Service Paris a Topics January, 2000 ——— cores a = 2 Nid ISX 188 ISC ISM 's Single-Cylinder Air Compressors T&R Manual ‘Shop Manual ‘Oa Mi Manual Riana ‘Specs Manual Orer Manuals Affected by This Service Parts topic ] ‘Bulletin No. “Woubleshooting and Repair Manual 3666142 3666238. 3666193 3666245, 3666322 Warranty Failure Codes - Heavy Duly Engines 3666256 This service parts topicinforms the field of new single-cylinder air compressors released by Cummins Engine Company, tno. The new air compressors will be used in production on the following engine families: Signature/ISX, ISM, N14, ISC, and ISB. This service parts topic includes information on the following: Parts, fal codes, specifications, flow diagrams, installation recommendations, and troubleshooting trees. To identity the new Cummins air compressor, a large C is cast on the crankcase. Parts Cummins Air Compressors Compressor Model Engine Production implementation Part No ate ‘Cummins 18.7 cfm SignatureiSX | June 1986 804d (single-cylinder design) Nie January 1993 3566169 1SC July 1998 3944525 | ISM, Jung 1986 3558163 | Cummins 16.2 cm 1SE January 1988 3944460 | (single-cylinder design) | Kit Name, Part No. Engine Model Kit Contents | Brace, Air Compressor 3945510 1SB Brace and Mounting hardware Brace, Air Compressor 39429Tt 1SC Brace and Mounting hardware Brace, Air Compressor 3071246 Nig Brace and Mounting hardware Brace, Air Compressor 3680444 Signature, ISX | Brace and Mounting hardwars Brace, Air Compressor 3892950 ISM Brace and Mounting hardware Brace, Air Compressor 3335585. ISM Brace and Mounting hardware | Head Assembly Kit "3800820 Signature, 1X | Cylinder head assembly and hardware Head Assembly Kit SBO0BAI Nia, TSM, ISO “Cylinder head assembly and hardware Fiead Assembly Kit SB0082 SB Cynder head assembly and iardwaro Rear Gasket Kit ‘3800827 Signatur, 18x, 186, ‘Orting and gasket 188 ‘arms Enging Conny, Ine Page 1 of t0712.5 Page2 {SB and IscFail Codes 00T12-5 Page 3 All Cummins single-cylinder air compressor fail codes begin with QS (for example: QS AY LO). The fail codes that are used with diagnosing the Cummins single-cylinder air compressor are: G5] Cummins Single-Gylinder Air Compressor [ites of Fatture ‘AY | Single-cylinder air compressor assembly BR, CO, CU, ID, TA, LO: LW, MA, Mit, PO, SE BK | Bracket BE, BR, CO, CU, MA, iM ‘CHF Cylinder head BE, BR, CA, CU, LO, LW, MA, Mii, PO, SE ov [Gover = BE, BR, MA, Mi GF | Mounting gasket BR. ER, LO, MA, Mi GH [Cover gasket BR, ER, LO, MA, MM | GK | Head gasket BE, BR, CU, ER, LA, MA, KIN MA | Mounting adapter BR, CU, MA, MM, WP ‘MD | Mounting hardware barring davies. BE, BR, CU, MA, Mil, WP MH | ‘Mounting hardware BE, BR, CU, MA, MM WP | ‘OR [Oring _ BR, CU, LOMA, MM, WO, WP | Note: Component/part codes GV, GH, MA, MD, and OF are not valid for compressors on ISM and NTA on- gines. Componeni/part codes MA and MD are not valid for compressors on I 3B and ISC engines.0071245 Page 4 Specifications Cummins 18.7-cfm Air Compressor (ISM/N14) oylinders a 6.6 liters/sec. {14.0 cfm} 318 ce [19.405 C.D] 85 mm [3.346 in] Compressor Swept Volume @ 1250 rpm ... Pision Displacement Bore .. Stroke 56 mm [2.204 in} Speed .. Engine Speed Gooting Engine Coolant Lubrication . Engine Lubricating Oil Plumbing Line Sizes: Coolant Intet and Outlet. Air Inlet soe Air Outlet Unloader Port | Governor Mounting Direct Height, Overall (approximate) .. Width, Overall (approximate) Length, Overall (approximate) Weight (approximate) 3/4 x 16 STOR* inch Nominal Hose M27 x 2 STOR" M10 x 1 STOR* MB x 1.25 217.4 mm [8.559 in} 142 mm [8.590 in} .