TLD

Operation & Maintenance Manual

ASU-600 Series Continuous Jet Start Units

Chapter 3
Table of Contents
Overhaul/Major Repair Chapter/Section Page
Component Overhauls ............................................................................. 3-1................................................ 1
1. Engine ......................................................................................................................................................2
A. Basic Engine Adjustment .................................................................................................................2
2. Compressor..............................................................................................................................................3
3. Trailer .......................................................................................................................................................3
A. Front Wheel Hub (See Figure 1)......................................................................................................3
B. Rear Axle Hub (See Figure 2) .........................................................................................................7
C. Brake Adjustment (See Figure 3) ..................................................................................................11
4. Engine Governor Adjustment .................................................................................................................12
A. Electronic Variable Speed Governor .............................................................................................12
5. Throttle Controller Adjustment................................................................................................................12
A. Required Equipment ......................................................................................................................12
B. Procedure ......................................................................................................................................12

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Component Overhauls
This section deals with the overhaul/repair of components within the ASU-600 Series Continuous
Jet Start Unit.

This section details the procedures recommended for the overhaul of the components after the
removal from the unit.

There are no specific overhaul periods recommended. The engine should run for many thousands
of hours without requiring major attention, but should the engine be removed for a major repair
after a considerable period of service, it is advisable to overhaul the unit or fit a factory
reconditioned replacement.

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1. Engine
If the engine needs to be overhauled, we recommend that a certified Detroit Diesel service station do
the work. Special tools and fixtures are needed to overhaul this engine and the cost of having a service
station do the work is well invested.

Regular maintenance and tune-up information is located in Chapters 2 and 5.

A. Basic Engine Adjustment

Adjustment procedures applicable to the diesel engine are included in the engine manual
(Manufacturer’s Literature, Chapter 5).

Specific information for this particular engine is listed below:

Manufacturer ................................................................. Detroit Diesel

Model ............................................................................ 6063-HK33

Type .............................................................................. 4 cycle diesel

Cylinder design ............................................................. In-line 6, turbocharged

Bore .............................................................................. 5.24 in. (133 mm)

Stroke ........................................................................... 6.61 in. (168 mm)

Displacement ................................................................ 855 cu. In. (14 liter)

Compression ratio ........................................................ 15.0 to 1

Horsepower .................................................................. 425 hp (317 kW) for 180PPM

.......................................................................... ………..630 hp (470 kW) for 270PPM

.......................................................................... ………..665 hp (496 kW) for 300PPM

Oil capacity ................................................................... 38 qts (36 liters) (with filters)

Engine coolant capacity ................................................ 24 qts. (23 liters)

Radiator & Plumbing coolant capacity.............. ………..48 qts. (40 liters)

Engine dry weight ........................................................ 2,360 lbs. (1,070 Kg)

Starter ........................................................................... 24 volt

Alternator ...................................................................... 24 volt

Governor ....................................................................... 1,000-2,100 rpm for 180, 200, or 270 PPM

……………………………………………………………….2,300 rpm for 300PPM

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2. Compressor
If the compressor needs to be overhauled, we recommend that a certified Aerzen service station do the
work. Special tools and fixtures are needed to overhaul this compressor and the cost of having a
service station do the work is well invested.
Regular maintenance, tune-up, and adjustment information is located in Chapter 2 and 5. Follow the
Ensure all troubleshooting steps have been followed.

3. Trailer

A. Front Wheel Hub (See Figure 1)

(1) Removal

(a) Chock the wheels opposite the axle being serviced.

(b) Loosen the lug nuts.
(c) Position jacks under the front axle lift points and raise the trailer until the wheels can be
freely rotated. Install jack stand supports.
(d) Remove the tire and wheel assemblies.

(2) Disassembly

(a) Remove the grease cap, cotter pin, castellated nut, keyed washer and outer bearing
cone and roller.
(b) Slide the hub off the spindle.
(c) Remove the grease seal and inner bearing cone from the hub. Discard grease seal.

