TC Kta-50

12/6/2016
Turbocharger
010033Turbocharger
GeneralInformation
withMechanicallyActuatedInjector
AllK38andK50enginesareturbocharged.AllturbochargersonK38andK50enginesareoil
cooledandlubricated.Theenginecanhavetwoorfourturbochargers.
Iftheenginehasfourturbochargers,thetwothataremountedontheexhaustmanifoldarethe
highpressureturbochargers,andthetwothataremountedonthesupportbracketsarethe
lowpressureturbochargers.
Thecorrectturbochargerassemblymustbeinstalled.Manyturbochargersappearthesame
physically,butcontaindifferentinternalparts.Ifthewrongturbochargerassemblyisinstalled,
theperformanceoftheenginewillbelessthanspecification,ortheenginewillbedamageddue
toexcessivepressureandtemperatureinthecylinders.
K38andK50enginescancontainturbochargersthataremanufacturedbyHolset,Brown
Boveri,orAiResearch.Insomecasesturbochargersfromtwodifferentvendorsareonthe
sameengine.Oneofthedataplatesthatisattachedtotheturbochargeridentifiesthevendor,
theturbochargermodel,andtheCumminspartnumber.CumminsInc.identifiesthe
turbochargerbythepartnumber,notthemodelnomenclature.
Thismanualdoesnotcontaininformationtorebuildtheturbocharger.Seethefollowing
turbochargerrebuildmanuals:
Manufacturer
Bulletin
ModelNumberandDescription
Holset
3810243
HC5ATurbochargerShopManual
Holset
3810386
HT100SeriesTurbochargerShopManual
BrownBoveri
3810235
BrownBoveriTurbochargerManual
AiResearch
3379091
T18A,TurbochargerRebuildManual
TwooilsupplyhosesareinstalledonK38andK50engines.ThelengthofthehoseforKT38,
KTA38,andKTA50enginesis1295mm[51in].ThelengthofthehoseforKTTA38andKTTA5O
enginesis1092mm[43in].
TheturbochargeroildrainassemblyfortheK38isshorteronengineswithdrytypeexhaust
manifoldsthanonengineswithwettypeexhaustmanifolds.Theturbochargeroildrain
https://quickserve.cummins.com/qs3/pubsys2/xml/en/procedures/28/28010033tr.html?q=turbo%20repair
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assemblyfortheK50isthesameasthatinstalledontheK38withawettypeexhaustmanifold.
Themethodforconnectingtheturbochargeroildraintothecylinderblockwaschanged.
Engineswithanengineserialnumber(ESN)of33106693andgreaterhaveaflangeandano
ringsealtypeconnectionthatissecuredwithacapscrew.EngineswithanESNof33106692
andlowerhavea90degreefittingwithpipethreads.
ArevisedturbochargercompressorwheelwasreleasedforKTA50GenginesinSeptember,
1985,ESNFirst33110070.
Turbochargerswithahosenippleonthecompressordischargeandahosetypeaircrossover
werereleasedforuseinproductionontheKTA38enginesinSeptember1986,ESNFirst
33111500.
AchamferwasaddedtothediffuserplateonHC5Aturbochargerstoallowoildrainbacktothe
sumpinFebruary,1987,ESNFirst33111870.
Arevisedprofile,turbochargermountinggasketwasreleasedinAugust,1987,ESNFirst
33112713.
Aturbochargeroildrainhosethatismanufacturedofflexiblehoseisavailableforenginesbuilt
previouslywithaoneortwopiecesteeltubefortheoildrainhose.Thetwopiecesteeltubethat
isconnectedbyahumphoseisavailableforserviceonenginesthathaveAiResearch
turbochargersonly.
TheKTTA50lowpressureturbochargeroildrainhoseanddrainlocationwaschangedin1988,
toprovideabetterdownhillreturntothecylinderblock.Therevisedoildrainhoseroutingalso
requiresarevisedturbochargersupport,whichismodifiedtoprovideclearanceforthenewoil
drainhoseandadifferentclamptoretaintheoildrainhose.
Therevisedhosedrainstheoiltodrillingsonthetopdeckatthefrontoftherightbankandthe
leftoftherearbankofthecylinderblock.Theholesusedarepartiallycoveredbythe
turbochargersupport.Thissupportrequiresmodificationorreplacement.
Themountingcapscrewfortheflangeandoringsealtypeturbochargerdrainhoseconnection
waschangedfrom0.250inch20UNCto0.375inch16UNC.Thecylinderblockwiththe
smallerholesrequiresaspacer,PartNumber3177195,betweentheconnectionflangeandthe
cylinderblockattheleftbankrearlocation.Ifthespacerisnotinstalled,anoilleakwillresult
becausetheoringsealwillnotbeintheborecorrectly.
Theflangeontheturbochargeroildrainhosethatfitstotheturbochargerisdifferentfor
HolsetandAiResearchturbochargers.TheoildrainhoseflangeisdifferentfortheBrown
Boveritypeturbocharger.Ifthemodelofturbochargerischanged,theoildrainhosemust
bechanged.
AK50turbinehousingwithathickenedflangebetweenthecapscrewholestoreduceflange
distortionwasreleasedinFebruary1988,ESNFirst33114833.ThisisfortheK50pulse
exhaustmanifoldsonly.
Longerstuds,nuts,andspacerswerereleasedfortheK50pulseexhaustmanifoldinMay,
1989,ESNFirst33115948.
TheK50turbochargermountingflangewascompletelythickenedtoimprovegasketreliability.
ThespacerisnolongerrequiredforK50pulseexhaustmanifoldenginesproducedinFebruary,
1990,ESNFirst33117281.
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TheK50pulseexhaustmanifoldreceivedabosstoallowuseofcapscrewsinplaceofstudson
enginesproducedfromFebruary,1990,ESNFirst33117392.
Asteeloilsupplyfittingreplacedthebrassfittingtopreventtorqueloss/looseningonengines
producedfromFebruary,1990,ESNFirst33117392.
Asteeloilsupplyfittingreplacedthebrassfittingtopreventtorqueloss/looseningonengines
producedfromSeptember1990,ESNFirst33118322.
TheHolsetHT100lowpressureturbochargerreplacedtheBrownBoveriRR151
turbochargerforC1800BandK2000enginesinJanuary1991,ESNFirst33119163.
NOTE:TheHT100turbochargercannotbeusedtoreplacetheBrownBoveriModel
RR153thatisusedontheKTTA50C1800Aengines.
TheHolsetHX80watercooledturbochargerdesignwasrevisedin1997,toallowfortheuse
ofGASfittingsonallcoolantpassageopeningsinthecasting.Oringsealfittingsarelessprone
toleakage,andareeasiertoremoveandinstall.Thediffuserplatewasalsochangedtoasunk
wheeldesign.
PreparatorySteps
WARNING
Batteriescanemitexplosivegases.Toreduce
thepossibilityofpersonalinjury,always
ventilatethecompartmentbeforeservicingthe
batteries.Toreducethepossibilityofarcing,
removethenegative()batterycablefirstand
attachthenegative()batterycablelast.
WARNING
Donotremovethepressurecapfromahot
engine.Waituntilthecoolanttemperatureis
below50C[120F]beforeremovingthe
pressurecap.Heatedcoolantsprayorsteam
cancausepersonalinjury.
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WARNING
Coolantistoxic.Keepawayfromchildrenand
pets.Ifnotreused,disposeofinaccordance
withlocalenvironmentalregulations.
WARNING
Toreducethepossibilityofpersonalinjury,
avoiddirectcontactofhotoilwithyourskin.
Disconnectthebatteries.RefertotheOEM
servicemanual.
TurntheairOFFtotheairstarter,if
equipped,andtagthevalveclosed.Referto
Procedure012022inSection12.
Drainthecoolingsystemtoapointbelow
theturbochargers.RefertoProcedure008
018inSection8.
Removethecoolantsupplyandreturnlines.
RefertoProcedure010041inSection10.
withElectronicallyActuatedInjector
WARNING
WARNING
Donotremovethepressurecapfromahot
engine.Waituntilthecoolanttemperatureis
below50C[120F]beforeremovingthe
pressurecap.Heatedcoolantsprayorsteam
cancausepersonalinjury.
WARNING
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WARNING
Toreducethepossibilityofpersonalinjury,
avoiddirectcontactofhotoilwithyourskin.
Disconnectthebatteries.RefertotheOEM
servicemanual.
TurntheairOFFtotheairstarter,if
equipped,andtagthevalveclosed.Referto
Drainthecoolingsystemtoapointbelow
theturbochargers.RefertoProcedure008
018inSection8.
Removethecoolantsupplyandreturnlines.
Removetheoilsupplylines.Referto
Removetheoildrainlines.Referto
Remove
NOTE:Theturbochargers,mounting
hardware,andconnectionsarenotthesame
forallmodelsofK38andK50engines.
Becausethepartsaredifferent,procedures
aregivenforremovalofthefollowing
turbochargers.
KT38,KTA38,andKTA50withCenter
MountAftercooler
KTTA38LowPressure
KTTA50LowPressure
K2000ELowPressure
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KTTA38,KTTA50,K1500E,K1800Eand
K2000EHighPressure,andKT38,KTA38,
andKTA50withOutboardAftercoolers
NOTE:Theoilinletanddrainhoseroutingand
clampscanbedifferentthanshown,
dependingontheageoftheengine.
KT38,KTA38,andKTA50withCenterMount
Aftercooler
NOTE:TheillustrationsshowaKTA38.The
KTA50hasalongerconnectionbetweenthe
turbochargerandtheaftercooler.
Olderenginescanhaveaspacerforthe
capscrew(23).Keepthespacerforfuture
assembly.
Detachtheoildrainhosefromthecylinderblock.
Removetheoringseal(21).
Discardtheseal.
Detachtheoildrainhosefromtheturbocharger.
Removethegasket(17).
Discardthegasket.
Checkthehose(18)fordamage.Discardthepart
ifitisdamaged.
Detachtheoilinlethose(16).Removalofthe
