................................................................................V-140 Tension Chart.........................................................................................V-140 Drive Belt, Alternator .................................................................................13-9 Finishing Steps.......................................................................................13-10 Inspect for Reuse......................................................................................13-9 Install........................................................................................................13-9 Preparatory Steps.....................................................................................13-9 Remove....................................................................................................13-9 Drive Belt, Cooling Fan ................................................................................8-5 Adjust.......................................................................................................8-11

Index Page X-3 Inspect for Reuse........................................................................................8-7 Install..........................................................................................................8-8 Remove......................................................................................................8-5 Dynamometer Worksheet ...........................................................................14-4 Worksheet................................................................................................14-4 ECM Cooling Plate ....................................................................................8-169 Assemble................................................................................................8-173 Clean and Inspect for Reuse...................................................................8-170 Disassemble...........................................................................................8-169 Finishing Steps.......................................................................................8-174 Install......................................................................................................8-174 Preparatory Steps...................................................................................8-169 Remove..................................................................................................8-169 ECM Cooling Plate Lines ..........................................................................8-175 Finishing Steps.......................................................................................8-178 Inspect for Reuse....................................................................................8-176 Install......................................................................................................8-177 Preparatory Steps...................................................................................8-175 Remove..................................................................................................8-175 Electrical System .....................................................................................V-131 Batteries (Specific Gravity)......................................................................V-131 Specifications.........................................................................................V-131 Engine Compression ................................................................................14-52 Finishing Steps.......................................................................................14-56 Preparatory Steps...................................................................................14-52 Pressure Differential Test........................................................................14-54 Setup......................................................................................................14-53 Engine Lifting Brackets ..............................................................................16-3 Clean and Inspect for Reuse.....................................................................16-3 Install........................................................................................................16-3 Remove....................................................................................................16-3 Engine Mounts ..........................................................................................16-33 Clean and Inspect for Reuse...................................................................16-33 Engine Run-in (Engine Dynamometer) .....................................................14-25 General Information................................................................................14-25 Run-In Instructions..................................................................................14-25 with Mechanically Actuated Injector.....................................................14-25 with Electronically Actuated Injector....................................................14-43 Engine Run-in (Without Dynamometer) ...................................................14-11 Run-In Instructions..................................................................................14-11 Engine Support Bracket, Front ..................................................................16-5 Finishing Steps.........................................................................................16-9 Inspect for Reuse......................................................................................16-7 Install........................................................................................................16-8 Preparatory Steps.....................................................................................16-5 Remove....................................................................................................16-5 Engine Testing (Chassis Dynamometer) ...................................................14-5 Test..........................................................................................................14-5 Engine Speed (rpm)..............................................................................14-5 Fuel Pressure.......................................................................................14-6 Fuel Rate..............................................................................................14-6 Fuel Inlet Restriction.............................................................................14-6 Fuel Drain Line Restriction....................................................................14-6 Intake Manifold Pressure......................................................................14-7 Intake Manifold Air Temperature Control - Chassis Dynamometer test.....147 Intake Air Restriction.............................................................................14-8 Intake Manifold Air Temperature Control - Chassis Dynamometer test.....148 Engine Blowby......................................................................................14-8 Lubricating Oil Pressure......................................................................14-10 Air Compressor...................................................................................14-11 Starting Motor.....................................................................................14-11 Engine Testing (Engine Dynamometer) ...................................................14-12 General Information................................................................................14-12 Install......................................................................................................14-12 Coolant Plumbing...............................................................................14-12 Intake Air Temperature Control...........................................................14-13 LTA.....................................................................................................14-13 Test....................................................................................................14-13 Engine Throttle Control.......................................................................14-15 Test........................................................................................................14-19 Engine Speed (rpm)............................................................................14-20 Fuel Drain Line Restriction..................................................................14-20 Intake Air Restriction...........................................................................14-20 Exhaust Air Restriction........................................................................14-21 Engine Blowby....................................................................................14-21 Lubricating Oil Pressure......................................................................14-23 Engine Coolant Pressure.....................................................................14-23 Air Compressor...................................................................................14-24 Starting Motor.....................................................................................14-24 Exhaust Connection Pipe ...........................................................................11-2 Clean and Inspect for Reuse.....................................................................11-2 Finishing Steps.........................................................................................11-3 Install........................................................................................................11-3 Preparatory Steps.....................................................................................11-2 Remove....................................................................................................11-2

