KV38/50 Technical Training

Trainer Alan Beale

 KV38/50 Technical Training

Registration form

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No Smoking Policy ~ Daventry Plant

Course Times: 9:00 - 12:00

Course Times: 13:00 - 16:30

Lunch Vouchers

Hotels ~ Transportation

Tour of Centre.
KV38/50 Technical Training

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 KV38/50 Technical Training

Daventry Service Training Centre

THIS PROGRAME HAS BEEN DESIGNED FOR

TRAINING PURPOSES ONLY, AND IS AN
UNCONTROLLED DOCUMENT.
KV38/50 Technical Training

Service Training Centre

Why are we here ?

Product Knowledge for

Individual Participants

Customer & Distributor

Expectations

Tooling updates and new

releases
 KV38/50 Technical Training

Service Training Centre

Target Audience:

Service Engineers

Field Service Engineers

Service Technicians
 KV38/50 Technical Training

Service Training Centre

Aim:

To provide the participant with a level of instruction

on the KV 38 & KV 50 Engine which will give an
understanding of some existing and future product
functionality and complexity.
 KV38/50 Technical Training

Service Training Centre

Objectives
Participants completing this course will be able to
recognise and describe the KV 38 & KV 50 Engine,
its unique components, and have a formal
understanding of its operation and applications.
 KV38/50 Technical Training

Service Training Centre

Objectives
To understand the basic operating principals,
features and controls of the of the Fuel
System.

To Get an understanding of Insite software for

diagnostics purposes.

To understand maintenance requirements and

procedures for the KV 38 & 50 engine.
 KV38/50 Technical Training

Service Training Centre

Quality Policy:

The Central Area Training Group are

totally committed to the philosophy of
training, “customer ” , and actively pursues
this policy via (Total Quality QS) procedures.
 KV38/50 Technical Training

Service Training Centre

Participants should have an understanding on:

Current KV38 & 50 Product.

Windows.

Insite.

Basic Electric's.
 KV38/50
Manufactured in Daventry, UK

Daventry, UK
K38/50 QSK38/50 QSK45/60
QSK78 QSV81/91-G
Oyama, Japan
Seymour, IN. USA QSK23
V903 K19 QSK19 QST30
Chongqing, China
Clovis, NM. USA K19 K38/50
GTA19 GTA28 GTA38/50
Pune, India
K19 V28 K38/50 QSK60
KV38/50 Technical Training
General Information
 KV38/50 Technical Training

Type: 4 stroke, 60 degree vee, 12 & 16 cylinders

Displacement: 38/50 L
Bore: 158.75mm (6.25 in)
Stroke: 158.75mm (6.25 in)
Compression Ratio: 15:1
Aspiration: Turbocharged / Aftercooled
Power Range K38 925/1450 HP
K50 1600/2000 HP
Approximate engine weight (dry): 38 approx 4000kg
50 approx 5300kg
 KV38/50 Technical Training
1. Turbochargers
2. Left-bank water outlet
3. Left-bank thermostat housing
4. Coolant filter head
5. Coolant filters
6. Fan pilot
7. Front gear cover
8. Accessory drive pulley
9. Direction of rotation
10. Crankshaft pulley
11. Vibration damper
12. Alternator drive pulley
13. Fan idler pulley
14. Fan hub
15. Right-bank thermostat housing
16. Right-bank water outlet.
 KV38/50 Technical Training
1. Turbochargers
2. Air connection
3. Air crossover connection
4. Aftercooler assembly
5. Rocker lever cover
6. Aftercooler water outlet tube
7. Left-bank water outlet
8. Thermostat housing support
9. Thermostat housing
10. Aftercooler water inlet tube
11. Cam follower cover
12. Front gear housing
13. Front gear cover
14. Air compressor drive
15. Air compressor
16. Dataplate
17. Fuel pump
18. Fuel filter head
19. Fuel filter
20. Full-flow lubricating oil filter
21. Crankcase breather
22. Oil level gauge
23. Lubricating oil filter head
24. Oil filler port
25. Flywheel housing.
 KV38/50 Technical Training
1. Oil cooler cover plate
2. Cylinder block
3. Turbocharger
4. Exhaust manifold
5. Air crossover connection
6. Rocker lever cover
7. Rocker lever housing
8. STC (HVT manifold)
9. Fuel manifold
10. Cylinder head
11. Flexplate
12. Flywheel housing
13. Oil pan
14. Oil pan adapter.
 KV38/50 Technical Training

