Assembly Instructions

QSK60-GS3 G4 G6
Air Cleaner Assembly A048E661

C1760 D5e
C2000 D5e
C2250 D5
C2000 D6

English
Original Instructions 1-2014 A048K922 (Issue 1)
Table of Contents
1. INTRODUCTION ...................................................................................................................... 1
1.1 About These Assembly Instructions .................................................................................. 1
1.2 Warning, Caution, and Note Styles Used In This Manual................................................. 1
1.3 Safety Precautions ............................................................................................................ 2
1.4 Lifting ................................................................................................................................. 2
1.5 Specifications .................................................................................................................... 3

2. PARTS INFORMATION............................................................................................................ 5
2.1 Introduction........................................................................................................................ 5
2.2 Air Cleaner Assembly........................................................................................................ 5

3. AIR CLEANER ASSEMBLY .................................................................................................... 7

3.1 Introduction........................................................................................................................ 7
3.2 Required Tools .................................................................................................................. 7
3.3 Items Required by Customer to Complete Installation...................................................... 7
3.4 Air Cleaner Assembly Instructions .................................................................................... 7

4. APPENDIX.............................................................................................................................. 17
4.1 Assembly Drawing .......................................................................................................... 17

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ii A048K922 (Issue 1)
1 Introduction
WARNING
Hazardous voltage.
Can cause severe personal injury or death and equipment damage.
Generator electrical output connections must be made by a trained and experienced
electrician in accordance with the installation instructions and all applicable codes.

WARNING
Electrical generating equipment.
Can cause severe personal injury or death.
Generator sets must be installed, certified, and operated by trained and experienced person
in accordance with the installation instructions and all applicable codes.

1.1 About These Assembly Instructions

The purpose of these instructions is to provide the assembly instructions and corresponding
parts list for the component or components listed on the front cover. These instructions
should be followed during the assembly and installation of equipment supplied without a
control system or wiring. They also contain a description of the conditions that must be
satisfied, so as to not compromise health and safety.
In addition to the requirements stated below, installers must comply with the requirements of
Cummins Application Engineering Bulletins (AEBs) which highlight interfaces, installation
requirements and operating limits, together with all applicable codes and product standards.
In line with Cummins policy of continuous development and improvement, the AEBs may be
updated from time to time. Installers should make sure that before commencing any work,
they have reviewed the latest information available.
Safe and efficient operation can be achieved only if the equipment is properly operated and
maintained. Many accidents are caused by failure to follow fundamental rules and
precautions.
It is the installer's responsibility to employ competent persons to carry out any installation
work.
Refer to the parts information prior to installing the assemblies. The numbers in parenthesis
() included in the instructions correspond to the part call-out numbers.
The information contained within the manual is based on information available at the time of
going to print. In line with Cummins Power Generation policy of continuous development and
improvement, information may change at any time without notice. The users should
therefore make sure that before commencing any work, they have the latest information
available. The latest version of this manual is available on QuickServe Online
(https://qsol.cummins.com/info/index.html).
For further assistance, contact your authorized distributor.

1.2 Warning, Caution, and Note Styles Used In This

Manual
The following safety styles and symbols found throughout this manual indicate potentially
hazardous conditions to the operator, service personnel, or the equipment.

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1. Introduction 1-2014

DANGER
Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING
Indicates a hazardous situation that, if not avoided, could result in death or serious
injury.

CAUTION
Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICE
Indicates information considered important, but not hazard-related (e.g., messages relating to
property damage).

1.3 Safety Precautions

WARNING
Incorrect installation.
Incorrect installation, service, or parts replacement can result in severe personal injury,
death, and/or equipment damage.
Service personnel must be trained and experienced to perform electrical and mechanical
component installations.

NOTICE
Sharp edges/burrs on housing panels/parts can cause severe cuts/abrasions. When
handling parts, always wear gloves.

Read these instructions completely and become familiar with safety warnings, cautions, and
procedures before starting the installation.
The installer must be familiar with the techniques of working on heavy machinery. A hoist
must be available which can support the weight of the assemblies, with an appropriate lifting
strength margin.

1.4 Lifting
• Take the necessary precautions when lifting the assembly.
• Never lift the assembly over a person. Clear the area before lifting.
• Never divert your attention from the lift.
• Never use a broken hoist.
• Never attempt to lift more weight than the hoist is rated for.
• Refer to the specification table for weights.
• The weight quoted does not include packing materials.
• The correct lifting device and sling must be used and attached in appropriate manner.
• All lifting operations must be carried out by qualified personnel and using suitably rated
and tested equipment in accordance with all applicable safety procedures.