Exhaust Manifold (Wet) Water Connections ............................................11-33 Clean and Inspect for Reuse...................................................................11-34 MAI.....................................................................................................11-34 Finishing Steps.......................................................................................11-35 MAI.....................................................................................................11-35 Install......................................................................................................11-34 MAI.....................................................................................................11-34 Preparatory Steps...................................................................................11-33 Remove..................................................................................................11-33 MAI.....................................................................................................11-33 Exhaust Manifold, Dry ................................................................................11-4 Assemble..................................................................................................11-9 Clean and Inspect for Reuse.....................................................................11-7 Disassemble.............................................................................................11-7 Finishing Steps.......................................................................................11-23 General Information..................................................................................11-4 Install......................................................................................................11-10 KT38 and KTA38 with Dry Exhaust Manifolds......................................11-10 KTTA38 with Dry Exhaust Manifolds....................................................11-11 KT38 and KTA38 with Dry Exhaust Manifolds......................................11-11 KTA50 Dry Exhaust Manifolds.............................................................11-13 KTTA50 Dry Exhaust, Log Type Manifolds..........................................11-14 K50 Dry Exhaust, Pulse Type Manifolds..............................................11-15 K38 and K50 Bellows Manifold............................................................11-20 Preparatory Steps.....................................................................................11-5 Remove....................................................................................................11-6 Exhaust Manifold, Wet .............................................................................11-24 Clean and Inspect for Reuse...................................................................11-26 EAI.....................................................................................................11-26 Finishing Steps.......................................................................................11-31 EAI.....................................................................................................11-31 Install......................................................................................................11-28 EAI.....................................................................................................11-28 Preparatory Steps...................................................................................11-24 EAI.....................................................................................................11-24 Remove..................................................................................................11-25 EAI.....................................................................................................11-25 Exhaust Restriction ..................................................................................11-31 Measure..................................................................................................11-31 Exhaust System .......................................................................................V-130 Specifications.........................................................................................V-130 Expansion Tank ..........................................................................................8-75 Clean and Inspect for Reuse.....................................................................8-77 Finishing Steps.........................................................................................8-80 Install........................................................................................................8-78 Preparatory Steps.....................................................................................8-75 Remove....................................................................................................8-75 Fan Clutch, Viscous ...................................................................................8-55 Measure...................................................................................................8-55 Fan, Cooling ...............................................................................................8-70 Finishing Steps.........................................................................................8-71 Install........................................................................................................8-71 Preparatory Steps.....................................................................................8-70 Remove....................................................................................................8-70 Fan Drive Idler Arm Assembly ...................................................................8-56 Assemble..................................................................................................8-60 Clean........................................................................................................8-59 Disassemble.............................................................................................8-58 Finishing Steps.........................................................................................8-62 Install........................................................................................................8-62 Preparatory Steps.....................................................................................8-56 Remove....................................................................................................8-57 Fan Hub Bracket .........................................................................................8-62 Clean and Inspect for Reuse.....................................................................8-63 General Information..................................................................................8-62 Install........................................................................................................8-64 Remove....................................................................................................8-63 Fan Hub, Belt Driven ..................................................................................8-64 Assemble..................................................................................................8-67 Clean and Inspect for Reuse.....................................................................8-65 Disassemble.............................................................................................8-66 Finishing Steps.........................................................................................8-70 Install........................................................................................................8-69 Preparatory Steps.....................................................................................8-64 Remove....................................................................................................8-65 Fan Shroud Assembly ................................................................................8-70 Inspect for Reuse......................................................................................8-70 Flexible Hose ..............................................................................................17-3 Inspect for Reuse......................................................................................17-3 Flexplate ...................................................................................................16-10 Clean and Inspect for Reuse...................................................................16-10 Finishing Steps.......................................................................................16-13 Install......................................................................................................16-12 Measure..................................................................................................16-12 Face Runout.......................................................................................16-12 Preparatory Steps...................................................................................16-10 Remove..................................................................................................16-10

