2. 100. 003. C Air Compressor Up-fit and Plumbing Guide For LDI B3 2.100.003.C Air Compressor Up-fit and Plumbing Guide For LDI B3.3 Engine Platform

Change Log Change Log Date Author Description Page 30Aug10 Steve Beem Initial publication All 4/5/11 Added vibration limits. 9, 32 4/28/11 Changed capscrew 3093939 torque values to 115 N-m (85 ft-lbs). 30 5/31/11 Added 6 mm clearance requirement for coolant lines and air inlet supply lines 9 6/14/11 Update the air compressor part number in option CP9610 to 5287012 (was 5256157) 15

Summary An engine mounted air compressor option cannot be ordered as a factory installed option on the IndustriaI B3.3 engine specifications (B3.3NA, B3.3T, B3.3TAA, QSB3.3). There is one air compressor option (CP9610) that can be ordered as an aftermarket kit and mounted by the Cummins Distributor on the Industrial B3.3 engines. This air compressor option requires a Rear Engine Power Take-Off (REPTO) flywheel housing (FH9686).

Summary, continued The intent of this Up-Fit Guide is to identify what specific parts to order from the Cummins Aftermarket Parts Business and to provide all the necessary instructions to up-fit a B3.3 engine with this air compressor option (CP9610). Disclaimer; Not all the components/options are released/available at the time of this publication. This publication will be updated as new information becomes available. As changes are made, the date on the Change Log (page 2) of this document will change.

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Table of Contents Page Requirements 7 Discussion 10 Engine Options to Select For A New Engine Specification 11 Aftermarket Parts to Order - All Engines 13 Parts Information 15 Special Instructions for An Engine that did not come with a REPTO flywheel housing 18 Installation Guide - All Engines 19 Check List 31

Requirements AEB 20.11 (Automotive and Industrial Installation Requirements - Air Compressor Systems) needs to be followed. If you are up-fitting the Rear Engine Power Take Off (REPTO) flywheel housing on an engine, you must remove cup plug 4988075 from the rear face of the block to allow oil to enter the REPTO housing.

Requirements, continued Original Equipment Manufacturer (OEM) must install air compressor tail support, which will attach to the transmission. Grade 8, M10 x 1.5 capscrews torqued to 47.5 N-m (35 ft-lbs) are recommended for attaching support to air compressor. Coolant hoses must be secured every 18 inches. Air discharge hose must be supplied by the OEM and must have a #8 or #9 hose diameter.

Requirements, continued No accessories can be driven off the rear of the air compressor. Submit an Engine Modification Form to update Engine History with the options changes as described in section 3 Appendix of AEB 15.55. The air compressor mounting system natural frequency must be greater than 313.5 Hz. Maintain minimum clearance of 6mm for coolant line(s) to other components. Maintain minimum clearance of 6mm for air inlet supply plumbing to other components.

Discussion The Wabco 15.2 CFM (CP9610) air compressor is the only air compressor compatible with the B3.3 engine. For air compressor installation information, refer to AEB 20.11Automotive and Industrial Installation Requirements - Air Compressor Systems.

Engine Options to Select For A New Engine Specification FH9686 REPTO flywheel housing CH9100 Coolant heater plug. The coolant heater option (CH9101) cannot be used because the port is needed for air compressor coolant. For B3.3NA, B3.3TAA, QSB3.3 the factory IC options will be discarded and replaced with aftermarket IC options (IC9755, IC9855, IC9854), which provide a port to supply air to the air compressor.

Engine Options to Select For A New Engine Specification, continued B3.3T engine specification does not require an IC option. The turbocharger cross-over tube in the TB option will be replaced with an aftermarket part to provide a port to supply air to the air compressor.

Aftermarket Parts to Order – All Engines Description Engine Engine has REPTO (FH9686) Engine does not have REPTO Flywheel Housing B3.3NA B3.3T B3.3TAA QSB3.3 none FH9686 Air Compressor Kit B3.3NA B3.3T B3.3TAA QSB3.3 CP9610 Air Intake Hose B3.3NA B3.3TAA QSB3.3 IC9755, IC9855, or IC9854 (select one) IC9755, IC9855, or IC9854 (select one) Air Crossover Connection B3.3T TBD

Aftermarket Parts to Order – All Engines Think ahead and order your parts early! It usually takes the service department 90 days from order to delivery of parts that are not on the shelf.

Parts Information – Air Compressor Kit The CP9610 air compressor option from aftermarket parts will includes the following kitted parts. Part No. Ref. Item Qty Part Description 4996937 9 2 Connector, Male 3929751 10 1 Gasket, Acc Drive Cover 4996624 11 Hose, Flexible 5261309 12 Hose Plain 3922844 13 Clamp, Hose 3657733 14 Clip 3900589 15 Nut, Hexagon Flange 3093939** 16 Screw, Hex Flange Head Cap M12 x 1.75 35 mm long, torque to 80 N-m (59 ft-lbs). Part No. Ref. Item* Qty Part Description 5287012 1 Compressor, Air 3281977 2 Coupling, Plain Hose 5272918 3 Bracket, Connection 3979410 4 Coupling, Elbow Hose 4930304 5 Clamp, Hose 3093931 6 Screw, Hex Flange Head Cap 144044 7 Hose, Plain 5256330 8 *Ref. Item numbers refer to corresponding numbers in illustrations within this document. ** These capscrews are not yet structured in this option. These are needed to mount the air compressor to the REPTO.

