Section 3 - Combustion Air System B Series Page 3-1 Section 3 - Combustion Air System Section Contents Aftercooler and Gasket.. Air Crossover Tub Replacement... Air System Flow - Diagrams. Charge Air Cooler - Cleaning and Inopection.. Charge Air Cooler - Troubleshooting Intake Manifold Pressure - Check Intake Manifold Temperature - Check. Combustion Air System - Service Tools 7 Combustion Air System Flow - General intormation........ Intake Air Restriction - Checking Lubricating Oi! Consumption ani Malfunctioning Turbocharger Turbocharged Engines - Air L ‘Turbocharged Engines - Exhaust Leaks Turbocharger Boost Pressure ~ Measurement « Turbocharger NoI8@ wuss Exhaust Manifold and Gaskets Replacement... Intake Air and Exhaust System Specifications. Intake Manifold Cover and Gasket .......0. Replacement. ‘Turbocharger - Testing, a Rotor Assembly Clearance - Measurement Turbocharger... Replacement... ‘Turbocharger Boost Pressure Speciticiations ‘Turbocharger Wastegate Actuator Calibration. Turbocharger Wastegate Actuator Boost Capsule Replacement. Turbocharger Westegate Capsule Checking) Turbocharger Wastegate Func! ‘Checking... Turbocharger Wastogate Valve Accembly ‘Checking.Combustion Air System Flow - General Information Section 3 - Combustion Air System Page 3-2 BSe Combustion Air System Flow - General Information ‘The engine was designed as a turbocharged engine, but a naturally aspirated version of the B engine is available for industrial applications. Air is pulled into the engine from an air filter, Clean air is very important to the life of the engine. Ingested dust and dirt can very quickly damage the cylinders. Make eure that an excellent quality air cleaner is used and that it is periodically replaced according to the manufacturer's recommendations. Intake air for the naturally aspirated engine flows from the air cleaner to the intake manifold. From the intake manifold, the air is pulled into the cylinders and used for combustion. After combustion it is forced out of the cylinders and through the exhaust manifold. On the turbocharged engines the intake air is drawn through the air cleaner into the compressor side of the turbocharger and then through the crossover tube and into the intake manifold. From the intake manifold the aie is forced into the cylinders and used for combustion. Energy from the exhaust gases is utilized by flowing the exhaust through the exhaust side of the turbocharger to drive the turbine wheel. The turbine wheel and shaft drives the compressor wheel which forces more air into the cylinders for combustion. The additional air provided by the turbocharger allows more fuel to be injected to increase the power output from the engine. On turbocharged-aftercooled engines, intake air from the turbocharger flows through the cooling fins of the aftercooler before entering the intake manifold. The cooled air becomes more dense and contains more oxygen which allows more fuel to be injected further increasing the power output from the engine. The 1991 to 1994 automotive engines use a chassis-mounted charge air cooler instead of an engine mounted aftercooler to provide cooler charge air to the engine to improve engine performance and reduce emissions. This system also uses large diameter piping to transfer the air from the engine turbocharger to the charge ait cooler, then returns the air from the charge air cooler to the engine intake manifold. NOTE: The long term integrity of the charge. air cooling system is the responsibility of the vehicle and component manufacturers, ‘Some turbocharged engines use a wastegated turbocharger to limit the maximum boost pressure that the turbo can develop. Wastegate operation is controlled by an actuator that senses compressor pressure and balances it against a preset spring load. The wastegate valve is located in the turbine inlet passage. When open, it diverts @ portion of the exhaust gas away from the turbine wheal, thereby controlling the shaft speed and boost. A Caution: The turbocharger is 4 performance part and must not be tampered with. The wastegate bracket is an integral part of the turbocharger, Tampering with the Wastegate Components can reduce durability by increasing cylinder pressure and thermal loading due to incorrect Infet and exhaust manifold pressure. Poor fuel economy and failure to meet regulatory emissions laws may result. Increasing the turbocharger boost will not increase engine power. ‘The turbine and compressor wheels and shaft are supported by two rotating bearings in the bearing housing. Passages within the bearing housing direct filtered, pressurized engine oil to the shaft bearings and thrust bearing. The oil is used to lubricate and cool the rotating components to provide for smooth operation. The oil then drains, from the bearing housing to the engine sump through the oil drain line. A restricted or damaged oil drain line can cause the turbocharger bearing housing to be pressurized causing oll to leak past the seais. NOTE: An adequate supply of good, filtered oil is very important to the life of the turbocharger. Make sure that an excellent quality oil is used and that it and the oil filter are changed according to the maintenance recommendations. Caution: A cetelyst is installed on all EPA and CARB approved automotive applications. Lubricating off blending is not permitted. it will plug up and eventually damage the catalyst. High sulfur fuels must not be used with the catalyst. No welding or modifications of the catalyst are permited without permission of catalyst manufacturer.n 3 - Combustion Air System Air System Flow - Diagrams B Series Page 3-3 Air System Flow - Diagrams Air System - Intake Air Noturally Aspirated Intake System ss a 1. take Al inet Ls Intake eyetcn 2 Intake Manors 1 Fs tote le ne 3 Intake Valve / nochrger Turkocharged-aftercootod Charge Air-Cocled Intake System A Intake System Ae Intake Alc iniet eR. | intake Air tnlot harper ADE | to Turbocnargor . 2, Turbocharger Air {a Charge Ait Cooter 8. Charge Air Cooter 40 Intake Manitore Naturally Aspirated ‘Turbocharged-with Wastegate Exhoust System 1 Cahavst Valve 2 Eats Matos ‘Turbocharged Exhaust SystemIntake Air and Exhaust System Specifications. Section 3 - Combustion Air System Page 3-4 B Series Intake Air and Exhaust System Specifications © Maximum allowable intake restriction (compressor inlet) (with dirty air filter element) Non turbo Turbo .... swcesne: 20 infH1z0 (50.8 cm/H,0) 25 infH0 (63.5 crm/H,0) © Maximum exhaust restriction at rated speed and load Non automotive 91 EPA Cert . . 