Index Page X-4 Flywheel ....................................................................................................16-14 Clean and Inspect for Reuse...................................................................16-15 Finishing Steps.......................................................................................16-18 Install......................................................................................................16-16 Preparatory Steps...................................................................................16-14 Remove..................................................................................................16-14 Flywheel Housing .....................................................................................16-19 Clean and Inspect for Reuse...................................................................16-21 Finishing Steps.......................................................................................16-31 Install......................................................................................................16-27 Measure..................................................................................................16-28 Alignment...........................................................................................16-28 Preparatory Steps...................................................................................16-19 Redowel..................................................................................................16-21 Remove..................................................................................................16-20 Flywheel Ring Gear ..................................................................................16-32 Assemble................................................................................................16-32 Fraction, Decimal, Millimeter Conversions .............................................V-143 Conversion Chart....................................................................................V-143 Fuel Pump Drive .........................................................................................9-23 Assemble..................................................................................................9-30 with Mechanically Actuated Injector......................................................9-30 with Electronically Actuated Injector......................................................9-33 Clean and Inspect for Reuse.....................................................................9-27 with Mechanically Actuated Injector......................................................9-27 with Electronically Actuated Injector......................................................9-28 Disassemble.............................................................................................9-25 with Electronically Actuated Injector......................................................9-25 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 Fuel Recommendations and Specifications ............................................V-135 General Information................................................................................V-135 Fuel System .............................................................................................V-125 Specifications.........................................................................................V-125 with Electronically Actuated Injector....................................................V-125 with Mechanically Actuated Injector....................................................V-125 General Engine .........................................................................................V-123 General Specifications............................................................................V-123 Generator (Alternator) Exciter Rotating Diodes ......................................21-18 Finishing Steps.......................................................................................21-22 Install......................................................................................................21-21 Preparatory Steps...................................................................................21-18 Remove..................................................................................................21-19 Generator (Alternator) Windings ..............................................................21-23 Clean......................................................................................................21-23 Finishing Steps.......................................................................................21-24 Preparatory Steps...................................................................................21-23 Generator Fuse Holder ...............................................................................21-1 Generator Rotor ........................................................................................21-30 Finishing Steps.......................................................................................21-36 Install......................................................................................................21-33 Preparatory Steps...................................................................................21-30 Remove..................................................................................................21-30 Generator, Main ..........................................................................................21-1 General Information..................................................................................21-1 Instrument Panel...................................................................................21-2 Heat Exchanger ..........................................................................................8-81 Assemble................................................................................................8-101 Tube Type..........................................................................................8-101 Plate Type..........................................................................................8-103 Box Type............................................................................................8-106 Clean........................................................................................................8-92 Tube Type............................................................................................8-92 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 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 Low-Temperature Aftercooler (LTA) Water Pump ...................................8-168 Maintenance Check................................................................................8-168 with Mechanically Actuated Injector.....................................................8-168 Lubricating Oil Recommendations and Specifications ...........................V-136 General Information................................................................................V-136 Lubricating Oil System ............................................................................V-126 Specifications.........................................................................................V-126 Newton-Meter to Foot-Pound Conversions .............................................V-144 Conversion Chart....................................................................................V-144 Permanent Magnet Generator ..................................................................21-25 Finishing Steps.......................................................................................21-29 Install......................................................................................................21-27 Preparatory Steps...................................................................................21-25 Remove..................................................................................................21-25 Pipe Plug ....................................................................................................17-4 Clean and Inspect for Reuse.....................................................................17-4 Install........................................................................................................17-4 Remove....................................................................................................17-4 Pipe Plug Torque Values .........................................................................V-145 Torque Table..........................................................................................V-145 Radiator ......................................................................................................8-72 Test..........................................................................................................8-72 Radiator Hoses ...........................................................................................8-74 Inspect for Reuse......................................................................................8-74 Radiator Pressure Cap ...............................................................................8-74 Inspect for Reuse......................................................................................8-74 Pressure Test...........................................................................................8-75 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 Sea Water Hoses ......................................................................................8-168 Inspect....................................................................................................8-168 Sea Water Pump .......................................................................................8-121 Assemble................................................................................................8-128 Gear Driven........................................................................................8-128