fitting(15)andtheoringseal(14)isnotrequired
unlesstheyaredamaged.
Removeanysupportclampsfromthehose.
Removethehose.Checkthehosefordamage.
Discardthepartifitisdamaged.
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Newerengineshaveahoseandclampsbetween
theturbochargersandairtransferhousings.
Theclampsarespecialhighstrengthparts.
Loosenthehoseclamps(2).
Olderengineshaveretainingstraps.
Removethecapscrewsandtheretainingstraps
(10).
Checkthestrapsfordamage.Discardthepartifit
isdamaged.
WARNING
Thecomponentorassemblyweighsgreater
than23kg[50lb].Topreventseriouspersonal
injury,besuretohaveassistanceoruse
appropriateliftingequipmenttoliftthis
componentorassembly.
Removethefourcapscrews(8)andnuts(9).
Removetheturbochargerandgasket.
Discardthegasket.
Onnewerengines,removetheclampsandthe
hose.
Discardthehose.
Checktheclampsfordamage.Discardthepartif
itisdamaged.
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Onolderengines,removethetube(5).Remove
theoringseals(4).
Discardtheseals.
Removethedustseal(3).
Ifthedustsealishardorsoakedwithoil,discard
thepart.
KTTA38LowPressure:
Removetheoildrainhose(30).Removethe
gasket(29)andtheoringseal(33).
Discardthegasketandseal.
Checkthehosefordamage.Discardthepartifit
isdamaged.
Detachtheoilinlethose(16).Theremovalofthe
fitting(15)andtheoringseal(14)isnotrequired
unlessdamaged.
Removethehose.
isdamaged.
WARNING
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Removethefourcapscrews(27)andthenuts
(28).
Removetheturbochargerandthegasket.
Discardthegasket.
Loosenthehoseclamps(24).Removethe
clampsandthehose(23)fromthehighpressure
turbochargerairconnection.
Removetheairconnection(21)fromthehigh
pressureturbocharger.Removetheoringseals
(19).
Discardtheseals.
Removethedustseal(22).Ifthedustsealishard
orsoakedinoil,discardthepart.
Theheavywashers(13)andcapscrewsare
specialheatresistantparts.
Removetheexhaustconnection(11)andthe
exhaustoutletpipe(10).
Removethevbandclamp(8)andtheexhaust
outletconnection(9).
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Removethesixcapscrews(7).Theheavyflat
washers(5)arespecial.Removethesupport
plate(4).
Removethesocketheadcapscrew(3).Remove
theturbochargersupportlegs(1).
KTTA50LowPressure
TheBrownBoveri,ModelRR151,
turbochargerscontainmetricfastenersfortheoil
connectionplates.
Removetheoildrainhose(48).
Removethegasket(47)andoringseal(51).
isdamaged.
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SomeBrownBoveriturbochargersdonot
containtheadapterplatesfortheoilinlet.
Detachtheoilinlethose.Theadapterplates(44)
andfittingsdonotrequireremoval.
Removeanysupportclamps.Removethehose.
isdamaged.
Removethegasket.
Discardthegasket.
Removethetwocapscrews(35)thatholdthe
exhaustsideoftheturbochargertothesupport
bracket.
Removethetwocapscrews(31)andnuts(34)
thatholdtheintakesupportbrackettothe
turbochargersupportbracket.
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WARNING
Removethelowpressureturbocharger(16).
Loosenthehoseclamps(12).Pulltheintake
connectionpipe(15)fromthehighpressure
turbocharger.Removeanddiscardtheoring
seals(13)andthehose(11).Removethedust
seal.
Ifthedustsealishardorsoakedwithoil,discard
thepart.
Removetheexhaustconnection(11)andoutlet
pipe(10).
Removethevbandclamp(8)andtheexhaust
outletconnection(9).
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Removethesixcapscrews(7).Removethe
turbochargersupportbracket(4).
Removethesocketheadcapscrews(3).Remove
theturbochargerbracketsupportlegs(1).
K2000ELowPressure:
Removetheoildrainhose(60).Removethe
gasket(59)andoringseal(63).
isdamaged.
Detachtheoilinlethose.Removalofthefitting,
plate,(56)andgasket(55)isnotrequired.
Removethehose.
isdamaged.
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Removetheheatshield(blanket)fromthe
interstageairhose.
LoosenthetwoTboltclamps(45)ontheair
intakepipe(47)andthecompressorinlet.
Removethefourcapscrews(49)andnuts(52)
thatholdtheairintakepipe(47)tothe
turbochargercompressoroutlet.
Removetheairintakepipe(47).
Checkthepipefordamage.Discardthepartifitis
damaged.
Loosenthevbandclamp(8).
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thatholdthetwoexhaustconnections(9and11).
thatholdtheexhaustconnectiontotheturbine
housing.
Removetheexhaustconnection.
thatholdthebracket(32)totheconnection(26).
Removethetwocapscrews(43)andthenuts(34)
thatholdthebracket(32)tothesupportbracket
(4).
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WARNING
thatholdtheturbochargerexhaustoutlet
connectiontothebracket.
Removetheturbocharger.
KTTA38,KTTA50,K1500E,K1800EandK2000E
HighPressure,andKT38,KTA38,andKTA50
withOutboardAftercoolers
IftheenginebeingservicedisaKT38,KTA38,or
KTA50,recordthedirectionoftheturbocharger
exhaustoutletandmarktheexhaustmanifoldsfor
location.Thiswillaidtheassemblyprocessasthe
exhaustcanbeeitherfrontoutorrearout.
Detachtheoildrainhosefromthecylinderblock.
Removetheoringseal(9).
Discardtheoringseal.
isdamaged.
Detachtheoildrainhosefromtheturbocharger.
Removeanysupportclampsandthehose.
Removethegasket(5).
Discardthegasket.
isdamaged.
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Removalofthefitting(15)andtheoring(14)is
notrequired.
Detachtheoilinlethose.Removeanysupport
clamps.Removethehose.
isdamaged.
WARNING
Removethefourcapscrews(3)andthenuts(4).
Discardthegasket.
Removethelowpressureturbochargerairintake
andbracket.
Removethelowpressureturbochargerexhaust
adapterandbracket.
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Removetheeightnuts,plainwashers,nuts,
capscrewsandpclipsfromtheairtransfer
connections.
Removetheairtransferconnectionsanddiscard
thegaskets.
NOTE:Notetheorientationofthecapscrews
andnutsinthetransfertubepriortoremoval.
Thecapscrewsmustbeinstalledinthesame
orientationduringinstallation.
Removetheeightnuts,plainwashers,and
capscrews,andremovetheairtransferpiping.
Discardthegaskets.
WARNING
Removethelowpressureturbochargers.
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Loosenandremovetheclampsandhoses
connectingtheturbochargerstotheintake
manifold.
Removetheclampsfromthehighpressure
turbochargerandairtransferconnection.
Removetheairtransferfromthehighpressure
turbocharger.
Removethefourcapscrews,nuts,andwashers
andremovetheexhaustoutletconnectionfrom
thehighpressureturbocharger.
Removetheexhaustoutletclampandoutlet
connectionfromtheturbocharger.
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Removethefourmountingcapscrews,nutsand
washersfromeachhighpressureturbocharger.
GasCompression
WARNING
Thiscomponentorassemblyweighsgreater
Removethemountingcapscrewsandlock
washers.
Discardthegasket.
Clean
CAUTION
Tapeorplugallopeningstopreventsolventor
steamfromenteringtheoilcavitiesinthe
turbocharger.
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Thisprocedureappliestoallmodelsof
turbochargeronK38andK50engines.See
GeneralInformationatthebeginningofthis
section.
WARNING
Whenusingsolvents,acids,oralkaline
materialsforcleaning,followthe
manufacturer'srecommendationsforuse.
Weargogglesandprotectiveclothingtoreduce
thepossibilityofpersonalinjury.
WARNING
Whenusingasteamcleaner,wearsafety
glassesorafaceshield,aswellasprotective
clothing.Hotsteamcancauseserious
personalinjury.
Usesolventorsteam.Cleantheexteriorofthe
turbocharger.
InspectforReuse
Inspecttheturbineandcompressorwheelsfor
frettingandbrokenvanes.
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Useadialdepthgauge,PartNumberST537,or
adialindicatortomeasuretheaxialmotion(end
toend).
CompressorImpellerAxialEndClearance
HolsetHC5,HC5A,(127
mmwheel)
HolsetHC5,HC5A,(130
mmwheel)
HolsetHX80/HX85
HolsetHT100
mm
in
0.025 MIN 0.001
0.152 MAX 0.006
0.025 MIN 0.001
0.152 MAX 0.006
0.025 MIN 0.001
0.152 MAX 0.006
0.050 MIN 0.002
0.152 MAX 0.006
MakesurethemovementiswithintheMIN/MAX
TotalIndicatorReadings(TIR)valuesshown
above.
NOTE:Iftheendclearanceexceedsthe
specifications,theturbochargermustbe
replacedorrebuilt.ContactaCummins
AuthorizedRepairLocation.Referencethe
HC5ATurbochargerShopManual,Bulletin
3810243,ortheHT100SeriesTurbocharger
ShopManual,Bulletin3810386,forrebuild
instructions.
Measuretheradialclearance(sidetoside)atthe
compressornose,usingadialgauge.
CompressorImpellerRadialClearance
mm
in
HolsetHC5,HC5A,(127 0.228 MIN 0.009
mmwheel)
0.686 MAX 0.027

