Cummins K38,K50,QSK38,QSK50 Engine Service Repair Manual

Service Manual K38, K50, QSK38 and QSK50 Volume 3

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 0 8 ............................................................................................................................ 8 Drive Units — Group 0 9 .................................................................................................................................... 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 2 1 ................................................................................................................ 21 Service Literature .............................................................................................................................................. L Component Manufacturers............................................................................................................................... M Specifications ..................................................................................................................................................... V Back ................................................................................................................................................................... back

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 K38. K50, QSK38. and QSK50 Section 8 — Cooling System — Group 08 Page 8-a

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...................................................................................................................................................... 8-82 Install......................................................................................................................................................................8-62 Preparatory Steps.................................................................................................................................................. 8-56 Remove.................................................................................................................................................................. 8-57 Fan Hub Bracket .................................................................................................................................................... 8-62 Clean and Inspect for Reuse................................................................................................................................. 8-83 General Information............................................................................................................................................... 8-82 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 K38, K50, QSK38. and QSK50 Pag© 8-b Section 8 — Cooling System — Group 08 Tube Type. Plate Type. 8-101 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 Low-Temperature Aftercooler (LTA) Water Pump ............................................................................................ 8-168 Maintenance Check............................................................................................................................................. 8-168 with Mechanically Actuated Injector................................................................................................................. 8-168 Radiator ................................................................................................................................................................... 8-72 Test........................................................................................................................................................................ 8-72 Radiator Hoses ....................................................................................................................................................... 8-74 Inspect for Reuse................................................................................................................................................... 8-74 Radiator Pressure Cap .......................................................................................................................................... 8-74 Inspect for Reuse................................................................................................................................................... 8-74 Pressure Test......................................................................................................................................................... 8-75 Sea Water Hoses ..................................................................................................................................................8-168 Inspect..................................................................................................................................................................8-168 Sea Water Pump .................................................................................................................................................. 8-121 Assemble............................................................................................................................................................. 8-128 Gear Driven....................................................................................................................................................... 8-128 Spline Driven.....................................................................................................................................................8-132 Clean and Inspect for Reuse............................................................................................................................... 8-127 Gear Driven....................................................................................................................................................... 8-127 Spline Driven.....................................................................................................................................................8-128 Disassemble......................................................................................................................................................... 8-122 Gear Driven....................................................................................................................................................... 8-122 Spline Driven.....................................................................................................................................................8-125 Finishing Steps.................................................................................................................................................... 8-136 Spline Drive....................................................................................................................................................... 8-136 General Information............................................................................................................................................. 8-121 Gear Driven....................................................................................................................................................... 8-121 Install................................................................................................................................................................... 8-136 Spline Drive....................................................................................................................................................... 8-136 Preparatory Steps................................................................................................................................................ 8-121 Spline Drive....................................................................................................................................................... 8-121 Remove................................................................................................................................................................ 8-122 Spline Drive....................................................................................................................................................... 8-122 Sea Water Pump Support ....................................................................................................................................8-136 Clean and Inspect for Reuse............................................................................................................................... 8-138 K38, K50. OSK38. and QSK50 Section 8 — Cooling System — Group 08 Page 8-c

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 K38, K50. QSK38. and QSK50 Page 8-d Section 8 — Cooling System — Group 08

K38. K50. QSK38. and QSK50 Section 8 — Cooling System — Group 08 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_____________________ Tool Illustration ST-647 Gear Puller Used to remove the water pump pulley and impeller. 3376326 Pulley Installation Tool Used to install drive pulleys. adBtogb 3375318 Water Pump Bearing Mandrel Used to press the bearing and shaft into the water pump body. 3»s*ia 3375319 Water Pump Bearing Mandrel Used to install the front water pump oil seal into the water pump body. 3375326 Bearing Separator Used to hold the bearing when removing it from the shaft. 3375411 Thermostat Seal Driver Used to install thermostat seal. __ y

Cummins K38,K50,QSK38,QSK50 Engine Service Repair Manual

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