Index Page X-5 Spline Driven......................................................................................8-132 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 with Mechanically Actuated Injector.....................................................8-138 with Electronically Actuated Injector....................................................8-138 Finishing Steps.......................................................................................8-140 Install......................................................................................................8-139 with Mechanically Actuated Injector.....................................................8-139 with Electronically Actuated Injector....................................................8-140 Preparatory Steps...................................................................................8-136 Remove..................................................................................................8-137 with Mechanically Actuated Injector.....................................................8-137 with Electronically Actuated Injector....................................................8-137 Sea Water System Diagnostics ................................................................8-165 General Information................................................................................8-165 Inspect....................................................................................................8-165 Pressure Test..........................................................................................8-167 Test........................................................................................................8-166 Service Literature Ordering Location ..........................................................L-2 Contact Information....................................................................................L-2 Service Tools ...............................................................................................8-1 Cooling System...........................................................................................8-1 Service Tools ...............................................................................................9-1 Drive Units..................................................................................................9-1 Service Tools ..............................................................................................10-1 Air Intake System......................................................................................10-1 Service Tools ..............................................................................................11-1 Exhaust System Dataplate........................................................................11-1 Service Tools ..............................................................................................12-1 Compressed Air System............................................................................12-1 Service Tools ..............................................................................................13-1 Electrical Equipment.................................................................................13-1 Service Tools ..............................................................................................14-1 Engine Testing..........................................................................................14-1 Service Tools ..............................................................................................16-1 Mounting Adaptations...............................................................................16-1 Starter Magnetic Switch ...........................................................................13-14 Inspect for Reuse....................................................................................13-14 Starter Solenoid ........................................................................................13-17 Voltage Check.........................................................................................13-17 Starter Switch ...........................................................................................13-16 Test........................................................................................................13-16 Starting Motor ...........................................................................................13-20 Clean and Inspect for Reuse...................................................................13-20 Finishing Steps.......................................................................................13-21 Install......................................................................................................13-21 Preparatory Steps...................................................................................13-20 Remove..................................................................................................13-20 Straight Thread Plug ..................................................................................17-5 Clean and Inspect for Reuse.....................................................................17-5 Install........................................................................................................17-6 Remove....................................................................................................17-5 Supplemental Coolant Additive (SCA) .....................................................8-140 Maintenance Check................................................................................8-140 Tap-Drill Chart - U.S. Customary and Metric ...........................................V-146 General Information................................................................................V-146 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 Turbocharger Blade Damage .................................................................10-140 Inspect for Reuse..................................................................................10-140 Turbocharger Compressor Seal Leaks ..................................................10-141 Inspect..................................................................................................10-141 Turbocharger Coolant Hoses .................................................................10-144 Finishing Steps.....................................................................................10-148 EAI....................................................................................................10-148 Inspect for Reuse..................................................................................10-146 EAI....................................................................................................10-146 Install....................................................................................................10-146 with Electronically Actuated Injector..................................................10-146 Marine Applications...........................................................................10-148 Preparatory Steps.................................................................................10-144 EAI....................................................................................................10-144 Remove................................................................................................10-144 with Electronically Actuated Injector..................................................10-144 Marine Applications...........................................................................10-145 Turbocharger Oil Drain Line ..................................................................10-148 Clean and Inspect for Reuse.................................................................10-150 Finishing Steps.....................................................................................10-153 with Electronically Actuated Injector..................................................10-153 Install....................................................................................................10-151 with Electronically Actuated Injector..................................................10-151 Preparatory Steps.................................................................................10-148 with Electronically Actuated Injector..................................................10-148 Remove................................................................................................10-149 Single Stage.....................................................................................10-149 Two Stage.........................................................................................10-149 Turbocharger Oil Supply Line ................................................................10-153 Clean and Inspect for Reuse.................................................................10-157 Finishing Steps.....................................................................................10-161 with Electronically Actuated Injector..................................................10-161 Install....................................................................................................10-158 Industrial Applications.......................................................................10-158 Two Stage.........................................................................................10-158 Low Pressure Turbocharger..............................................................10-159 Marine Applications...........................................................................10-160 Preparatory Steps.................................................................................10-153 with Electronically Actuated Injector..................................................10-153 Remove................................................................................................10-154 Industrial Applications.......................................................................10-154 Two Stage.........................................................................................10-155 Low Pressure Turbocharger..............................................................10-155 Marine Applications...........................................................................10-156 Turbocharger Radial Bearing Clearance ................................................10-161 Finishing Steps.....................................................................................10-162 Measure................................................................................................10-161 Preparatory Steps.................................................................................10-161 Turbocharger, Water-Cooled ..................................................................10-130 Finishing Steps.....................................................................................10-137 Install....................................................................................................10-134 Left Bank..........................................................................................10-134 Right Bank........................................................................................10-136 Preparatory Steps.................................................................................10-130 Remove................................................................................................10-131 Left Bank..........................................................................................10-131 Right Bank........................................................................................10-132 Setup....................................................................................................10-133 Water Manifold .........................................................................................8-141 Clean and Inspect for Reuse...................................................................8-141 Water Pump ..............................................................................................8-142 Assemble................................................................................................8-154 with Mechanically Actuated Injector.....................................................8-154 Clean and Inspect for Reuse...................................................................8-148 with Mechanically Actuated Injector.....................................................8-148 with Electronically Actuated Injector....................................................8-149 Disassemble...........................................................................................8-149 with Mechanically Actuated Injector.....................................................8-149 Finishing Steps.......................................................................................8-164 with Mechanically Actuated Injector.....................................................8-164 with Electronically Actuated Injector....................................................8-165 General Information................................................................................8-142 with Mechanically Actuated Injector.....................................................8-142 Inspect....................................................................................................8-152 with Mechanically Actuated Injector.....................................................8-152 Install......................................................................................................8-160 with Mechanically Actuated Injector.....................................................8-160

