Creation: 03.09 - 2011 2-1-1

ASU-600 Series

CHAPTER 2

Maintenance Pro

perty

of A

mer

ican

Airline

s

Creation: 03.09 - 2011 2-1-2

ASU-600 Series

I - Servicing

1. Periodic Maintenance

In order to ensure a properly running unit, periodic maintenance and inspections are necessary. In addition to the pre-operational instructions given in Chapter 1, the unit must be maintained on a regular basis and any malfunctions or problems with the unit must be fixed at once. Delaying repairs on machinery that is running improperly may create an unsafe situation and will increase mechanical problems.

When working on any system in the unit, extreme caution must be used to avoid personal injury or death.

WARNING:

KEEP HANDS AND LOOSE CLOTHING AWAY FROM ROTATING MACHINERY AND BELTS.

WARNING:

ELECTRIC SHOCK MAY RESULT IN SEVERE INJURY OR DEATH. ALWAYS SHUT UNIT OFF AND DISCONNECT BATTERY BEFORE PERFORMING ANY MAINTENANCE.

CAUTION:

IF ANYONE IS WELDING OR GRINDING ON THE GALVANIZED BASES SAFETY GLASSES AND A DUST FILTRATION MASK MUST BE WORN TO PREVENT EXPOSURE TO FUMES AND DUST.

WARNING:

PROPER ENGINE MAINTENANCE IS REQUIRED, AS ROUGH RUNNING, MISFIRING, OR LOW FUEL PRESSURE IN THE ENGINE CAN LEAD TO COMPRESSOR COUPLER FAILURE.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-3

ASU-600 Series

A. Lubrication and Maintenance

Chart 1 shows the frequency of maintenance required on the listed component

Component Maintenance Required

Engine oil Check daily, change initially after 50 hours, and every 150 hours thereafter.

Engine oil filter Change every 150 hours.

Engine fuel filters Check daily, change as necessary.

Engine fuel water separator Drain water every 300 hours

Engine air intake filter Check daily, change as necessary.

Engine coolant Check daily, change every 24 months.

Engine coolant filter Change every 12 months

Fan belt Check and adjust every 100 hours. Replace every 2,000 hours

Alternator belt Check and adjust every 100 hours. Replace every 2,000 hours

Compressor oil Check daily, change after the first 6 months and every 12 months thereafter.

Compressor oil filter Change after the first 6 months and every 12 months thereafter.

Compressor air filter Check daily, change as necessary.

Compressor oil breather Clean every 750 hours or annually

Compressor Coupler Inspect every 6 months

Signal air filter Check daily, drain as necessary.

Delivered Air pressure and flow Check every 200 hours or 6 months*

Exhaust Silencer Remove plug and clean quarterly.

Tow bar pivot Lubricate every 200 hours or quarterly.

Fifth wheel pivot Lubricate every 200 hours or quarterly.

Wheel bearings Lubricate every 24 months.

Wheel lug nuts Torque every 200 hours or quarterly

General unit lubrication Lubricate every 200 hours or quarterly.

* Refer to procedure in section 2-1, page 27. ** Refer to procedure in section 2-1, page 19.

LUBRICATION & MAINTENANCE CHART 1

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-4

ASU-600 Series

B. Filters and Lubrication

Filters and lubricants for periodic maintenance are listed with their corresponding ACE Part Number in Chart 2. Further information on specific lubricants may be found in the Manufacturer’s Literature in Chapter 5.5.

Nomenclature ACE Part Number

Qty. Per Unit

Engine Oil* 1012342 38 Quarts (with Filters)

Oil Filter 1019506-P1 2

Fuel Filter 1030544-P1 1

Engine Air Filter 1017688 1

Engine Coolant 1033604-50 19 Gallons

Coolant Inhibitor Element 1035574-P1 1

Fan Belts 1035361 1

Alternator Belt 1035574-P2 1

Compressor Air Filter Element (Non-Hush Kit) - (100 PPM) 1032486 1

Compressor Air Filter Element (Hush Kit) - (100 & 150 PPM) 1030742 1

Compressor Air Filter Element (Non-Hush Kit) (150 to 300 PPM) 1017697 1

Compressor Air Filter Element (Hush Kit) (180 to 300 PPM) 1030829 1

Signal Line Filter Element 1000196 1

Compressor Oil (180PPM)** 1000247 5.3 Gallons

Compressor Oil (270 & 300 PPM)** 1000247 7.9 Gallons

Compressor Oil Filter 1018150-P8 1

* See (3) below for a list of approved engine oils. ** See (J) on page 19 below for approved compressor oils.

FILTERS & LUBRICANTS CHART 2

(1) Lubrication Schedule

The time schedules indicated in Chart 1 are approximate. They are based on average operating conditions. It may be necessary to reduce the times shown under harsh operating conditions such as low engine temperatures, excessively heavy loads, high oil temperatures, intermittent operation, and operation in particularly arid or dusty environments.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-5

ASU-600 Series

(2) Oil Specification

Engine oil recommended by the manufacturer is identified by A.P.I. (American Petroleum Institute) classification CG-4/CF-4. Further information on oil specification is contained in the Manufacturer’s Literature in Chapter 5.

(3) Oil Viscosity

The use of a 15W-40 grade oil is recommended for year round service. Further information is contained in the Manufacturer’s Literature in Chapter 5. The following is a list of approved oils:

1. Mobil Delvac 1300 15W-40

2. Valvoline All-Fleet Plus 15W-40

3. AMSOIL Synthetic Heavy Duty Diesel and Marine Motor Oil (AME) 15W-40

(4) Changing Engine Oil

Follow the instructions contained in the Manufacturer’s Literature in Chapter 5.

(5) Changing Engine Oil Filter

Follow the instructions in the Manufacturer’s Literature in Chapter 5.

C. Engine Air Cleaner (See Figure 1)

The engine air cleaner is a unitized assembly consisting of a cone type pleated paper element and integral housing that is totally replaceable. A definite time schedule for changing the element cannot be specified due to varying operating conditions. The filter should be replaced as a unit whenever a red band, identifying a clogged filter, is visible on the service indicator mounted on the air intake plumbing or a high engine air intake filter restriction fault occurs.

(1) Filter Replacement

(a) Loosen the hose clamp securing the rubber adapter elbow to the filter outlet.

(b) Remove the fasteners securing the mounting clamps to the filter housing. Spread the clamps to release the filter assembly.

(c) Remove the filter assembly and discard as a unit.

(d) Position the replacement filter in the mounting clamps. Reinstall and tighten the fasteners removed.

(e) Install the adapter elbow over the filter outlet. Position and tighten the hose clamp.

(d) Reset the restriction indicator.

CAUTION:

THE FILTER IS A NON-WASHABLE SELF-CONTAINED ASSEMBLY. DO NOT ATTEMPT TO CLEAN OR DISASSEMBLE THE FILTER. THE PLEATS ARE PERMANENTLY LOCKED IN PLACE. DISCARD AS A UNIT.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-6

ASU-600 Series

2

4

1. ... Hose clamp 2. ... Restriction indicator and switch 3. ... Air filter assembly 4. ... Mounting clamps (2)

ENGINE AIR CLEANER FIGURE 1

2

3

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-7

ASU-600 Series

D. Coolant Inhibitor Element Replacement (See Figure 2)

(1) Disable engine start by opening battery disconnect switch.

