Creation: 9.23 - 2015

ACU-804

Cummins Tier 4 Supplement

PARTS AND MAINTENANCEPrope

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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. Prolonging 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.

1. Maintenance The following charts show the frequency of maintenance required on the listed components.

Component Maintenance Required

Engine air filter(1) Check indicator daily. Engine oil and filter Check daily; change every 500 hours.

Engine fuel filter Change every 500 hours. Fuel pre-filter/water separator Change every 500 hours.

DEF Filter (Tier 4 Final Only) (1) Change every 4500 hours. Fan belts Check every 500 hours. Replace if belt is visibly worn.

Engine coolant Check daily; change every 24 months. Latches and hinges Lubricate every 300 hours or 6 months.

Wheels Rotate every 1200 hours or 24 months. Wheel hubs and fifth wheel hub Repack bearings every 24 months.

Steam wash engine radiator

250 hours** Torque wheel lug nuts 500 hours or 6 months

Table 1: Maintenance by Hours

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

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

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* Change as required, which should be indicated by visual inspection. ** Always clean radiator from the front nose area of the unit.

(1) This operation should be performed at more frequent intervals under dusty or low temperature conditions. The time schedules indicated in Chart 1 are approximate. They are based on average conditions. Reduction of the interval shown may be necessary under harsh operating conditions such as low engine temperature, excessively heavy loads, and high oil temperatures, or operation in particularly arid or dusty environments.

(1) Lubrication Schedule

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

(2) Engine Oil Specification and Viscosity

Information on engine oil specification is contained in the Manufacturer's Literature in Chapter 5. The use of the proper engine oil is critical in Tier 4 engines to ensure a long life of the catalyst.

(3) Changing the Engine Oil

Follow the instructions in the Manufacturer's Manual.

(4) Changing the Engine Oil Filter

Follow the instructions in the Manufacturer's Manual.

2. Air Filter Maintenance Filter servicing disturbs the seals of the filter and housing and exposes the clean side of the intake system to contamination, which can occur when dirt is dislodged from the filter element during removal and handling. Since excessive filter servicing may introduce more contaminants into the engine through filter removal and handling than are prevented by the use of a clean filter element, service the air filter only when necessary to maintain the inlet restriction within the dirty filter restriction limit indicated by the restriction indicator near the engine’s air filter. The primary air filter should be changed when the indicator displays on the PLC to indicate excessive pressure drop, or after two years, regardless of usage. The secondary air filter should be changed at every third change of the primary air filter, or after one year, regardless of usage. Tier 4 Final Engines

The Tier 4 Final engine air cleaner assembly consists of replaceable primary and secondary air filter inside a plastic housing. It is designed to be maintained without tools. Refer to

Table 2 to see the necessary parts for the maintenance of the air cleaner. A definite time schedule for changing the element cannot be determined because of varying operating conditions. Check the filter indicator on the near the engine’s air filter daily and change the element as required.

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Air Filter Replacement

1. Turn off the unit battery switch and open the doors on the fuel fill side of the unit.

2. Unbolt the Air Filter from its bracket (Refer to Figure 2: ACU-804 Tier 4 Final Engine Air Cleaner Installation).

3. Remove the air filter element cover (Refer to Figure 1: Tier 4 Final Engine Air Cleaner). This is done by pulling on the latches on the air cleaner assembly.

4. The primary air filter can now be pulled out. Remove the primary air filter to expose the secondary air filter.

5. Before removing the secondary air filter, make sure there is no debris left inside the air cleaner. Remove and replace the secondary air filter if it is necessary. Replace it by pushing the filter straight into the air cleaner housing until the gasket on the filter seats properly.

6. Replace the primary air filter by pushing the filter straight into the air cleaner housing until the gasket seats properly.

7. Replace the air inlet cover by moving the cover into place and latching the four metal latches.

8. Replace the air flow straightener by locating the plastic locking tabs and pressing firmly on the cover to snap it in place.

Figure 1: Tier 4 Final Engine Air Cleaner

CAUTION: DO NOT ATTEMPT TO CLEAN OR REUSE THE AIR FILTER

ELEMENT.

Metal Latches x 4

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Figure 2: ACU-804 Tier 4 Final Air Cleaner Installation

3. Fuel System Quality Tier 4 engines MUST be operated only on Ultra Low Sulfur diesel fuel (less than15 PPM), use of any other fuel will damage the catalyst permanently and void the engine warranty. Further information on fuel specifications can be found in the Engine Manufacturer’s Manuals.

The use of low sulfur diesel fuel allows for 500 hour oil change intervals. Use of high sulfur diesel fuel shortens the oil change interval for the engine.

Fuel Filter

Refer to the Manufacturer's Literature in Chapter 5 for information on removal and replacement of the fuel filter elements.

WARNING: The use of non-low sulfur diesel fuel or any type of jet fuel in any unit equipped with a Tier 4 (Stage 3B/Stage4) engine will cause permanent damage to the engine catalyst and void the engine warranty.