- 216 mm [8.503 in} 15 kg [95.0 1b] Cummins 18.7-cfm Air Compressor (ISC) Cylinders vennveeene 1 Compressor Swept Volume @ 1250 rpm 6.6 litersisec. [14.0 cfm} Piston Displacement . 318 oc [19.405 C.D] Bore . 85 mm [8.346 in} Stroke 56 mm [2.204 in} Speed Engine Speed Cooling Engine Coolant Lubrication Engine Lubricating Oil Plumbing Line Sizes: Coolant inlet and Outlot... ee 3/4 x 16 STOR" Air Inlet +-inch Nominal Hose Air Outlet M27 x 2 STOR* Unioader Port M10 x 1 STOR* M8 x 1.25 217.4 mm [8.859 in} . 142 mm {5.590 in} Length, Overall (approximate) 216 mm [8.503 in} Governor Mounting Direct Height, Overall (approximate) ... Width, Overall (approximate) .... Weight (approximate) 7 18.14 kg [40.0 Ib} NOTE: * Straight-Thread O-Ring00T12-5 Page 5 Cummins 15.2-cfm Air Compressor (ISB) Cylinders . Compressor Swept Volume @ 1250 rpm Piston Displacement mmr 1 +. 5.21 liters/sec, (11.0 efra] 250 cc [15.255 C.1.D.] Bore .. 75 mm [2.952 in} Stroke... .. 56 mm {2.204 in} Speed .. .. Engine Speed Cooling .. s. Engine Coolant Lubrication Engine Lubricating Oit Plumbing Line Sizes: Coolant Inlet and Outlet 3/4 x 16 STOR" Air Inlet .. ‘inch Nominal Hose Air Outlet .. M27 x 2 STOR* Unioader Port M10 x 1 STOR” MB x 1.25 .. 217.4 mm [8.559 in] . 142 mm [5.590 in} 216 mm [8.503 in} 15 kg [35.0 Ib} Governor Mounting Direct, Height, Overall (approximate) Width, Overall (approximate) Length, Overall (approximate) ... Weight (approximate) Cumi is 18.7-cfm Air Compressor (Signature/ISX) Oylinders Compressor Swept Ve Volume @ 1250 rpm Piston Displacement : 1 66 liters/sec. [14.0 cfm] 818 cc [19.405 C.1.D.] Bore ... 85 mm [3.246 in] Stroke . 56 mm [2.204 in} Speed .. . Engine Speed Cooling .. Engine Coolant Lubrication Engine Lubricating Oil Plumbing Line Size: Coolant Inlet and Outlet Air Intet Air Outlet Unloader Port Governor Mounting Direct Height, Overall (approximate) Width, Overall (approximate) ... Length, Overall (approximate) Weight (approximate) NOTE: * Straight-Thread 0-1 ing . M10 x 1 STOR” MB x 1.25 217.4 mm [8.559 in] 142 mm [5.590 in} 216 mm [8.503 in} 18.14 kg [40.0 Ib]0072-5 Page 6 Flow Diagrams ISMIN14 18.7-cfm Air Compressor 41. Coolant 3. Lubricant Signature/ISX 18.7-cim Air Compressor 1. Coolant 3. Lubricant 2. Airo0T12-500T12-5 Page 8 Installation Recommendations Complete installation recommendations are found in Gummins Engine Company, Inc. publication, Automotive and Bus Insiallation Recommendations, Air Compressor Systems, Bulletin No. 3884946. Cummins Single-Cylinder Air System Air Governor Discharge Line Air Dryer Supply Tank Check Valve Primary Tank ‘Secondary Tank Check Valve . Ait Compressor SeNogsen= Compressed Air System Checklist This checklist is to be used with the troubleshooting trees to be sure that the air system is working properly. NOTE: If no is checked, for further assistance, contact © Dealers, contact your distributor. * Distributors, contact the appropriate Service Engineering Group. The air compressor model used for the vehicle application is the model recommended in Table 1 of these recom- mendations, or a larger capacity model, Ye No ‘The air dryer model used is compatible with the air compressor model and compressor air supply plumbing (turbo- charged or naturally aspirated) as outlined in Table S of these recommendations. Yes___No_ The air inlet supply line is @ minimum of 22-mm {7/8-in] inside diameter or -16 reinforced hose. Yes__No_. ‘The air governor is mounted to the air compressor or with a maximum unloader line length of 0.6 m [2 ft. Yes_"_No The air governor cutout setting is no greater than 1000 kPa [145 psif; Yes___No. 862 KPa [125 psi] is the preferred governor cutout setting, ‘The air governor reservoir line meets the minimum line size of 1/4-inch ID. Yes, No00T12-5 