1. Turbocharger
2. Air crossover connection
3. Aftercooler assembly
4. Water tubes
5. Exhaust manifolds
6. Rocker lever cover
7. Aftercooler water outlet tube
8. Right-bank thermostat housing
9. Right-bank water outlet
10. Thermostat housing support
11. Fan hub support
12. Fan hub shaft
13. Left-bank thermostat housing
14. Left-bank water outlet
15. Flywheel housing
16. Oil cooler cover plate.
KV38/50 Technical Training
Engine Dataplate
Located on front gear cover, LB
KV38/50 Technical Training
Engine Serial Number
also stamped on pan rail
 KV38/50 Technical Training
Cylinder Block

KV 50 block is made from grey cast iron and is a one piece configuration.
Material is durable but not too rigid or hard to allow for a degree of flexibility and
for machining.
 KV38/50 Technical Training
Cylinder Block
Counter bore ring is
installed to set liner
stand-proud, two sizes
available. Made from
hard steel so that it can’t
be crushed.

Counterbore Ring
 KV38/50 Technical Training
Main Bearings are
Crank Shaft Main Bearings
Tri-metal shells with
oil grove and bore in
block shell, no grove
or bore in cap shell.
Grease Lubricated
during manufacture.
 KV38/50 Technical Training
Crank Shaft Thrust Bearings
Install the thrust bearings
with the grooved /
scalloped sides towards the
thrust flange of the
crankshaft, moving the
crankshaft to the front or
rear to aid in installation.
 KV38/50 Technical Training
Crank Shaft Thrust Bearings
Check thrust retainer for
cleanliness or damage, install
over the crankshaft thrust
flange with the machined face
facing towards the front of the
engine.
 KV38/50 Technical Training
Crank Shaft Main Caps
The cylinder block has a number that is
used to keep the block and main bearing
caps together.
The number is located on the bottom
(oil pan flange) of the block at the left
bank rear.

The cap's location number on

the cap is in two places.
Notice that the numbers are
located on the opposite
side of the cap from the slot for
the bearing tang.
 KV38/50 Technical Training
Crank Shaft Main Caps
Only newer K38 and K50
engines have the ring dowel
(1) that protrudes from the
main bearing cap.
Do not install a cap with a
dowel ring in the block that
does not have a ring dowel on
the other caps. If you are not
sure, try to fit the dowel ting in
the correct capscrew hole in
the block. If it requires force,
do not install the ring dowel.
 KV38/50 Technical Training
Crank Shaft Main Caps
Three different designs of
capscrew have been used.

12-point capscrews that are

black
6-point capscrews that are
light gray
6-point capscrews with angle
marking (Part Number
3628452).
NOTE: Capscrews (1 and 2)
use the torque procedure
for tightening.

They can be intermixed and

installed in the same cap.
Capscrew (3) uses the torque
turn procedure for tightening.
 KV38/50 Technical Training
Crank Shaft Main Caps

NOTE: All engines built using the torque turn procedure are to have the
torque turn procedure applied when rebuilt or repaired in the field.
These engines can be identified by the capscrew markings.
Older engines, unless block line bored, retain the old torque
values. In cases where the torque turn procedure is not possible,
due to limited access, a torque value of 814 N•m [600 ft-lb] can be
used in place of the torque turn procedure.

NOTE: As the torque required for the torque turn procedure is

significantly higher than the torque only procedure, Cummins Inc.
recommends that a torque multiplier and breaker bar be used when
advancing the capscrew the final 90 degrees. A standard torque wrench
with 406 N•m [300 ft-lb] minimum capability, is to be used
(without the torque multiplier) to obtain the initial 339 N•m [250 ft-lb]
torque value.
 KV38/50 Technical Training
Under Skirt Cooling

Ensure that the mounting

faces on the block and
valve body are clean.

Fit nozzle assembly to

mounting pad, locating
the dowels in the holes in
pad face.
 KV38/50 Technical Training
Cylinder Liner

Cylinder Liner are spun cast for even

distribution of material, reduced risk of
porosity and cavitation

Gas Nitrided And Plateau Honed

Liner Improves durability
 KV38/50 Technical Training
Cylinder Liner
Use a hydrocarbon solvent, to
Clean the counterbore ledge, it
must be dry
Or the sealant applied in
assembly will not dry.

