Application

Engineering
Bulletin
Subject This AEB is for the following applications:
Fleetguard® Composite Fuel and
Lubrication Filters. Automotive Industrial Marine

G-Drive Genset

Filtration Emissions Solution

Date: August 29, 2008 AEB Number 74.17

Engine Models included: All Engines

Author: Todd Forrest Approver: per Procedure 9183OPS-04-10- Page 1 of 6

01

This AEB supersedes AEB

74.17 dated March, 2006

Document Overview:
Fleetguard® is launching new fuel filter and lubrication filter products that are applicable to Cummins
Engines. These new products offer advantages over the existing filtration products while maintaining
equivalent filtration capabilities.

Introduction:
A new product line of Fluid Filtration products is now launched by Fleetguard® for Cummins Inc.
products. The initial product launch has global focus on aftermarket midrange engines and specifically
on the 7.6 – 9.5 cm (3 - 3.75 in) diameter fuel filter product.

Filter Type Cummins P/N (Current) New Cummins P/N FGD P/N (Current) New FGD P/N
Fuel Filter 3931063 4990879 FF5052 FF42000
Fuel Filter 3964763 4990879 FF5494 / FF5494FZ FF42000

The new P/N listed above is now a factory-available option, released on all non-Marine options where
the two legacy metal filters are used. The only difference between 3931063 and 3964763 is the outer
seal material, and the 4990879 includes a seal that has been validated to meet the requirements of
both.

The new User Friendly Filter is certified per UL 1105 (http://database.ul.com/cgi-bin/XYV/cgifind.new/

LISEXT/1FRAME/srchres.html, ITUQ.MQ1049). While this is sufficient for recreational marine
markets, commercial marine applications require additional agency certifications, and for this reason,
Cummins MRE has determined to release the new P/N on only non-Marine options. From an
aftermarket standpoint, the new composite product will displace the current steel shell dependent upon
regional business conditions. LF option changes are planned for 2009.

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Performance:

From an application standpoint, the performance of the new Fleetguard® filter(s) has equivalent
filtration efficiency and capacity to the current steel shell filters in use today. All service intervals as
published in Operation and Maintenance Manuals (O&M) and marketing literature will remain
unchanged.

Cummins Inc. Certification Compliance:

The new product line of Fleetguard® composite filters meets or exceeds all Cummins Inc. material and
performance specifications required for Engine Filtration on Cummins products. In addition, the new
Fleetguard® product line offers compliance with many Industry and/or Market specific certification
agencies. The publication of these certification compliance(s) within this AEB is to provide to the
Cummins customer and OEM with the background required for proper application of this product into
their specific applications as noted in Table 1 below. This testing and subsequent compliance
ensures that when properly applied, the integrity, performance, and mechanical functionality of the
composite design offers a robust filtration product solution.

Cummins
Task Description Engineering Industry Standard Compliance
Standard
a. Single Pass Rating Test 10508 / 14283 (4.1.1) SAE J1985 / ISO 19438 / ISO 13353 94 TR
b. Filter Media Migration Test 10508 / 14283 (4.1.2) N/A
c. Resistance to Flow Test 10508 / 14283 (4.1.3) J905 / ISO4020 / CES14283
d. Burst Pressure Test 10508 / 14283 (4.1.4) ISO 4548-6
e. Vibration Fatigue Test 10508 / 14283 (4.1.5) ISO 4548-7
g. Filter Capacity Test 10508 / 14283 (4.1.7) SAE J905 / ISO 19438
k. Pressure Cycle Fatigue Test 10508 / 14283 (4.1.11) ISO 4548-5
Field Test 25ea. X 25k. Miles 10508 (4.4.2.2) N/A
Thermal Cycle Performance 14277 N/A
Element Collapse 14225 / ISO 4020-1 N/A
In Place of 10508
Accelerated endurance vibration test N/A
(4.4.2.1)
Impact Testing N/A Modified ASTM D2444-99
Element Fabrication Integrity (Bubble Test) N/A ISO 2942
Underwriters Laboratory N/A UL 1105
Ultra-violent Testing (material level soak test) N/A ASTM D1499

Table 1. Cummins / Industry Test Descriptions

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Supplemental Validation:

In addition to the above Cummins Standard Testing, Fleetguard® went beyond the base requirements
and has completed additional validation. This additional testing to again ensure product robustness is
listed in Table 2.