Page 9 The air governor reservoir line slopes continuously downward from the air governor to the supply or receiver tank Yes Nc mee The alr compressor discharge ling to the ai dyer or receiver tank is Teflon™tinod braided steel, copper, or ste! (es, No. ‘The compressed air temperature at the air dryer inlet does not exceed 66°C [150°F], or the length and diameter meet the requirements in Table 2 of those recommendations. Yes. No_ The air compressor discharge fine from the air compressor to the air dryer or receiver tank slopes continuously downward with no dips. Yes__No. For single-cylinder air compressor installations, the air tank volume does not exceed 98 liters [6000 n°] Yes No ‘There are no unheated valves in the exhaust line, Yes. No There are no flow-restrictive devices in the exhaust line. Yes_ No, Cummins Single-Cylinder Air Compressor Models. ‘Table 1: Engine/Air Compressor Availability Matrix Engine 1SB isc isi ISX Nia Signature Single 75.2 cfm 16.7 cfm 18.7 cfm 16.7 chm 78.7 cfm 18.7 cfm Table 2: Recommended Dischargs Line Sizes for Various Compressed Air Systems Compressed Air System ‘Minimum Length Minimum Line Single-cylinder compressor - standard-duty 3.7m [12 ft] Tamm [1/2-in] 10 (10) Single-cylinder compressor - heavy-duty 6.4m (21 fy "T6-mnm [6/8-in} 1D (12) Table 3: Air Dryer Selection Chari for Cummins Single-Cylinder Turbocharged Air Compressor ‘Air Dryer Manufacturer Wodel Dryer/Condenser ‘Acceptable for Use in Systerm(s) Aeroquip Aerofiner 1 and Wh “Air yer No. ‘Anchortoke Condenser T ‘Condenser i No. Bendix AGS Air diver Yes (AD-9 Drop-in ‘Air dryer No, ADIP Air dryer ‘Yes ADIP Drops Air dryer No ‘ADSP. Air dryer Yes ‘ADSP Drop-in Air dryer, No. ‘AD-9 OLU ‘Aig dryer Yes, ‘AD? and ADS ‘Air dryer, No) (Continued)o0T12-5 Page 10 ‘Table 3: Air Dryer Selection Chart for Cummins Single-Gylinder Turbocharged Air Compressor ‘Air Dryer Manufacturer Model Air Dryer/Condenser Acceptable for Use in System(s) _ ‘CR (Chicago Rawhide) Turbo 2000 Air dryer, “* Turbo 3000 Air dryer ee Turbo AC Condenser baled HD 2000 Air dryer Ne XD 2000 Air aryer No. Turbo 2000/620600 Air dryer os Brakemasier Condenser No. Cysloguard I Condenser I Condenser I No Graham-White I Air dryer, I Air dryer T Yes Gruenwald I Hider i Tir dryer I Yes Haldex I eT, T Ar ayer I No. Horton ‘XL21 Air dryer No. EXPELLO Condenser No Midland Pure air Air dryer No Pure ait plus Air dryer Yes Puro air plus € Air dryer No. “Tomado. Condenser No. Wabco 351000 Ar ayer Yes 81200 Air oryer Yes. SS1200E Air dryer No. 'SS12000 Air dryer No’ SS Twin Air dryer No. ** 7) Do not use Econtype-compatible air dryers. Use of Econlype models could cause continuous air com pressor cycling and premature failures. 2.) For Chicago Rawhide dryers, contact CR for compatible model availability.00T12-5 Page 11 Troubleshooting Trees Air Compressor Air Pressure Rises Slowly Cause ‘Check/Correction Remarks Air Compressor Replacement ‘Air intake system restriction to air ‘compressor is, ‘Check the air compressor intake piping. Check engine air intake restriction if the air compressor inlet excessive is plumbed to the vehicle or equipment intake system. Refer to Procedure 010-031. ‘ir system leaks Block the vehicle wheels and check | Monitor the primary ‘Compressor head the air system for leaks with spring | secondary gauges to help | gasket leak brakes applied and released. Check | isolate leaks. {or leaks from the air compressor {gaskets and the air system hoses, tings, and valves. Flefer to Procedure 012-019 and the OEM service manuals. ‘Ai governor is Check the air governor for correct | Replacing the governors | None. malfunctioning or | operation. Refer to Procedure