94 EPA Cert. with oxidation catalyst 3 in/Hg (76.2 mm/Hg) ~ 4.5 infHg (114.3 mm/Hg) 6 In/Hg (152.6 mmiHg) Turbocharger Boost Pressure Specificlations Refer to the following table for the critical parts fist (CPL), engine model, engine rating and cortesponding rated turbocharger boost pressure. NOTE: Measurement of boost pressure is not a short cut to logical troubleshsooting. Low power can be caused by the fuel used, fier maintenance and several engine components. Follow the logic charts for “Engine Power Output Low” and measure boost pressure as indicated. Refer to page 3-13 for measurement instructions, ‘These pressures are valid only at rated conditions (rated speed and power). Any attempt to use the values at engine speeds and loads other than those specified will result in an incorrect diagnosis. Table 1. B Series Boost Pressure Specifications RATED ENGINE BOOST ENGINE RATING PRESSURE cP, MODEL (HP @ RPM) (in. Ha) 0592 4873.9 100 @ 2500 22 to 28 86 @ 2300 19 to 25 84 @ 2200 18 10 24 13 @ 2200 18 t0 24 2 @ 2109 16 t0 22 80 @ 2200 140 20 71 @ 2200 12 to 16 70 @ 2100 11 to 17, 0594 48TA3.9 91 @ 2200 17 0.28 25 @ 2200 18 to 24 107 @ 2300 21 to 27 409 @ 2200 2310 29 112 @ 2300 24 to 30 116 @ 2500 27 to 35 125 @ 2200 27 t0 33 @ 2500 32 to 40 0595, 48TA3.9 120 120 @ 2800 34 to 42Section 3 - Combustion Air System ‘Turbocharger Boost Pressure Specificlations B Series Page 3-5 RATED ENGINE BoosT ENGINE RATING PRESSURE CPL MODEL {HP @ RPM) Gs. Ho) 0597 6BT5.9 83 @ 2000 1010 16 £9 © 2000 1010 16 £9 @ 2200 18 to 19 100 @ 2200 14 to 20 120 @ 2100 18 to 24 122 @ 2200 18 10 24 124 @ 2400 20 to 26 124 @ 2500 21 to 7 126 @ 2100 19 to 25 180 @ 2100 21 to B7 480 @ 2500 23 to 2 135 @ 2200 22 10 28 187 @ 2000 1B 10 24 140 @ 2200 24 to 80 142 @ 2100 24 to. 30 143 @ 2200 25 to 31 145 @ 2200 25 to 31 148 @ 2300 27 to 83 152 @ 2500 28 to 26 0598 68T5.9 160 @ 2500 28 to 36 160 @ 2800 31 to 39, 0599 6BTAS.9 141 @ 2200 27 1035 152 @ 2500 83 to 41 187 @ 2200 33 to 41 160 @ 2200 84 to 42 167 @ 200 85 to 43 169 @ 2. 86 to 44 174 @ 2200 89 to 47 176 @ 2300 40 to 48 177 @ 2400 80 to 38 177 @ 2600 41 10.49 0600 BTA. 180 @ 2500 39 to 47 646 ABT3.9 82 @ 1800 41 to 17 7 @ 1800 91015 692 6BT5.9 160 @ 2500 80 to 38 160 @ 2600 31 to 39, 696 4BT3.9 102 @ 1800 19 to 25 87 @ 1500 15 to 21 0897 6BT5.9 118 @ 1500 15 to 4 134 @ 1800 2110 27 ose8, 6876.9 143 @ 1800 25 to 3t 166 @ 1800 82 to 40 orto 4873.9 75 @ 2200 13 to 19 100 @ 2600 22 to 28 ont 48T3.9 71 @ 1500 9 tot! 82 @ 1800 tito‘Turbocharger Boost Pressure Specificlations Page 3-8 or, ona ona ors one 727 0728 0729 0730 741 0742 o7é1 762 0763 766 ore7 ENGINE MODEL 6815.9 6BTS.9 GBTAS.9 6BT5.9 4873.9 6BTS.9 6BT5.9 ABT3.9 6BT5.9 4873.9 4BT3.9 6BT5.9 4873.9 ENGINE RATING (HP @ RPM) 88 @ 2000 98 @ 2200 100 @ 2200 120 @ 2100 122 @ 2200 124 @ 2400 180 @ 2100 120 @ 2500 185 @ 2200 143 @ 1500 134 @ 1800 143 @ 2100 186 @ 2500 105 @ 2500 128 @ 2800 180 @ 2650 134 @ 2200 70 @ 2100 75 @ 2200 77 @ 2200 79 @ 2350 80 @ 2200 84 @ 2200 85 @ 2500 20 @ 2000 91 @ 2200 $2 @ 2100 93 @ 2200 96 @ 2300 100 @ 2560 190 @ 2500 180 @ 2600 180 @ 2500 210 @ 2600 160 @ 2800 108 @ 2500 105 @ 2800 67 @ 2200 71 @ 2200 160 @ 2500 160 @ 2800 105 @ 2500 105 @ 2800 Section 3 - Combustion Air System RATED BOOST PRESSURE Gin, Hig) 10 to 16 18 to 19 18 to 19 1B to 24 1B to 24 20 to 26 20 to 26 23 to 29 22 to 28 15 to 24 21 to 27 26 to 82 45 to 53 46 10 54 19 to 25 19 to 25 23 to 29 10 to 16 131019, 18 to 19, 14 t0 20, 1410.20 16 to 21 17 t0 23 16 to 22 17 to 23, 16 to 22 18 to 24 19 to 25 22 to 28 18 to 24 25 to 31 89 to 47 47 10 85 29 to 37 28 to 38 81 to 39, 10 to 16 10 to 16 28 to. 36 51 to 29, 24 to 31 27 to 83 B SeriesSection 3 . Combustion Air System B Series ort o7g2 o7e3 0804 0807 0826 0856 0857 0858 912 0937 928, 0947 ENGINE MODEL 6BT5.9 4873.9 6BT5.9 6BTS.9 4873.9 6BTAS.S 6BIAS.9 4873.9 4BT3.9 GBTAS.9 4873.9 6BT5.9 6BTAS.S 6BT5.9 6875.9 6BT5.9 ‘Turbocharger Boost Pressure Specificlations ENGINE RATING {HP @ RPM) 115 @ 1500 135 @ 1800 74 @ 1800 86 @ 1800 145 @ 2600 160 @ 2500 99 @ 2200 87 @ 1500 102 @ 1800 180 @ 2500 180 @ 2500 120 @ 2500 105 @ 2500 190 @ 2600 192 @ 2800 74 @ 1500 86 @ 1800 88 @ 2000 100 @ 2200 120 @ 2000 113 @ 2100 121 @ 2200 124 @ 2400 124 @ 2500 125 @ 2200 126 @ 2100 180 @ 2100 120 @ 2500 134 @ 2100 137 @ 2000 140 @ 2200 142 @ 2100 145 @ 2200 148 @ 2300 182 @ 2500 190 @ 2500 120 @ 2100 145 @ 2600 160 @ 2500 160 @ 2600 190 @ 2500 145 @ 2600 RATED BOOST PRESSURE fin, Hg) 16 to 22, 22 to 26 10 t0 16 1210 18 39 to 47 44 to 52 1310 19 15 to 24 19 to 25 32 to 40 46 to 54 40 to 48 35 to 43 84 to a2 87 to 45 10 to 16 12t0 18 10 to 18 44 to 20 150 21 16 to 22, 1B to 24 21 to 27 21 0 27 20 to 26 49 t0 25, 21 to 27 23 to 23 22 to 28 48 to 24 24 0 30, 24 to 30 25 to 31 27 to 33 28 to 36 42 to 50 18 t0 24 24 t0 30 29 t0 87 Si to 39 20 to 26 24 to 30 Page 3-7‘Turbocharger Boost Pressure Specificlations Page 3-8 cP 949 0950 0953, 0964 0962 0970 0971 0983 “09868 *0987 0998, 1160 1165 1168 12101 1202 1207 1208 1247 1266 ENGINE MODEL 6875.9 6BTS.9 6BTAS.O 68TS.9 6BT5.9 6BTAM2 4BT3.9 6BTAS.9 83.9-120 B5.9-230 6BTAS.9 6875.9 6BTAS.9 6BT5.9 4813.9 4873.9 6aT 6BTAS.9 6BTAS.9 6BTS.9 ENGINE RATING (HP @ RPM) 88 @ 2000 121 @ 2200 124 @ 2400 126 @ 2100 130 @ 2500 140 @ 2200 142 @ 2100 145 @ 2200 148 @ 2300 182 @ 2500 120 @ 2100 220 @ 2600 250 @ 2600 115 @ 1500 135 @ 1800 143 @ 1800 166 © 1800 300 @ 2800 96 @ 2200 400 @ 2500 187 @ 2500 177 @ 2500 120 at 2500 230 at 2500 200 @ 2600 160 @ 2500 227 @ 1760 265 © 2100 148 @ 2300 182 @ 2500 80 @ 2500 74 @ 2500 145 @ 2600 176 @ 2300 220 @ 2500 250 @ 2600 142 @ 2500 Section 3 - Combustion Air System RATED Boost PRESSURE in. 9) 10 to 16 14 to 20 24 to 27 19 to 25 23 to 29 24 t0 30 24 to 80 25 to. 31 27 to 33, 28 to 36 28 to 31 82 to 40 46 to 54 19 to 25 22 to 28 35 to 43 38 to 46 27 to 86 39 to 48 45 to 68 2910 37 87 to 45 46 to 54 25 to 31 27 to 35. 