Parts Information – B3.3NA, B3.3TAA, QSB3.3 Intake Connection IC9755 has the same inlet orientation as IC9536 IC9855 has the same inlet orientation as IC9533 IC9854 has the same inlet orientation as IC9532

Parts Information – B3.3T Crossover Tube TBD replaces the crossover tube in TBNEW.

Special Instructions for An Engine that did not come with a REPTO flywheel housing You MUST REMOVE the specified cup plug (PN 4988075) from the block to allow oil to enter the REPTO housing. (This step is not needed if REPTO is factory installed.)

Installation Guide - All Engines The air compressor mounting flange (PN 4989452) that will come with your REPTO flywheel housing option (FH9686) will not have the correcting mounting holes for attaching your air compressor. You will have to drill and tap holes in the flange as shown on the next slide. A new flange (5263684) is being designed/released to replace the current flange, but is not yet available.

Installation Guide - All Engines, continued

Installation Guide – All Engines, continued OEM must install tail support for air compressor. The coolant hoses must be secured every 18 inches to avoid excessive vibration. Advised locations shown on next page. Air Discharge thread is M27 x 2. Air Discharge tube will be supplied by OEM and must have a #8 or #9 hose diameter or larger per AEB 20.11 Air compressor tail support flange includes two M10 x 1.5 tapped holes to support air compressor. Flange thickness is roughly 16mm. Grade 8, M10 x 1.5 capscrews torqued to 47.5 N-m (35 ft-lbs) are recommended.

Installation Guide – All Engines Advised Hose Support Locations Provisions for clipping oil line are supplied in the air compressor kitted option (CP 9610). The water lines and air line may be supported by the engine chassis.

Installation Guide – AC Air Supply Line for B3.3NA, B3.3TAA, QSB3.3 AC Coolant Return Line Oil Line In 13 Air Line In OEM must remove factory supplied Intake connection and corresponding gasket, and install new gasket and connection air intake from IC 9854/ IC 9855/IC 9755. 12 13 AC Coolant Supply Line Long air supply boss/connection. Noun Name Part Number Item Ref. Qty Notes Clamp, Hose 3922844 13 2 Torque to 8 N·m [71 in-lb] Hose 5261309 12 1 40 inches long

Installation Guide – AC Air Supply Line for B3.3T

Installation Guide – All Engines AC Oil Supply Line 15 11 Remove plug and mount connector on 1 of the 5 possible oil rifle drillings as shown. 9 14 9 Oil Line Location: Machined surface near front and top. More detail on next page. Noun Name Part Number Item Ref. Qty Notes Connector 44996937 9 2 Torque to 24 N·m [18 ft-lb] . Note: 4996937 comes with 2 O-rings: Larger size (toward the hose): 3922794 & Smaller size (toward the block): 3678925 996937 Hose 4996624 11 1 Clip 3657733 14 Nut, Hexagon Flange 3900589 15

Installation Guide – All Engines Mounting Detail 7 5 AC Air Supply 4 12 13 AC Coolant Return 11 8 5 9 7 AC Coolant Supply Oil Line: In

Installation Guide – All Engines AC Coolant Return Line 5 4 7 5 AC coolant Return Line Mount Hose to Water Pump Inlet Inlet is near the cast number ”9” 2 Noun Name Part Number Item Ref. Qty Notes Coupling Elbow 3979410 4 1 Torque to 24 N·m [18 ft-lb] Clamp, hose 4930304 5 2 3281977 Add sealant to threads. Torque to 35 N·m [25 ft-lb] Hose 144044 7 32 inches long

Installation Guide – All Engines AC Coolant Supply Line Air Discharge (M27 x 2) Remove Metal Plug Before mounting Bracket, Connection. OEM must apply a layer of liquid gasket to prevent fluid leaks between cylinder block and bracket. 8 7 5 AC coolant Supply 5 Noun Name Part Number Item Ref. Qty Notes Coupling Elbow 5256330 8 1 Torque to 24 N·m [18 ft-lb] Clamp, hose 4930304 5 2 Hose plain 144044 7 Cut to 29 inches long

Installation Guide – All Engines - Tail Support Two M10 x 1.5 thru holes Flange is roughly 16mm thick. Center to Center Hole Distance is 47.32 mm.

Installation Guide – All Engines Air Compressor Mount and AC Coolant Supply Bracket Connection Remove Metal Plug Before mounting Bracket, Connection. 16 3 6 10 Noun Name Part Number Item Ref. Qty Notes Screw 3093931 6 4 Torque to 35 N·m [26 ft-lb] Screw, Hex Flange Head Cap 3093939 16 2 M12 x 1.75 35 mm long, torque to 115 N-m (85 ft-lbs). Bracket, Connection 5272918 3 1 Gasket, Acc Drive Cover 3929751 10

Check List Has AEB 20.11 been followed? Is the air discharge line size a #8 or #9 hose diameter or larger ? Does the AC coolant supply line come from the coolant heater (CH) port on the cylinder block? Does the AC coolant return line plumb into the water pump inlet? Is there a rear bracket supporting the compressor? Has the metal plug in the cylinder block, where the air compressor coolant supply line is plumbed, been removed?

Check List Has a layer of liquid gasket been applied between cylinder block and bracket connection (PN 5272918) to prevent fluid leaks? Have all capscrews been properly torqued? Has sealant been added to the coupling elbow that is threaded into the water pump inlet? (This elbow does not have an O-ring seal.) Is the air compressor mounting system natural frequency greater than 313.5 Hz.

Future Actions to be captured here Release Option CP9610 Release Options IC9755, IC9855, IC9854 Need instruction/illustration on plumbing the air line into the crossover for B3.3T engines. Release flange 5263684 (which has correct air compressor mounting holes) into option FH9686 replacing 4989452