(2) Open radiator pressure cap.

(3) If the cooling system is protected by a coolant inhibitor element, the coolant inhibitor element should be replaced as necessary. (Refer to Manufacturer’s Literature in Chapter 5)

(4) Use a suitable container to collect and dispose of any coolant that drains out of the coolant inhibitor element.

(5) Close the valves on the adapter head to prevent the coolant from draining out of the system.

(6) Remove the spin-off coolant inhibitor element.

(7) Install new coolant inhibitor element.

(8) Open the valves mounted on the adapter head after the coolant inhibitor element is replaced.

(9) Close battery disconnect switch to enable engine start.

(10) Start engine and run for a few minutes to get any air out of the system. Add coolant as necessary. Fill radiator to 1 inch below filler neck.

(11) Close radiator pressure cap.

WARNING:

NEVER REMOVE THE COOLANT INHIBITOR ELEMENT WHILE THE ENGINE IS HOT. ALLOW ENGINE TO COOL.

WARNING:

NEVER REMOVE THE RADIATOR PRESSURE CAP WHILE THE ENGINE IS HOT. ALLOW ENGINE TO COOL.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-8

ASU-600 Series

1 …. Adapter 2..... Coolant inhibitor element 3..... Valve

1

COOLANT INHIBITOR ELEMENT FIGURE 2

2

3

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-9

ASU-600 Series

E. Engine Fuel System (See Figure 3)

(1) Quality

Diesel fuel of either Grade No. 1-D or No. 2-D with sulfur content less than 0.5 percent by weight is recommended. Further information on fuel specifications can be found in the Manufacturer’s Literature in Chapter 5.

(2) Dependant on fuel used, varying amounts of water may be introduced into the fuel system.

The fuel/water separator is used to remove the water. Every 300 hours (or sooner if necessary) the water must be drained from the filter element. This is accomplished as described below:

(a) Turn off the engine.

(b) Open the fuel filter vent.

(c) Open the fuel drain valve.

(d) Collect water into a cup. Drain until fuel starts to flow into cup.

(e) When changing the fuel filter element, drain fuel to one inch below the fuel filter collar level.

(f) Close the drain valve (Drain minimum amount of fuel possible).

(g) Close the fuel filter vent.

(h) Start the engine. Raise RPM for one minute to purge air.

(3) The fuel filter must be replaced when the filter element is completely covered by fuel. Refer to Manufacturer’s Literature in Chapter 5.

(a) Turn off the engine.

(b) Open the fuel filter vent.

(c) Open the fuel drain valve.

(d) Collect fuel in suitable container.

(e) Drain fuel to one inch below the fuel filter collar level.

(f) Close the fuel drain valve.

(g) Remove the fuel filter cover. Use a strap wrench to remove the fuel filter collar.

(h) Remove the fuel filter element and dispose of properly.

(i) Install clean fuel filter element. Ensure grommet is in place on threaded filter stud.

(j) Install fuel filter cover seal on fuel filter cover.

(k) Install filter spring.

(l) Install fuel filter cover.

(m) Hand tighten fuel filter collar.

(n) Remove fuel filter vent.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-10

ASU-600 Series

(o) Fill with fuel until fuel is one (1) inch above fuel filter collar. Ensure there are no fuel leaks.

(p) Replace fuel filter vent.

(q) Start engine. Raise RPM for one minute to purge air.

FUEL FILTER FIGURE 3

1 .....Fuel filter collar 2 .....Fuel filter vent cap 3 .....Fuel filter cover 4 .....Fuel filter spring 5 .....Fuel filter element 6 .....Fuel filter seal 7 .....Fuel filter heater (Option) 8 .....Fuel filter drain

1

2

3

4

5

6

7

8

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-11

ASU-600 Series

F. Cooling System

A permanent type (ethylene glycol) antifreeze is recommended for use in the cooling system. Coolant requirements may be found in the Manufacturer’s Literature in Chapter 5.

(1) Coolant Level Check (See Figure 4)

(a) Open radiator pressure cap.

(b) Coolant must reach the bottom of the filling neck. Add treated engine coolant as necessary until it is at proper level.

(c) Run engine at idling speed to allow any air trapped in the system to escape.

(d) Close the radiator pressure cap.

CAUTION:

DO NOT USE METHYL ALCOHOL BASE ANTIFREEZE. DO NOT USE METHOXY PROPANOL ANTIFREEZE. DAMAGE MAY OCCUR TO THE RUBBER SEALS ON THE CYLINDER LINERS WHICH ARE IN CONTACT WITH THE COOLANT.

CAUTION:

NEVER POUR COLD COOLANT INTO A HOT ENGINE.

NOTE: The minimum coolant level is automatically monitored by DDEC.

WARNING:

NEVER REMOVE THE RADIATOR PRESSURE CAP WHILE THE ENGINE IS HOT. ALLOW ENGINE TO COOL.

NOTE: The engine will shut down automatically if the coolant level drops below the necessary level (via the low coolant level switch). Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-12

ASU-600 Series

COOLANT LEVEL CHECK FIGURE 4

1 Radiator cap 2 Coolant overflow reservoir 3 Low coolant level switch

1

3

2

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-13

ASU-600 Series

G. Coolant Drain and Fill (See Figure 5)

Disable engine start by opening battery disconnect switch.

(1) Before draining coolant, open cap on coolant overflow tank.

(2) Open radiator pressure cap.

(3) Use a suitable container to collect and dispose of the coolant.

(4) Open radiator coolant drain plug.

(5) Allow all coolant to drain from radiator.

(6) Close radiator drain plug.

(7) Fill engine coolant system to bottom of radiator filler neck. Fill coolant expansion tank to approximately half full (if provided).

(8) Close coolant overflow tank cap.

(9) Close battery disconnect switch to enable engine start.

(10) Start engine and run for a few minutes to get any air out of the system. Fill radiator to 1” below filler neck.

(11) Close radiator pressure cap.

WARNING:

NEVER REMOVE THE RADIATOR PRESSURE CAP WHILE THE ENGINE IS HOT. ALLOW ENGINE TO COOL.

CAUTION:

NEVER POUR COLD COOLANT INTO A HOT ENGINE.

CAUTION:

ALWAYS FILL THE COOLANT SYSTEM AT THE RADIATOR FILLER CAP TO ENSURE THE RADIATOR IS FILLED TO THE TOP. THE OVERFLOW TANK SHOULD ALSO BE FILLED TO THE INDICATOR LINE, BUT ITS MAIN PURPOSE IS TO RECOVER OVERFLOW COOLANT. IT IS MOST IMPORTANT TO FILL THE SYSTEM AT THE RADIATOR CAP.

AFTER FILLING, RUN THE ENGINE FOR 1 MINUTE, THEN FILL AGAIN. REPEAT UNTIL THE LEVEL IN THE RADIATOR REMAINS AT THE TOP. FOLLOW THE INSTRUCTIONS IN THE ENGINE MANUAL.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-14

ASU-600 Series

1

1..... Radiator drain plug

COOLANT DRAIN AND FILL FIGURE 5

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-15

ASU-600 Series

H. Engine Oil Level Checking, Draining and Filling (See Figure 6)

The engine oil level may be checked before starting the engine and after shutdown.