mmwheel)
0.762 MAX 0.03

HolsetHX80/HX85
0.254 MIN 0.01
0.787 MAX 0.031

HolsetHT100
0.254 MIN 0.01
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0.813 MAX 0.032
TIRvaluesshownabove.
NOTE:Iftheclearanceexceedsthe
specifications,theturbochargermustbe
replacedorrebuilt.ContactaCummins
AuthorizedRepairLocation.SeeHC5A
TurboShopManual,Bulletin3810243,or
HT100SeriesTurbochargerShopManual,
Bulletin3810386,forrebuildinstructions.
NOTE:Checkthemodelofturbocharger
installedontheengine,thisisfor:
BrownBoveri,ModelRR153andRR151.
Tomeasureaxialclearance,usePartNumberST
537,DialDepthGauge,oradialindicator.
Measuretheaxialmotion.
BBC(RR151)and(RR153)EndClearance
mm
0.09
0.13
in
0.004
0.005
MIN
MAX
Iftheendclearanceexceedsthespecifications,
theturbochargermustbereplacedorrebuilt.
Usethefollowingmanualforrebuildinstructions.
ReferencetheBrownBoveriTurbocharger
Manual,Bulletin3810235.
NOTE:Thecompressorandturbinecasings
donotrequireremovaltomeasuretheradial
clearance.Thepartsshownareremovedfor
clarity.
Useafeelergaugetomeasuretheradial
clearance.
BBC(RR151)and(RR153)BearingRadial
Clearance
mm
RR153
0.55
in
MAX
0.021
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RR151
0.75
MAX
0.030
Iftheradialclearanceexceedsthespecification,
thepartmustbereplacedorrebuilt.Usethe
followingmanualforrebuildinstructions.
ReferencetheBrownBoveriTurbocharger
Manual,Bulletin3810235.
NOTE:Checkthemodelofturbocharger
installedontheengine,thisisfor:
AiResearch,ModelT18A.
Useadialindicatortomeasuretheend
clearance.
AiResearchT18AEndClearance
mm
0.10
0.23
MIN
MAX
in
0.004
0.009
Iftheendclearanceexceedsthespecifications,
theturbochargermustbereplacedorrebuilt.
Usethefollowingmanualforinformation
concerningrebuildinstructions.Referencethe
TurbochargerComponentShopManual,Bulletin
3379091.
AiResearchMethodOne:
Checktheradialclearanceofboththe
compressorimpellerandturbinewheel.
Useyourhandtopushthecompressorimpelleror
turbinewheeltowardthehousing.
Useafeelergaugethatisnotmorethan13mm
[0.5in]wide.Measuretheclearancebetweenthe
impellerandthehousingattheminimum
clearancepoint.
AiResearchT18AImpellerandTurbineWheel
RadialClearance
mm
0.08
0.18
MIN
MAX
in
0.003
0.007
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Iftheclearanceexceedsthespecifications,the
turbochargermustbereplacedorrebuilt.Use
thefollowingmanualforinformationconcerning
rebuildinstructions.ReferencetheTurbocharger
ComponentShopManual,Bulletin3379091.
AiResearchMethodTwo:
Tomeasurethedirectbearingradialclearanceon
theT18A,placeadialindicatorthroughtheoil
drainholeasillustrated.Besuretheindicator
touchesthehighestpartoftheshaft.
Movetheturbineandcompressorwheelsbyhand
totheupperandlowerlimits.
AiResearchT18ABearingRadialClearance
mm
0.20
0.46
MIN
MAX
in
0.008
0.018
Iftheclearanceexceedsthespecifications,the
turbochargermustbereplacedorrebuilt.Use
thefollowingmanualforinformationconcerning
rebuildinstructions.ReferencetheTurbocharger
ComponentShopManual,Bulletin3379091.
Allmodels:
Aftertheturbochargerhasbeenchecked:
Lubricatethebearingswithengineoil
throughtheoilinletfitting
Coverallopeningstoprevententryofdirt
untilinstalledontheengine.
NOTE:Checkthemodeloftheturbocharger
installedontheengine.Thisisfor:
Honeywell,allmodels.
Specificationsforcheckingradialandaxial
clearancearenotavailable.
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Inspectforsignsofcontactbetweenthe
turbochargervanesandhousing.
Checkthebearingsystemforwear:
Holdbothendsoftheturbochargershaft
androtatetheshaftwhileapplyingpressure
downonthecompressorsideanduponthe
turbineside.Itshouldrotatefreelyandthere
shouldbenocontactbetweenthe
compressorwheelandthecompressor
housing,ortheturbinewheelandthe
turbinehousing.
Replacetheturbochargerifanymalfunctionsare
identified.
Disassemble
Removetheoringanddiscard.
Ifthecompressorcoverhasaninletbaffleitcan
beremovedwithaflattipscrewdriver.Prythe
retainingringupandremovetheretainingring.
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CAUTION
Usecautioninhandlingtheturbineblades.The
turbinebladescanbeeasilydamagedwhen
theturbinehousingisremoved.
Removetheturbinehousingbybendingthelock
platetabsawayfromthecapscrewheads.
Removethecapscrews.
Makesuretheturbinewheelrotatesfreelyinside
theturbinehousing.Tapontheturbinehousing
withamallettoseparatetheturbinehousingfrom
thebearinghousing.
Removetheoilsupplyfittingsandthecoolant
linesfromthecenterhousingassembly.
Discardtheorings.
CleanandInspectforReuse
WARNING
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Somesolventsareflammableandtoxic.Read
themanufacturer'sinstructionsbeforeusing.
WARNING
Whenusingsolvents,acids,oralkaline
materialsforcleaning,followthe
manufacturer'srecommendationsforuse.
Weargogglesandprotectiveclothingtoreduce
thepossibilityofpersonalinjury.
Cleanthecompressorcoverandturbinehousing
inpartscleanertoloosendeposits.
WARNING
Wearappropriateeyeandfaceprotection
whenusingcompressedair.Flyingdebrisand
dirtcancausepersonalinjury.
Drythecompressorhousingwithcompressedair.
Useasoftbristlebrushtoremoveheavyscale
deposits.
Washanddrythepartsafterbrushing.
CAUTION
Donotusecompressedairtodryorspinthe
turbinewheelasthiscancausedamagetothe
turbochargerbearingsystem.
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Turbocharger
Ifchemicalandbrushcleaningisnoteffective,
beadblastwithplasticabrasivemedia,Part
Number3822735,orequivalent.
Washanddrypartsafterbeadblasting.
Thecenterhousingrotatingassemblycanbe
cleanedwithelectricalcontactcleaner,Part
Number3824510,orequivalent.
Donotspraycontactcleanerintotheoiland
coolantports.
Inspectthecompressorcoverforcracks,dents,
andotherdamage.
Inspecttheinsideofthecompressorcoverfor
signsofscoringordamagefromthecompressor
wheel.Replacethecompressorcover,if
damaged.
Inspecttheturbinehousingforcracksand
damage.Crackslargerthan10mm[0.39in]can
causeanexhaustleak.Replacetheturbine
housingifdamageisfound.
Followthecriteriashownintheillustration.
Minorcracksintheturbinehousinginternalwall,
whereexhaustgasflowenterstheturbinewheel,
isanacceptablecondition.Theturbinehousing
canbereused.
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Turbocharger
Inspecttheturbinehousingforsignsofcontact
withtheturbinewheel.Damagedturbinehousings
mustbereplaced.
Inspectthecenterhousingrotatingassemblyfor
anysignsofcracks,damagedthreads,orother
damage.
Rotatetheturbinewheelbyhandtomakesureit
spinsfreely.
Replacethecenterhousingrotatingassemblyifit
isdamagedordoesnotspinfreely.
Inspectthecompressorwheelfordamage,
broken,orbentblades.
Donotattempttorepairorstraightentheblades.
Instead,replacethecenterhousingrotating
assembly.
Inspecttheturbinewheelfordamaged,broken,or
bentblades.
Donotattempttorepairorstraightentheblades.
Instead,replacethecenterhousingrotating
assembly.
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Turbocharger
Measure
Useadialdepthgauge,PartNumberST537,or
adialindicatortomeasuretheaxialmotion(end
toend).
CompressorImpellerAxialEndClearance
mm
in
mmwheel)
0.152 MAX 0.006