1910.25 18 to 24 23 to 29 30 to 36 80 to 96 39 to 47 27 to 35 seriesSection 3 - Combustion Air System B Series ort 1247 +4260 “1261 1268 1288 1922 +1381 1419 “4422 1518 1519 1620 1521 1823 1524 1525 1526 1527 74549, 1550 4551 “1652 ENGINE MODEL 6BTAS.9 B3.9-105 B5.9-190 ABT3.9 eer 6BT-Mi B5.9-160 eat B5.9-210 6BT-G2 6ET-A1 6BI-G2 4BT-G2 487-41 eBT-G2 6BT-G1 4BT-G2 4BT-G1 6BTA 6BTAS.9 6BTAS.9 BBTA5.O OBTAS.S ‘Turbocharger Boost Pressure Speciticlations ENGINE RATING (HP _@ RPM) 220 @ 2500 250 @ 2600 105 @ 2500 190 @ 2500 105 @ 2500 105 @ 2800 152 @ 2500 250 @ 2600 160 @ 2500 250 @ 2200 210 @ 2500 102 @ 1e00 87 @ 1500 74 @ 1500 86 @ 1800 143 @ 1500 166 @ 1800 115 @ 1500 135 @ 1800 102 @ 1800 74 @ 1500 68 to 1800 86 to 1800 175 @ 2500 160 @ 2500 175 @ 2500 190 @ 2300 210 @ 2300 210 @ 2500 RATED BoosT PRESSURE (in Hg) 23 1029 44 10 52 20 to 28 87 to 45 28 to 86 31 10 89 28 to 36 42 10 50 31 to 39 38 to 46 38 to 46 20 to 26 25 to 33 421018 20 to 26 16 to. 22 25 to 33 431019 20 to 26 to 17 61012 6 toe 1210 18 88 to 46 30 to 38 30 to 38 4d to 52 45 10 83 45 to 53 Page 3-9‘Turbocharger Boost Pressure Specificlations Section 3 - Combustion Alr System Page 3-10 B Series RATED ENGINE BOOST ENGINE RATING PRESSURE PL MODEL (HP @ RPM) (in. Hg) +1553 6BTAS.9 230 @ 2300 47 to 87 1570 6BT-Mt 220 @ 2500 36 to 44 1577 68TA 210 @ 2500 35 to 43 1879 6BTA 160 @ 2500 31 to 39 1613 6BTA-M2 250 @ 2600 36 to 44 * Designates 1991, ** designates 1994 charge air cooled ratings. Boost readings measured at the turbocharger ‘compressor outlet may be 4-6 in Hg higher than the values shown in the following table due to a normal pressure drop through the charge air cooler, Be sure charge air cooler relatad components are not the cause of a low pressure reading.Section 3 - Combustion Air System Combustion Air System - Service Tools B Series Page 3-11 Combustion Air System - Service Tools The following special tools are recommended to perform procedures in Section 3. The use of these toolsis shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Too! Illustration i Dial Depth Gauge Measure turbocharger axial motion. ST537 Pressure Gauge (0-75 in. Hg.) Used to measure the intake manifold pressure and exhaust back sti273 | Pressure. Turbocharger Wastegate Pressure Setting Kit e Used to set wastegate pressure. 3823799Diagnosing Air System Malfunctions Page 3-12 —— ally | Aspirated | | [250 in, IMac] Mex oT |® Section 3 - Combustion Alr System B Series, gnosing Air System Malfunctions Clean Air The correct amountof clean air to the cylinders is required for good performance. As discussed earlier in Air Flow Sysiem, ingested dust and cirt will damage the engine cylinders. Dust and dirt can also damage th and guides es well as wear down the turoo compressor vanes affecting efficiency. Lar blades of the turbocharger. Al ilow restriction results In excessive smoke and low power. Restriction increases as the filter removes contaminants from the intake air. Restricted air flow changes the air to-fuel ratio, reducing power and increasing smoke from the engine. Verify that the air cleaner is being maintained correctly. Intake Alr Restriction - Checking Replace the air cleaner element when the restriction reaches the maximum limit at rated engine power end speed. Naturally Aspirated Turbocharged 50.8 cm H0 63.5 om H,0 {20 in. HO} [25 in. H,0} For turbocharged engines, measure the restriction just before the turbocharger. Measure just before the intake manifold for naturally aspirated engines.Section 3 - Combu: B Series in Air System Damage From Non-fiitered Air Loose connections or cracks in the suction side of the intake pipe and after the air filter can allow debris to be ingested by the engine causing rapid wear in the cylin- ders. Leaks at the intake manifold, unsealed bolt holes or man- ifold cover gasket can also allow dust and dirt to be in- gested into naturally aspirated engines. Loose connections or cracks in the suction side of the ‘ntake pipe and after the air filter on turbocharged en- gines can allow debris to be ingested into the turbo- charger compressor and forced into the engine. Debris drawn into the air suction side can damage the compressor blades causing an imbalance resulting in bearing failure. To verify a bearing failure or damaged compressor, re- move the intake and exhaust piping and check for con- act. The rotor assembly must rotate freely and should not be damaged. Measurement of axial and radial clearance is described in this Section, Turbocharged Engines - Air Leaks, Pressure Side Excess smoke and low power from a turbocharged engine can be caused by pressurized air leaking from loose connections or cracks in the crossover tube or intake manifold. This can also cause a noise problem. iagnosing Alr System Malfunctions Page 3-13Diegnosing Air System Malfunctions Page 3-14 he ® Section 3 - Combustion Air System B Series In addition to the visual inspection for cracks and loose fittings, liquid soap can be applied to the charge air cooler, connections and the manifold cover seating surfaces to find the leeks. The leaks will create bubbles thet are easier to detect. Measurement of manifold pressure is, described in this Section. ‘Turbocharged Engines - Exhaust Leaks Inspect for exhaust leaks at the exhaust manifold and turbocharger, gasket leaks, or exhaust pipe, muffler or catalyst restrictions. Leaks or restrictions will cause the turbine and impeller to operate at a lower speed and reduce the amount of air being forced into the cylinders. Again, the symptom will be excess emoke, low manifold pressure and low power, ‘Turbocharger Boost Preseure - Measurement Measure the boost pressure at the intake manifold by using one of the tapped or pluaged intake access holes shown in the illustration, Refer to the specifications in this, section, NOTE; If the engine has charge ait cooling, testing must be done to ensure that the charge air cooler system is not leaking or restricting the turbo boost pressure - refer to Procedure (3-08) for charge air cooler testing. Exhaust leaks can usually be detected audibly or visually by a discoloration caused by the escaping hot gases. Don'tovertook exhaust restriction as a cause of low power. lithe exhaust gasses can not flow freely, the turbocharger will not operate eificiently.Section 3 - Combustion Air System B Series Malfunctioning Turbocharger Failure of the internal components of the turbocharger an reduce its effectiveness and also cause excessive smoke and low power. A bearing failure can produce friction which will slow the speed of the rotor assembly. Failed bearings can also allow the blades of the rotor assembly to rub the housings, thus reducing the rotor assembly speed. Malfunctioning turbocharger wastegate failure or miscal- ibration of the turbocharger wastegate can result in ex- cessively high or low boost pressures. Low boost pres- sures can cause excessive smoke and low power. High boost pressures can cauise major engine damage. Lubricating Oil Consumption and Leaks Engine lubricating oil is used to lubricate the bearings and provide some cooling for the