(1) Checking the oil before starting the engine.

(a) Withdraw dipstick from guide tube and wipe clean.

(b) Reinsert dipstick into guide tube completely.

(c) Wait a few seconds, then withdraw dipstick and check oil lever.

(d) Engine oil level must be between the minimum and maximum marks. If necessary, add oil to bring level up to the MAX mark.

(e) Insert dipstick into guide tube.

(2) Checking after engine shutdown.

(a) Remove the oil dipstick from the guide tube five minutes after engine shutdown.

(b) Engine oil level must be between the minimum and maximum marks. If necessary, add oil to bring level up to the MAX mark.

(c) Insert dipstick into guide tube.

(3) Engine Oil Draining

(a) Drain both engine oil filters.

(b) Drain used oil from the oil pan at the oil drain valve assembly located on the frame rail. Open the drain valve assembly and drain oil into a suitable container.

NOTE: Drain engine oil with the engine at operating temperature.

CAUTION:

ENGINE OIL IS HOT AND CAN CONTAIN COMBUSTION RESIDUES WHICH ARE HARMFUL TO HEALTH. TO AVOID INJURY, WEAR PROTECTIVE GLOVES. AVOID EXTENDED AND INTENSIVE CONTACT WITH SKIN. DO NOT INHALE OIL VAPOR.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-16

ASU-600 Series

(e) Remove oil filters with a strap wrench.

(f) Drain the remaining oil from filters into a container.

(g) Check the rubber sealing ring of the new engine oil filter, and coat with oil.

(h) Install new engine oil filter and tighten with a strap wrench.

(i) Replace other engine oil filter in the same way.

(j) Ensure oil drain valve assembly is closed.

(k) Fill engine oil to MAX mark on the oil dipstick. Do not overfill.

(l) Reconnect batteries.

(m) Enable engine start.

(n) Check for leaks.

(4) Engine oil filling

NOTE: Oil filters should be serviced per DDC publication engine service fluid and filter requirements (See Chapter 5 – Vendors Literature).

CAUTION:

TO AVOID INJURY WHEN USING THE CHEMICAL SUBSTANCES AND MATERIALS LISTED BELOW, IT IS ESSENTIAL TO OBSERVE THE MANUFACTURER’S INSTRUCTIONS FOR USE, SAFETY INSTRUCTIONS AND WASTE DISPOSAL SPECIFICATIONS. OIL, GREASES, TREATED ENGINE COOLANT, FUELS, CLEANING AGENTS.

NOTE: Always use only new, DDC approved engine oil per DDC publication Engine Service Fluid and Filter Requirements. See Chapter 5 – Vendors Literature.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-17

ASU-600 Series

(a) To fill engine oil

1. Turn the oil filler tube cover counterclockwise until in can be removed.

2. Pour engine oil in at oil filler tube up to MAX mark when checked on the dipstick.

3. Start engine and run at idle for approximately one to two minutes

4. Shut down engine, after approximately five minutes withdraw dipstick from guide tube and wipe clean.

5. Carry out oil level check.

Engine oil level must be between the minimum and maximum marks. If necessary, add oil to bring level up to the MAX mark.

6. Insert dipstick into guide tube.

7. Replace oil filler tube cover.

NOTE: Do not fill engine oil above the MAX mark.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-18

ASU-600 Series

1….Oil fill cover 2….Engine oil fill 3….Engine oil drain 4….Oil filters 5….Drain hose 6….Drain valve assembly

4

3

2

1

6

5

ENGINE OIL DRAIN AND FILL FIGURE 6

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-19

ASU-600 Series

I. Drive Belts

(1) Fan

A single poly-vee belt from the crankshaft pulley are used to drive the cooling fan. For proper engine operation, This belt should be in good condition and at the proper tension at all times.

(a) Checking Belt Tension

Check belt tension every 100 hours of engine operation. Belts which are too tight will cause damage to the bearings of the fan belt drive pulley. A loose belt will slip and cause inefficient operation of the cooling fan.

Proper belt tension may be determined by using either a belt tension checking tool or by the deflection method. Further information is contained in the Manufacturer’s Literature in Chapter 5.

(b) Belt Adjustment

To adjust the belt tension, loosen the fan pulley mounting bolts and turn the adjusting screw to obtain the correct tension. Retighten the mounting bolts.

When the new belt is fitted, it will be necessary to run the engine for a short period to allow the belt to seat and any initial stretching to occur.

(2) Alternator

One belt is used to drive the alternator. For proper operation this belt should be in good condition and at the correct tension at all times.

(a) Checking Belt Tension

Check belt tension every 100 hours of engine operation. A belt which is too tight will cause damage to the alternator drive end bearing. A loose belt will slip and cause inefficient operation of the alternator.

Proper belt tension may be determined by using either a belt tension checking tool or by the deflection method. Further information is contained in the Manufacturer’s Literature in Chapter 5.

CAUTION:

INADEQUATE BELT TENSION MAY RESULT IN BELT SLIPPAGE, EXCESSIVE WEAR OR BREAKAGE. OVER TIGHTENING MAY CAUSE BEARING AND DRIVE COMPONENT DAMAGE AS WELL AS DAMAGE TO THE BELT FROM OVERHEATING AND STRETCHING. NEVER PRY AGAINST THE ALTERNATOR CASE. ALLOW BELT TO COOL BEFORE TENSIONING.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-20

ASU-600 Series

J. Compressor Maintenance (See Figure 7)

(1) Compressor Oil Level Checking, Draining, and Filing

The air compressor requires a minimum amount of maintenance.

(a) Check oil reservoir level daily. With the unit off, the compressor oil level should stand at the center of the upper oil sight glass. During operation, the oil level should not be below the center of the lower sight glass.

(b) Change the oil filter at each oil change.

(c) Drain the compressor oil every 6 months and replace it with an approved oil (see Manufacturer’s Literature in Chapter 5). The compressor oil drain valve will only function with the drain hose coupler assembly provided with the unit. The ball check valve is pushed in by the hose coupler assembly to allow the oil to drain. The compressor is filled with Mobil SHC 626 oil. The following is a list of approved alternates:

1. Esso Ultron 5W-40

2. Shell Helix Diesel Ultra 5W-30

3. Aral High Tronic 5W-40

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-21

ASU-600 Series

1 ... Compressor oil fill 2. .. Restriction indicator and switch 3. .. Compressor oil drain plug

COMPRESSOR OIL DRAIN AND FILL FIGURE 7

1

2

3

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-22

ASU-600 Series

(2) Compressor Coupler Inspection (See Figure 8)

(1) Disable engine start by opening battery disconnect switch.

(2) Remove the four bolts holding the inspection plate access cover on the compressor bell housing. Set the inspection plate access cover and bolts aside for reinstallation.

(3) Inspect the rubber disc for severe deterioration. Replace if found defective.

(4) Reinstall the inspection plate access cover on the compressor bell housing.

(5) Close the battery disconnect switch.

(6) Perform operational check.

CAUTION:

DISCONNECT THE BATTERY BEFORE WORKING ON THE UNIT.