NOTE:
The inner and outer bearing cups are pressed into the hub.

(3) Cleaning

(a) Wash the bearing cone and roller assemblies, keyed washer, castellated nut, spindle
and cups using an approved solvent. Wipe dry with a clean, lint-free cloth.
(b) Remove existing grease from hub caps and hub cavity.

CAUTION:
DO NOT ALLOW SOLVENT TO CONTACT TIRES.

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(4) Inspection

(a) Check the condition of the bearings and cups. Replace excessively worn or damaged
parts.
(b) Check the integrity of welds on the axle, spindle, and carrier assembly.
(c) Inspect the spring leaves for flattened condition and worn bushings.
(d) Check for loose or damaged fasteners.
(e) Inspect the towbar assembly for damage or wear.

(5) Repair

The repair of any defective part is accomplished by the replacement of the part concerned.

(6) Assembly

(a) Distribute wheel bearing lubricant (UMG2-1) evenly inside the hub between the bearing
cups. Pressure pack the bearing cone and roller assembly with fresh lubricant using a
bearing packer.

NOTE:
If a pressure packer is not available, hand pack the bearings,
making sure to work as much lubricant as possible between the
bearing cage, cone, and rollers.

CAUTION:
DO NOT INTERMIX WHEEL BEARING LUBRICANTS
CONTAINING DIFFERENT THICKENING AGENTS. CALCIUM,
ALUMINUM, BARIUM, AND LITHIUM SOAP BASED
LUBRICANTS SHOULD NOT BE MIXED. THE USE OF
INCOMPATIBLE BEARING LUBRICANTS MAY RESULT IN
PREMATURE LUBRICANT BREAKDOWN.

(b) Install the inner bearing cone and roller assembly in the hub; then position and install a
new grease seal.
(c) Position and install the hub on the spindle keeping the hub centered to avoid damaging
the grease seal or spindle threads. Install the outer bearing cone and roller assembly,
keyed washer, and castellated nut on the spindle.
(d) Adjust wheel bearings as follows:
1 Tighten the spindle nut to 12 ft. lbs. (16 Nm) torque to seat the bearings while
turning the wheel forward by hand.

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2 Adjust the spindle nut by hand. Back off the nut the minimum amount required to
align the hole in the spindle with a slot in the nut.

CAUTION:
DO NOT BACK OFF THE NUT MORE THAN ¼ TURN.

3 Install a new cotter pin making sure that the cotter pin ends do not interfere with the
dust cap. Bend over the ends of the cotter pin against the nut and cut off any extra
pin length.

CAUTION:
TO AVOID POSSIBLE FAILURE FROM METAL FATIGUE, NEVER
REUSE COTTER PIN FASTENERS. USE ONLY STEEL COTTER
PINS APPROVED FOR USE IN WHEEL HUB APPLICATIONS.

4 Measure hub end play. Correct end play should be 0.001 to 0.008 in.
(0.03 to 0.20 mm).

NOTE:
If end play is excessive, the bearing cone and roller assemblies
and cups are worn and should be replaced.

(e) Fill the dust cap with bearing lubricant and reinstall the cap.

CAUTION:
NEVER PRELOAD THE WHEEL BEARINGS. DAMAGE CAN
RESULT FROM STEADY PRESSURE APPLIED TO THE ROLLER
ENDS.

(f) Install the wheel and tire assembly on the hub. Install and pre-tighten wheel nuts. Check
tire pressure.
(g) Raise the trailer using floor jacks; remove jack stand supports; lower the cart and
remove jacks. Tighten wheel nuts evenly and alternately. Engage the parking brake
and remove wheel chocks.