often the best practice. ot set correctly 012-017. Carbon buildup is | Check for carbon buildup. Replace | This is usually a None. excessive in the air | the air compressor discharge line it | hammering sound. discharge line or necessary. Refer to Procedure Only check lines check valve 012.003. Check the turbocharger for | following Procedure oll leaks. Check the intake tube for | 012-003. Do not clean or oll, Refer to Procedures 010-040 and | remove the air 010-049. compressor cylinder head. ‘Air system Verity proper operation of OEM ‘Common failures are the | None. ‘component is installed components; for example, _| purge valve on the bottom malfunctioning check valves and the air dryer. Refer to the manufacturer's instructions. of the dryer andor the air suspension valves. Unioader valve is ‘malfunctioning ‘Check the unloader valve and unloader body seal. Refer to Procedure 012-013. ‘Only do Procedure 012-013-001 Air compressor does not pump air with air gover- nor removed. Air system installation issues Refer fo the air system checklist. fan item is checked NO, for further assistance, dealers need to contact their distributor; distribu- tors, the appropriate Ser- vies Engineering Group, Failed compressor Replace the air compressorPage 12 00T12-5 Air Compressor Cycles Frequently Cause ‘Check/Correction Remarks ‘Air Compressor Section G in the Master Repair Manual, Holset® Air Compressors, Bulletin’ No. 3666121 tributor; distributors, the appropriate Service Eng neering Group. Replacement Situation, Air ystem leaks Block the vohicle wheels and check | Monitor the primaryr ‘Compressor head the air system for leaks with spring | secondary gauges to-help | gasket leak. brakes applied and released. Check | isolate leaks. for leaks from the air compressor gaskets and the air system hoses, fittings, and valves. Refer to Procedure 012019 and the OEM service manuals. ‘Air governor is Check the air governor for correct | Replacing the alr None. maifunctioning or not | operation. Refer to Procedure jovernor is often. sot correctly, O12.017. the best practice Air system Verify proper operation of OEM ‘Common failures are the | None. ‘component is installed components; for example, _| purge vaive on the bottom matfunctioning check valves and air dryer. Refer Of the dryer andior the air to the manufacturer's instructions. _| suspension valves. Carbon buildup is | Check for carbon buildup. Replace | This is usually a None. ‘excessive in the air | the air compressor discharge line if | hammering sound. discharge line or necessary. Refer to Procedure Only check lines check vaive 012.003. Check the turbocharger for _| following Procadure oll leaks. Check the intake tube for | 012-003. Do not clean or oil, Refer to Procedures 010-040 and. | remove the air 10-049, ‘compressor cylinder head. ‘Air dryer outlet check | Lubricate or replace the air dryer | This will be characierized "| Nona. valve is sticking outlet check valve assembly. Refer | by an alr leak from what to the manufacturer's instructions. | is commonly referred to as the spittor ‘Air system installation | Refer to alr system ched Tan item is checked NO, | None. issues for further assistance, dealers need to contact their distributor, distribu tors, the appropriate Ser- vice Engineering Group. ‘Air compressor not | Check the air compressor duty oyole [If this is considered as a | W Service Engr designed for to determine if a larger air possible issue, dealers | neering recom- application ‘compressor is needed. Refer to heed to contact their dis- mends a larger compressor. Failed compressor Replace air compressor,00T12-5 Air Compressor Noise Is Excessive Page 13 Cause