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

2

Change Log

Date Author Description Page

30Aug10 Steve Beem Initial publication All

4/5/11 Steve Beem Added vibration limits. 9, 32

4/28/11 Steve Beem Changed capscrew 3093939 torque values to 115 N-m (85 ft-lbs). 30

5/31/11 Steve BeemAdded 6 mm clearance requirement for coolant lines and air inlet supply lines

9

6/14/11 Steve BeemUpdate the air compressor part number in option CP9610 to 5287012 (was 5256157)

15

12/13/11 Steve Beem Added TB92120 & TB9121 13

1/4/12 Steve BeemAdded reference to TB91550 & TB91560. Added flange PN 5289421 reference

17,19, 33

Change Log

3

SummaryAn 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).

4

Summary, continuedThe 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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Summary, continued If you have suggestions for improvement on this

document please advise.

Click here for Response

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Table of Contents Page

Requirements 7Discussion 10Engine Options to Select For A New

Engine Specification 11Aftermarket Parts to Order - All Engines 13Parts Information 15Special Instructions for An Engine that did

not come with a REPTO flywheel housing 18 Installation Guide - All Engines 19Check List 31

7

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.

8

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.

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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.

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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.

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Engine Options to Select For A New Engine SpecificationFH9686 REPTO flywheel housingCH9100 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.

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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.

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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 CP9610

Air Intake HoseB3.3NA B3.3TAA QSB3.3

IC9755, IC9855, or IC9854 (select

one)

IC9755, IC9855, or IC9854 (select one)

Air Crossover Connection B3.3T TB92120 HMFO

TB92121 HMRO TB92120 HMFO TB92121 HMRO

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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.

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Parts Information – Air Compressor Kit

Part No.Ref.

Item* Qty Part Description

5287012 1 1 Compressor, Air

3281977 2 1 Coupling, Plain Hose

5272918 3 1 Bracket, Connection

3979410 4 1 Coupling, Elbow Hose

4930304 5 4 Clamp, Hose

3093931 6 4 Screw, Hex Flange Head Cap

144044 7 2 Hose, Plain

5256330 8 1 Coupling, Elbow Hose

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 1 Hose, Flexible

5261309 12 1 Hose Plain

3922844 13 2 Clamp, Hose

3657733 14 1 Clip

3900589 15 1 Nut, Hexagon Flange

3093939 16 2

Screw, Hex Flange Head Cap M12 x 1.75 35 mm long, torque to 80 N-m (59 ft-lbs).

*Ref. Item numbers refer to corresponding numbers in illustrations within this document.

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Parts Information – B3.3NA, B3.3TAA, QSB3.3 Intake Connection

IC9755 has the same inlet orientation as IC9536IC9855 has the same inlet orientation as IC9533IC9854 has the same inlet orientation as IC9532

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Parts Information – B3.3T Crossover Tube

TB92120 HMFO replaces crossover tube TB91560. TB92121 HMRO replaces crossover tube TB91550.

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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.)

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Installation Guide - All EnginesThe 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 (5289421) is now released to replace the current flange.

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Installation Guide - All Engines, continued

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Installation Guide –All Engines, continued

• OEM must install tail support for air compressor.

• 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.

• 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

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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.

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Installation Guide – AC Air Supply Line for B3.3NA, B3.3TAA, QSB3.3

Long air supply

boss/connection.

Air Line In

AC Coolant Supply Line

AC Coolant Return Line Oil 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.

13

13

12

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

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

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Installation Guide – All Engines AC Oil Supply Line

Noun Name Part Number Item Ref. Qty Notes

Connector 4996937 9 2Torque 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 1

Nut, Hexagon Flange 3900589 15 1

Oil Line Location: Machined surface near front and top. More detail on next page.

• Remove plug and mount connector on 1 of the 5 possible oil rifle drillings as shown.

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11

9

14

15

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Installation Guide – All EnginesMounting Detail

AC Air Supply

AC Coolant Return

AC Coolant Supply

Oil Line: In

13

12

85

7

4

5 7

9

11

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Installation Guide – All Engines AC Coolant Return Line

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

Coupling Elbow 3281977 2 1 Add sealant to threads. Torque to 35 N·m [25 ft-lb]

Hose 144044 7 1 32 inches long

AC coolant Return Line

Mount Hose to Water Pump Inlet

Inlet is near the cast number ”9”

4

5

2

57

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Installation Guide – All Engines AC Coolant Supply Line

AC coolant Supply

Air Discharge (M27 x 2)

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 1 Cut to 29 inches long

• 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

5

7

5

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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.

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Installation Guide – All Engines Air Compressor Mount and AC Coolant Supply Bracket Connection

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 1

6

16

3

Remove Metal Plug Before mounting Bracket, Connection.

10

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Check ListHas 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?

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Check ListHas 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.

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Future Actions to be captured hereNeed instruction/illustration on plumbing the air

line into the crossover for B3.3T engines.Release flange 5289421 (which has correct air

compressor mounting holes) into option FH9686 replacing 4989452