Use vegetable oil to Lubricate

the packing
ring bores of the cylinder block.

Install the shims (1) if required,

the following
table gives the available
thickness.

0.46mm - 0.018in
0.52mm - 0.0205in
0.56mm - 0.022in
0.79mm - 0.031in

.
 KV38/50 Technical Training
Cylinder Liner
Installation is a Top Stop Lower Press Fit
with 3 Sealing Rings, Top seal is a Crevice
seal and middle and bottom seals are “D”
ring design for coolant and for oil.
There is no seal installed at the top,
Use RTV™ sealant, Part Number 3377132.
Apply a bead of sealant at the bottom of the
cylinder liner flange. The sealant must be
applied to the bottom of the counterbore
ridge (5).
RTV™ Sealant Bead Size 1.1 to 1.6mm

The counterbore ring must be positioned

with the curved edge as illustrated.
Install the counterbore ring (5).
 KV38/50 Technical Training
Cylinder Liner

Liner is fitted by hand in service, always check stand proud.

 KV38/50 Technical Training
Crankshaft
Crank Shafts are
forged steel with
induction hardened
journals and fillets
with eight Bolt on
counterweights.
Both for V12 and
V16
 KV38/50 Technical Training
Crankshaft
Crank Shafts are fitted with
Both front and rear gears
For oil pump drive and
Timing gears.
 KV38/50 Technical Training
Cam Shaft Bushings
The K38 and K50 engines contain two camshaft bushings in each bore, except in the
bores in the "LB" front and "RB" rear. They contain one bushing only.

It is recommended that if
one bushing of the engine
bank must be replaced,
that all of the bushings for
that bank be replaced.
Part Number 205230, with
an internal oil groove, is
available for service.
 KV38/50 Technical Training
Cam Shaft Bushings

Use the camshaft bushing driver assembly, Part Number 3376637, and the driver
kit, Part Number 3376634.

For ease of removal/installation, hydraulic cam bushing tools are available.

They include hydraulic actuator kit, Part Number 3823621, installations/removal kit,
Part Number 3823647, and centering guide kit, Part Number 3823653.

NOTE: The camshaft bushing driver kit, Part Number ST-1228, contains the camshaft
bushing driver assembly and all of the engine kits (mandrels) required to perform this
procedure on any engine manufactured by Cummins Inc.
 KV38/50 Technical Training
Cam Shafts
DIAGRAM SHOWING THE CORRECT
CAMSHAFT TO BE FITTED TO
CORRECT BANK OF THE ENGINE

Cam lobes and journals are

Induction hardened and are Micro
finished.
 KV38/50 Technical Training
Cam Shafts
The camshafts for the K38 and K50 are different, however the installation procedure is the same.
See the CPL for the engine being serviced. Some of the newer K50 engines have
camshafts that cause the engine to have a different firing order, part number stamped on the end
of the camshaft for reference.
Use Lubriplate™ to lubricate each camshaft and all of the camshaft bushings completely.
Use camshaft pilot, Part Number 3376280.Install the two camshafts.
 KV38/50 Technical Training
Pistons
Pistons are aluminum, with an
anodized crown.
New one piece design, with oil
cooling gallery
With new ring pack
Decreased oil consumption
Improved engine efficiency
Longer life to rebuild.

Do not bead blast.

 KV38/50 Technical Training
New one piece piston Pistons
(sectioned) shows oil galleries
cast in crown, oil from piston
cooling nozzles is targeted
into one side of piston and
leaves via cast opening on the
other side
 KV38/50 Technical Training
Pistons
Ceramic Coated Top Ring (CKS)
• Increases fatigue strength
• Reduces scuffing

Positive Twist Second Compression Ring

• Has a top inside groove cut in it

Targeted Piston Cooling Nozzle

• Prevent coking under bowl
• Reduces piston temperature

Unique bowl design for specific applications

 KV38/50 Technical Training
Pistons and Con Rod Assembley
The piston has a cast arrow on the
bottom of the pin bore.

Assemble the offset pin with the

arrow pointing
toward the front of the engine.
NOTE: When properly assembled,
the arrow is on
the same side as the large chamfer
(A) and the lock tang on left bank
rods.