1....Outer ring 2....Rubber Disc 3....Inner Hub 4....Inspection plate access cover

ENGINE/COMPRESSOR COUPLING INSPECTION FIGURE 8

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-23

ASU-600 Series

(3) Air Filter (See Figure 9)

Clean or replace the compressor air filter when the restriction indicator and switch mounted on the compressor inlet (Fig. 7) identifies that a high pressure drop condition exists (red band visible, high compressor air intake filter restriction warning on unit dispaly).

The air filter is equipped with a washable paper element. Remove and clean the element as follows:

(a) Secure the end cover of the filter housing and remove the end cover. Unbuckle the clamps on each side of the buttom of the air cleaner filter housing and remove the top cover.

(b) Remove the contaminated element.

(c) Clean foreign material from the filter housing. Ensure that the inside is clean and dry.

(d) Gently pat the side of the element to loosen dirt deposits. If the element is damp, allow it to air dry before cleaning.

1 Water Cleaning. Soak the filter element for 15 minutes in a solution of warm water and mild detergent. Agitate the filter element gently several times. Rinse thoroughly under low pressure water and air dry.

2 Compressed Air Cleaning. Carefully direct low pressure compressed air (30 psi maximum) (210 kPa) through the dry element, opposite the normal direction of flow.

(e) After cleaning, inspect the element using a bright light inside the filter to check for pin hole leaks or ruptured pleats.

(f) If the element is damaged, replace it.

(g) Replace the top cover, then buckle the clamps on both sides of the air filter housing and reset restriction indicator.

CAUTION:

DO NOT CLEAN OR DRY WITH HIGH PRESSURE COMPRESSED AIR.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-24

ASU-600 Series

1…..End cover

2….Element 3…..Housing 4…..Buckle

COMPRESSOR FILTER ELEMENT FIGURE 9

1

2

3

4

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-25

ASU-600 Series

(3) Compressor Oil Heat Exchanger (See Figure 10)

Blow clean the compressor oil heat exchanger with low pressure compressed air. Refer to Manufacturer’s Literature in Chapter 5.

1 .....Compressor oil heat exchanger

COMPRESSOR OIL HEAT EXCHANGER FIGURE 10

1

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-26

ASU-600 Series

K. Trailer Maintenance (See Figure 11)

Trailer maintenance is limited primarily to ensuring that the trailer is correctly lubricated at the appropriate time intervals. Refer to Chart 1 for time intervals and Chart 3 for lubricants to use.

Nomenclature ACE Part Number

Wheel bearing grease UMG5-3

Trailer grease UMG5-1

Lubricating oil UMO1-6

TRAILER LUBRICATION CHART 3

NOTE: A light grease may be used instead of lubricating oil if it is preferred.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-27

ASU-600 Series

1 .... Tow bar pivot 2 .... Fifth wheel steering plate 3 .... Wheel bearing 4 .... Brake assembly

TRAILER MAINTENANCE FIGURE 11

270, 300ppm trailer package shown (dual rear wheels); 180 & 200ppm trailer package has one rear wheel per side.

3

4

2

1

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-28

ASU-600 Series

L. Battery

Two 12 VDC batteries connected in series provide 24 VDC power for operation of the engine electrical system and the panel lights.

(1) Battery Location

The batteries are located on the left side of the unit. The batteries are easily accessible for checking and maintenance.

(2) Battery Care

(a) Maintain batteries in fully charged condition.

(b) Ensure batteries are fastened securely to prevent damage.

(c) Maintain battery fluid at the proper level.

(d) Keep the battery terminal posts and clamps clean.

(3) Liquid Level

The electrolyte level in each cell should be above the plates at all times to prevent battery failure. When the electrolyte level is low, add pure distilled water. Do not use hydrant water or any water that has been in contact with a metal container.

M. Battery Disconnect Switch

A Battery disconnect switch is provided for use when servicing the unit. The battery disconnect switch disconnects the battery voltage from all components on the unit. It should be switched to off when the unit will be out of use for a period of time greater than 2 weeks.

WARNING:

NEVER ALLOW SPARKS OR OPEN FLAME TO COME NEAR THE BATTERIES. AVOID SPILLING ELECTROLYTE ON HANDS OR CLOTHING.

NOTE: It is especially important to keep the batteries at a full charge for cold weather operation. Add distilled water to the batteries in freezing temperatures only when the engine is to operate for several hours to ensure the fluid is thoroughly mixed or damage to the batteries will result from the water freezing. Pro

perty

of A

mer

ican

Airline

s

Creation: 03.09 - 2011 2-1-29

ASU-600 Series

N. Delivered Air Pressure and Flow Check a. Pressure check

i. Run the unit in jet start mode with both delivered air shutoff valves closed.

ii. Observe the delivered air pressure. It should be between 39 - 41 psi.

iii. If it is not, follow the troubleshooting procedures in chapter 2-2, page 1 & 2.

b. Flow check

i. Run the unit in jet start mode with both delivered air shutoff valves open. CAUTION: The hose couplers must first be properly secured to avoid dangerous whipping action.

ii. Observe the engine speed on the electronic engine gage. It should be 2050-2125 rpm for a 180, 200, or 270 ppm unit; 2250-2325 for a 300ppm unit. If the proper speed is obtained, the flow will be as rated.

iii. If it is not, follow the troubleshooting procedures in chapter 2-2, page 1 & 2.

Repeat the same checks for air pacs mode (31-33 psig, same speed as jet start mode). If the pressures and engine speeds are correct, the unit is in normal operating condition. Note that some customers have an air pacs setting of 24 psig.

O. Air Pressure Regulator Adjustment (see figure 12)

(1) Set up per Figure 12 below. It may be easiest to remove regulator assembly from unit.

a. Disconnect regulator assembly from compressor, Black Box Recorder, and Bypass Valve.

b. Connect 40 psi regulated air source and calibrated pressure gauge per Figure 12.

c. Cap unused port.

d. Connect Pressure Regulator to a DC power supply.

(2) Calibrate pressure regulator zero.

a. Set supply voltage to 1 ± 0.02 V.

b. Adjust zero screw until pressure gauge reads 3.0 psi.

(3) Calibrate pressure regulator span.

a. Set supply voltage to 9 ± 0.02 V.

b. Adjust span screw unit pressure sensor (PV-350) reads 27.0 psi.

WARNING: THE ELECTRONIC PRESSURE REGULATOR IS FACTORY CALIBRATED AND

SEALED. TAMPERING WITH THE SEAL MAY VOID THE UNIT WARRANTY. THE FOLLOWING PROCEDURE MUST BEPERFORMED BY A TLD TECHNICIAN.

NOTE: THE UNIT WILL AUTOMATICALLY COMPENSATE FOR DRIFT OF THE PRESSURE REGULATOR IN ALL BUT THE MOST EXTREME CASESE.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-30

ASU-600 Series

(4) Recheck zero and span.

(5) Reseal zero and span screws on pressure regulator.

(6) Reconnect to unit. Refer to assembly drawings in Chapter 4 of manual if necessary.

FIGURE 12 AIR PRESSURE REGULATOR ASSEMBLY

P. Trim Height Sensor Adjustment

Cap this port

Compressed air, 40 psi

Calibrated Pressure Gauge

DC power supply

WARNING: THE TRIM HEIGHT SENSOR IS FACTORY CALIBRATED AND SEALED. TAMPERING WITH THE SEAL MAY VOID THE UNIT WARRANTY. THE

FOLLOWING PROCEDURE MUST BEPERFORMED BY A TLD TECHNICIAN.