turbocharger. The fu- bricating off supplied to the turbocharger through the supply line is at engine operating pressure, A return line connected to the bottom of the turbocharger routes the lubricating oil back to the engine lubricating oil pan, Seal rings are used on each end of the rotor assembly. ‘The primary function of the sgels is to prevent exhaust gases and compressed air from entering the turbocharger housing. Lubricating oil leakage {rom the seaisis rare, but it can occur, NOTE: Excessive crankcase pressure will not allow the oil to drain trom the turbocharger. This will load the bearing hous- ing and allow jubricating oil to leak past the compressor seals and into the engine. tfturbine seal leakage into the exhaust occurs on engines with a catalyst, check the exhaust restriction during the repair A restricted or damaged lubricating oil return tine will cause the turbocharger housing to be pressurized caus- ing lubricating oil to migrate past the seals. Diagnosing Alr System Malfunctions. Pege 3-15Diagnosing Air System Malfunctions Page 3-16 ,@ Section 3 - Combustion Air System B Series Additionally, high intake or exhaust restrictions can cause a vacuum between the compressor and the turbocharger housing resulting in oil leaking past the seals. To verify lubricating oil leakage past the seals, remove the exhaust pipe and crossover tube and look for lubricating oll in the turbine casing and the crossover tube, Locate and correct the restriction as previously discussed. Turbocharger Noise itis normal for the turbocharger to emit a “whine” sound that varies in intensity depending on engine speed and load. The sound is caused by the very high rotational ‘speed of the rotor assembly. Consequently, the sound will be more audible at full speed. It possible, operate the engine at full speed to verify the noise level. Leaks in the air system intake and/or exhaust compo- nents can produce additional noises. Pressurize the intake system and check for air intake and crossover tube leaks.Section 3 - Combustion Air System B Series Before removing the turbocharger, make sure that the noise complaint is not caused by leaks in the air sys- tem components. Look for loose turbocharger mounting, exhaust manifold gasket leaks, and cracks in the exhaust manifold. Lower pitch sounds or rattles at slower engine speeds can indicate debris in the system or the rotor assembly is touching the housings. Turbocharger - Testing (3-01) Rotor Assembly Clearance - Measurement Measure the shaft end play. Service tool Part No. ST-537. End Play (A) mm in 0.10 MIN [0.003] 016 MAX {0.006} "* 0.03 MIN [0.001] 0.08 MAX {0.003} For turbochargers with a serial number before 840638. ** For turbochargers with a serial number 840638 and after. ‘Turbocharger - Testing (3-61) i Page $17 ly i ee @\-Turbocharger Wastegate Valve Assemibly (3-02) Page 3-18 eS Section 3 - Combustion Air System B Series Measure radial clearance of the shaft. Fiadial Clearance (8) mm in ; MIN Toi2y 0.46 MAX (0.018) The turbocharger must be removed for replacement or rebuild if the clearances are beyond these limits. Refer to the Turbocharger Shop Manual, Bulletin No. 3810321, for rebuild procedures. Turbocharger Wastegate Valve Assem- bly (3-02) Checking inspect the lever pin. Replace the turbine housing assembly if worn exces- sively. Refer to the Turbocharger Shop Manual, Bulletin No. 3810321. Inspect the valve and valve seat for cracks or erosion. Replace the turbine housing assembly if worn exces- sively. Refer to the Turbocharger Shop Manual, Bulletin No, 3810321. Actuate the lever by hand to be sure that the shaft rotates: freely and is not seized. Cheok for excessive movement between the shaft and bushing. Replace the turbine housing if the shaft and bushing are damaged or seized. Refer to the Turbocharger Shop Manual, Bulletin No. 3810321.Section 3 - Combustion Air System B Series Turbocharger Wastegate Capsule (3-03) Checking Visually inspect the wastegate actuator hose for cracks or holes. Replace the hose if damaged. Visually inspect the wastegate mounting bracket, actu- ator rod, and lever for damage. A bent wastegate mount- ing bracket, actuator rod, or lever can cause improper operation. Ifthe wastegate mounting bracket, actuator rod, or lever is bent, it must be replaced. Refer to Procedure 3-05. Turbocharger Wastegate Functional (3-04) Checking Attach a dial indicator (1) as shown, so that its shaft is in line with the wastegate actuator rod. Set the indicator to zero, with no air pressure applied to the wastegate cap- sule. Connect clean regulated air pressure and a pressure gauge to the capsule (2). Apply 200 kPa [29 psi] to make sure the wastegate is functioning properly. The rod should move approximately 5 mm [0.200 in] with- out any sticking or air leakage. NOTE: No air should be heard to leak through a functional wastegate capsule, NOTE: A small amount of travel when air pressure is first applied is normai, the tolerance is being removed from the system. aS ‘Turbocharger Wastegata Capsule (3-03) Page 3-19Turbocharger Westegate Actuator Boost Capsule (2-05) Section 3 - Combustion Air System Page 3-20 B Series Replace the actuator if no movement of the actuator rod and lever is detected. Refer to Procedure 3-05, | Turbocharger Wastegate Actuator Boost Capsule (3-05) Replacement NOTE: Prior to removal, note position length of the control rod from the boost capsule housing and orientation of the boost capsule hose connector in relation to the mounting bracket. Air regulator with pressure gauge Remove the retaining clip from the control lever. Disconnect the boost capsule actuator rod end from the turbocharger wastegate lever. This can be accomplished by applying regulated air pressure to the boost capsulein @ sufficient amount to activate control rod movement. Disconnect the control rod from the turbocharger waste- gate lever pin. Caution: Be careful not to bend the control lever. NOTE: If the boost capsule diaphragm material is ruptured and will not hold air pressure other than by hand, manually pull the control rod outward in order to overcome boost capsule spring tension for removal of the control rod from the turbochager wastegate lever pin.Section 3 - Combustion Air System ‘Turbocharger Westegate Actuator Boost Capsule (2-05) ge 3: B Series Loosen the boost capsule mounting capscrews, discon- nect the air supply hose and remove assembly from the mounting bracket. Remove the adjusting link end from the boost capsule actuator. Install the adjusting