Section F - Familiarization

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1 Exhaust System - Overview Page F-56 Section F - Familiarization Longer capscrews (7/16-14 x 5 1/2 in) must replace the old capscrews (7/16-14 x 5 in) due to increased manifold thickness. Use of the old capscrews can result in an exhaust leak and engine damage. The gaskets and associated water connection hardware was not changed. The turbocharger end sections and closed end sections have tapped holes for the coolant vent line attachment. Dry Pulse Exhaust Manifold The K1800E, K2000E, KTA50 and KTTA50 engines and QSK50 engines with electronically actuated injectors, with Dry Exhaust systems use Pulse Type manifolds. The K1800E and single stage QSK50 engines with electronically actuated injectors, use two different exhaust manifold center sections to allow both exhausts and inlets to be in the same direction (towards front or rear of the engine). The K2000E and dual stage QSK50 engines with electronically actuated injectors, use exhaust manifold center sections (turbocharger mounting) which are identical on both banks of the engine. However, one manifold center section is turned 180 degrees when compared to the other manifold center section. The KTA50 engines with pulse type manifolds, contain a straight center section on one bank and a curved section on the other bank. The manifold center sections must be installed on the correct bank for the engine exhaust piping to fit the application. If the exhaust is to be towards the rear of the engine, the manifold with the straight center section must be installed on the left bank. If the exhaust is to be toward the front of the engine, the straight center section must be installed on the right bank. The KTTA50 engines and QSK50 engines with electronically actuated injectors, with pulse type manifolds, contain a straight center section on both banks. These manifolds can be installed on either bank. Bellows Style Exhaust System The bellows style exhaust system was introduced into production for K2000, K2000E, C1800, K1800E and C1600 rear engine power take-off engines in January, 1998 (ESN ), and for QSK50 engines with electronically actuated injectors in January A service kit, which was introduced for all K50 industrial application engines, converts older slip-joint style engines. The exhaust manifold system provides a bellows joint between exhaust manifold sections, which improves serviceability and reduces exhaust gas leaks. A minimum of one full bank must be replaced when switching from slip-joint manifolds to bellows style manifolds. To allow for proper alignment of bellows manifolds after rebuild, three gaskets were introduced into service. The three gaskets have thicknesses of mm [0.020 in], mm [0.025 in], and mm [0.035 in]. These gaskets are used once head alignment is determined through the use of the KV exhaust manifold/head alignment tool. NOTE: The bellows style manifolds can be retrofitted on any K50 engine that is equipped with pulse type exhaust manifolds.

2 Exhaust System - Overview Section F - Familiarization Page F-57 Exhaust Manifold Mounting Capscrews Some of the manifold mounting capscrews require hardened washers and some require spacers. Be sure the correct washers and spacers are installed or failure will result. Failure will result if standard capscrews are installed to mount the exhaust manifold. If the wrong washer is used, an interference condition can exist between the exhaust manifold capscrew and head bolt. This interference can cause exhaust leaks and capscrew breakage. The exhaust manifold mounting capscrews are manufactured from a special high strength material. A thicker washer must be used on all dry exhaust manifolds. Some of the older manifold mounting capscrews have locking type threads. The newer capscrews do not have the locking type threads and are stamped with the letter "N" on the capscrew head to indicate non-locking type threads. Capscrews with the "N" stamped on the capscrew head must have a lockplate installed to prevent the capscrews from loosening. Exhaust Manifold Mounting Gaskets New gaskets have been released to improve the sealing capability. The new gaskets are a dull gray color. The old gaskets shine similar to metal. The old gaskets must not be used on engines with a dry exhaust manifold. The old gaskets can be used on engines with a wet exhaust manifold. Do not combine the old and new gaskets on the same engine, because the new gaskets are thicker.