Index Page X-6 with Electronically Actuated Injector....................................................8-162 Preparatory Steps...................................................................................8-144 with Mechanically Actuated Injector.....................................................8-144 with Electronically Actuated Injector....................................................8-144 Remove..................................................................................................8-145 with Mechanically Actuated Injector.....................................................8-145 with Electronically Actuated Injector....................................................8-145 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 Mechanically Actuated Injector..............................................................9-68 Water Pump Drive Gear and Shaft .............................................................9-70 Assemble..................................................................................................9-71 Mechanically Actuated Injector..............................................................9-71 Disassemble.............................................................................................9-70 Mechanically Actuated Injector..............................................................9-70 Inspect for Reuse......................................................................................9-70 Mechanically Actuated Injector..............................................................9-70 Water Pump Drive Pulley ...........................................................................9-71 Finishing Steps.........................................................................................9-72 Install........................................................................................................9-72 Preparatory Steps.....................................................................................9-71 Remove....................................................................................................9-71 Weights and Measures - Conversion Factors .........................................V-147 Conversion Chart....................................................................................V-147 Woodward Governor Drive .........................................................................9-72 Assemble..................................................................................................9-77 with Mechanically Actuated Injector......................................................9-77 Clean and Inspect for Reuse.....................................................................9-73 Clean for Rebuild......................................................................................9-75 with Mechanically Actuated Injector......................................................9-75 Disassemble.............................................................................................9-73 with Mechanically Actuated Injector......................................................9-73 General Information..................................................................................9-72 with Mechanically Actuated Injector......................................................9-72 Inspect......................................................................................................9-75 with Mechanically Actuated Injector......................................................9-75

281522_Cummins_CovV3.mpc:281522_Cummins_CovV3

3/28/08

7:07 AM

Page 1


Cummins Inc. Box 3005 Columbus, Indiana, U.S.A., 47202

Registered Office Cummins Ltd. 49 - 51 Gresham Road, Staines, Middlesex TW18 2BD, England Registration 573951 England Copyright© 2008 Cummins Inc.

Bulletin 4021528 Printed in U.S.A. 27-MARCH-2008

p174


4021528-vol3

Recommend Documents