CUMMINS Diesel Engine K38 K50 QSK38 QSK50 Service Manual
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Service Manual
K38, K50, QSK38 and QSK50
Volume 3
€
Service Manual
K38, K50, QSK38 and QSK50
Volume 3
Copyright' 2006
Cummins Inc.
All rights reserved
Bulletin 4021528
Printed 27-MARCH-200B
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
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$71.99
Covering the service and repair of K38, K50, QSK38, and QSK50 engines, this manual provides comprehensive information essential for professional mechanics and DIY enthusiasts alike. Whether you are maintaining, troubleshooting, or overhauling your engine, this manual offers detailed guidance. Please note that this manual is available in .PDF format and does not require an internet connection for viewing.