3 Exhaust System - Overview Page F-62 Section F - Familiarization Reference Number Description Quantity (per Engine) 1 Manifold, Exhaust (Closed End Section) 4 2 Manifold, Exhaust (Plain Center Section) 2 3 Manifold, Exhaust (Turbocharger Center Section) 2 4 Gasket, Exhaust 16 5 Washer, Hard 56 6 Capscrew, (Special) [7/16-14 x 5.50 inch] 64 7 Lockplate 32 8 Spacer, mm [4.159 inch] Length 8 Exhaust Manifold, KTTA50 Dry, Pulse Type - Exploded View Reference Number Description Quantity (per Engine) 1 Manifold, Exhaust - Turbocharger Center Section 1 (Straight) (See to Note 1) 2 Manifold, Exhaust - Center Section (Curved) (See to 1 Note 2) 3 Manifold, Exhaust (Closed End Section) 6 4 Pipe, Exhaust 2 5 Gasket, Exhaust 16 7 Capscrew, (Special) [7/16-14 x 3.00 inch] 64 8 Spacer, mm [1.670 inch] Length 64 9 Lockplate 32 NOTE: Left bank for exhaust to rear of engine. Right bank for exhaust to front of engine. NOTE: Right bank for exhaust to rear of engine. Left bank for exhaust to front of engine.

4 Exhaust Manifold, Dry Page AS-36 Section AS - Engine Assembly - Group 00 Cylindrical Oil Cooler NOTE: The manifolds can be installed on either engine bank. NOTE: Install capscrews (3) that are 140 mm [5.5 in] in length. Install hardened washers (1) on all of the capscrews except at the end of the closed-end section. Install spacers (2) that are mm [4.149 in] in length on the capscrews at the end of the closed-end section. Install the hardened washers (1) and spacers (2) on the capscrews (3). Apply an anti seize compound on the threads of the capscrews. Do not use gasket adhesives. The adhesives can cause the molybdenum disulfide coating on the gasket to lose its effectiveness and cause a gasket or capscrew failure NOTE: The gasket must be installed so that the raised bead on the gasket is toward the manifold. WARNING This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component. Install the gaskets (4), the manifold (5), and the capscrews. Check to be sure the gasket is aligned properly with the manifold and the cylinder head. 140 mm [5.5 in] Capscrew with "N" Stamped on Head: Torque Value: 55 N m [ 40 ft-lb ] NOTE: The capscrews without the "N" stamped on the head have special threads to lock the capscrew and are not available for service. These are not recommended for installation on KTTA50 engines. Use a [0.625 in 12 point] socket and a mallet. Install each lockplate (6) on the heads of two capscrews. Do not break the lockplate. KTA50, KTTA50, K1500E, K1800E and K2000E Dry Exhaust, Pulse Type Manifolds KTA50 engines with pulse type manifolds contain a straight center section (1) on one bank and a curved center section (2) on the other bank. The manifold center sections must be installed on the correct engine bank for the engine exhaust piping to fit the application. If the exhaust is to be toward the rear of the engine, the manifold with the straight center section (1) must be installed on the left bank. If the exhaust is to be toward the front of the engine, the straight center section must be installed on the right bank. KTTA50 engines with pulse type manifolds contain a straight center section (1) in both banks. These manifolds can be installed on either engine bank.

5 Exhaust Manifold, Dry Section AS - Engine Assembly - Group 00 Page AS-37 A variety of changes were made to the K50 pulse type exhaust manifolds (1,2,3 and 2) and manifold mounting parts (7,8 and 9). A revised straight center section, Part Number , replaced the previous straight center section, Part Number This revised straight center section is to be used on non-uprate K50 engines that require a pulse manifold (example: KTA50C-1600 engine). This manifold, Part Number , can be identified by a notch in the exhaust port nearest to the two exhaust inlets or double end. The previous manifold, Part Number , did not have a notch. The notch can also be seen in the lower exhaust inlet.

6 Exhaust Manifold, Dry Page AS-38 Section AS - Engine Assembly - Group 00 The uprate construction straight center section, Part Number , is to be used on the K2000E, KTTA50- C1800-B version, and on the left bank of the K1800E. A dogleg exhaust manifold section, Part Number , was released for use on uprate K50 construction engines to accommodate this increased distance. The uprate construction straight center section, Part Number , is to be used on the K2000E, KTTA50- C1800-B version, and on the left bank of the K1800E. The construction uprate curved center section is to be used on the right bank of the K1800E. The K1800E right-bank center section allows for rear-out exhaust. Engine Serial Number First for Sections Serial Number Section Part Number * * Engine serial number first build date is March 1994.