mmwheel)
0.152 MAX 0.006

HolsetHX80/HX85
0.025 MIN 0.001
0.152 MAX 0.006

HolsetHT100
0.050 MIN 0.002
0.152 MAX 0.006

Replacethecenterhousingrotatingassemblyif
theaxialclearanceisnotwithinspecifications.
Measuretheradialclearance(sidetoside)atthe
compressornose,usingadialgauge.
CompressorImpellerRadialClearance
mm
in
mmwheel)
0.686 MAX 0.027

mmwheel)
0.762 MAX 0.03

HolsetHX80/HX85
0.254 MIN 0.01
0.787 MAX 0.031

HolsetHT100
0.254 MIN 0.01
0.813 MAX 0.032
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Turbocharger
Replacethecenterhousingrotatingassemblyif
theradialclearanceisnotwithinspecifications.
Assemble
CAUTION
Usecautionwhenhandlingtheturbineblades.
Theturbinebladescanbeeasilydamaged
wheninstallingintheturbinehousing.
Assemblethecenterhousingrotatingassembly
ontotheturbinehousing.
Lubricatethethreadsofthenewcapscrewswith
antiseizecompound,PartNumber3824732,or
equivalent.
Installthecapscrews,withnewlockplates,tothe
turbochargerturbinehousing.
TorqueValue:20.3n.m[180inlb]
Useahammerandpunchtofoldthelockingplate
ontotheflatofthecapscrew,toprevent
loosening.
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Assembletheinletbaffleintothecompressor
coverandsecurewitharetainingring.Holdone
endoftheretainingringinthegroove.Pressthe
remainderoftheretainingringintoposition.Usea
flattipscrewdrivertomakesuretheretainingring
iscorrectlyseatedinthecompressorcover
groove.
NOTE:TheHX83Turbochargerusesa
titaniumcompressorwheel.Theedgeofthe
wheelisverysharp.Handlethecompressor
wheelwithcare.
Assemblethecompressorhousingneworingon
theturbocharger.
CAUTION
Donotdamagethecompressorwheelblades
duringassembly.
Assemblethevbandclampandcompressor
coverontotheturbocharger.
Placethevbandclampinposition.
Tightenthevbandclamp.
TorqueValue:12n.m[106inlb]
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Turbocharger
Makesurethecompressorwheelandturbine
wheelrotatefreely.
Install
CAUTION
Checktobesurethecorrectturbocharger
assemblyisinstalled.Theturbocharger
assemblynumberisonthedataplatethatis
mountedontheturbocharger.Comparethe
assemblynumberwiththenumberinthe
ControlPartsList(CPL)Manualwiththe
correspondingCPLfortheenginebeing
serviced.Manyturbochargersappearthe
samephysically,butcontaindifferentparts.If
thewrongturbochargerassemblyisinstalled,
theperformanceoftheenginewillbelessthan
specification,ordamagecanresulttothe
engineduetoexcessivecylinderpressureand
temperature.
Theturbochargers,mountinghardware,and
connectionsaredifferentforvariousmodelsof
K38andK50engines.Becauseofthedifferent
parts,installationproceduresaregivenfor:
KT38,KTA38,andKTA50Turbochargers
withCenterMountAftercooler
KTTA38andKTTA50HighPressure,and
KT38,KTA38,andKTA50Turbochargers
withOutboardAftercoolers
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Turbocharger
KTTA38LowPressureTurbochargers
K2000E,K1800EandK1500EHigh
PressureTurbochargers
K2000ELowPressureTurbochargers
Duringturbochargerinstallation,itisoften
necessarytoadjusttheangleofthebearing
housingoildrainandtheangleofthecompressor
housingoutlet.Instructionsfortheseadjustments
aredescribedfollowingtheprocedureforthe
KTTA50LowPressureTurbocharger.
Oilinletanddrainhoseroutingandclampscanbe
differentthanshownbecauseoftheageofthe
engine.Besuretheoilhoseshavethecorrect
clampsinstalledtopreventdamagefromvibration
orheatfromanotherpart.
KT38,KTA38,andKTA50Turbochargerswith
CenterMountAftercooler
NOTE:TheillustrationsshowaKTA38.The
KTA50hasalongerconnectionbetweenthe
aftercoolerhousingandtheturbocharger.
Theprocedureisthesameforthesemodels.
Newerengineshaveahoseandclampsto
connecttheturbochargertotheaftercooler
connection.Olderengineshaveatubewithadust
sealandtwooringsealstoconnectthe
turbochargertotheaftercoolerconnection.
Theclampsarespecialtoallowahighertorque.
StandardTbolttypeclampscanloosenandallow
anairleak.
NewerEngines:
Installthehose(1)andclamps(2)onthe
aftercoolerconnection.Donottightentheclamps.
SomeofthenewerK50engineshaveahoseand
heavydutyclampsinstalledoverthetubeando
ringasshowninthenextpicture.
OlderEngines:
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Turbocharger
Installthedustseal(3)andoringseals(4)onthe
tube(5).
Usevegetableoil.Lubricatetheoringseals.
Installthetubeintheboreoftheaftercooler
housing.Pushthetubeintotheboreuntilit
touchesthestepinthebore.
WARNING
Installthegasket(6)ontheexhaustmanifold.The
gasketmustbeinstalledsothattheraisedbead
onthegasketistowardtheturbocharger.
Installtheturbocharger(7).Pushthe
compressorhousingintothehoseoronthehose.
Thecapscrews(8)withnuts(9)aremanufactured
fromheatresistantmaterial.Ifheatresistant
capscrewsarenotinstalled,thepartswillfail,
causinganexhaustleak.
Applyanantiseizecompoundonthethreadsof
thecapscrew.
Installthefourcapscrews(8)withthenuts(9).
TorqueValue:
Capscrews40n.m[30ftlb]
Someofthecompressorhousingisnotshown
removedforclarity.
Checktheangleoftheoildrainandthealignment
ofthecompressorhousingtotheaftercooler
connection.Iftheangleoralignmentisnotcorrect,
adjusttheturbochargeroildrainangle,oradjust
theturbochargercompressorhousingalignment,
describedlaterinthissection.
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Turbocharger
NewerEngines:
Tightentheclamps(2).
TorqueValue:
K389n.m[80inlb]
TheK50requiresaspecialclamp.
TorqueValue:
K5015n.m[133inlb]
OlderEngines:
Installtheparts.
Retainingplates(10)
Flatwashers(11)
Lockwashers(12)
Capscrews(13).
TorqueValue:
Capscrews16n.m[142inlb]
NOTE:Holsetturbochargershaveafitting
thathasstraightthreadsandrequiresano
ringseal.AiResearchturbochargershavea
fittingwithpipethreads.Thetorquevalueis
thesameforbothtypesofthefittings.
Installtheoringseal(14)ontheoilinletfitting
(15).Installthefitting.
TorqueValue:
OilInletFitting35n.m[26ftlb]
Connecttheturbochargeroilinlethose(16)to
thefitting.
Installtheclampsfortheoilinlethose.
Theotherendoftheoilinlethosemustbe
connectedtoafittinginthecylinderblock.Refer
toProcedure001026inSection1.
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Turbocharger
Installtheparts.
Gasket(17)
Hose(18)
Lockwashers(19)
Capscrews(20).
TorqueValue:
Newerengineshaveaflangeandanoringseal