link end onto the new replacement boost capsule actuator assembly into approximately the ‘same position as originally removed. Fit the new boost capsule actuator assembly to the act- uator mounting bracket and install the mounting cap- screws. Torque Value: 4.5 Nem [40 in-tb] specnne‘Turbocharger Wastegate Actuator (3-08) Page 3-22 Section 3 - Combustion Air System B Series Turbocharger Wastegate Actuator (3-06) Calibration NOTE: The wastegate is set accurately from the factory. Adjustment is not necessary unless the capsule is removed. Connect clean regulated air pressure to the boost cap- sule (2). Regulate the air pressure to the wastegate capsule per the following table. Model Rating Prassure Pressure Year (HP) Application _ (kPa). &psi) “Hr ROR Automonve” | TES BET 94 160-175 Automotive 133, 193 94 190-280 Automotive 198 28.7 94 A Industrial 191 art Measure actuator travel (1). Specified wastegate mea- surement is 0.33 to 1.3 mm [0.013 to 0.050 inch}. Caution: Do not pull or push of force alignment of the levis pin. Adjust the wastegate if necessary to achieve specified travel. © Pull the wastegate lever to the foremost closed po- sition (lever toward boost capsule). * Adjust the length of the clevis end of the control rod to where the clevis pin hole aligns to the wastegate lever. ¢ Install the adjusting link and retaining clip. * After adjusiment is completed, tighton actuator rod jam nuts. Disconnect regulated air pressure line from the boost capsule, Connect the turbo boost line to the boost capsule and secure hose clamp. If possible, a more accurate method of wastegate adjust- ment is to check the manifold pressure at rated RPM per turbocharger boost pressure specifications on pages 3-4. to 3-11 of this section.Section 3 - Combustion Air System B Series EXHAUST RESTRICTION - MEASURE- MENT (3-07) Install pressure gauge, Part no. ST-1278 to the pressure tap in the exhaust head pipe or at the inlet to the catalyst? muffler assembly. ‘Operate the engine at rated speed and load. Record the exhaust restriction. It restriction exceeds specification, inspect the oxidation catalyst and/or muffler and replace per vehicle manufac- turers instructions. Industrial... 91 EPA certification 94 EPA Certification with oxidation catalyst .. . 78 mm Hg [3 in Hg} 114 mm Hg [4.5 in Hg] 152 mm Hyg [6 in Ho} Charge Air Cooler - Troubleshooting (3-08) NOTE: The fong term integrity of the charge air cooler sys- tem is the responsibility of the vehicle and component man- uufacturers; however, the following symptoms can be checked by any Cummins Authorized Repair Location: Intake Manifold Pressure - Check Instail pressure gauge, Part No, ST-1273, to the fitting in the turbocharger outlet. Install another pressure gauge, Part No. ST-1273, in the intake manifold. Operate the engine at rated RPM and load. Record the readings on the two gauges. I the differential pressure is greater than 21 kPa [3 psi], check the charge air cooler for plugging. Clean or replace if necessary. Reter to Procedure 2-09, EXHAUST RESTRICTION - MEASUREMENT (3-07) Page 2-23Charge Air Cooler - Troubleshooting (3-08) Page 3-24 Section 3 - Combustion Alr System B Series intake Manifold Temperature - Check Install a temperature gauge in the intake manifold. Lock the fan drive in the ON mode to prevent erratic test results. This can be done by installing a jumper across the. temperature switch or supplying shop air to the fan. Refer to the fan drive manufacturer for lock-up procedure. NOTE: Some trucks have a manual switch that will lock on the fan. Operate the engine at rated RPM and load. Record the intake manifold temperature. Measure the ambient temperature atleast two feet in front of the vehicle. The maximum temperature differential must not be greater than 25°C [45°F]. If the temperature differential is greater than 25°C [45°F], check the charge air cooler for dirt and debris on the fins, and clean as necessary. If the problem still exists, check the cooler for internal contamination or plugging, ‘To check the charge air cooler for cracked tubes or header, remove the inlet and outlet hoses from the cooler. Remove the charge air cooler. Install a cap over the outlet side of the cooler. Install a Pressure gauge and a shop air supply line to the inlet side of the cooler, Apply 207 kPa [30 psi] of air pressure to the cooler. I the pressure drop is 45 kPa {7 psi] or less in 15 seconds, the cooler is okey. If the pressure drop is greater than 48 kPa [7 psi] in 15 seconds, the charge air cooler must be repaired or re- placed. Refer to the CAC manufacturer for ropair instruc- tions. NOTE: A leak tank can be used to locate the air leak.Section $ - Combustion Air System B Series Charge Air Cooler - Cleaning and Inspection (3-09) If the engine experiences a turbocharger failure or any other occasion where oil or debrisis putinto the CAC, the CAC must be cleaned. Remove the CAC from the vehicle. Refer to the vehicle manufacturer's instructions. Flush the CAC internally with solvent in the opposite direction of normal air flow. Shake the CAC and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. Continue flushing until all debris or oil is removed. Use a flashlight and mirror to visually inspect the CAC for internal debris. Caution: If internal debris cannot be removed, serap the CAC. Caution: Do not use caustic cleaners to clean the CAC. Damage to the CAC will result. After the CAC has been thoroughly cleaned of all oif and debris with solvent, wash the CAC internally with hot soapy water to remove the remaining salvent. Rinse thor- oughly with clean water. Blow compressed air into the CAC in the opposite direc- tion of normal air flow until the CAC is dry interanlly. Visually inspect the CAC for cracks, holes or damage. Inspect the tubes, fins and welds for tears, breaks or other damage. If any damage causes the CAC to fail the air leak check mentioned eariier in this publication, the GAC must be replaced. install the CAC on the vehicis. Refer to the vehicle manufacturer for instructions. and Inspection (3-09) 8 Page 2Air Crossover Tube (3-10) Page 3-26 Section 3 - Combustion Air Systern B Series Air Crossover Tube (3-10) Replacement Removal and Installation 8 mm or Screwdriver Loosen the hose clamps and position the hose so the crossover tube can be removed. Use new hose and clamps as required to install the cross- ‘over tube. Torque Value: 8 Nem [72 in-tb] Intake Manifold Cover and Gasket (3-11) Replacement Preparetory Steps: * Disconnect the cold