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7
9 10
8

5 6
4
2 3

11

1
12
13

1. ....Cap, grease 8. ....Bearing, inner cup

2. ....Pin, cotter 9. ....Bearing, inner cone
3. ....Nut, castellated 10. ..Seal, grease
4. ....Washer, keyed 11. ..Bolt, mounting wheel
5. ....Bearing, outer cone 12 ...Lockwasher, mounting
6. ....Bearing, outer cup 13 ...Nut, mounting
7. ....Hub

FRONT HUB ASSEMBLY

FIGURE 1

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B. Rear Axle Hub (See Figure 2)

The Rear Axle has a single wheel assembly on each side for 180ppm and 200ppm units.
The Rear Axle has a dual wheel assembly on each side for 270ppm and 300ppm units.

(1) Removal

(a) Chock the wheels opposite the axle being serviced.

(b) Loosen the lug nuts.
(c) Position jacks under the rear axle lift points and raise the trailer until the wheels can be
freely rotated. Install jack stand supports.
(d) Remove the tire and wheel assemblies.

(2) Disassembly

(a) Remove the outer hub flange (Figure 2, Item 2), by removing the ferry head screws (1),
and remove the nut (3) and the washer (4) from the spindle.
(b) Withdraw the outer bearing cone (6) and pull the hub assembly (7) off the spindle.
Separate the brake drum from the hub.
(c) Remove the inner bearing cone (9) and the grease seal (10) from the spindle.

NOTE:
The inner and outer bearing cups are pressed into the hub.

(3) Cleaning

(a) Wash the bearing cone and roller assemblies, keyed washer, castellated nut, spindle
and cups using an approved solvent. Wipe dry with a clean, lint-free cloth.
(b) Remove existing grease from hub caps and hub cavity.

CAUTION:
DO NOT ALLOW SOLVENT TO CONTACT TIRES.

(4) Inspection

(a) Check the condition of the bearings and cups. Replace excessively worn or damaged
parts.
(b) Check the integrity of welds on the axle, spindle, and carrier assembly.
(c) Inspect the spring leaves for flattened condition and worn bushings.

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(d) Check for loose or damaged fasteners.

(e) Inspect the towbar assembly for damage or wear.

(5) Repair

The repair of any defective part is accomplished by the replacement of the part concerned.

(6) Assembly

(a) Distribute wheel bearing lubricant (UMG2-1) evenly inside the hub between the bearing
cups. Pressure pack the bearing cone and roller assembly with fresh lubricant using a
bearing packer.

NOTE:
If a pressure packer is not available, hand pack the bearings,
making sure to work as much lubricant as possible between the
bearing cage, cone, and rollers.

CAUTION:
DO NOT INTERMIX WHEEL BEARING LUBRICANTS
CONTAINING DIFFERENT THICKENING AGENTS. CALCIUM,
ALUMINUM, BARIUM, AND LITHIUM SOAP BASED
LUBRICANTS SHOULD NOT BE MIXED. THE USE OF
INCOMPATIBLE BEARING LUBRICANTS MAY RESULT IN
PREMATURE LUBRICANT BREAKDOWN.

(b) Install the inner bearing cone and roller assembly in the hub; then position and install a
new grease seal.
(c) Assemble the brake drum and hub.
(d) Position and install the hub on the spindle keeping the hub centered to avoid damaging
the grease seal or spindle threads. Install the outer bearing cone and roller assembly,
keyed washer, and castellated nut on the spindle.
(e) Adjust wheel bearings as follows:
1 Tighten the spindle nut to 12 ft. lbs. (16 Nm) torque to seat the bearings while
turning the wheel forward by hand.

2 Adjust the spindle nut by hand. Back off the nut the minimum amount required to
align the hole in the spindle with a slot in the nut.

CAUTION:
DO NOT BACK OFF THE NUT MORE THAN A ¼ TURN.

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3 Install a new cotter pin, making sure that the cotter pin ends do not interfere with the
dust cap. Bend over the ends of the cotter pin against the nut and cut off any extra
pin length.

CAUTION:
TO AVOID POSSIBLE FAILURE FROM METAL FATIGUE, NEVER
REUSE COTTER PIN FASTENERS. USE ONLY STEEL COTTER
PINS APPROVED FOR USE IN WHEEL HUB APPLICATIONS.