typeoildrainhoseasshown.Thenewerhose
connectstothecylinderblockwithacapscrew.
Olderengineshaveahosethathasatubingnut
andconnectstotheblockwithafittingthathas
pipethreads.
Ifaflangeandanoringtypeconnectionis
installedonanolderblock,aspacerisrequired
betweentheholeintheblockforthecapscrew
andtheflange.Ifthespacerisnotinstalled,anoil
leakwillresult.
Installtheoringseal(21)onthehoseflange.
Usevegetableoil.Lubricatetheseal.
Installtheflange,thelockwasher(22),andthe
capscrew(23).
TorqueValue:
FlangeCapscrews40n.m[30ftlb]
Repeatthisproceduretoinstalltheother
turbochargerandconnecttheoilhoses.
KTTA38andKTTA50HighPressure,andKT38,
KTA38,andKTA50Turbochargerswith
OutboardAftercoolers
Theturbochargersmustbemountedonthe
correctenginebank.
KTTA38andKTTA50HighPressure:
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Turbocharger
Theturbochargerontheleftbankmustbe
installedwiththecompressorhousingpointed
towardthefrontoftheengine.Theturbocharger
ontherightbankmustbeinstalledwiththe
turbinehousingpointedtowardthefrontofthe
engine.
KT38,KTA38,andKTA50withOutboard
Aftercoolers:
Theturbinehousingonbothturbochargersmust
pointthesamedirection,eithertowardthefrontof
theengineortowardtherearoftheenginesothat
theexhaustpipingwillfittheapplication.
WARNING
NOTE:TheturbochargersfortheK50engine
withpulsetypeexhaustmanifoldsaretobe
mountedwithfourstudsandnuts,not
capscrewsandnuts.Thetorquevalueisthe
same.SomeK38enginesdonotrequirethe
nuts.
Thegasketmustbeinstalledsothattheraised
beadonthegasketistowardtheturbocharger.
Installthegasket(1)ontheexhaustmanifold.
thecapscrewsorstuds(3).
Installtheturbocharger(2),thecapscrewsor
studs(3),andthenuts(4),ifrequired.
TorqueValue:
TurbochargerCapscrews40n.m[30ftlb]
NOTE:Someofthecompressorhousingis
shownremovedforclarity.
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Turbocharger
Checktheangleoftheoildrain.Thealignmentof
thecompressorhousingtotheaircrossoverscan
notbecheckeduntiltheaftercoolerassemblyis
installed.Iftheangleisnotcorrect,adjustthe
turbochargeroildrainangle,describedlaterinthis
section.
thesameforbothtypesoffittings.
TorqueValue:
thefitting.
Installtheparts.
Gasket(5)
Hose(6)
Lockwashers(7)
Capscrews(8).
TorqueValue:
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Turbocharger
Installtheflangeintheboreoftheblock.Install
thelockwasher(10)withthecapscrew(11).
TorqueValue:
Repeatthisproceduretoinstalltheother
turbochargerandconnecttheoilhoses.
NOTE:Theenginehastwolowpressure
turbochargers.Theillustrationsshowthe
installationofoneturbocharger.Itis
recommendedthatthetwolowpressure
turbochargersbeinstalledatthesametime.
Theenginehassixturbochargersupports.Two
aremountedonthefrontoftherightbankandtwo
ontherearoftheleftbank.Oneismountedon
thefrontoftheleftbankandoneontherearof
therightbank.
Installtheturbochargersupports(1)andthelock
washers(2),withthesocketheadcapscrews(3).
TorqueValue:
TurbochargerSupport
Donottightentheclampsorfastenerstofinal
torqueuntilthetorquevalueisgiven.Tightenthe
partsenoughtoholdthemtogether,butloose
enoughtoallowthepartstobemovedfor
alignment.
Installtheparts.
Bracket(4)
Flatwashers,heavy(5)
Lockwashers(6)
Capscrews(7).
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Turbocharger
Therearesixeachoftheflatwashers,lock
washers,andcapscrews.
Installthevbandclamp(8)andtheexhaustoutlet
connection(9).
Applyanantiseizecompoundtotheslipjointsof
theexhaustoutletconnection(9),exhaustoutlet
pipe(10),andtheturbochargerconnection(11).
Installthepipe(10)totheconnection(9).Install
theconnection(11)inthepipe(10).
thecapscrews(12).
Installthefourcapscrews(12)throughthe
connectionandbracket.
Installtheheavyflatwashers(13),thelock
washers(17),andthenuts(18).
Installthelargeoringseal(19)andthesmallo
ringseal(20)ontheairinletpipe(21).
Installthedustseal(22)ontheairinletpipe.
Installtheairinletpipeinthehighpressure
turbocharger.
Installthehose(23)andthetwoTboltclamps
(24)ontheairinletpipeandhighpressure
turbocharger.
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Turbocharger
WARNING
beadonthegasketistowardtheturbocharger
Installthegasket(25).
Installthelowpressureturbocharger(26).Push
thecompressorhousingontheairinletpipe.
Applyanantiseizecompoundtothethreadsof
thecapscrews(27).
Installthefourcapscrews(27)andlocknuts(28).
Checktheangleoftheoildrain.Checkthe
alignmentofthecompressorhousingtotheairinlet
pipe.Iftheangleoralignmentisnotcorrect,see
Turbocharger,OilDrainAngle,Adjust,or
Turbocharger,CompressorHousingAlignment,
Adjust,describedinthissection.
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Turbocharger
Tightenthesixcapscrews(7)thatholdthe
brackettothesupports.
TorqueValue:
BrackettoSupports90n.m[66ftlb]
Tightenthefourcapscrews(12)andnuts(18)that
holdtheconnectiontothebracket.
TorqueValue:
ConnectiontoBracket90n.m[66ftlb]
holdtheturbochargertotheconnection.
TorqueValue:
TurbochargerConnection40n.m[30ftlb]
Tightenthevbandclamp(8).
TorqueValue:
VbandClamp7n.m[62inlb]
Useamallet.Taparoundtheclamptobesureitis
seated.
Torquetheclampnuttothesametorquevalue.
Continuetappingandtighteningtheclampuntil
thenutdoesnotturnatthespecifiedtorqueafter
tapping.
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Turbocharger
TightenthetwoTboltclamps(24).
TorqueValue:
TboltClamps9n.m[80inlb]
thesameforbothtypesoffittings.
TorqueValue:
Installthefollowingparts.
Gasket(29)
Hose(30)
Lockwashers(31)
Capscrews(32).
TorqueValue:
NOTE:SomeolderKTTA38enginesequipped
withAiResearchlowpressure
turbochargershaveadrainhosethathastwo
piecesconnectedbyatemperatureresistant
humphose.
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Turbocharger
capscrew(35).
TorqueValue:
NOTE:Theenginehastwolowpressure
turbochargers.Theillustrationsshowthe
installationofoneturbocharger.Itis
recommendedthatthetwolowpressure
turbochargersbeinstalledatthesametime.
Theenginehassixturbochargersupports.Two
aremountedonthefrontoftherightbank,and
twoareontherearoftheleftbank.Oneis
mountedonthefrontoftheleftbank,andoneon
therearoftherightbank.
Installtheturbochargersupports(1),thelock
washers(2),andthesocketheadcapscrews(3).
TorqueValue:
TurbochargerSupport
Donottightentheclampsorfastenerstofinal
torqueuntilthetorquevalueisgiven.Tightenthe
partsenoughtoholdthemtogether,butloose
enoughtoallowthepartstobemovedfor
alignment.
Installthebracket(4),thesixlockwashers(6),
andthesixcapscrews(7).
Installthevbandclamp(8)andtheexhaustoutlet
connection(9).
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Turbocharger
Applyanantiseizecompoundtotheslipjointsof
theexhaustoutletconnection(9),theexhaust
outletpipe(10),andtheturbochargerconnection
(11).
Installthepipe(10)ontheoutletconnection(9).
Installtheconnection(11)inthepipe(10).
Installthehose(11)andthetwoTboltclamps
(12)onthehighpressureturbocharger.
Installthetwooringseals(13)andthedustseal
(14)ontheairinletpipe(15).
Installtheairinletpipeinthehighpressure
turbocharger.
CAUTION
KTTA50enginesequippedwithLOGtype
exhaustmanifoldsmusthaveBrownBoveri
Corporation(BBC),ModelNumber153,
turbochargers.KTTA50engineswithPULSE
typeexhaustmanifoldsmusthaveBBC,
ModelNumberRR151,turbochargers.Be
surethecorrectturbochargersareinstalled,
ordamagetotheenginecanresult.
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Turbocharger
CAUTION
NewerBBCRR153turbochargershave
fastenerthreadsthatareU.S.Customaryinch.
OlderBBCRR153turbochargershave
fastenerthreadsthataremetricmillimeter.The
fastenerthreadsinallBBCRR151are
metricmillimeter.Besurethecorrectfasteners
areinstalledorthepartscanbedamaged.
NOTE:Theexhaustandintakeadaptersfor
theBBCRR153andRR151appearthe
same,buthavedifferentdimensions.Besure
toinstallthecorrectpart.
Applyanantiseizecompoundtotheboreofthe
lowpressureturbocharger(16)fortheexhaust
outletconnection(17),andthethreadsofthe
capscrews(19)and(20).
Theconnectionmustbeinstalledasshownso
thattheflangewithtwoholesalignswiththe
bracket.
Thetwocapscrews(19)arelongerthanthesix
capscrews(20).
Installtheexhaustoutletconnection(17),thelock
washers(18),andthecapscrews(19)and(20).
TorqueValue:
ExhaustOutletConnection
Installthepartsontheairintakeconnection(26).
Capscrews(21)
Bracket(22)
Flatwashers,heavy(23)
Lockwashers(24)
Nuts(25).
Installtheoringseal(27)inthegrooveonthe
connection(26).
Useengineoilorlubriplatetosecurethesealin
thegroove.
Installthepartsonthelowpressure
turbocharger.
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Turbocharger
Connection(26)
Flatwashers(28)
Lockwashers(29)
Capscrews(30).
Tightenonlythecapscrews(30).
TorqueValue:
WARNING
Useahoistandliftingstrap.Putthe
turbocharger(16)inpositionandpushthe
compressorhousingontheairpipe.
Installthecapscrews(31)throughtheheavyflat
washers(32),andthebrackets(22)and(4).
Installtheheavyflatwashers(32),lockwashers
(33),andthenuts(34).
thecapscrews(35).
Installthetwocapscrews(35)throughthe
exhaustoutletconnection(17)andthebracket
(4).
Installtheheavyflatwashers(36),thelock
washers(37),andthenuts(38).
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Turbocharger
beadonthegasketistowardtheturbocharger.
Installthegasket(39)betweentheturbocharger
turbinehousingandtheexhaustconnection.
thecapscrews(40).
Installthefourcapscrews(40)throughtheholes
intheturbinehousing,thegasket,andthe
connection.
Installthelockwashers(41)andthenuts(42).
alignmentofthecompressorhousingtotheairinlet
pipe.Iftheangleoralignmentisnotcorrect,see
Turbocharger,OilDrainAngle,Adjust,or
Turbocharger,CompressorHousingAlignment,
Adjust,describedinthissection.
TorqueValue:
BrackettoSupports90n.m[66ftlb]
Tightenthetwocapscrews(35)andnuts(36)that
holdtheturbochargerexhaustoutletconnection
tothebracket.
TorqueValue:
ExhaustOutletConnectionto
Bracket90n.m[66ftlb]
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Turbocharger
NOTE:Besurethebracket(32)isflatagainst
theflangeontheairinletconnection.
Tightenthetwocapscrews(43)andthenuts(34)
thatholdtheairintakeconnection(32)tothe
bracket(4).
TorqueValue:
AirIntakeConnectiontoBracket40n.m[30ft
lb]
Tightenthetwocapscrews(31)andthenuts(25)
thatholdthebracket(32)totheconnection(26).
TorqueValue:
BracketCapscrews40n.m[30ftlb]
holdtheexhaustconnectiontotheturbine
housing.
TorqueValue:
ExhaustConnectionCapscrews90n.m[66ftlb]
Tightenthevbandclamp(8).
TorqueValue:
VbandClamp7n.m[62inlb]
Useamallet.Taparoundtheclamptobesureitis
seated.
Tightentheclampnuttothesametorquevalue.
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Turbocharger
thenutdoesnotturnatthespecifiedtorqueafter
tapping.
TightenthetwoTboltclamps(45)ontheairinlet
pipe.
TorqueValue:
TboltClamps7n.m[62inlb]
CAUTION
Besurethecorrectcapscrewsareinstalled.If
thewrongcapscrewsareinstalled,failureof
thepartcanresult.
NOTE:NewerBBCRR153turbochargers
haveafittingthatisthreadeddirectlyintothe
bearinghousing.OlderBBCRR153
turbochargersrequireanadapterplate,Part
Number3176567,andagasket,PartNumber
3176568,attachedtothebearinghousingwith
twocapscrews.
NOTE:AllBBCRR151turbochargershave
anadapterplateandgasket.Theadapterplate
andgasketaredifferentthanontheolder
BBCRR153turbochargers.
Installthepartsfortheturbochargeroilinlet.
Gasket(55)
Plate(56)
Lockwashers(57)
Capscrews(58).
TorqueValue:
OilInletCapscrew40n.m[30ftlb]
Ifthefittingisnotinstalledintheplate,installthe
oilinletfitting.
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Turbocharger
TorqueValue:
FittingTorque35n.m[26ftlb]
Connecttheturbochargeroilinlethose.
Installthepartsfortheturbochargeroildrain.
Gasket(47)
Hose(48)
Lockwashers(49)
Capscrews(50).
TorqueValue:
OilDrainCapscrews40n.m[30ftlb]
capscrews(53)intheproperholesinthecylinder
block.
TorqueValue:
OilDrainFlangeCapscrews40n.m[30ftlb]
K2000EandK1800EHighPressure
Turbochargers
TheK2000EusesHolsetHC5AHighPressure
Turbochargers(2),theHT100LowPressure
Turbochargers(1)installationisdescribedlater
inthissection.
TheK1800Eengineissinglestageturbocharged
anddoesnotusetheturbochargerinterstage
connectionsorassemblyproceduresasdoesthe
K2000E.
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TheK1800EengineusesHolsetHX85
turbochargers(1).
NOTE:Thehighpressureturbochargers(2)
aremountedtotheexhaustmanifoldusing
fourcapscrews(3)andnuts(4).These
capscrewsandnutsaremanufacturedfrom
highstrengthstainlesssteelthathashigh