starting aid, if used. © Remove the air crossover tube, if used. * Disconnect the charged air cooler hose, if used. * Remove the high pressure fuel lines. Removal 10 mm Remove the manifold cover, gasket, and grid heater if equipped. Cleaning Clean the sealing surface. NOTE: Keep the gasket material and any other material out of the air intake.Section 3 - Combustion Air System Aftercooler and Gasket (3-12) B Series Page 3-27 Installation 10 mm Install the cover and a new gasket. Torque Value: 24Nem [18 fb] pK] @ 2) Assemble the intake piping and connect the cold starting éajs, aid if used. & ‘Torque clamps to 8 Nem [75 in-Ib]. Aftercooler and Gasket (3-12) Replacement Preparatory Steps: * Disconnect the cold starting aid, if used. © Remove the air crossover tube. * Drain 2 litres [2.1 U.S. quarts] of coolant. Removal mm Remove the coolant supply tube (1) and the coolant return tube (2).Aftercooler and Gasket (3-12) Page 3-28 Be ay Section 3 - Combustion Air System jerles 10 mm Remove the aftercooler housing and gasket. Cleaning lean the sealing surface. NOTE: Keep the gasket material and any other material out of the air intake, Installation 10mm NOTE: The holes shown inthe illustration are dritled through. Apply liquid teflon sealant to the capscrews. Install the aftercooler housing and a new gasket. Torque Value: 24 Nem [18 ft-lb} 8mm Install the coolant supply tubs (1) and coolant return tube: 2). Install the air crossover tube (3). ‘Torque Value: 6 Nem [75 in-tb]Section 3 - Combustion Air System Turbocharger (8-13) B Series Page 3-29 Caution: Be sure to vent the engine and aftercooler to prevent entrapment of air as the system is filled. Fill the coolant system with a premixture of 50 percent water and 50 percent ethylene-glycol type antifreeze. Turbocharger (3-13) Replacement Preparatory Steps: © Remove the air crossover tube, if used. * Disconnect the charge air cooler hose, * Disconnect the boost capsule actuator hose. * Disconnect the intake and exhaust piping. Removal 10 mm Remove the capscrews from the oil drain tube. 46 mm Disconnect the oil supply line. NOTE: Engines built after June 1993 may use a copper Re washor in both ends of the turbocharger lubricating cil sup- ply fine. The washer should be replaced whenever the line is removed.Turbocharger (3-13) Page 3-30 R] Re ® eS Section 3 - Combustion Air System B Series Remove the intake manifold pressure supply line from the boost capsule. 415 mm and 7/16-inch Remove the exhaust clamp, turbocharger, and gasket. Cleaning and Inspection Clean the sealing surfaces. Inspect the sealing surface and mounting studs for damage. NOTE: Ifthe turbocharger is not to be immediately replaced, cover the opening to prevent any material from falling into the manifold. Inspect turbocharger wastegate linkage, valve shaft, mod- ule, and pressure signal iine, Check or calibrate wastegate, Refer to Turbocharger Shop Manual, Bulletin No. 3810821, for calibration procedures.Section 3 - Combustion Air System B Series Installation Install a new gasket and apply anti-seize compoundtethe <2 mounting stud. fe 15mm Install the turbocharger. Torque Value: 45 Nem [33 ft1b] Oe 10 mm and 7/16-inch Use a new gasket and connect the oil drain tube. Torque Value: 24Nem [18 ftib] Og] NOTE: New turbochargers must be prolubricated before startup, Pour 50 to 60 oc [2 to 3 ounces] of clean engine oil into the oil supply fitting. Rotate the turbine wheel to allow the il to enter the bearing housing.Turbocharger (3-13) Page 3-32 © @ Section 3 . Combustion Air System B Series 16mm Connect the oil supply line. ‘Torque Value: 35 Nem [26 ft-lb] 7A6 inch {frequired, loosen the compressor housing V-band clamp and position the housing to align with the turbocharger air ‘outlet tube. 7/16 inch, Plastic Hammer Tighten the band clamp. Tap around the clamp with a plastic hammer and tighten again. ‘Torque Value: 8.5 Nem [75 in-tb] NOTE: Effective Oct. 1, 1990 all Holset Turbochargers use silver plated nuts with the v-band clamp. The silver plated nuts require a lower torque than the stainless steel nut to provide the same v-band clamp load. Install the boost control capsule actuator hose.Section 3 « Combustion Alr System Exhaust Manifold and Gaskets (3-14) B Series Page 3-33, Install the air inlet and exhaust piping, Operate the engine and check for leaks. Torque Value: 8 Nem {72 into] DEB Exhaust Manifold and Gaskets (3-14) Replacement Preparatory Steps: * Remove the air crossover tube, if used. * Disconnect the charge air cooler hoss (automotive engines only). © Disconnect the air intake and exhaust piping. © Remove the turbocharger, if used. Removal 15 mm 2 Remove the exhaust manifold and gaskets. JOP ht Cleaning and Inspection Clean the sealing surfaces and inspect the exhaust man- ifold for cracks, burn-out, or damaged threads..Exhaust Manifold and Gaskets (3-14) Page 3-34 Section 3 - Combustion Air System 8 Series Installation 15mm Install the exhaust manifold and new gaskets. Torque Value: 43 Nem [32 ft-lb} Follow the tightening sequence shown in the illustration. Install the parts previously removed. Operate the engine and check for leaks.Section 4 - Compressed Air System B Series Page 4-1 Section 4 - Compressed Air System Section Contents Page 422 424 423 425 420 se 448 Air Compressor - Removal Air Compressor Timing (For Single Gylinder Air Compressor only Inspection. Installation. Air Governor - ChECK sone Air Governor and Compressor Unloeder Valve - Check Carbon Buildup, Air Compressor - Check.. Compressed Alr System - General Compressed Air System - Service Tools Flow Diagrams - Compressed Air System... Gasket Leaks, Air Compressor, Check. 418 Specifications - Compressor Air System sonentnnnennes 46 Unloader and Cylinder Head Disassomb! 49 ‘Assembly. 