Usage:
(1) Install shaft assembly in housing as follows:
a. Install spacer (3) and spring (2) on shaft assembly (1).
b. Install the assembly in the housing. Turn spring (2) until it engages correctly with pin (4).
c. Install handle (10) on the shaft assembly (1). Turn shaft assembly (1) upward and install pin (13) so handle (10) can rest on pin (13).
d. With the shaft assembly and handle (10) in contact with pin (13), install plate assemblies (5) and (6) on the shaft assembly.
e. Remove pin (13) to release the handle and let plate assemblies (5) and (6) move to the "shutoff" position. A 0.08 mm (.003 in.) feeler gauge should not pass between each plate assembly and the housing.
f. Remove handle (10) and install spacer assembly (12), pin (13), the gasket, cover assembly and handle (10).
(2) Spring.
(3) Spacer for spring (2):
Bore in spacer for shaft ... 20.80 ± 0.25 mm (.819 ± .010 in.)
Diameter of shaft ... 18.94 ± 0.02 mm (.746 ± .001 in.)
(4) Pin.
(5) Plate assembly.
(6) Plate assembly.
(7) Hydraulic cylinder must be installed before the air shutoff can be installed on the engine. Put the air shutoff group in the "open" position and install the gasket, flange and cylinder with cylinder shaft (15) between the spacer assembly in the shaft lever and spacer assembly (16). The bolts that hold the unit to the aftercooler housing can now be installed.
(8) Torque for nut that holds cylinder to flange ... 45 ± 7 N·m (33 ± 5 lb.ft.)
(9) Diameter of pin ... 6.299 ± 0.008 mm (.2480 ± .0003 in.)
Bore in spacer bushing for pin (after assembly) ... 6.314 ± 0.011 mm (.2486 ± .0004 in.)
Bore in spacer for bushing ... 7.938 ± 0.013 mm (.3125 ± .0005 in.)
(10) Handle.
(11) Diameter of pin (13) ... 6.299 ± 0.008 mm (.2480 ± .0003 in.)
Bore in housing for pin ... 6.408 ± 0.051 mm (.2523 ± .0020 in.)
Bore in spacer bushing for pin (after assembly) ... 6.314 ± 0.011 mm (.2486 ± .0004 in.)
Bore in spacer for bushing ... 7.938 ± 0.013 mm (.3125 ± .0005 in.)
(12) Spacer.
(13) Pin.
(14) Diameter of shaft ... 18.94 ± 0.02 mm (.746 ± .001 in.)
Inside diameter of bushings for shaft ... 19.050 ± 0.044 mm (.7500 ± .0017 in.)
(15) Hydraulic cylinder shaft.
(16) Spacer assembly.
(2W7163)
(1) Hydraulic shutoff cylinder. Make an alignment of cylinder port and vent hole (9) in a vertical downward position at assembly.
(2) Torque for nut that holds cylinder (1) to the flange ... 45 ± 7 N·m (33 ± 5 lb.ft.)
(3) Diameter of cylinder rod ... 7.920 ± 0.013 (.3118 ± .0005 in.)
Bore in bushing after assembly ... 7.996 ± 0.044 mm (.3148 ± .0017 in.)
Bore in housing for bushing ... 9.525 ± 0.013 mm (.3750 ± .0005 in.)
Install bushing with split along centerline (8) toward front or rear.
(4) 2V244 Spring for shutoff actuator pin:
Length under test force ... 29.2 mm (1.15 in.)
Test force ... 8.9 ± 0.7 N (2.00 ± .16 lb.)
Free length after test ... 54.6 mm (2.15 in.)
Outside diameter ... 9.04 mm (.356 in.)
(5) Torque for carrier (put 2P2506 Thread Lubricant on the threads) ... 70 ± 10 N·m (50 ± 7 lb.ft.)
(6) Bore in spring bushing ... 19.30 ± 0.25 mm (.760 ± .010 in.)
Diameter of shaft ... 18.97 ± 0.02 mm (.747 ± .001 in.)
(7) Diameter of shaft ... 18.97 ± 0.02 mm (.747 ± .001 in.)
Bore in two shaft bushings (after assembly) ... 19.050 ± 0.044 mm (.7500 ± .0017 in.)
Bore in housing for bushings ... 22.205 ± 0.013 mm (.8742 ± .0005 in.)
(2W5216)
(1) Latch.
(2) Shutoff cylinder rod.
(3) Install shutoff cylinder as follows:
a. Assemble shutoff cylinder on the flange at the angle shown.
b. Tighten the nut that holds the shutoff cylinder to the flange to a torque of ... 45 ± 7 N·m (33 ± 5 lb.ft.)
c. Install the flange on the air shutoff housing. Make sure cylinder rod (2) is engaged in the notch of lever (11).
NOTE: The cylinder vent hole, between the ports, must be in the downward position.
(4) Knob.
(5) Diameter of shaft assembly at seal ... 15.88 ± 0.05 mm (.625 ± .002 in.)
(6) Air shutoff spring.
(7) Diameter of shaft assembly ... 24.88 ± 0.02 mm (.980 ± .001 in.)
Bore in bushings for shaft assembly (after assembly) ... 25.017 ± 0.040 mm (1.0035 ± .0016 in.)
Bores in housing for bearings ... 27.997 ± 0.010 mm (1.1230 ± .0004 in.)
(8) Shaft assembly.
(9) Plate assembly.
NOTE: With plate assembly (9) in the closed (shutoff) position, a 0.8 mm (.03 in.) feeler gauge must not pass between the plate assembly and the housing bore at any position.
(10) Lever return spring.
(11) Lever.
(12) Sleeve.
(13) Diameter of sleeve ... 14.945 ± 0.009 mm (.5995 ± .0004 in.)
Bore in bushing (after assembly) ... 15.024 ± 0.034 mm (.6026 ± .0014 in.)
Bore in lever for bushing ... 17.009 ± 0.009 mm (.6823 ± .0004 in.)
NOTE: Install both bushings to a dimension of 0.8 ± 0.3 mm (.03 ± .01 in.) below the surface of lever ends.
(14) Dimension to install end of two bushings from machined housing bore ... 0.35 ± 0.15 mm (.014 ± .006 in.)