KTA50 - Aftercooler

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html)
Preparatory Steps
 WARNING 
Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with
local environmental regulations.
 WARNING 
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below
50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause
personal injury.
 WARNING 
Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate
the compartment before servicing the batteries. To reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the negative (-) battery cable last.
This procedure describes several aftercooler arrangements.
Outboard Aftercooler - Standard Cooling System

Outboard Aftercooler - Low Temperature Aftercooler (LTA) Cooling System
Center Mount Aftercooler.
Disconnect the batteries. See equipment manufacturer service information.

Drain the cooling system. Refer to Procedure 008-018 in Section 8.
(/qs3/pubsys2/xml/en/procedures/28/28-008-018-tr.html)
Remove air coolant plumbing. Refer to Procedure 010-002 in Section 10.
Remove
Standard
Note : This procedure is performed while the intake

manifold (aftercooler housing) remains on the engine.
Remove the 21 capscrews and flat washers (5).
Note : Do not damage the gasket surfaces if it is necessary

to use a wedge to separate the parts.
Remove the aftercooler cover (6). It will be necessary to move the
cover so it will not hit the nipple on the core.
Remove the gasket (7) from the intake manifold (8).
 WARNING 
When using a steam cleaner, wear safety glasses or a face
shield, as well as protective clothing. Hot steam can cause
serious personal injury.
 WARNING 
When using solvents, acids, or alkaline materials for cleaning,

follow the manufacturer's recommendations for use. Wear
goggles and protective clothing to reduce the possibility of
personal injury.
 CAUTION 
Use a solvent that will not harm copper.
Remove the eight captive capscrews (9). Notice that the washers
on the capscrews are spring-type washers.
Remove the core (10) from the intake manifold (8).
Clean the element.

Use solvent or steam. Clean the remaining parts.
Check for damage.
LTA
Remove the capscrews and spring washers.
Remove the aftercooler element and rectangular strip seal.
Center-Mount
 WARNING 
When using a steam cleaner, wear safety glasses or a face
shield, as well as protective clothing. Hot steam can cause
serious personal injury.
 WARNING 
When using solvents, acids, or alkaline materials for cleaning,

follow the manufacturer's recommendations for use. Wear
goggles and protective clothing to reduce the possibility of
personal injury.
Remove both of the aftercooler covers (13) and gaskets (14).
Remove the aftercooler cores (15) and the gaskets (14) from the
housing (16).
Clean all o-ring bores and grooves. Clean all gasket surfaces.
Use solvent and steam. Clean the parts.
Check the parts for cracks or damage.

Note : If the K50 aftercooler housing does not contain cross
bolts, or contains a rib in the center of the housing, it is
recommended that the housing be modified for the cross
bolts before it is installed again.
Refer to Procedure 010-002 (Aftercooler Assembly) in Section 10.
Inspect for Reuse

Standard
Clean and check element for reuse. Refer to Procedure 010-002 in
Section 10. (/qs3/pubsys2/xml/en/procedures/28/28-010-002-
tr.html)
LTA
Clean and check the element for reuse.
Inspect the rectangular strip seal (3). Discard the seal if it is ripped,
cracked, or worn.
Center-Mount
Clean and check the element for reuse. Refer to Procedure 010-002
in Section 10. (/qs3/pubsys2/xml/en/procedures/28/28-010-002-
tr.html)
Install
Standard
Install the core (10) in the manifold (8). Install the eight capscrews
(9) that contain the captive spring washers.
Torque Value: 25 n•m [ 20 ft-lb ]
Install a new gasket (7) and cover (6). Install the 21 captive
capscrews and flat washers (5).

LTA
Install the seal (2) into the groove in the air intake manifold housing
(4). If a new seal (3) has been installed, check the length that is
protruding outside the housing. This protrusion must be flush to 3
mm [1/8 inch] in length outside the housing at both sides. If
required, clip the seal to this length. Apply a bead of sealant. Install
the aftercooler core (1).
Note : All aftercooler cores are identical and are inserted
into the housing with the water inlet and outlet just below the
air intake connection.
Install the 3 inch capscrews and spring washers into the holes
shown.
Capscrews at position 1 can only be placed in the rear intake

manifold assemblies at this time.
Tighten the inserted capscrews just enough to hold the aftercooler

element in place.
Install the 6.75 inch capscrews and spring washers into the holes
shown.
Capscrews will be inserted in the open positions either during the

installation of the aftercooler plumbing or the intake manifold
assembly.
Tighten all of the inserted capscrews just enough to hold the
aftercooler core in place.
Use the sequence shown. Tighten the capscrews.

Center-Mount
Install the housing-to-core flange gasket (14). Be sure the proper
holes are aligned with the roll pin.
Install the cooler core (15). Install a new cover-to-core flange gasket
(14) and the cover (13).
Note : Each cover contains 18 capscrews.

Install the flat washers, lock washers, and capscrews.

Repeat this step for the other side of the assembly.
Finishing Steps
 WARNING 
Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with
local environmental regulations.
 WARNING 
Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate
the compartment before servicing the batteries. To reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the negative (-) battery cable last.
Install air and coolant plumbing. Refer to Procedure 010-002 in Section 10

(/qs3/pubsys2/xml/en/procedures/28/28-010-002-tr.html).
Fill the cooling system. Refer to Procedure 008-018 in Section 8.
Connect the batteries. See equipment manufacturer service information.
Operate the engine. Check for leaks.
Last Modified: 12-Sep-2019

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(/qs3/pubsys2/xml/en/manual/4021528/4021528-titlepage.

This procedure describes several aftercooler arrangements.

Outboard Aftercooler - Standard Cooling System

Disconnect the batteries. See equipment manufacturer service information.

Note : This procedure is performed while the intake

Note : Do not damage the gasket surfaces if it is necessary

Remove the gasket (7) from the intake manifold (8).

When using solvents, acids, or alkaline materials for cleaning,

Remove the core (10) from the intake manifold (8).

Clean the element.

Check for damage.

Remove the aftercooler element and rectangular strip seal.

When using solvents, acids, or alkaline materials for cleaning,

Remove both of the aftercooler covers (13) and gaskets (14).

Use solvent and steam. Clean the parts.

Check the parts for cracks or damage.

Inspect for Reuse

Torque Value: 25 n•m [ 20 ft-lb ]

Capscrews at position 1 can only be placed in the rear intake

Tighten the inserted capscrews just enough to hold the aftercooler

Capscrews will be inserted in the open positions either during the

Use the sequence shown. Tighten the capscrews.

Torque Value: 45 n•m [ 35 ft-lb ]

Note : Each cover contains 18 capscrews.

Torque Value: 25 n•m [ 20 ft-lb ]

Install air and coolant plumbing. Refer to Procedure 010-002 in Section 10

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