415 Cleaning. aHCompressed Air System - General Information Section 4 - Compressed Air System Page 4-2 8 Series Reservoit Compressed Air System - General Information ‘The compressed air system normally consists of a gear driven air compressor, an ait governor, air tanks and all necessary plumbing. Governor (wet Tent) Reservoir casoige The Holset SS191B air compressor is an engine-driven, piston-type compressor which supplies compressed air to operate air activated devices. The compressor operates continuously but has a “loaded” and ‘‘unloaded”” ‘operating mode. The operating mode is controlled by a pressure activated governor and the compressor unloading assembly. When the air system reaches a predetermined pressure, the governor applies an air signal to the air compressor unloader assembly causing the unloader valve to hold the compressor intake valve open and com- pressed air stops fiowing into the air system. As the air in the air system is used, the pressure drops. At a predetermined pressure the governor exhausts the air signal to the compressor unloader assembly allowing the compressor to again pump compressed aif into the air system. This air compressor is availabie in an air cooled or water cooled version, the only difference being changes to the oylinder head to incorporate a water passage. This air compressor is also available with or without a power steering pump housing. Other brands of compressors may be used on the B sories engine. Troubleshooting procedures are very similar for these air compressors compared to the Holset SS 191B. Refer to the specific air compressor manufacturer's manual for detailed repair information including torque values. NOTE: The cylinder head and unloader components of the Holset S$191B air compressor can be serviced without removal of the air compressor on many engine applications. This troubleshooting manual will cover servicing of the air compressor unloader components while the compressor is still on the engine. All other servicing of the air compressor internal components should be done after the compressor has been removed from the engine. Reference the SS191B Shop Manual, Bulletin No. 3810433, for detailed disassembly and assembly information of the air compressor. The Holset SS296 single cylinder air compressor is an engine-driven piston-type compressor which supplies compressed air to operate air activated devices. The compressor runs continuously but has a loaded and unloaded operating mode, The operating mode is controlled by a pressure-activated governor and the compressor unloading assembly. The $8296.air compressor used on B series engines uses an (E-type) unloader. The Economy (E-type) unloader system waé designed to reduce pumping losses and engine boost pressure losses through the compressor intake valve while operating in unloaded mode. When the air system reaches a predetermined pressure, the governor applies an air signal to the air compressor unloader assembly causing the unloader cap to seal off incoming air at the intake valve, and compressed air stops flowing inte the air system. NOTE: System pressure must be maintained on the outlet side of the discharge vaive to keep the discharge valve closed. ‘As the air in the air system is used, the pressure drops, At a predetermined pressure the governor exhausts the air signal to the compressor unioader assembly allowing the compressor to again pump compressed air into the air systern, Caution: Vehicles equipped with air dryers vented to atmosphere during unloaded compressor operation, using the Holset (E-type) alr compressor, require the installation of an Econ vaive to prevent excessive oll consumption. If the air system pressure is not maintained on the discharge valve during unloaded operation, air will be pumped out of the compressor cylinder causing a low pressure (vacuum) condition to form in the cylinder. With the intake valve sealed off by the unloader cap, and the exhaust valve being a one-way pressure actuated valve, no alr willSection 4 - Compressed Air System Compressed Air System - General Information B Series, Page 4-3, be allowed to enter the cylinder. When the compressor cylinder pressure falls below crankcase pressure, oil will be drawn past the piston rings and pumped into the air system. Other brands of compressors may be used on B seties engines. Troubleshooting procedures are very similar for these air compressors compared to the Holset SS296. Refer to the specific air compressor manufacturers manual for detailed repair information and torque specifications.Section 4 - Compressed Air System Flow Diagrams - Compressed Air System B Series Page 4-4 Flow Diagrams - Compressed Air System Reservoir t— <— E Untoader =e omen |] eee Se = Intake — | = fet Tank | = hd Check Valve (Normally Built Into Dryer) Ale Dryer Ld To Spitter Valve re With Alr Dryer Reservoir gq ceo Governor Diocharte Compressor (Wet Tank} Without Air Dryer = ReservoirSection 4. Compressed Air System Fiow Diagrams - Compressed Air System B Series Page 4-5 Flow Diagrams - Compressed Air System (Continued) ‘Secondary Pressure A Une Econ fave 7 | == et Tank) Si check vatve {Normally Bult into Dryer) Lu i = "To Spiter Valve With Air Dryer ote Holset SS296BE E-Type System With Air DryerSpecifications - Compressor Air System Section 4 - Compressed Air System Page 4-8 B Series Specifications - Compressor Air System Holset $S191B Single Cylinder Air Compressor Compressor Swept Volume @ 1250 RPM .. eee .- 8.6 of Piston Displacement .. ne . 191.5 0¢ [11.69 C.D] Bore 80 mm [3.15 in| Stroke .. . 38.1 mm [1.50 in] .98 Times Engine Speed .- Engine Coolant or Air Cooled Speed . Cooling Lubrication Plumbing Line Sizes Coolant Inlet and Outlet (Pipe Fitting) ... Air Inlet (Inside Diameter) Air Outlet (Minimum Inside .. Engine Lubricating Oil .. [12 in NPTF} [12 in} 4/2 in.) Height, Overall (Approximate) .- 268 mm (11 in.) Width, Overall (Approximate) 125 mm [5 in.] Length, Overall (Approximate) 186 mm [7.32 in] Weight (Approximate) .. 18.6 kg (30 Ib] Holset $$296 Single Cylinder Air Compressor Compressor Swept Volume @ 1250 RPM .. Piston Displacement .... Bore Stroke 6.2 L per sec. (18.20 CFM] .. 296 co [18.06 C.D] 92.08 mm [3.625 in.] 44,45 mm [1.750 in.] Speed ..... sate -135 times greater than Engine Speed Cooling .. ete Engine Coolant Lubrication .. . Engine Lubricating Oil Plumbing Line Sizes Coolant Inlet and Outlet (Pipe Fitting) Air Inlet (Inside Diameter) ...... Air Outlet (Minimum inside Diameter) .. . 9/8 in NPTE 19 mm [0.750 in} 1/2" NPTF 12.7 mm [0.50 in] 28.5 mm [9.25 in.) +. 14.6 om [5.75 in.) seeonnes 26.7 mn [10.5 in] 20 kg [44.0 Ib] Height, Overall (Approximate) Width, Overall (Approximate) . Length, Overali (Approximate) Weight (Approximate)Compressed Air System - Servi Section 4 - Compressed Air System B Series Compressed Air System - Service Tools ‘The following spacial tools are recommended to perform procedures in Section 4. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Too! illustration Tool No. Tool Description Valve Spring Tester Use to check spring tension. 3375182 L = ‘Air Compressor Seat Socket E Use to remove the exhaust valve seat and the inlet vaive cage.