7 Exhaust Manifold, Dry Section AS - Engine Assembly - Group 00 Page AS-39 The manifolds have been changed by increasing the size of the dowel hole (A) to the same diameter, 15 mm [0.591 in], as the other seven mounting holes within each section. The smaller dowel hole was used to locate the manifold front to rear to make sure the slip joint was properly positioned. Guide pins or studs must be used or the manifolds will not be positioned properly, causing the manifold cylinder head capscrews to break. Use locating pins to position the new manifolds properly. Use one pin in each section. The diameter of the pin provides the proper manifold position and alignment. The locating pin dimensions are listed below so they can be locally manufactured. (A) Diameter: 13.8 mm to 14.0 mm [0.543 in to in]. (B) Undercut to thread root diameter (C) Thread size in x 14 in x 0.50 in long (D) Unthreaded length 99.2 mm [3.91 in]. NOTE: Wrench flats are optional on unthreaded end. Inadequate clearance between exhaust manifold sections (A and B) will result in failed capscrews, exhaust manifolds, or cylinder heads. Use guide pins or studs to make sure the manifolds have proper clearance (C and D). The typical manifold clearance (C) ranges from 4.0 to 9.5 mm [0.158 to in].

8 Exhaust Manifold, Dry Page AS-40 Section AS - Engine Assembly - Group 00 Longer exhaust manifold mounting capscrews and spacers provide improved gasket sealing while permitting slippage or movement at the cylinder head and exhaust manifold interface. Part Name Old Dimension New Dimension Spacer-A 42.4 mm [1.67 in] mm [4.16 in] Spacer-B 76.2 mm [3.00 in] mm [5.50 in] NOTE: The longer capscrews and spacers can be used in all positions except the left-bank front without any component changes. Installation of longer capscrews and spacers in the left-bank front position requires a new thermostat housing support and water transfer tube. New capscrews and spacers can be used on any K50 pulsetype manifold part number. WARNING This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component. Do not use gasket adhesives. The adhesives can cause the molybdenum disulfide coating on the gasket to lose its effectiveness and cause a gasket or capscrew failure. Apply an anti-seize compound on the threads of the capscrews. NOTE: The gasket must be installed so the raised bead on the gasket is toward the manifold. Install the gaskets, manifold, and mounting capscrews and spacers. Check to be sure that the gasket is aligned properly with the manifold and the cylinder head. Torque Value: 55 N m [ 41 ft-lb ] NOTE: When installing the lockplate over the capscrew head, install the plate to approximately one-half of the head height. Installing the lockplate until it bottoms will cause it to break. In order to obtain clearance (A) for the longer capscrews and spacers, three other component changes have been made. 1. A clearance (A) has been cast into the thermostat housing support to permit wrench and lockplate clearance.

9 Exhaust Manifold, Wet Section AS - Engine Assembly - Group 00 Page AS The water transfer tube (A) from the front of the V- cavity to the thermostat housing support interferes with the capscrew lockplate (B). A flat has been added to the water transfer tube (A) to help prevent interference with the capscrew lockplate (B) when the longer spacers are used. The dotted line (C) represents the flat added to the tube. NOTE: Do not install the old lockplate, Part Number , upside down to clear the water tube. The lockplate will either break or not be retained properly on the capscrew head. 3. To increase the water-tube-to-lockplate clearance even more, a new lockplate was released. The new lockplate has the V-bend pointed downward toward the manifold, rather than upward. These changes were introduced in November 1994 (ESN first ). Exhaust Manifold, Wet ( ) General Information See General Information and Exploded Views in Section 11, Exhaust System, of this manual for additional information. The following installation procedures assume that the manifold is assembled as shown in Section 11. The procedures show the installation of one manifold. Each engine has two manifolds. The manifold parts and mounting hardware are not the same for all K38 and K50 engines. Because the parts are different, procedures are described for installation of the exhaust manifolds for: KT38 & KTA38 Dry Exhaust Manifolds KTTA38 Dry Exhaust Manifolds KT38 & KTA38 Dry Exhaust Manifolds with Center Mount Turbochargers (Outboard aftercoolers) KT38, KTA38, and KTA50 Wet Exhaust Manifolds KTA50 Dry Exhaust Manifolds KTTA50 Dry Exhaust, Log Type Manifolds KTA50, KTTA50, K1500E, K1800E and K2000E Dry Exhaust, Pulse Type Manifolds

EGR Actuator Slow Learn April Installation of the DD13 Exhaust Gas Recirculation Valve Actuator Pull Rod

1 4 07-13 SUBJECT DATE EGR Actuator Slow Learn April 2013 Additions, Revisions, or Updates Publication Number / Title Platform Section Title Change DDC-SVC-MAN-0083 Installation of the DD13 Exhaust Gas