NOTE: When properly assembled,

the arrow is on
the opposite side of the large
chamfer (A) and the
long tang on the right bank rods.

Install a new snap ring in the piston

pin bore.
 KV38/50 Technical Training
Con Rods
Con rods have straight cut cap with two bolt fixing
and located with dowel pins
Inspect the threads of the connecting rod
capscrew for damage.
Check under the capscrew head for cracks.
Measure the connecting rod capscrew.
Capscrew Length (1)

Min 136.14MIN 136.91MAX

Capscrew outside diameter (2)

min15.27 MIN 15.37 MAX0.605

Capscrew outside diameter (3)

mmin17.35 MIN 17.45 MAX

The part must be replaced if it is not

within specifications.
 KV38/50 Technical Training
Con Rod Bolt Stretch Check
Rod Capscrew Stretch Specification

Min 0.343mm (0.0135in)

Max 0.470mm (0.0185in)

If the capscrew stretch is greater than

specification, loosen both capscrews and
remove and discard the one that was
greater than specification.

Install the new capscrew using the

specified torque steps and repeat the
capscrew stretch measurement
procedure, assuming the other capscrew
was within specifications.
KV38/50 Technical Training
Fly wheel housing
 KV38/50 Technical Training
Fly wheel housing
Housing and gasket located onto
block with guide pins and torqued
in sequence
 KV38/50 Technical Training
Fly wheel housing
The seal must be installed dry, no oil
is to be used at all.

Note: The sealing lip must be treated

with great care, any damage to the lip
could possibly result in an oil leak.
The seal must be installed within a
maximum of 10 minutes after
removing from packaging.
 KV38/50 Technical Training
Fly wheel

Fly wheel is located on a dowel,

Tighten bolts in sequence

1 5
12 7
10 3
4 9
8 11
6 2

Fly wheel and housing should be

checked for run out
KV38/50 Technical Training
Front Gear Housing
 KV38/50 Technical Training
Front Gear Housing
Install two guide pins in
gear housing capscrew
holes in front of cylinder
block (one in upper corner
of each bank).
Install gasket and gear
housing onto guide pins and
dowel pins and fit to the block
face start capscrews with
washers by hand as required.
KV38/50 Technical Training
Timing Gears
 KV38/50 Technical Training
Timing Gears
FIT IDLER SHAFTS

Lightly grease bores in

block to where idler shafts
fit. (Mobiflex 48 grease)
 KV38/50 Technical Training
Timing Gears
FIT IDLER SHAFTS
Select idler shafts and put
into block using a nylon
headed mallet ensuring
all oil holes are horizontal.
 KV38/50 Technical Training
Timing Gears
FIT WATER PUMP IDLER
GEAR

Turn crank until markings

are horizontal, V on right
bank and two V"s on left
bank.
Lightly grease idler shafts
(mobiplex 48 grease) and
fit one thrust washer to
each of the three idler
shafts with the grooved
side outwards.
Lightly grease thrust
washer. (Mobiplex 48
grease) Select biggest
sized gear (water pump
idler gear) and lightly coat
inside of bush with grease.
 KV38/50 Technical Training
Timing Gears
Slide gear onto idler shaft
Fit the second thrust
washer with the grooved
side pointing towards the
engine and ensuring it is
lightly coated in grease.
(Mobiplex 48 grease)
Locate an idler shaft
retaining washer over idler
shaft and secure with the
longer of the three
capscrews (having coated
the threads with 15w40
oil).
 KV38/50 Technical Training
Timing Gears
FIT THE RIGHT CAM IDLER

Using same procedure as before

 KV38/50 Technical Training
Timing Gears
FIT LEFT BANK CAMSHAFT
IDLER GEAR

Select middle size idler gear (left

bank camshaft idler gear) and
lightly coat inside bush with
grease.

Slide gear onto idler shaft

ensuring no damage is caused to
the gear bush and making sure
timing marks line up.
 KV38/50 Technical Training
Timing Gear Alignment

RIGHT BANK LEFT BANK

CAMSHAFT CAMSHAFT

RB
CAM
IDLER

LB
CAM
IDLER
WATER CRANK
PUMP
IDLER
 KV38/50 Technical Training
Front Cover
Carefully install gear
cover using dowels by
guiding the gear cover
onto the guide pins so
that the guide pins
protrude through the
cover. Standing in front of
the cover, push gear
cover up to gasket.
 KV38/50 Technical Training
Front Cover Engine Support
LUBE FRONT GEAR
COVER AND SUPPORT.