Check/Gorrection Remarks ‘Air Compressor Replacement situation Carbon buildup is | Check for carbon buildup. Replace | This is usually a None. excessive in the air | the alr compressor discharge line if | hammering sound. discharge line or _| necessary. Refer to Procedure ‘Only check ines check valve 012-003. Check the turbocharger for | following Procedure oll Ieaks. Check the intake tube for oll. | 012-003. Do not clean or Refer to Procedures 010-040 remove the air and 010-049, ‘compressor cylinder head, ‘Air Compressor is | install 4 ping lank between the alr None: sending air pulses | dryer and wet tank. Refer to the into the air tanks —_| manufacturer's insiructions, ‘Accessory drive is | Check the accessory drive axial end None: worn (axial end play | play. Inspect the shatt for wear. Refer is out of specification) | to Procedure 009-001. ‘Air compressor timing | Check the air compressor tmming. | Procedure Is the Same Tor | None. is not correct Refer to Procedure 012-014. all compressors except on the Signature and ISX Series engine, ‘Air compressor drive | Taspect the agocesony dive gars and | Procedure is the same for | None gear or engine gear | goar train. Refer to Procedures all air compressors. Gan train is worn 609-001, 601-036, 001-039, be located in the or damaged and 001.040. respective troubleshooting and repair manual Te buildup in the air” | Chack for Ice Th Tow spots of the alr None: system components discharge line, dryer inlet, and elbow fittings. Failed compressor Replace air compressorPage 14 00T12-5, Air Compressor Pumping Excess Lubricating Oil into the Air System Cause Check/Correction Remarks ‘Air Compressor Replacement jituation Lubricating olf drain interval is excessive Verify the correct lubricating oll drain interval. Refer to Section 2in the correct operation and maintenance manual. None. Air intake system restriction to air compressor is excessive Check the air compressor intake piping. Check engine air intake restriction if the air compressor inet s plumbed fo the vehicle ‘oF equipment intake system. Refer to Procedure 010-031. None. Contaminants are building up in the | system reservoirs, Drain the reservoirs daily. Rafer to the operation and maintenance manual None, Air dryer desiccant cartridge needs replaced Replace the desiccant cartridge on the air dryer (if equipped). Refer to OEM service manual. Restricted dryer desiccant causes high cylinder pressures, consequently carbon and oil passage. None designed for the application to determine if a larger air compressor is needed. Refer to Section G in the Master Repair Manual, Holset® Air Compressors, Bulletin'No, 3666121 possible issue, dealers need to contact their dis- tributor, distributors, the appropriate Service’ Engi- neering Group. Carbon buildup is | Check for carbon buildup. Replace | This is usually a None. excessive in the air | the air compressor discharge line it | hammering sound discharge line or necessary. Refer to Procedure Only check lines check valve 012-003. Check the turbocharger for | following Procedure oil leaks. Check the intake tube for | 012-003. Do not clean or all. Refer to Procedures 010-040 remove the air and 010-049. compressor cylinder head. ‘Air compressor Check the air governor for correct | Replacing the air None. pumping too high of | operation. Refer to Procedure governor is often the air pressure 012-017. best practice. Crankcase pressure | Check for excessive Dlowby. Reter to None. is excessive Section 14. Refer to the Crankcase Gases (Blowby) Excessive symptom tree. Tabricating om ‘Check the oll pressure. Rafer to None. pressure is above _| Procedure 007-028. specification ‘Ait compressor