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1.5 Specifications
TABLE 1. SPECIFICATIONS

Item Description Data

1 Air cleaner weight 24.5 kg (54 lb)
2 Base air cleaner 80 kg (176 lb)
3&4 Brace air cleaner 13.5 kg (29.8 lb)
6&7 Support bracket air cleaner 8 kg (18 lb)
12 Steel tube 177.8mm x 1610mm (7 in x 63 in) 10.5 kg (23 lb)

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4 A048K922 (Issue 1)
2 Parts Information
2.1 Introduction
Refer to the parts information prior to installing the assembly to ensure that all components
listed are in the kit provided. Any discrepancies contact your authorized distributor.

2.2 Air Cleaner Assembly

FIGURE 1. AIR CLEANER ASSEMBLY

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TABLE 2. A048E661 TABULATION

No Part Number Description Qty

1 AH1907600 Air cleaner 4
2 394094900 Base-air cleaner 1
3 395184400 Brace-air cleaner 1
4 395184500 Brace-air cleaner (LH) 1
5 395184700 Brace-air cleaner (RH) 1
6 395184900 Bracket-air cleaner (LH) 1
7 395185000 Bracket-air cleaner (RH) 1
8 394895100 Band Mounting (18") 8
9 394035600s Cap-Rain 4
10 394092900 Elbow reducing 90° (8" to 7") 2
11 394094700 Steel tube black 7" x 534 2
12 331659200s Elbow reducing (8" to 7") 4
13 331662700s Hose reducing (8" to 7") 2
14 Q617286-20 Steel tube black 7" x 1610 2
15 331657600s Elbow reducing 90° 7" 2
16 394093100 Steel tube black 7" x 369 2
17 394093000 Bracket air cleaner tube 1
18 394867600 Clamp hose 8" (210.8-221-.0) 2
19 394420500 Clamp hose 5.5" (147.3-157.5) 2
20 394420600 Clamp-Hose 7" (185.4-195.6) 4
21 Q365962-20 Shield-Heat 2
22 394632600s Indicator restriction 4
23 396037900 Clamp hose 8" 2
24 396038100 Clamp hose 7" 2
25 395701500 M12 Flat washer 32
26 397486900 M12 Nut 16
27 394849900 M12 Spring washer 16
28 *A048J078 M12 Nut 16
29 *A048J057 M20 flat washer 4
30 *A048J058 M20 Spring washer 4
31 *A048J061 Bolt M20 x 35 4
32 397846900 Flange Head bolt M8x30 4
33 *A048J085 Flange Head bolt M8x18 20
34 395372200 Kit box (Not Illustrated) 1
35 Q05348-10 End cap 2
36 Q458047-20 1/8" NPT M-M adaptor 2
37 397664600 T Bolt clamp 2

Note: *Items are Cummins filtration parts and not Cummins power generation parts.

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3 Air Cleaner Assembly
3.1 Introduction
Refer to the parts information prior to installing the assembly to ensure that all components
listed are in the kit provided. Any discrepancies contact your authorized distributor.

3.2 Required Tools

The following tools are required to complete this installation.
• Lifting straps with shackles capable of lifting 292 Kg (643 lb)
• Platform suitable for working at heights
• Torque wrench minimum value 0-400 Nm (0-295 ft-lb)
• White paint pen
• 6,10,and 13 mm Wrenches
• 6,10,13 and 20 mm Impact sockets
• Air ratchet wrench or 12V/18V cordless drill

3.3 Items Required by Customer to Complete

Installation
The following items are required to complete this installation.

Part Description QTY Where Used

Hose Lubricant A/R Hose Installation

3.4 Air Cleaner Assembly Instructions

WARNING
Lifting.
Incorrect lifting can result in severe personal injury, death, and/or equipment damage.
Lifting and repositioning of the air cleaner assemblies must only be carried out using
suitable lifting equipment, shackles, and spreader bars, in accordance with local guidelines
and legislation, by suitably trained and experienced personnel.

NOTICE
It is the responsibility of the installer to ensure that safe working practices are
adhered to. It is recommended to use over head lift and scaffolding to carry out the
installation safely. Always work from a platform or scaffolding NOT from the engine,
bed frame or alternator. Failure to do so may result personal injury or equipment
damage.

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NOTICE
To prevent the ingress of dirt or debris entering into the turbo assemblies or air
filtration system during installation, shipping covers should be left in place until the
air cleaner assembly is ready to be installed.

NOTICE
Mark the bolt heads with white pen to indicate that the required torque has been
set.

NOTICE
Remove any blanking plugs from the turbochargers.

NOTICE
To aid installation apply hose lubricant to the elbows and hose connectors.