Lubricate the outside

diameter of the wear ring
on the front gear cover
with Castrol grease.

Note: Ensure that the

engine support moves Grease nipple
axially and can rotate
freely on the gear cover
wear ring.

Grease Nipple to the

side of the Front
engine support.
 KV38/50 Technical Training
Vibration Damper and Adapter
Vibration dampers have a limited
service life.
The vibration dampers must be
inspected at 6,000 hours
or two years and replaced at
24,000 hours of service.
 KV38/50 Technical Training
Cam Followers
Cam follower assembly has
three followers the Injector
followers is Larger for the high
injection Pressures.
Follower shaft has a Lubrite
coating.
Cam rollers are Micro finished
Location is through two bolts
with aligning dowel rings, oil is
fed from the cam shaft bushing
through to the follower shaft by
drillings.
 KV38/50 Technical Training
Push Rods
Push Rods are solid and
are the same length for exhaust
and inlet.
The injector push rod is the
same length but slightly thinner.
 KV38/50 Technical Training
Rocker Levers
The rocker leavers are cast.
The exhaust rocker lever is
longer and bigger than the
intake rocker lever
All three rockers use the same
adjustment method.

Rocker shaft is Lubrite coated

 KV38/50 Technical Training
Cylinder Head
The KV 38/50 cylinder head
accommodates injectors, valves,
valve guides, valve stem seals
During the machining process
two drillings are required for the
fuel system.
 KV38/50 Technical Training
KV38/50 Valve Train
4-Valve Per Cylinder Design
Optimizes air/fuel mixture with
faster response across the
rpm band

Advanced Valve Metallurgy

Enhanced thermal durability
Intake valves with Nitride
coating & triballoy valve seats
Inconel exhaust valves with
rotators.
Stemless crossheads
Upgraded with cast iron valve
guides & chrome valve stems
 KV38/50 Technical Training
KV38/50 Valve Train
The rocker housing assembly
Acts as a support for the rocker
Shaft and transfer of cooling to the
Return manifold.
 KV38/50 Technical Training
Lubrication System General Information
The K38 and K50 engines have different lubricating oil pumps. All pumps are
mounted to the bottom rear of the cylinder block. The pump is driven by a gear
that is mounted on the rear of the crankshaft.

The K38 and K50 (mechanically actuated injectors) and the QSK38 and QSK50
(electronically actuated injectors) engines have different lubricating oil pumps.
 KV38/50 Technical Training
Lubrication System General Information
Specifications

Lubricating Oil Pressure, Main Oil Rifle (15W-40 oil at 107°C [225°F]):
Maximum at rated rpm....................483 kPa [70 psi]
Minimum at rated rpm.....................310 kPa [40 psi]
Minimum at idle rpm.......................138 kPa [20 psi]
Maximum oil pressure spike on a cold engine.....................1655 kPa [240 psi]
Maximum lubricating oil flow to all accessories....................57 liters/min [15 gpm]

Lubricating Oil Temperature - Maximum in Sump....................121°C [250°F]

K38 Lubricating Oil Pan Capacity Between 87lts (23 gals) and 185lts (49 gals) depending on application

K50 Lubricating Oil Pan Capacity Between 121lts (32 gals) and 246lts (65 gals) depending on application

Maximum Oil Consumption....................0.47 liter/hr [0.50 qt/hr]

 KV38/50 Technical Training
Lubrication Flow
1. Oil inlet tube
2. Lubricating oil pump
3. High-pressure relief valve (K38)
4. High-pressure relief valve (K50)
5. Jumper cover
6. Oil cooler
7. Oil filter
8. Piston cooling rifle (outboard)
9. RB Oil cooler rifle
10.Cam oil rifle.