runs | if coolant temperature 1s above None. hot normal, refer to Coolant Temperature Above Normal Gradual Overheat symptom tree. ‘Air compressor not | Cheok the air compressor duly cycle | Ihis is considered as a} 1 Service Enar ooring recom mends a larger compressor. ‘Air system installation issues Refer to the air system checklist, fan item is chacked NO, for further assistance, dealets need to contact their distributor; distribu- tors, the appropriate Ser- vice Engineering Group. None. Failed compressor Fleplace air compressor.00T12-5 Page 15 Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously) Cause CheckiCorection Remarks ‘Air Compressor Replacement Situation, Air system leaks Block the vehicle wheels and check | Monitor the primary/ ‘Compressor head the air system for leaks with the secondary gauges to help | gasket leak. spring brakes applied and released. _ | isolate leaks, Check for leaks from the air compressor gaskets and the air system hoses, fittings, and valves. Refer to Procedure 012-019 and the OEM service manuals. ‘Air governor 1s ‘Check the air governor for correct | Replacing the governor 1s | None. ‘malfunctioning or not set correctly, operation. Refer to Procedure 012.017. often the best practice, ‘Air system installation issues Refer to the air system checklist Tran item is checked NO, ‘or further assistance, dealers need to contact their distributor; distribu- tors, the appropriate Ser- vive Engingering Group, Unioader valve is malfunctioning Check the unloader valve and unloader body seal. Refer to Procedure 012-013, ‘Only do Procedure 012-013-001 ‘Air compressor does not pump air with air ‘governor femoved. Falled compressor Feplace air compressor00T12-5 Page 16 Air Compressor Will Not Pump Air Cause CheckiCorrection Remarks ‘Air Compressor Replacement situation ‘Air governor is ‘Check the air Governor for correct | Replacing the governor is | None. ‘malfunctioning or ot set correctly ‘operation. Refer to Procedure 012.017. often the best practice. Unioader valve is malfunctioning Check the untoader valve and unloader body seal. Refer to Procedure 012-013. ‘Only do Procedure 012-013-001 ‘Air Compressor does not pump ait with air governor removed Failed air compressor Replace air compressor0712-5 Air Compressor Will Not Stop pumping Page 17 malfunctioning check valves and air dryer. Refer to the manufacturer's instructions, Cause CheckiCorrection Remarks ‘Air Compressor teplacement ituation ‘Air system Teaks Block the vehicle wheels and check — | Monitor the primary ‘Compressor head the air system for leaks with the secondary gauges to help | gasket leak spring brakes applied and released. _| isolate leaks. Check for leaks from the air Compressor gaskets and the air system hoses, fitings, and vaives. Refer to Procedure 012-019 and the OEM service manuals. ‘Air governor Is ‘Check the air governor for correct | Replacing the governor is | None. malfunctioning or __| operation. Refer to Procedure often the best practice. not set correctly 012.017. Ait governor signal | Inspect the signal line and actuator | THis can be a reoze-up | None. line or actuator line is | line. Refer to the manufacturer's problem if the weather is | plugged instructions. cold Air system Verify proper operation of OEM: ‘Common failures are the | None. component is installed components; for example, _| purge valve on the bottom of the dryer and/or the air suspension valves. Unloader valve is malfunctioning ‘Check the unloader valve and unloader body seal. Refer to Procedure 012.013. ‘Only do Procedure 012-013-001 ‘Air compressor ‘does not pump air with air governor Femoved, Failed compressor Replace air compressor