temperaturecapability.Donotsubstitutewith
lowerqualityparts.
Thegasketmustbeinstalledwiththeraisedbead
(2)towardtheturbocharger.
Installthegasket(1)ontheexhaustmanifold.
Coatthethreadsofthecapscrewswithantiseize
compound.
Installtheturbocharger(2),capscrews(3)and
nuts(4).
TorqueValue:
TurbochargerMounting
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Turbocharger
NOTE:Someofthecompressorhousinghas
beenremovedforclarity.
Checktheangleoftheoildrainandthealignment
ofthecompressorhousingtotheaircrossovers
(thiscannotbecheckeduntiltheaftercooler
assembliesareinstalled).
Iftheangleisnotcorrect,thebearinghousing
mustberotatedinrelationtotheturbinehousing.
Adjusttheturbochargeroildrainangle.
Ifthealignmentiscorrectoraftertheadjustment,
lockthebearinghousingtotheturbinecasing
lockplatetabs.
thefitting(15).
Installthegasket(5),hose(6),lockwashers(7)
andtwocapscrews(8)totheturbochargeroil
drain.
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Turbocharger
Installtheoringseal(9)onthehoseflange.Use
engineoiltolubricatetheseal.Installtheflangein
theboreoftheblock.Installthelockwasher(10)
andthecapscrew(11).
TorqueValue:
OilInletCapscrews40n.m[30ftlb]
Repeattheproceduretoinstalltheother
turbochargerandconnecttheoilsupplyandthe
drainhose.
K2000ELowPressureTurbochargers
TheK2000Eenginecontainstwolowpressure
turbochargers.Thisillustrationshowsthe
installationofonlyoneturbocharger.The
recommendationistoinstallbothlowpressure
turbochargersatthesametime.
TheK2000Eenginecontainssixturbocharger
supports.Twoofeachofthesupportsare
mountedonthefrontoftherightbankandrearof
theleftbank.Oneofeachofthesupportsis
mountedonthefrontoftheleftbankandrearof
therightbank.
Installtheturbochargersupports(1),andthe
lockwashers(2),andthesocketheadcapscrews
(3).
TorqueValue:
TurbochargerSupport
NOTE:Fromthispointon,donottightenthe
clampsorfastenerstotheirfinaltorque
unlessthetorquevalueisgiven.Tightenonly
enoughtoallowthepartstomovefor
alignment.
Installthebracket(4),sixlockwashers(6),and
sixcapscrews(7).
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Turbocharger
Installthevbandclamp(8)andexhaustoutlet
connection(9).
Applyantiseizecompoundtothethreadsofthe
capscrews(12).Installthegasket(10),capscrews
(12),lockwashers(13),andnuts(14).
Useantiseizecompoundtocoattheslipjointsof
theexhaustpipe(11)andtheturbocharger
connection(16).
Installtheturbochargerconnection(16)onthe
exhaustpipe(11).
Afterallinterstageconnectionsareinplace,there
mustbeaminimumof3.18mm[0.125inch]
expansionspacebetweenconnections(11and
16).
Thegapcanbeadjustedbymovingthelow
pressureturbochargerorlowpressure
turbochargermountingbracket.
Useantiseizecompoundtocoattheboreonthe
lowpressureturbocharger(22)fortheexhaust
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Turbocharger
outletconnection(17),andthethreadsofthe
capscrews(19and20).
Thebracket(21)mustbeorientedtoprovide
properturbochargeralignment.
NOTE:Thetwocapscrews(19)arelongerthan
thesixcapscrews(20).
Installtheexhaustoutletconnection(17),lock
washers(18),andcapscrews(19and20).
TorqueValue:
ExhaustOutletCapscrews40n.m[30ftlb]
Installthetwocapscrews(31),bracket(32),
heavyflatwasher(23),lockwashers(24),and
nuts(25)ontheairintakeconnection.
Installtheoringseal(27)inthegrooveonthe
connection(26).UseengineoilorLubriplateto
holdthesealinthegroove.
Installtheconnection(26),fourflatwashers(28),
lockwashers(29),andcapscrews(30),onthe
lowpressureturbocharger.Tightenonlythefour
capscrews(30).
TorqueValue:
AirIntakeConnectionCapscrews40n.m[30ft
lb]
Useahoistandliftingstraptopositionthe
turbochargerandtoalignthecapscrewholesin
thebrackets.
Installthecapscrews(43)throughtheheavyflat
washer(44)andbothbrackets(32and4).Install
theheavyflatwashers(44),lockwashers(33)
andthenuts(34).
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Turbocharger
Useantiseizecompoundtocoatthethreadsof
thecapscrews(35).
Installthetwocapscrews(35)throughthe
exhaustoutletconnection(17)andthebracket
(4).Installtheheavyflatwashers(36),lock
washers(37),andnuts(38).
Theraisedbeadonthegasket(39)mustbe
towardtheturbocharger.
Installthegasket(39)betweentheturbocharger
turbinehousingandtheexhaustconnections(16).
Useantiseizecompoundtocoatthethreadsof
thecapscrews(40).
Installthefourcapscrews(40)throughtheholes
intheturbinehousing,gasket,andconnection.
Installthelockwashers(41)andnuts(42).
SlideoneTboltclamp(45)andhose(46)over
theendoftheintakepipe(47).Slidethehoseon
farenoughtoinstallthepipe.Installthesecond
clamp(45)overthecompressoroutlet.
Positiontheintakepipe(47)betweenthe
turbochargersandinsertthegasket(48).Secure
theflangeswithfourbolts(49),flatwashers(50),
lockwashers(51),andnuts(52).
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Turbocharger
NOTE:Someofthecompressorhousinghas
beenremovedforclarity.
alignmentofthecompressorhousingtotheair
inletpipe.
Iftheangleoralignmentisnotcorrect,the
bearinghousingmustberotatedinrelationtothe
turbinehousing.SeeTurbocharger,Compressor
HousingAlignment,AdjustandTurbocharger,Oil
DrainAngleAlignment,Adjust,describedinthis
section.
Priortoanyofthecapscrewsbeingtightened,
checktobesurethereisaminimumof3.18mm
[0.125in]expansionspaceattheslipjointson
bothexhaustinterstageconnections.
TorqueValue:
SupportBracketCapscrews95n.m[70ftlb]
holdtheturbochargerexhaustoutletconnection
tothebracket.
TorqueValue:
BracketCapscrews95n.m[70ftlb]
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12/6/2016
Turbocharger
Thebracket(32)mustbeflatagainsttheflange
ontheairinletconnection.
holdthebracket(32)tothesupportbracket(4).
TorqueValue:
AirInletConnectionCapscrews40n.m[30ftlb]
holdthebracket(32)totheconnection(26).
TorqueValue:
BracketConnectionCapscrews40n.m[30ftlb]
holdtheexhaustconnectiontotheturbine
housing.
TorqueValue:
ExhaustConnectionCapscrews95n.m[70ftlb]
Tightenthethreecapscrews(19)thatholdthe
bracket(21)totheexhaustoutletconnection(17).
TorqueValue:
ExhaustOutletConnection
holdthetwoexhaustconnections(9and11).
TorqueValue:
ExhaustOutletConnections95n.m[70ftlb]
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Turbocharger
Tightenthevbandclamp.
TorqueValue:
VBand9n.m[80inlb]
Useamallet.Tapallaroundtheclamptomake
sureitisseated.
Tightentheclampnuttothesametorquevalue.
thenutwillnotturnatthespecifiedtorqueafter
tapping.
holdtheairintakepipe(47)totheturbocharger
compressoroutlet.
TorqueValue:
IntakePipeCapscrews40n.m[30ftlb]
CAUTION
ThehosesandTboltclampsoftheairintake
systemareofheavydutydesigntowithstand
temperaturesandpressurestowhichtheyare
exposed.Onlyspecifiedpartsaretobeused.
Theclampscanberemovedandtightened
againamaximumofthreetimes.Thetorque
retentiononthenutwillbebeyondreuseafter
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12/6/2016
Turbocharger
this.Atthistime,asecondnutMUSTbeadded
todoublelockthenutoranewclampMUST
beused.
Centerthehose(46)overthehighpressure
turbochargercompressorinletandthepipe(47).
SecurethetwoTboltclamps(45).
NOTE:Donotpositiontheclampsoverthe
hosebeads.Theclampsmustbepositioned
betweenthehosebeadsandtheendofthe
hose.Aportionofthehosemustextend
outsidetheclamp.
TightenthetwoTboltclamps(45)ontheair
intakepipe(47)andtheturbocharger
compressorinlet.
TorqueValue:
IntakePipeClamps8n.m[71inlb]
Theseclampsneedtobetightenedagainafter
theenginehasoperatedafewhours.
Wraptheinterstageairhosewithaheatshield
(blanket).Theblanketissecuredbyplacingthe
eyeletsthatarelocatedoneachendofthe
blanketoverthehoseclampTbolts.Useflat
washersandnutsontheTboltstoretaintheheat
shield.
Installthegasket(55),plate(56),lockwashers
(57),andcapscrews(58)forthelowpressure
turbochargeroilinlet.
TorqueValue:
LowPressureTurbochargerOil
Inlet25n.m[18ftlb]
Installtheoilinletfitting.
TorqueValue:
Connecttheturbochargeroilinlethose.
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Turbocharger
Installthegasket(59),thehose(60),thelock
washers(61),andthecapscrews(62)forthelow
pressureturbochargeroildrain.
TorqueValue:
TurbochargerOilDrain25n.m[18ftlb]
Installtheseal(63)onthehoseflange.Use
engineoiltolubricatetheseal.Installtheflange,
lockwasher(64)andthecapscrews(65)inthe
properholesinthecylinderblock.
TorqueValue:
HoseFlange40n.m[30ftlb]
NOTE:Theturbochargeroildrainlinemust
rundownhillfromtheturbochargertothe
cylinderblock.
WARNING
NOTE:ThewordOUT,orraisedbeadonthe
gasketmustbepositionedtowardthe
turbocharger.
Liftthehighpressureturbochargers,using
approvedliftingstraps,andplacethemontothe
middlemountingpadswiththeairoutletsfacing
outboard.
Installthecapscrews,washers,andnuts,and
tighten.
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Turbocharger
TorqueValue:
TurbochargerMountingCapscrewsand
Nuts45n.m[33ftlb]
Installtheexhaustoutletandclamp.
Applyantiseizecompound,PartNumber
3824397,orequivalenttobothendsofthe
exhaustinterstagepipingflanges.
Installbothhalvesoftheexhaustinterstageusing
newgaskets.
3824397,orequivalenttothemounting
capscrews.
Tightentheexhaustoutletconnectionclamp.
TorqueValue:
HoseClamp8n.m[71inlb]
Installthecapscrews,washersandnutsfinger
tighttoallowforalignment.
Installthehoseandclamps(withtightening
screwsfacingdownward)totheinletsideofthe
turbocharger.
Tightenthehoseclampclosesttothe
turbochargerinlet.
TorqueValue:
HoseClamp8n.m[71inlb]
Installtheintakeairpipingintothehoseand
looselytightentheclamptoallowforalignment.
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Turbocharger
WARNING
Liftthelowpressureturbochargers,using
approvedliftingstraps,ontothemountingpads
andalignthemwiththeinterstageairtransfer
connections.
Installnewsteelgasketsbetweentheouterlow
pressureturbochargerandtheouterlow
turbochargerexhaustconnection.Checkthatthe
raisedbeadsonthegasketsarefacingtheouter
turbocharger.
Installthecapscrews,washersandnutsinthe
sameorientationnotedpriortoremovalandhand
tighten.
Checkthealignmentandtightenthecapscrews.
TorqueValue:
ExhaustConnectionCapscrewsand
Nuts95n.m[70ftlb]
Installanewpapergasketbetweentheairintake
connectionandtheturbochargerandinstallthe
capscrews,washersandnuts.Handtightenonly
toallowforalignment.
Addthepcliptothetoprightcapscrew.Donot
tightenthisboltuntiltheoilsupplylineisinstalled.
Oncealignmentischecked,tightenthe
capscrews.
TorqueValue:
AirIntakeConnectionCapscrewsand
Nuts48n.m[35ftlb]
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Turbocharger
Checkthatallairtransferconnectionsarealigned
andtightentheinterstagehoseclamps.
TorqueValue:
InterstageHoseClamp8n.m[71inlb]
Installtheairintakeandbracketontothelow
pressureturbochargerandtrollyassembly.
3824394,orequivalent,tothemounting
capscrewsandinstall.
Tightenallcapscrewswiththeexceptionofthe
twocapscrewsnotconnectedtothemounting
bracket.
TorqueValue:
AirIntakeCapscrews48n.m[35ftlb]
3824394,orequivalent,totherearturbocharger
outletflangeandinstalltheexhaustadapterand
bracketontothelowpressureturbochargerand
trollyassembly.
3824394,orequivalent,totheeightmounting
capscrewsandinstall.
TorqueValue:
ExhaustAdapterCapscrews48n.m[36ftlb]
FinishingSteps
WARNING
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Turbocharger
WARNING
Somestateandfederalagencieshave
determinedthatusedengineoilcanbe
carcinogenicandcausereproductivetoxicity.
Avoidinhalationofvapors,ingestion,and
prolongedcontactwithusedengineoil.Ifnot
reused,disposeofinaccordancewithlocal
environmentalregulations.
WARNING
Fillthecoolingsystem.RefertoProcedure
008018inSection8.
TurntheairONtotheairstarter,if
equipped.RefertoProcedure012022in
Section12.
Connectthebatteries.RefertotheOEM
servicemanual.
WARNING
Installtheoildrainlines.RefertoProcedure
010045inSection10.
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Turbocharger
Installthecoolantsupplyandreturnlines.
Fillthecoolingsystem.RefertoProcedure
008018inSection8.
TurntheairONtotheairstarter,if
equipped.RefertoProcedure012022in
Section12.
Connectthebatteries.RefertotheOEM
servicemanual.
LastModified:03Nov2015
Copyright20002010CumminsInc.Allrightsreserved.
69/69

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12/6/2016

0.686 MAX 0.027

0.762 MAX 0.03

0.787 MAX 0.031

0.813 MAX 0.032

0.152 MAX 0.006

0.152 MAX 0.006

0.152 MAX 0.006

0.152 MAX 0.006

0.686 MAX 0.027

0.762 MAX 0.03

0.787 MAX 0.031

0.813 MAX 0.032

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