FIGURE 2. SERVICE INDICATOR

1. Install the 4 service indicators (22) onto the 4 air cleaners (1).

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FIGURE 3. END CAPS

2. Insert the adaptors (36) into the steel tubes (14) and fit the end caps (35).

FIGURE 4. BAND MOUNTING

3. Using 16 M20 x 35 bolts (26), 32 M12 flat washers (25), M20 flat washers (27) and M12
nuts (28) install the 8 band-mountings onto the base-air cleaner (2). Torque the bolts to 80
Nm (59 ft-lb).

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FIGURE 5. SUPPORT BRACKETS

3. Fit the air cleaner vertical support brackets (6) (7) to both sides of the flywheel housing,
using 4 M20 x 2.5mm x 35 screw hex bolts (31) with M20 flat washers (29) and M20 spring
washer (30), make sure the brackets are level, and torque the bolts to 388 Nm (286 lb-ft).
4. Using 12 M8x18 flange head bolts (33), fit the air cleaner brace (3) to the support
brackets (6) (7) and torque the bolts to 23 Nm (17 lb-ft).
5. Using 4 M8x30 flange head bolts (32), fit the left (4) and right (5) air cleaner braces to the
support brackets (6) (7) and torque the bolts to 23 Nm (17 lb-ft).
6. With the aid of another person and using 4 M8x30 flange head bolts (33), fit the air
cleaner base (2) to the air cleaner braces (4) (5) and torque the bolts to 23 Nm (17 lb-ft).

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FIGURE 6. AIR CLEANER ASSEMBLY (MIDDLE)

7. Using 2 hose clamps (18) assemble 2 of the hose reducers (13) to 2 of the air cleaners
(1), and torque the hose clamps to 5.7 Nm (4 lb-ft). Loosely fit a further 2 hose clamps (20)
over hose connecting, do not fully tighten at this stage.

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FIGURE 7. AIR CLEANER MIDDLE (MOUNTING)

8. Insert 2 air cleaners (1) into the band-mountings (8) on the air cleaner base (2) and
tighten the band clamp bolts to 23 Nm (17 lb-ft).
1. Fit the rain caps (9) (optional at this stage).

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FIGURE 8. FRONT HOSE ASSEMBLY

9. Using the following components assemble the 2 front hose connections for the front turbo
chargers. Do not fully tighten the clamps at this stage.
1. 8 x Clamp hose (20).
2. 4 x Clamp hose (19).
3. 4 x Elbow 90° 177.8mm (7 in) (15).
4. 4 x Elbow reducing 90° 177.8mm x 139.7mm (7 in to 5.5 in) (12).
5. 4 x Steel tube 177.8mm x 369mm (7 in x 14.5 in) (16).

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FIGURE 9. REAR HOSE ASSMBLY

10. Using the following components assemble the 2 rear hose connections for the rear turbo
chargers. Do not fully tighten the clamps at this stage.
1. 4 x Clamp hose (24).
2. 4 x Clamp hose (20).
3. 2 x Elbow 90° 177.8mm (7 in) (12).
4. 2 x Elbow reducing 90° 177.8mm x 139.7mm (7 in to 5.5 in) (10).
5. 2 x Steel tube 177.8mm x 534mm (7 in x 21 in) (11).
11. Connect the 2 front hose connection assemblies to the front turbo chargers. Do not fully
tighten the hose clamps at this stage.

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FIGURE 10. TUBE ASSEMBLY CONNECTION TO FRONT TURBOCHARGERS

12. Slide two hose clamps (37) over the 2 steel tubes (14).
13. With the aid of another person, insert the 2 steel tubes (14) between the hose
connections (15) (20), making sure the front hose connections are at 90°. Torque the hose
clamps to 5.7 Nm (4 lb-ft).
14. Using the 2 clamps (37) fit the bracket (17) between the steel tubes (14). Torque the
clamps to 5.7 Nm (4 lb-ft).

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FIGURE 11. AIR CLEANER ASSEMBLY MOUNTING (OUTER)

15. Insert 2 air cleaners (1) into the band-mountings (8) on the air cleaner base (2) and
tighten the band clamp bolts to 23 Nm (17 lb-ft).
16. Connect the 2 rear hose connection assemblies to the air cleaners and rear turbo
chargers. Torque the clamps (20) (23) to 5.7 Nm (4 lb-ft).
17. Fit the 2 heatshields (21) to the elbow connections (12) 1 on the right bank rear
turbocharger and 1 on the front left turbocharger see Figure 1 .

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4 Appendix
4.1 Assembly Drawing

FIGURE 12. ASSEMBLY DRAWING

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18 A048K922 (Issue 1)
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Cummins, the "C" logo, and "Our energy working for you." are trademarks
of Cummins Inc.