| CK 9823528 Pr i Tools Page 4-7Carbon Buildup, Air Compressor - Check (4-01 Page ae IP, pres (4-01) Re ID of Carbon Bulld Up Section 4 - Compressed Air System B Series, Carbon Buildup, Air Compressor - Check (4-01) Shut off the engine. Open the draincock on the wet tank to release com- pressed air from the system. Use steam to clean the compressor. Use compressed air to dry. Remove the air inlet and outlet connections from the air compressor. Measure the total carbon deposit thickness inside the air discharge line as shown. NOTE: The carbon deposit thickness must not exceed 1.6 mm [1/16 inch].Section 4 - Compressed Air System 8 Series Werning: The air discharge tine mustbe capable of with- standing extreme heat and pressure to prevent personal jury and property damage. Refer to the manufacturer's specifications. NOTE: If the total carbon deposit thickness exceeds spec- ification: * Remove and clean or replace the air discharge line. Refer to manufacturer's material specifications. * Remove and inspect untoader components and cylinder head. Unloader and Cy! sembly (4-02) 1-1/4 inch Remove the following parts: * Unloader cover (1) * Copper washer (2) © Unloader pin (4) * Spring (5) Discard the copper washer. der Head Disas- Remove and discard the o-ring (3). 9/16 inch Remove the four cylinder head capscrews (6). Remove the oylinder head (7). Remove and discard the cylinder head gasket (8). Service Tip: Scribe a mark to show proper head orien- tation before removing the head. Unloader and Cylinder Head Disassembly (4-02) Page 4-3 A @ e exseenalUnloader and Cylinder Head Disassembly (4-02) Page 4-10 AM Section 4 - Compressed Air Systern B Series Part No. 3823528, Air Compressor Seat Socket or 3/4 inch Allon Wrench. Install the head with the bottom side up in a soft jawed Remove the exhaust valve seat (8). Remove the following parts: © Exhaust valve disc (10) © Spring (11) * Copper washer (2) Discard the copper washer. NOTE: The exhaust vaive stop is pressed in place and must not be removed. Part No. 3823528, Air Compressor Seat Socket Remove the inlet valve cage (12). Remove the following parts: © Spring (11) © Inlet valve disc (10) © Inlet valve seat (13) © Copper washer (2) Discard the copper washerSection 4 - Compressed Air System B Series Cleaning Warning: When using solvents, acids, or alkaline mate- rials fer cleaning, follow the manufacturer's recommen- dations for use. Wear goggles and protective clothing. ‘Soak the parts in a kerosene emulsion based cleaner designed to remove carbon. The cleaner must have a pH of 9.5 or less to avoid turning aluminum parts black. The cleaner manufacturer or supplier can be contacted about solution concentration, temperature and soak time. Caution: Do not use a scraper to remove carbon and scale. This can damage sealing surfaces. Use a stiff non-metalic bristle brush to scrub the parts. Cleaning Valve Dises inspect and replace if cracked, pitted or grooved in ex- cess of 0.13 mm {0.008 in}. Inlet Valve Seat Measure the distance from the valve seating surface to the surface that contacts the valve cage. Intake Valve Seat mm. fn 0.597 MIN 0.0235 0.673 MAX 0.0265 Replace the intake valve seat if not within limits or if cracked or damaged. Unioader and Cylinder Head Disassembly (4-02) Page 4-11 4Unioader and Cylinder Head Disassembly (4-02) ection 4 - Compressed Air System Page 4-12 B Series Exhaust Valve Seat Inspect the seat for damage and wear. eptoone Measure the valve guide diameter. Valve Guide Diameter rom in 25.55 MIN 7.005 25.65 MAX 1.010 LY Replace the exhaust valve seat if nat within limits. c2eour Measure the distance from the top of the valve seat to the valve seating surface. Seat Height mm in 4.01 MIN’ 0.158 2 L an MAX 0.162 Replace the exhaust valve seat if not within limits. se0008 epevoea Inlet Valve Cage Inspect the inlet valve cage for damage and wear.Section 4 - Compressed Air System B Series Measure the valve guide diameter. Valve Guide Diameter mm. in 25.53 iN 7.005 25.65 MAX 1.010 Replace the inlet valve cage if net within Measure top of cage to valve stop. ‘Stop Depth mm 3.63 MIN 0.145 3.78 MAX 0.149 Exhaust Valve Stop Inspectthe exhaust valve stop. Replace the cylinderhead assembly if the stop is loose or damaged. Measure the distance from the valve end of the stop to the face of the cylinder head. ‘Stop Height mm In. “4.42 MIN 0.176 4.70 MAX 0.185 Replace the cylinder head if not within limits. Unloader and Cylinder Head Disassembly (4-02) @ @ Page 4- cp2nuno epsoone|Untoader and Cylinder Head Disassembly (4-02) Section 4 - Compressed Air System Page 4-14 series eptpiee Unloader Pin @ Inspect for scoring or pitting. Measure the length of the pin. Fin Length mm. in 40.51 MIN 1.595 40.72 MAX 1.603 Replace the pin if not within limits. coterta Valve Springs Use vaive spring tester, Part No. 3875182, to check the springs. Replace if not within limits in Table 1, shown below. NOTE: Cummins Engine Company, Inc, recommends that new springs be installed during rebuild. ‘Table 1: Spring Date. Toad Required tc Compress Spring to Lenath nim Length um Maximum mm Kg Kg fin} Tb} ib} Inlet Valve 5.08 0.272 0.340 0.20) {0-60} 10.75} Unloader 40.0880 1.58 4.90 (0.995) 18.38} (4.18) Exhaust Valve 5.08 0.272 0.340 10.20) {0-60} 10.75}Section 4 - Compressed Air System B Series Cylinder Head Inspect and replace if cracks, threads are found. Inspect the unloader seal bore fer scoring or pitting. Replace the cylinder head if damaged. Assembly ‘Turn the cylinder head bottom side up and install it in a soft jawed vise, Install the following parts. a, New washer b, Inlet vaive seat c. Inlet valve d. Inlet valve spring Air Compressor Seat Socket, Part No. 3623526 and Torque Wrench Tighten the cage. Torque Value: 108 Nem (80 ft-lb} nicks, gouges or damaged 6 XQ) © Unloader and Cylinder Head Disassembly (4-02) Page 4-15 ep000e|Unloader and Cylinder Head Disassembly (4-02) Page 4-16 om B—.. s—~cD pace Section 4 - Compressed Air System B Series Gy Install the following parts: = Noreen b. Exhaust valve spring ©. Exhaust valve disc 3/4 inch Allen Wrench or Air Compressor Seat Socket, Part No. 3823628, and Torque Wrench Tighten the seat. Torque Value: 108 Nem QI) [80 ft-lb] Install a new gasket and the oylinder head to the cylinder block, aligning the scribe marks.

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  Description: Necessity of Turbocharger and Supercharger

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• Description: Necessity of Turbocharger and Supercharger

  

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