NOTE: THE UNIT WILL AUTOMATICALLY COMPENSATE FOR TRIM HEIGHT SENSOR

IN ALL BUT THE MOST EXTREME CASESE. Pro

perty

of A

mer

ican

Airline

s

Creation: 03.09 - 2011 2-1-31

ASU-600 Series

8

1

6

4, 5

3

2

7

(1) Measure system voltage.

(2) Connect the positive lead of the voltmeter to the signal output of the trim height sensor (wire 49) and the negative lead of the voltmeter to ground (wire 1). This should be done with the trim height sensor still plugged into the unit harness, or by using jumper wires to allow the trim height sensor to still be plugged into the unit harness.

(3) With the trim of the bypass valve fully seated (down position), adjust the mounting position of the trim height sensor so that the actuating arm is touching the valve trim, but not being displaced by it.

(4) With the actuating arm in the fully lowered position, adjust the rheostat of the Trim Height Sensor so that the sensor output is system voltage less 0.1 V.

(5) With the actuating arm still in the fully lowered position, slowly adjust the rheostat of the Trim Height Sensor until the sensor outputs system voltage +0.01/-0.00 V.

(6) Re-seal adjustment screw and arm.

1) Trim Height Sensor 6) Bypass Valve 2) Cylinder 7) Actuating Arm 3) Cylinder Rod 8) Connector 4) Trim Guide 9) Digital Voltmeter 5) Trim 10) Unit Power Supply

THROTTLE CONTROLLER ADJUSTMENT FIGURE 13

+-

- +

01

9

10

07

B

A

C

49

24 VDC

SIGNAL

GND.

SUPPLY

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-32

ASU-600 Series

Operating ASU-600 Series Jet Starters at Altitudes other than Sea Level The continuous screw compressor operates with a maximum pressure differential. Therefore, at higher altitudes where the ambient pressure is lower, the unit will automatically decrease the delivered air pressure if the maximum outlet pressure for that barometric pressure is lower than the standard delivered air pressure. Also, the less dense air will result in a lower mass flow rate through the compressor. See the chart below for maximum pressure and flow at various altitudes; expect observed pressure to be 1-2 psi less and flow to be slightly lower.

Note: Flow rates are corrected for barometric pressure only and will degrade further at temperatures above 68°F (20°C).

Altitude Barometric Inlet Outlet Air Flow Maximum (Lb/min)

Feet Pressure Pressure Pressure 180 ppm 200 ppm 270 ppm 300 ppm

Psia Psia Psig Max. Nominal Nominal Nominal Nominal

-500 14.96 14.76 40.00 183 203 274 305 0 14.70 14.50 40.00 180 200 270 300

500 14.43 14.23 40.00 177 196 265 294

1000 14.17 13.97 40.00 173 193 260 289

1500 13.92 13.72 40.00 170 189 256 284

2000 13.66 13.46 40.00 167 185 250 278

2500 13.42 13.22 39.66 164 182 246 274

3000 13.13 12.93 38.79 161 179 241 268

3500 12.93 12.73 38.19 158 175 237 263

4000 12.69 12.49 37.47 155 172 232 258

4500 12.46 12.26 36.78 152 169 228 254

5000 12.23 12.03 36.09 149 166 224 249

5500 12.00 11.80 35.40 146 162 219 244

6000 11.78 11.58 34.74 144 160 216 240

6500 11.56 11.36 34.08 141 157 212 235

7000 11.34 11.14 33.42 138 153 207 230

7500 11.13 10.93 32.79 136 151 203 226

8000 10.92 10.72 32.16 133 148 200 222

8500 10.71 10.51 31.53 130 145 195 217

9000 10.51 10.31 30.93 128 142 192 213

9500 10.31 10.11 30.39 126 140 188 209

10000 10.11 9.91 29.73 123 137 185 205

10500 9.91 9.71 29.13 121 134 181 201

11000 9.72 9.52 28.56 118 131 177 197

11500 9.53 9.33 27.99 116 129 174 193

12000 9.35 9.15 27.45 114 126 171 189

12500 9.17 8.97 26.91 111 124 167 186

CHART 4

ALTITUDE PRESSURE CHART

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-33

ASU-600 Series

2. Preventative Maintenance

A. Engine

(1) Fuel

(a) Check fuel level daily.

(b) Check fuel filters and change elements in accordance with the instructions in the Manufacturer’s Literature in Chapter 5.

(c) Open the fuel tank drain bi-weekly to drain off water and sediment. (Or more frequently if the fuel supply at customer’s location is easily susceptable to moisture problems).

(2) Lubrication

(a) Check crankcase oil level daily.

(b) Lubricate in accordance with the Lubrication & Maintenance Chart 1 on Page 2.

(3) Coolant

(a) Check coolant level daily.

(b) Inspect for signs of rust or corrosion. Inspect for signs of leakage. Inspect hoses for deterioration or cracking.

(4) Exhaust System

(a) Inspect muffler and pipework for signs of approaching failure.

(b) Check for any gasket or joint leaks.

(5) Air Intake System

(a) Check air filter service indicator daily. Change element when red band is visible, identifying a clogged filter element.

B. Compressor

(1) Lubrication

(a) Check oil level daily. During compressor standstill, the oil level should stand at the center of the upper oil sight glass. During operation, the oil level should not be below the center of the lower sight glass.

(b) Check oil condition and change element in accordance with the instructions in the Manufacturer’s Literature in Chapter 5.

(c) Check air filter service indicator daily. Change or clean filter element when red band is visible.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-1-34

ASU-600 Series

C. Electrical System

(1) Lights

Check all lights for correct operation daily. Replace any defective bulbs as soon as discovered.

(2) Wiring and Connections

Inspect all cables and leads for broken, worn or damaged insulation. Check electrical connection for tightness.

D. Trailer

A general visual inspection of the trailer should be done at the same time that routine maintenance is done. In addition, the following steps should also be performed:

(1) Check the tire pressure in all tires. Tire pressure should be 85 psi when cold.

(2) Check the operation of the parking brake, adjust as necessary.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-2-1

ASU-600 Series

II - Troubleshooting

1. General Practice

Before troubleshooting the ASU-600 Continuous Jet Start Unit and its associated components, the following areas of the unit should be checked:

A. Engine Electrical System

The engine's electrical system should be in proper working order.

B. Engine Oil

The engine oil should be filled to the proper level and the engine oil pressure should be above 15 PSI. Proper oil pressure is required to keep the engine running.

C. Unit Electrical System

Check all electrical connections for loose or broken wires.

2. Troubleshooting Chart

This chart should be used in conjunction with the electrical schematics and connection diagrams to find the problem and understand the remedy.