High Pressure Relief Valve

Opens @ 160 PSI, Dumps to Sump
 KV38/50 Technical Training
Lubrication Flow
1. Oil supply to filter head
2. Oil return to pan
3. Oil supply to filters
4. Oil pressure regulator
5. Oil filter
6. Control rifle
7. Filter bypass valve
8. Piston cooling control valve
9. Piston cooling rifle
10.Piston cooling nozzle
11.Main oil rifle
12.Piston cooling control valve
13.Piston cooling nozzle

Oil pressure regulator

40-70 PSI @ rated speed,
dump to sump
Filter bypass valve,
opens @ 51 PSI,
dump to post filter gallery
Piston cooling nozzle regulator, 15-20 PSI
 KV38/50 Technical Training
Lubrication Flow
1. Main oil rifle
2. Piston cooling rifle
3. Cam oil rifle
4. Piston cooling nozzle
5. Orifice
6. Cam follower
7. Rocker lever (exhaust)
8. Oil supply to main bearings
9. Oil supply to connection rod
10.Piston cooling nozzle

Engines with inboard piston

Cooling nozzles will not be
equipped with items(2) and (4).

Older engines with outboard

Piston cooling nozzles will not be
Equipped with item (10).
 KV38/50 Technical Training
Lubrication Flow
1. Main oil rifle
2. Idler gear
3. Oil flow through gear housing
into front cover
4. Oil to water pump
5. Oil to air compressor
6. Oil to hydraulic pump drive
7. Air compressor oil drain
(Cummins two-cylinder air
compressor).

Oil flow to the idler gears (2) is

through the cylinder block.
 KV38/50 Technical Training
Lubrication Flow
1. From main oil rifle
2. Oil supply to thrust bearing
3. Camshaft oil rifle
4. Idler gear
5. Oil supply to upper output housing
6. Turbocharger oil supply
7. Turbocharger oil drain.
 KV38/50 Technical Training
Lubrication System Eliminator Option
Engine mounted oil filter which cleans itself as it cleans the engine oil
Eliminates the need for disposable spin-on filters
Maintains the cleanest oil in the industry
 KV38/50 Technical Training
Eliminator™ Filtration
First Stage: full-flow stainless steel filter screen removes particles down to 20 microns. Sends
95% of clean oil to engine
Second Stage: remaining 5% backflushes the filter.
Back flushed oil is routed to a 2 micron centrifugal separator
 KV38/50 Technical Training
Extended Service:
Centinel™ Oil Management
Electronically controlled continuous
oil replacement system.
Automatically replaces lube oil at load
factor dependent intervals.
Burns the used oil with the fuel during
combustion as an additional energy
source.
Enables oil change intervals to be
dramatically extended using oil
analysis.
1:1 removal / replacement based on
fuel consumption providing
consistently high quality for all
applications.
Major reduction in used oil disposal
cost.
 KV38/50 Technical Training
Extended Service:
Centinel™ Oil Management
Self-monitoring, continuous oil replacement system controlled by engine ECM

Note: The Centinel System is Not an Oil Level Management System.

The Engine Oil Level Must be Checked at the Recommended Intervals
 KV38/50 Technical Training
Prelube Standard On Industrial Engines

Oil to Engine

Oil from
sump

Pump runs for up to 30 seconds after key-on and generates 5 to 10 PSI depending on
version in the lubrication system to prevent dry start up.
 KV38/50 Technical Training
Engine Cooling System Specifications
Cooling System Type......................................................................1 or 2 Pump - 2 Loop

Minimum Operating Block Coolant Temperature............................70°C [160°F]

Minimum Pressure Cap Rating at Sea Level..................................76 kPa [11 psi]

Maximum Pressure Cap Rating at Sea Level.................................103 kPa [15 psi]

Engine Coolant Circuit Thermostat Opening Temperature..............82°C [180°F]

Engine Coolant Circuit Thermostat Fully Open Temperature..........94°C [202°F]

Maximum Allowable Deairation Time..............................................25 minutes

Low Temperature Aftercooler (LTA) Circuit

LTA Circuit Thermostat Opening Temperature.................................66°C [115°F]

LTA Circuit Thermostat Fully Open Temperature.............................79°C [135°F]

 KV38/50 Technical Training
Coolant Flow Marine with LTA
1. Coolant flow from block to transfer tube
2. Rear transfer tube
3. Heat shields
4. Heat shield vents
5. Coolant supply to turbocharger
6. Turbocharger coolant return
7. Coolant return to thermostat
8. Aftercooler coolant return
9. LTA coolant outlet
10. LTA coolant inlet
11. Aftercooler coolant supply
12. Coolant outlet
13. Thermostat housing
14. Coolant bypass to coolant pump
15. Lubricating oil cooler
16. Aftercooler vent line
17. Coolant supply to block
18. Coolant pump
19. Coolant inlet
 KV38/50 Technical Training
Flow Through Thermostat Housing
1. From coolant manifold
2. Main engine thermostats
3. Bypass flow to coolant pump
4. Coolant to engine heat exchanger
5. LTA thermostat
6. Coolant supply from vee-cavity
7. To LTA heat exchanger
8. To aftercoolers
9. From LTA heat exchanger
10. From aftercoolers
11. Vent to expansion tank.

