IMPORTANT INFORMATION

Transcription

1 IMPORTANT INFORMATION Do Not Proceed Until You Read This! Walker Engineering makes every effort to ensure our orders are packed to withstand the rigors of shipping and arrive at their destination intact and undamaged. Unfortunately we cannot control the handling of our packages once they leave our facility. Small parts may become lodged in AirSep and Air Cleaner housings creating a potential hazard. You must inspect the contents of this shipment to verify you have all the components listed on the invoice or kit list before beginning installation. It is the responsibility of the installer to ensure that any air intake components are free of loose parts or packing material before installation, or before starting engine. Thank you for choosing Walker Engineering products, we appreciate your business and look forward to serving you again. If you have any questions please call: Walker Engineering Enterprises (818) (Phone) (818) (Fax) Visit our website at: Copyright 2006, Walker Engineering Enterprises

2 AIRSEP KIT # KW INSTALLATION INSTRUCTIONS FOR CUMMINS B SERIES MARINE ENGINE (210HP) SINGLE TURBO 1. List of Parts Included In Kit Part # KW (Rev. 8/17/2004) (Drwg.# ER1) Parts Number of Parts Part # Walker AirSep (5" ST Filter) S35GB (w/3/8" x 45 barb) Vacuum Regulator Assembly 1 VR 1000 OIL DRAIN ASSEMBLY 1 -LISTED- Drain Check Valve 1 CD246 1/2 Hose (10.25 Long) 1 CD285 1/2 Hose (8.5 Long) 1 CD285 1/4 NPT x 1/2 Hose Barb 1 CD243 1/4 NPT x1/2 Fem Hose Barb 1 CD529 1/2 Clamp, Hose 4 CD291 Hose End Fitting 1 CD621 Oil Pan Fitting 1 CD /4" 'P' Clamp 1 CD622 3/4 x 1-1/4 x 10 3/4" Adapter Hose 1 CD625 3/4" Clamp, Hose 1 CD /4 Clamp, Hose 3 CD /4" x 120 "J" Hose 1 CD273 3 x 3" long Silicone Connection Hose 1 CD /2" T-Bolt Clamp, Hose 1 CD /2 Worm Drive Clamp 1 CD307 Note: Before starting the installation verify all parts are present, if there is any question please contact Walker Engineering. 2. Engine Preparation Prior To Installing The AIRSEPS To receive optimum performance from your engine and the maximum benefits from the AirSep it is advisable to clean the air induction system of the engine, including the aftercooler or intercooler. IF THE ENGINE HAS MORE THAN 100 HOURS OF USE. - Continue

3 - Page 2 of 3 KW Walker Engineering recommends that you take a Manometer reading before and after AirSep Installation. Most engines will read positive crankcase pressure before installation of the Walker AirSep and negative (or a significant reduction) after installation. SPECIAL NOTE: THIS INSTALLATION REQUIRES SWITCHING THE EXISTING OIL DRAIN PLUG WITH A FITTING. IT MAY BE CONVENIENT TO SCHEDULE THIS INSTALLATION FOR A REGULAR OIL CHANGE. DUE CARE SHOULD BE EXERCISED TO MINIMIZE OIL LEAKAGE INTO THE BILGE. 3. Installation Instructions The following instructions must be followed for the proper installation of an AirSep on a Cummins 6 BT (210H.P.) Single Turbo engine. (a) From the turbo charger, remove the existing air cleaner, silencer and hump hose. Disconnect and remove the existing breather tube from the breather located on the side of the engine. Also remove any existing brackets. (1) Connect the supplied 3/4 by 1-1/4 Breather adapter hose to the engine breather. Tighten Clamp. The hose will travel up and toward the flywheel area of the engine. (2) Connect the AIRSEP SIDE of the Vacuum Regulator Assembly to the 1 1/4" "J" hose supplied. Note that the Vacuum Regulator is marked with an arrow showing direction of installation. The hose should be pre-assembled to the regulator so that it appears to loop to the right side of the regulator tee body when viewed from the hose end of the assembly. Tighten clamp. 3) Attach the AirSep unit to the turbo inlet as indicated in the attached diagram and secure with the tee-bolt clamps provided. The 1-1/4 breather inlet on the AirSep must be on top and the 1/2 oil drain outlet must be on the bottom. It is important to note that the 1/2 drain must be in the "6 o'clock" position in relation to the AirSep (it should be pointed straight down). If the position of the 1/2 drain deviates more than 5 from perpendicular the AirSep will not operate properly. (4) Now connect the other end of the regulator to the breather adapter hose already installed. The regulator filter element should be positioned to point in the direction of the engine block with the "J" hose pointing to the flywheel area. (5) Attach the loose end of the "J hose to the breather inlet of the AIRSEP. (6) The regulator should be positioned 90 (3 o'clock) in relation to the adapter hose going to the engine breather. (When viewed from the back of the engine) - Continue