Problem Probable Cause Suggested Remedy

1 Engine fails to crank when the ignition button is held

A Poor, loose, or dirty battery cable connections

A Clean the battery cable terminals and tighten all connections

B Discharged or defective battery

B Recharge or replace the battery

C Defective or open fuse C Replace fuse and determine the cause for the circuit overload

D Defective starter solenoid. D Replace defective starter solenoid. refer to engine manufacturer's instructions

E Defective start relay E Replace defective start relay

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-2-2

ASU-600 Series

2 Engine cranks, but fails to start when the ignition button is held

A Empty fuel tank, fuel leak, or obstructed fuel lines

A Service the fuel tank, repair or replace leaking or obstructed fuel lines and connections

B Clogged fuel filter B Replace fuel filter elements

C Defective fuel pump C Refer to engine manufacturer's instructions

D Defective fuel injector(s) D Refer to engine manufacturer's instructions

E Restricted or pinched fuel line

E Repair or replace restricted line

F Low compression due to worn or maladjusted valve, piston rings/liners, or leaking head gaskets

F Determine cause for low compression and repair engine; refer to engine manufacturer's instructions

G Air in fuel system G Bleed air from fuel system; refer to engine manufacturer's instructions

3 Engine starts, but will not continue running

A Fuel system air locked A Bleed air from fuel system; refer to engine manufacturer's instructions

B Shutdown fault occurring B Check unit display for shutdown faults and correct as needed.

C Malfunctioning engine shutdown device

C Check wiring and repair as needed.

D Fuel contaminated D Drain contaminated fuel and fill tank with fresh, clean fuel of the recommended grade. Refer to engine manufacturer's instructions.

4 Engine cranks slowly A Battery discharged or defective

A Clean the battery cable terminals and tighten all connections

B Poor, loose, or dirty battery cable connections

B Recharge or replace the battery

C Defective starter motor C Replace defective starter motor. Refer to engine manufacturer's instructions

D Defective starter solenoid. D Replace defective starter solenoid. Refer to engine manufacturer's instructions

E Improper viscosity lubricating oil

E Refer to engine manufacturer's instructions.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-2-3

ASU-600 Series

A Engine air intake airflow restricted

A Inspect engine air intake filter and replace as required

B Maladjusted or defective engine

B Refer to engine manufacturer's instructions

5 Engine speed does not reach rated speed or 2100 rpm (2300 rpm for 300ppm unit) when both shutoff valves are open and the coupler butterfly valves are held open (see flow check in section 2-1, page 27).

C Excessive exhaust system restriction

C Determine and correct exhaust system restriction. Refer to engine manufacturer's instructions as needed.

D Excessive or irregular fuel distribution

D Refer to engine manufacturer's instructions

E Improper engine adjustments

E Refer to engine manufacturer's instructions

F The unit PLC is not receiving the sensor signal that the trim valve is fully closed.

F1 Check V1 Bypass valve is in the fully down position. Check Trim Height Sensor (R18) to ensure the arm is touching the trim or on the bottom stop.

F2 If Trim Height Sensor is on the bottom stop, check for engine fault codes. Adjust the Trim Height Sensor as necessary.

G The unit PLC is not receiving the signal that the delivered air pressure is low.

G Delivered Air Pressure Sensor (S16) is out of calibrations. Replace.

6 Engine Overheats A Defective engine thermostat

A Test thermostat and replace as necessary

B Coolant level low B Add coolant to the recommended level. Check for coolant leaks and repair as necessary

C Radiator core damaged or obstructed

C Clean or repair radiator

D Radiator hose collapsed D Replace defective hose

E Engine oil level incorrect E Add or drain oil level as needed. Check for engine oil leaks and repair as needed.

F Slipping or broken fan belt F Replace broken belt or damaged drive

G Radiator cap defective G Replace defective cap

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-2-4

ASU-600 Series

7 Engine temperature too low; ready light will not come on

A Incorrect or defective thermostat

A Refer to engine manufacturer's instructions. Test and replace defective or incorrect thermostat

8 Engine shuts down due to low oil pressure

A Engine oil has dropped below required pressure

A1 Check oil level, lines, and filters and repair or replace as needed. Refill oil as needed.

A2 Refer to engine manufacturer's instructions

9 Engine loosing oil A External leakage from hoses, fittings, or gaskets

A Inspect all hoses, fittings, and gaskets; replace or tighten as needed

B Excessive crankcase pressure

B Refer to engine manufacturer's instructions

C Internal oil leaks from oil cooler or worn exhaust guides

C Refer to engine manufacturer's instructions

D Excessive oil in the crankcase

D Refer to engine manufacturer's instructions

10 Engine operation uneven or subject to frequent stalling

A Insufficient fuel A Refer to engine manufacturer's instructions

B Fault injectors B Refer to engine manufacturer's instructions

C Low compression pressure

C Refer to engine manufacturer's instructions

D Engine control module problem

D Refer to engine manufacturer's instructions

11 Unusual engine noises A Serpentine belt loose or damage

A Replace a damaged belt, verify tensioner operation

B Defective alternator B Repair or replace alternator

C Air intake system leaking or damaged

C Repair air intake system

D Loose, rubbing, or vibrating components

D Locate vibrating components and correct the cause of vibration

E Internal engine damage or excessively worn components

E Refer to engine manufacturer's instructions

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-2-5

ASU-600 Series

12 J1939 Engine Communications Fault

A Communication between PLC and engine computer interrupted.

A Check wiring and connections. Repair or replace as needed.

B Electronic engine gauge faulty or calibrated incorrectly

B Remove and restart unit to check. Replace or recalibrate as needed.

13 Engine bogs when switching modes

A Fuel being used is Jet-A and unit is not calibrated for Jet-A

A1 Drain Jet-A and replace with diesel of the correct grade

A2 Calibrated to run with Jet-A

CHART 5 ENGINE TROUBLESHOOTING

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-2-6

ASU-600 Series

Problem Probable Cause Suggested Remedy

1 Delivered air pressure low.

A Leak in signal line A Leak check signal line components. Repair or replace as necessary.

B Air delivery pressure switch (S9) open

B Check switch setting. Recalibrate or replace if faulty.

C Air delivery control solenoid valve (L5) faulty

C Replace.

D Bypass valve (V1) stuck open

D Check for free movement of trim and actuating piston.

E Relief valve (V2) open at low pressure

E Replace faulty relief valve.

F Pressure regulator (V34) setting low

F Recalibrate control system. If this does not fix problem, Contact TLD technician for V34 adjustment.

2 Unit shuts down due to low compressor oil pressure

A Compressor oil level low. A Refill compressor oil as needed. Check for leaks and repair as needed.

B Faulty or incorrectly calibrated compressor oil pressure switch (S4)

B Check setting of compressor oil pressure switch. Reset or replace as necessary.

C Faulty or incorrectly calibrated compressor oil pressure relief valve (V37)

C Check setting of relief valve. Reset or replace as necessary. Fill compressor oil as needed.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-2-7

ASU-600 Series

3 Unit shuts down due to high compressor oil temperature

A Compressor oil temperature switch (S11) faulty

A Check calibration of compressor oil temperature switch. Replace as needed.

B Compressor oil level incorrect

B Check and correct compressor oil level. Check for leaks and repair as needed.

C Compressor oil dirty C Change compressor oil filter and oil as needed.

D Compressor air intake filter clogged or dirty

D Check filter restriction. Clean or replace filter as needed.

E Compressor oil cooler dirty or damaged

E Clean oil cooler core. Contact compressor manufacturer for repairs to compressor oil cooler.