4 Measure hub end play. Correct end play should be 0.004 to 0.008 in.
(0.03 to 0.20 mm).

NOTE:
If end play is excessive, the bearing cone and roller assemblies
and cups are worn and should be replaced.

(f) Fill the dust cap with bearing lubricant and reinstall the cap.
(g) Install the wheel and tire assembly on the hub. Check tire pressure.

CAUTION:
NEVER PRELOAD THE WHEEL BEARINGS. DAMAGE CAN
RESULT FROM STEADY PRESSURE APPLIED TO THE ROLLER
ENDS.

(h) Raise the trailer using floor jacks; remove jack stand supports; lower the axle and
remove jacks. Engage the parking brake and remove wheel chocks.
(i) Check and readjust the parking brake tension if required. Tighten wheel nuts evenly and
alternately. Refer to Paragraph C, for parking brake adjustment.

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10
9
8

6
5
4
2 3

1
11

1. .... Ferry head cap crew 7..... Hub with cups

2. .... Outer hub flange 8..... Inner cup
3 ..... Nut, 1-14 UNF 9..... Inner cone
4. .... Washer, tongued 10... Grease seal
5. .... Outer cup 11... Wheel stud
6. .... Outer cone

REAR AXLE HUB

FIGURE 2
180 & 200 PPM units have a single wheel per side hub assembly.

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C. Brake Adjustment (If equipped) (See Figure 3)

The brake operating mechanism consists of an Orscheln type handle connected to a brake cable
which in turn connects to a cross-shaft. This cross-shaft connects two short linkages, which
attach to the brake operating levers on the wheel assemblies.
Minor adjustment to compensate for wear of the brake shoe linings is accomplished by turning the
knurled grip of the handle.
Larger adjustment is made by turning one or both of the forked yokes at the end of the brake rod.
This will adjust both brakes equally. To adjust one brake only or to balance the brakes adjust one
or the other of the shorter brake linkages by following the same procedure.

4
1

1....Brake assembly
2....Cross shaft
3....Short linkage
4....Brake cable
5....Lever

BRAKE ADJUSTMENT
FIGURE 3

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4. Engine Governor Adjustment

A. Electronic Variable Speed Governor

Engine speed is electronically controlled by the Detroit Diesel Electronic Control System (DDEC).
Adjustment is not required. Refer to the Detroit Diesel Engine Operator’s Guide in Chapter 5 for a
complete description of the electronic control system.

5. Throttle Controller Adjustment (See Figure 4)

A. Required Equipment
DC power supply, adjustable from 0 to 12 VDC.

B. Procedure
(1) Set the power supply output at precisely 5 VDC.
(2) Make connections as shown in Figure 4.
(3) Move the trim on the bypass valve fully up. The actuating arm of the throttle controller should
move up with the trim valve. Adjust the mounting bracket to obtain 0.68 VDC (1,000 rpm).
(4) Allow the trim valve to seat. The actuating arm of the throttle controller should move down
with the trim valve. Adjust the mounting bracket to obtain 4.47 VDC (2,100 rpm for 180ppm,
200ppm & 270ppm; 2300 rpm for 300 ppm).

NOTE:
There is a maximum speed limiting standoff on the throttle
controller to prevent a high voltage signal. The electronic
control module will shut down the unit if signal voltage is too
high (approximately 4.75 VDC).

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64 GND.
A

B 63 SIGNAL

62
2
C SUPPLY

- +

1 3
9

8 4, 5
- +
10
5 VDC 7
6

1..... Throttle controller 6. ....Bypass valve

2..... Cylinder 7. ....Actuating arm
3..... Cylinder rod 8. ....Connector
4..... Trim guide 9. ....Digital voltmeter
5..... Trim 10. ..Power supply

THROTTLE CONTROLLER ADJUSTMENT

FIGURE 4

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