Thermostat Opening Temperature

82°C [180°F]
 KV38/50 Technical Training
Coolant Filters/DCA canisters
DCA filter mounting without LTA

DCA filter mounting with LTA

 KV38/50 Technical Training
Cooling System Drain Locations

Block drain right bank Block drain left bank

LTA drain cock

KV38/50 Technical Training
Air System
 KV38/50 Technical Training
Air System K50 with top box
1. Intake air inlet to
turbocharger
2. Turbocharger
3. Turbocharger air to
aftercooler
4. Intake air to cylinders.
 KV38/50 Technical Training
Air System 38 with top box
K38 with top box intercooler
Very early version
Not all engines had the
Intercooler but all had the
hardware.
If there were no coolant
pipes then there was no
After Cooler.

A few are still built today.

 KV38/50 Technical Training
Air System 50
K38’s and single stage K50’s
Have one turbo per bank.
The K50 two stage has
Two turbos per bank, one
Low pressure and one high.

Turbos are usually HX80 or

HX83.
Low pressure turbos are oil
Cooled. High pressure
turbos are
Water and oil cooled.

1. Intake air inlet to turbocharger

2. Low-stage turbocharger
3. High-stage turbocharger
4. Turbocharged air to aftercooler.
 KV38/50 Technical Training
Single Stage Engine LTA Air System
 KV38/50 Technical Training
Single Stage Engine HX80 LP Turbo

Oil Supply

Oil Return
KV38/50 Technical Training
2 Stage Engine HX83 HP Turbo

Oil Supply

Coolant Return

Oil Return

Coolant Supply
 KV38/50 Technical Training
After-coolers

The cast iron after-

cooler housings are
very heavy. Handle
With Caution!

Hoist or other
appropriate lifting
device is highly
recommended.

Aspiration Specifications

Maximum Intake Air Restriction (HD air cleaner)

Dirty Filter.................................................................63.5 cm-H 2O [25 in-H 2O]
Clean Filter...............................................................30.48 cm-H 2O [12 in-H 2O]
Minimum Dirt Holding Capacity HD Air Cleaner........25 g/cfm
Recommended Intake Piping Size I.D. ....................15.2 cm [6 in]
KV38/50 Technical Training
Exhaust System
 KV38/50 Technical Training
Exhaust System

1. Exhaust manifold
2. Turbocharger
3. Turbocharger exhaust outlet.
 KV38/50 Technical Training
Exhaust System
1. Exhaust manifold
2. High-stage turbocharger
3. Low-stage turbocharger
4. Turbocharger exhaust outlet.

Exhaust Specifications
Maximum allowable back pressure in piping and silencer............................75 mm-Hg [3.0 in-Hg]
Exhaust Restriction at Rated Power (maximum)
KTA38-G3/G4/G5, KTA50-G1/G2, Industrial, and Marine..................75 mm Hg [3.0 in Hg]
KTA38-G6/G7 and KTA50-G3/G6/G7/G8/G9.....................................51 mm Hg [2.0 in Hg]
Industrial (K2000E).............................................................................38 mm Hg [1.5 in Hg]
Normal exhaust pipe diameter
KT(A)38, KTTA38, KTA50...................................................................152 mm [6 inch]
KTTA50...............................................................................................203 mm [8 inch]
 KV38/50 Technical Training
Exhaust System Manifolds
Standard Log type configuration
Simple fitting and alignment.
 KV38/50 Technical Training
Exhaust System Manifolds
New configuration for Pulse
Type Turbos to ensure correct
Exhaust gas flow for optimum
Engine performance and
Emissions.
 Technical Support Everywhere

Over 100,000 HHP engines in-service

Global support

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Distributors:
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Independent
KV38/50 Technical Training

The End