F Compressor oil cooler fan not functioning

F Check compressor oil cooler fan for restriction or damage. repair or replace as needed.

4 Unit shuts down due to high compressor discharge temperature

A Compressor air intake filter clogged or dirty.

A Check filter restriction. Clean or replace filter as needed

B Discharge air blocked. B Check for blockages. Clear obstructions.

C Delivered air temperature sensor (S10) faulty

C Check calibration and connections. Replace as needed.

5 Unit frequently / repeatedly vents delivered air

A Air delivery pressure switch (S9) open at low pressure

B Check switch setting. Recalibrate or replace if faulty.

B Relief valve (V2) open at low pressure

B Check valve setting. Replace as necessary

C Delivered air pressure high due to mis-calibration of signal pressure regulator (V34)

C Run auto-cal function. contact TLD as necessary.

CHART 6 COMPRESSOR / DELIVERED AIR TROUBLESHOOTING Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-2-8

ASU-600 Series

Problem Probable Cause Suggested Remedy

1 Low battery output. A High circuit resistance. A Clean and tighten battery connections.

B Low battery charge. B Charge battery.

C Damaged battery. C Replace damaged battery.

2 Low battery charge A Defective alternator A Repair or replace the alternator.

3 Low charging circuit voltage.

A High resistance in the charging circuit connections.

A Inspect circuit for loose or corroded connections. Clean and tighten as required.

B Defective wiring. B Locate broken or undersize wire.

C Poor alternator ground. C Clean ground connection.

D Defective alternator. D Repair or replace the alternator.

4 Low charging circuit output

A Slipping drive belt. A Refer to the engine manufacturer’s instructions.

B Defective alternator. B Repair or replace the alternator.

5 High charging circuit voltage.

A High resistance in alternator connections

A Clean and tighten connections.

B Defective alternator regulator.

B Replace defective regulator

6 Noisy engine alternator A Defective or worn drive belt.

A Replace drive belt.

B Worn or defective bearings. B Replace bearings.

C Loose mount or drive pulley.

C Tighten mount and pulley

D Misaligned drive belt or pulley

D Align pulley.

7 Sluggish starting motor operation

A Low battery charge. A Charge battery.

B High circuit resistance. B Clean and tighten all connections. Repair or replace faulty wiring

C Defective starting motor. C Repair or replace the starting motor as required.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-2-9

ASU-600 Series

8 Starting motor inoperative.

A Defective ignition switch. A Replace defective switch.

B High resistance in starting circuit or defective wiring.

B Clean and tighten all connections and replace faulty wiring.

C Defective solenoid switch. C Replace defective switch.

D Defective starting motor. D Repair or replace the starting motor.

9 Starting motor solenoid switch stutters

A Low battery charge. A Charge battery.

CHART 7 ELECTRICAL TROUBLESHOOTING

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-3-1

ASU-600 Series

3. Using the Schematic and Connection Diagrams

A. Component Codes

All components on the schematic and connection diagrams carry a designation number (e.g., DS1, M1), which aids in identifying and discussing specific items. The codes are as follows: B……………………………………………… Motor BT……………………………………………. Battery C……………………………………………… Major component or capacitor CB……………………………………………. Circuit Breaker D……………………………………………… Diode DS……………………………………………. Light F……………………………………………… Filter, fuse, or cooling fan G……………………………………………... Gauge HR……………………………………………. Heater HS……………………………………………. Heat sink K……………………………………………… Relay L……………………………………………… Solenoid or governor relay M……………………………………………… Meter or magnetic speed sensor P……………………………………………… Access port, plug R……………………………………………… Resistor, rheostat, or sender S……………………………………………… Switch T……………………………………………… Transformer or thermostat TB……………………………………………. Terminal block V……………………………………………… Valve VR……………………………………………. Voltage regulator W…………………………………………….. Jumper X……………………………………………… Receptacle

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-3-2

ASU-600 Series

THIS PAGE INTENTIONALLY LEFT BLANK.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-4-1

ASU-600 Series

III - Repairs

1. General Whenever making repairs to the unit or to its components, it is important to follow general mechanic's guidelines for tightening fasteners. The information provided in Chart 5 and Chart 6 covers standard fastener torque values. Observe the following precautions when installing fasteners:

CAUTION:

DO NOT USE THESE VALUES IF A DIFFERENT TORQUE VALUE OR TIGHTENING PROCEDURE IS LISTED FOR A SPECIFIC APPLICATION. THE TORQUE VALUES LISTED ARE FOR GENERAL USE ONLY.

FASTENERS SHOULD BE REPLACED WITH THE SAME OR HIGHER GRADE AND TIGHTENED TO THE STRENGTH OF THE ORIGINAL.

MAKE CERTAIN THAT THE FASTENER THREADS ARE CLEAN AND PROPERLY ENGAGED TO AVOID POSSIBLE FAILURE WHEN TIGHTENED.

NOTE: “Lubricated” means coated with engine oil or other lubricant. “Dry” means plain or zinc plated without any lubrication.

NOTE: Tighten nylon insert lock nuts to approximately 50 percent of the value listed.

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-4-2

ASU-600 Series

HEAD

SIZE/TYPE SAE

GRADE 2

SAE GRADE

3

SAE GRADE

5

SAE GRADE

6

SAE GRADE

7

SAE GRADE

8

SOCKET HEAD

SET SCREW

S.S. CAP & MACH.

NO.6 --- --- --- --- --- --- --- 9 LB/IN 9.6 LB/IN

NO.8 --- --- --- --- --- --- --- 16 LB/IN 20 LB/IN

NO. 10 --- --- --- --- --- --- --- 30 LB/IN 23 LB/IN

1/4 6 9 9 12.5 12.5 13 14 70 LB/IN 75 LB/IN

5/16 11 17 18 24 24 28 30 12 11

3/8 19 30 31 43 43 46 50 18 20

7/16 30 47 50 69 69 75 81 29 31

1/2 45 69 75 106 106 115 121 43 43

9/16 66 103 110 150 150 165 176 63 57

5/8 93 145 150 209 209 225 240 100 92

3/4 150 234 250 350 350 370 395 146 124

7/8 202 372 378 550 550 591 629 --- 194

1 300 551 583 825 825 893 964 --- 259

1 1/8 474 872 782 1304 1304 1410 1523 --- 390

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-4-3

ASU-600 Series

RECOMMENDED ASSEMBLY TORQUE VALUES LB/FT CHART 5

HEAD MARKING

SIZE METRIC CLASS

4.8

METRIC CLASS

8.8

METRIC CLASS

9.8

METRIC CLASS

10.9

METRIC CLASS

12.9

SOCKET HEAD 12.9

M6 4.5 8.5 12 14.5

M8 11 20 30 35

M10 21 40 60 70

M12 37 70 105 120

M14 60 110 165 190

M16 92 175 225 300

M18 125 250 350 410

M20 180 350 500 580

M22 250 475 675 800

M24 310 600 850 1000

M27 450 875 1250 1500

M30 625 1200 1700 2000

M33 850 1650 2350 2750

M36 1075 2100 3000 3500

4.8 12.9 12.910.99.88.8

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-4-4

ASU-600 Series

RECOMMENDED ASSEMBLY TORQUE VALUES N-M CHART 6

Decimal and Fraction Equivalents Listed in Chart 7 are the decimal and fraction equivalents:

Fractions of an inch Decimal (In.) Metric (mm)

1/64 0.015625 0.39688

1/32 0.3125 0.79375

3/64 0.046875 1.19062

1/16 0.0625 1.58750

5/64 0.078125 1.98437

3/32 0.09375 2.38125

7/64 0.109375 2.77812

1/8 0.125 3.175

9/64 0.140625 3.57187

5/32 0.15625 3.96875

11/64 0.171875 4.36562

3/16 0.1875 4.76250

13/64 0.203125 5.15937

7/32 0.21875 5.55625

15/64 0.234375 5.95312

¼ 0.250 6.3500

17/64 0.265625 6.74687

9/32 0.28125 7.14375

19/64 0.296875 7.54062

5/16 0.3125 7.93750

21/64 0.328125 8.33437

11/32 0.34375 8.73125

23/64 0.359375 9.12812

3/8 0.375 9.52500

25/64 0.390625 9.92187

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-4-5

ASU-600 Series

13/32 0.40625 10.31875

27/64 0.421875 10.71562

Fractions of an inch Decimal (In.) Metric (mm)

7/16 0.4375 11.11250

29/64 0.453125 11.50937

15/32 0.46875 11.90625

21/64 0.484375 12.30312

½ 0.500 12.70000

33/64 0.515625 13.09687

17/32 0.53125 13.49375

35/64 0.546875 13.89062

9/16 0.5625 14.28750

37/64 0.578125 14.68437

19/32 0.59375 15.08125

39/64 0.609375 15.47812

5/8 0.625 15.87500

41/64 0.640625 16.27187

21/32 0.65625 16.66875

43/64 0.671875 17.06562

11/16 0.6875 17.46250

45/64 0.703125 17.85937

23/32 0.71875 18.25625

47/64 0.734375 18.65312

3/4 0.750 19.05000

49/64 0.765625 19.44687

25/32 0.78125 19.84375

51/64 0.796875 20.24062

13/16 0.8125 20.63750

53/64 0.828125 21.03437

27/32 0.84375 21.43125

55/64 0.859375 21.82812

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-4-6

ASU-600 Series

7/8 0.875 22.22500

57/64 0.890625 22.62187

Fractions of an inch Decimal (In.) Metric (mm)

29/32 0.90625 23.01875

59/64 0.921875 23.41562

15/16 0.9375 23.81250

61/64 0.953125 24.20937

31/32 0.96875 24.60625

63/64 0.984375 25.00312

1 1.00 25.40000

DECIMAL AND FRACTION EQUIVALENTS

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-4-7

ASU-600 Series

CHART 7

English to Metric Conversion

Listed in Chart 8 are the English to Metric conversions.

Multiply Length By To get equivalent number of:

Inch (in.) 25.4 Millimeters (mm)

Foot (ft) 0.3048 Meters (m)

Yard (yd) 0.9144 Meters (m)

Mile (mile) 1.609 Kilometers (km)

Multiply Area By To get equivalent number of:

Inch2 (in.2) 645.2 Millimeters2 (mm2)

Inch2 (in.2) 6.45 Centimeters2 (cm2)

Foot2 (in.2) 0.0929 Meters2 (m2)

Yard2 (yd2) 0.8361 Meters2 (m2)

Multiply Volume By To get equivalent number of:

Inch3 (in.3) 16387 Millimeters3 (mm3)

Inch3 (in.3) 16.387 Centimeters3 (cm3)

Inch3 (in.3) 0.0164 Liters (L)

Quart (qt) 0.9464 Liters (L)

Gallon (gal) 3.785 Liters (L)

Yard3 (yd3) 0.7646 Meters3 (m3)

Multiply Mass By To get equivalent number of:

Pound (lb) 0.4536 Kilograms (kg)

Ton (ton) 907.18 Kilograms (kg)

Ton (ton) 0.907 Tonne (t)

Multiply Force By To get equivalent number of:

Kilograms 9.807 Newtons (N)

Ounce (oz) 0.2780 Newtons (N)

Pound (lb) 4.448 Newtons (N)

Multiply Temperature By To get equivalent number of:

Degree Fahrenheit (oF) ( F-32) / 1.8 Degree Celsius (oC)

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-4-8

ASU-600 Series

Multiply Acceleration By To get equivalent number of:

Foot/second2 (ft/sec2) 0.3048 Meter/second2 (m/s2)

Inch/second2 (in./sec2) 0.0254 Meter/second2 (m/s2)

Multiply Torque By To get equivalent number of:

Pound-inch (lb-in.) 0.11298 Newtons-meters (N-m)

Pound-foot (lb-ft) 1.3558 Newtons-meters (N-m)

Multiply Power By To get equivalent number of:

Horsepower (hp) 0.746 Kilowatts (kW)

Multiply Power By To get equivalent number of:

Inches of water (in. H2O) 0.2491 Kilopascals (kPa)

Pounds/square in. (lb/in2) 6.895 Kilopascals (kPa)

Multiply Energy or Work By To get equivalent number of:

British Thermal Unit (Btu) 1055 Joules (J)

Foot-pound (ft-lb) 1.3558 Joules (J)

Kilowatt-hour (kW-hr) 3,600,000. or 3.6 X 106 Joules (J = one W/s)

Multiply Light By To get equivalent number of:

Foot candle (fc) 10.764 Lumens/meter2 (lm/m2)

Multiply Fuel Performance By To get equivalent number of:

Miles/gal (mile/gal) 0.4251 Kilometers (km/L)

Gallons/mile (gal/mile) 2.3527 Liter/kilometer (L/km)

Multiply Velocity By To get equivalent number of:

Miles/hour (mile/hr) 1.6093 Kilometers/hour (km/hr)

ENGLISH TO METRIC CONVERSIONS CHART 8

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-5-1

ASU-600 Series

IV - Special Tools/Fixtures

1. General

The following special tools and/or fixtures are available from TLD, Windsor, Connecticut or may be purchased directly from the tool manufacturer or authorized distributor at the address listed below each item. All tools and fixtures are grouped by component. The tool or fixture may be fabricated by the customer, material specifications and dimensions are provided.

A. Diagnostic Data Reader

The hand held diagnostic data reader (DDR) is used to display engine data, fault codes, and to program ECM calibration. This information can be sent to an attached printer.

The DDR is available from:

Kent-Moore

29784 Little Mack

Roseville, MI 48066-2298

Tel: (800) 328-6657

B. Detroit Diesel Data Link (DDDL)

Software Disc & Interface connector to engine computer.

See DDC Website (www.detroitdiesel.com) or Buy ACE Part #1036579

Prope

rty o

f Am

erica

n Airli

nes

Creation: 03.09 - 2011 2-5-2

ASU-600 Series

(1) Diagnostic Data Reader and Printer

(2) DDR Replacement Parts

ITEM MFG PART NUMBER ACE P/N

DDEC PC Card J-38500-2300 1031251

Cartridge J-38500-1500C 1031253

Paper J-38480-5 1031255

SPECIAL TOOLS/FIXTURES

J-38500-IDDACE P/N 1031254

J-38480 ACE P/N 1017550

Prope

rty o

f Am

erica

n Airli

nes