Air Cleaner

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4. Belts

A single poly-V belt driven by the engine crankshaft pulley is used to drive the battery charging alternator, the radiator fan, and the engine coolant pump. The belt system is equipped with an automatic tensioner which eliminates the need for periodic tensioning. The belt must be inspected on a regular basis and replaced when excessive stretch or cracking are present.

The belt replacement is as follows:

1. Turn off the unit battery switch 2. Open the doors to the unit on both sides for access. 3. Remove the overflow bottle from alternator guard on the left side of the unit and set it

aside carefully. 4. Remove the alternator guard. 5. Remove the fan guard from the radiator. 6. Rotate the tensioner to relieve tension on the drive belt and, while holding the tensioner,

remove the belt from the alternator pulley. 7. Release the tensioner. 8. Make note of the routing of the belt and remove it from the pulleys. 9. Remove the belt by moving it over the fan blades. 10. Installation is the reverse of the removal.

Figure 3: Engine Drive Belt Routing

Water Pump Pulley

Fan Pulley

Alternator Pulley

Crank Pulley

Tensioner Prope

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5. Diesel Exhaust Fluid System

Diesel Exhaust Fluid DEF must be refilled periodically as it is consumed during operation. Determine if replenishment of the DEF is necessary by reading the gauge displayed on the control box murphy gauge, Figure 5. DEF must be of sufficient quality or the engine will derate and/or fault out the engine. Fill the DEF tank by pouring ISO-compliant DEF or AdBlue into the fill port indicated with the “DEF or AdBlue” label and the blue cap. Avoid overfilling the DEF tank by watching the gauge on the control box murphy gauge, and stopping the fill when the gauge reaches 100%.

Figure 4: DEF Fill Port Location Figure 5: DEF Fill Level

NOTE:

When DEF level falls below 2.5% of the maximum capacity, engine power output will be reduced to comply with emission regulations. This may cause an interruption in power delivery to attached aircraft.

DEF Fill

DEF Fill Level Prope

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Diesel Exhaust Fluid Filters Contamination can enter through the DEF vent and through the DEF filler and accumulate. Over time the DEF tank filter and the DEF supply module filter will become clogged and negatively impact the flow rate resulting in an engine fault that can derate and possibly disable the engine. Two common faults are:

• FC1682: Unable to build DEF pressure during priming state. • FC3547: Unable to maintain DEF pressure during dosing.

Figure 5: DEF Filter Location Prope

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Figure 6: DEF Filter Location

• DEF Supply Module Filter The DEF supply module contains a filter that needs to be replaced at a maximum of every 4500 hours of service. The filter can be replaced by unscrewing the filter base in figure 7, removing and replacing the filter element, and then replacing the filter base back onto the supply module.

DEF Tank

DEF Supply Module

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Figure 7: DEF Supply Module Filter

• DEF Tank Filter The DEF tank contains a filter that needs to be cleaned at a maximum of every 4500 hours of service. Failure to regularly flush tank and clean the filter will lead to fault codes and premature servicing. The DEF tank servicing is as follows:

1. Turn off the unit battery switch 2. Open both doors to the unit for access. 3. Remove the DEF tank from the unit. 4. Remove the header assembly from the tank. 5. Flush the tank and header assembly. 6. Remove, clean and inspect, then reinstall the DEF tank filter. 7. Reinstall the tank header assembly. 8. Reinstall tank and fill with fresh DEF fluid

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Figure 8: DEF Tank

9. Filters and Lubricants

Filters and lubricants for periodic maintenance are listed below. The chart includes the name, TLD part number, and description of the item needed to maintain this unit.

Header Assembly

DEF Tank Filter

Filler Neck and Vent

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Nomenclature Cummins P/N TLD P/N

CUMMINS Tier 4 Final ACU-802

Description

Engine Air Filter, Primary

5261249 (AF55014) N/A Air Filter

Element

Engine Air Filter, Secondary

(AF55308) N/A

Air Filter Element,

Secondary

Engine Oil Filter

3937736

N/A Spin On Filter

Engine Oil*

N/A

1048606 15W-40 API CJ-4 or better oil

Engine Fuel Filter

5319680

N/A Fuel filter/water

separator

5303743

N/A Fuel Filter

DEF Pump Filter

5303604

1076484-P10 DEF Pump Filter

Engine Coolant

N/A

1033604-50 Long Life Ethylene glycol

Hinge/latch lubricant

N/A

UMO1-9 SAE30 Engine Oil

Radiator fan/alternator belt

3289448

1109572-P4 Poly-V Belt

Engine Alternator

5282841

N/A Alternator 24V 70 amp

Engine Starter Motor

4996707

N/A Starter Motor

Engine Oil Dipstick 3974757 N/A Engine Oil Dipstick

* This oil is recommended for use in ambient temperatures ranging from 0°F to 120°F. For information on recommended oil for ambient temperatures outside this range, consult the Engine Manufacturer's manual in Chapter 5.

Table 2: Filters and Lubricants

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