Task Description Status

Vibration Back-off Testing Completed & Approved
Installation & Removal Torque Testing Completed & Approved
Thermal Soak Testing (creep study) Testing Completed & Approved
Cold Temperature Gasket Sealing Testing Completed & Approved
Installation @ Thermal Load Testing Completed & Approved
Vibration Fatigue @ Thermal Load Testing Completed & Approved
Pressure Cycle Fatigue @ Cycled Thermal Load Testing Completed & Approved
Hydrostatic Burst @ Thermal Load Testing Completed & Approved
Fuels Compatibility Testing Completed & Approved
Standpipe Suction Testing Completed & Approved

Table 2. Additional Testing Descriptions

Specific Market Requirements:

Marine Market:
The Marine market requires certification with various tests/agencies. Compliance has been completed
per UL 1105 (Underwriters Laboratory), one such agency which is specific to the US Coast Guard.
Vessels that require Marine Society Classification will require metallic shell filter(s), however,
recreational vessels can utilize a non-metallic (composite) application.

Industrial Market:
The new composite material filter does not meet some of the OEM requirements in forestry
applications And does not meet the requirements for UL 558 at this time, required by some forklift
OEMs. Therefore the composite material filter should not be used in these applications.

Installation Application Requirements:

There are no current installation requirements for the application of a composite (non-metallic) fuel or
lubrication filter elements. However, when applying this product to Cummins engines, it is advisable to
be aware that proximity to heat sources will need to be addressed. Engine-mounted fuel filters are
typically located on the cold-side of the engine, away from turbo and exhaust tubing, so this concern is
primarily for lubrication filters and remote-mounted fuel filters.

Fleetguard® has done extensive testing regarding heat susceptibility, and it has been concluded that
although the canister is a non-metallic shell, the weakest point due to expected or unexpected heat
sources is the filter gasket material and not the shell.

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For Installation requirement purposes, both Fuel and Lubrication filters should not be applied or
located near a heat source per the following constraints (see Figure 1):

Filter Element (Type) Heat Source Temperature Minimum allowable Distance

to Heat Source
Fuel or Lube Filter 593 deg C (1100 deg F) 12.7 cm (5 in)
Fuel or Lube Filter 426 deg C (800 deg F) 7.6 cm (3 in)
Fuel or Lube Filter 204 deg C (400 deg F) 1.3 cm (0.5 in)
A heat source may include such items as an exhaust manifold, turbocharger outlet, exhaust tubing, or
exhaust components. If you are in doubt of the actual surface temperature that the element will be
exposed to, it is recommended to utilize a temperature measuring device or data logger with high
temperature thermocouple compatibility.

Example: Temperature Verification Application for

Composite (non-Metal) Filter Element(s)

Exhaust Outlet Lubrication

Filter

Note: Ensure that Filter is

applied at least the
Minimum Distance per
above table to Heat Source

Figure 1. Proximity to a Heat Source

Physical Size Difference:
As shown below, the new Fleetguard® composite filter envelope is nearly identical to the current steel
shell design. The two exceptions to the envelope are the weld joint on the diameter which is 2 mm
(0.08 in) larger and the bottom ribs which protrude out on the radius at the bottom of the shell. For
dual filter options (two filter elements with a common filter head), serviceability is not compromised.

Current Filter Envelope

New Filter Envelope

Areas shown with

Arrow extend beyond
the envelop of the
current filter element

Figure 2. Overlay of Filter Envelopes

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Product Benefits to Customers and Applications:

- Dent proof
- Lightweight design (50% less weight than metal)
- Corrosion (rust) free
- Completely incinerable
- Eliminates painting, fumes, etc
- Bottom hand-hold/gripping ribs
- No Tip, upright standing design
- One-way ½ “ square drive removal cavity
- Standard strap wrench removal
- Easy installation and service

Figure 3. One-way ½ “ square drive removal cavity

Figure 4. Integrated bottom hand-hold/gripping ribs

Product Disposability:

The new composite filter product can be disposed of according to the same disposal practices of the
metal filters they are replacing. The new User Friendly Filter can be drained, crushed, cut-open,
and/or land-filled just like the metal filters. These new elements however, may offer some additional
disposal advantages to customers or markets over the metal filters. In addition to the standard
disposal techniques, these filters could be fully incinerated, recycled, or used as waste energy fuel, all
without the need for component or material sorting/separation due to the all composite material design
of the filter.

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Change Log
Date Author Description Page(s)
Mar, 2006 D Venable Initial Release All
29Aug2008 T Forrest New Part Numbers added 1l
Added UL1105 certification 1
Added Industrial Market requirements 3
Updated installation application requirements section 4

Cummins Confidential