4 - Page 3 of 3 KW NOTE: SINCE THE ENGINE IS FULL OF OIL, CARE SHOULD BE TAKEN WHEN REPLACING THE OIL DRAIN PLUG WITH THE WALKER DRAIN FITTING. (b) The oil separated by the AirSep must be drained from the AirSep through the check valve back into the crankcase. In most cases this can be done through an auxiliary plug located on back bottom area of the oil pan. The drain hose assembly is pre-cut. Carefully remove the oil pan plug and replace it with the elbow fitting attached to the drain hose assembly. NOTE: Some engines will have an aftermarket oil pump out fitting installed at the aft oil pan plug. Such cases will require installing a tee fitting at the oil pan. THIS FITTING IS NOT SUPPLIED AND MUST BE OBTAINED FROM YOUR CUMMINS DEALER OR LOCAL FITTING SUPPLY STORE. (c) Connect the upper end of the drain hose assembly to the AIRSEP drain barb located on the bottom of the AIRSEP. Secure hose clamps. Make sure the check valve is installed with arrows pointed down. If the check valve is installed up side down it will not operate and oil will not drain out of the AirSep. The oil drain check valve should not be at more than a 30 angle off of vertical. Be sure there are no low spots in the 1/2 drain line from the AirSep drain to the check valve or from the check valve to the point oil is returned to the crankcase. (d) Secure the drain hose assembly with the 'P' clamp provided. (e) Tighten any clamps not previously tightened. Be very careful not to over tighten any clamp placed on the AirSep. Over tightening a clamp on the AirSep will damage the unit and void the warranty. (f) Note: The AirSep is a closed crankcase system. Be sure all openings into the engine (such as the oil filler cap, the dip stick hole and any other openings) are closed off. The AirSep will not operate properly if the vacuum in the crankcase is compromised. Carefully review the enclosed maintenance requirements for the AirSep filter. If the air restriction gauge on the AirSep turns red the air filter must be cleaned or replaced. The filter supplied with the AirSep can under normal circumstances be cleaned and re-oiled up to three times. Cleaning and re-oiling Kits, part # DDF 9000, are sold by Walker Engineering and our dealers. For questions involving the installation of the AirSep contact Walker Engineering Enterprises at (818) or Fax (818) Visit the Walker website:

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6 W a lk e r E n g in e e r in g E n t e r p r is e s AIR FILTER CLEANING INSTRUCTIONS FAQ s and Air Filter Cleaning Tips 1) PRE-CLEANING Remove air filter from AIRSEP. Tap filter element to dislodge any large dirt particles. Gently brush with a soft bristle brush. 2) SPRAY ON CLEANER Spray liberal amount of cleaning solution onto entire filter element and allow to soak for 10 minutes. 3) RINSE OFF Rinse off the element with low pressure water. Always flush from the clean side to dirty side. This removes the dirt and does not drive it into the filter. 4) DRYING THE FILTER Always dry naturally. After rinsing, shake off all excess water and allow the element to air dry naturally or in the sun. 5) RE-OILING THE FILTER After cleaning air filter always re-oil before using. Apply oil down each pleat. Wait ten minutes and re-oil any light visible spots 6) CLEAN VACUUM REGULATOR/LIMITER Using a slot head screwdriver, loosen clamp and remove filter. Then follow steps 1 through 5. To clean the Vacuum Limiter do not attempt to remove the filter. Remove the entire vacuum limiter and follow steps 1 through 5. 7) AIR FILTER INSTALLATION Reinstall air filter on AIRSEP. Use Walker Air Filter Sealing Compound (CD955) when reinstalling air filter. Be sure to inspect springs and replace if worn. This kit cleans and oils up to four (4) 9x12 or equivalent sized filters. How often do I need to clean my air filter? You should clean your air filter every 250 to 300 hours, or every year whichever comes first. How often should I replace my air filter? Replace your air filter after four (4) cleanings or every 3 or 4 years depending on condition of filter. Is it better for my engine if I clean the air filter more often? No, follow the cleaning interval listed above. Cleaning too often will impair the vacuum action of the AIRSEP. Can I use other liquids to clean and oil my air filter? No, your AIRSEP air filter may be damaged by harsh detergents or liquids other than the recommended cleaner in this kit. Other oils may be too light or too heavy to properly capture airborne dirt. Use the appropriate Walker kit to clean and recondition your standard or blue air filters. CAUTION NEVER CLEAN USING: Gasoline Part Cleaner Solvents Caustic Cleaning Solutions Strong Detergents High Pressure Water High Pressure Air Steam Cleaners NEVER OIL FILTER: Using Transmission Fluid Using Motor Oil Using Diesel Fuel Using WD-40 Using Other Oils Walker Engineering Enterprises, Sun Valley CA Walker Engineering Enterprises. All Rights Reserved. Made in U.S.A.