Trielectron Mn1080 90t400sln TR Rev F

TECHNICAL MANUAL
OPERATION AND MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS

BREAKDOWN
GROUND POWER UNIT
CumminsB Engine 6BT WoodwardB Governor

John DeereB Engine 6059T GACB Governor
Marathon@Generator - 2000 RPM
JET-A Fuel Compatible KatoB Generator - 2400 RPM
Block eater KIM B Hotstart TRI - 80012000 Amperes
Ether Start 0Racot-6) Filter T R I .5 - 105012000 Amperes
Low Fuel Shutdown TR2.2 - 150012500 Amperes
Low Fuel Warning Beacon TR2 - l5OOl25OO Amperes
Neutral Fault Shutdown TR3 - l5OOl25OO Amperes
a 11001 Hwy. 41 North Palmetto, FL 34221

TRILECTRON
MAN# MN1080
INDUSTRIES, INC. I
TEL.
(94 1) 721-1000
FAX
(941) 723-3160
JULY 15,2000
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its con-
stituents are known to the State of Califor-
nia to cause cancer, birth defects, and
other reproductive harm.
a 90T400SLN
GROUND POWER UNIT
RECORD OF CHANGES
This manual is published by Trilectron Industries, Inc., Palmetto, Florida. Please log changes to
your manual as they are inserted, indicating the date of the change and the date the change is
inserted in the manual. If any changes
- or pages
. - are missing, contact Trilectron Industries, Inc.
for additional copies.
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NO.
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1-2 . . . . . . . . . . . . . . . . 4 . . . . . . . . . June 02. 1997 2-2 . . . . . . . . . . . . . . . . I 8. . . . . . .January 15. 1999
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Chapter1 Chapter1
Section Paae Date Section Paae Date
2-2 . . . . . . . . . . . . . . . . 29/30 . . . .January 15.1999 4.2 . . . . . . . . . . . . . . . . .2 . . . . . November 15.1995
2-2 . . . . . . . . . . . . . . . . 31132 . . . .January 15. 1999 4-2. . . . . . . . . . . . . . . . .3 . . . . . November 15.1995
2-2 . . . . . . . . . . . . . . . . 33134 . . . .January 15. 1999 4-2. . . . . . . . . . . . . . . . . 4 . . . . . November 15.1995
2-2 . . . . . . . . . . . . . . . . 35/36 . . . .January 15. 1999 4.2 . . . . . . . . . . . . . . . . .5 . . . . . November 15,1995
2-2 . . . . . . . . . . . . . . . . 37138 . . . .January 15.1999 4.2 . . . . . . . . . . . . . . . . . 6 . . . . . November 15,1995
2-2 . . . . . . . . . . . . . . . . 39/40 . . . .January 15. 1999 4-2. . . . . . . . . . . . . . . . . 7 . . . . . November 15,1995
2-2 . . . . . . . . . . . . . . . . 45/46 . . . .January 15. 1999 4-2. . . . . . . . . . . . . . . . .9 . . . . . November 15.1995
2-2 . . . . . . . . . . . . . . . . 47148 . . . .January 15.1999 4-2. . . . . . . . . . . . . . . . .10 . . . . November 15.1995
2-2 . . . . . . . . . . . . . . . . 49/50 . . . .January 15.1999 4-3. . . . . . . . . . . . . . . . .1 . . . . . . . January 15.1999
2-3 . . . . . . . . . . . . . . . . 1 . . . . . .November 15. 1995 4-3. . . . . . . . . . . . . . . . . 2 . . . . . . . January 15,1999
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2-4 . . . . . . . . . . . . . . . . 1 . . . . . . . .January 15.1999 4-3. . . . . . . . . . . . . . . . .10 . . . . . . January 15. 1999
2-4 . . . . . . . . . . . . . . . . 2. . . . . . . .January 15. 1999 4-3. . . . . . . . . . . . . . . . .11 . . . . . . January 15. 1999
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2-4 . . . . . . . . . . . . . . . . 8.. . . . . . .January 15.1999 4-3. . . . . . . . . . . . . . . . . 17 . . . . . . January 15.1999
2-4 . . . . . . . . . . . . . . . . 9.. . . . . . .January 15,1999 4-3. . . . . . . . . . . . . . . . .18 . . . . . . January 15.1999
2-4 . . . . . . . . . . . . . . . . I 0.. . . . . .January 15,1999 4-3. . . . . . . . . . . . . . . . . 19 . . . . . . January 15,1999
2-4 . . . . . . . . . . . . . . . . I 1 . . . . . . .January 15.1999 4-3. . . . . . . . . . . . . . . . .20 . . . . . . January 15.1999
2-4 . . . . . . . . . . . . . . . . I2.. . . . . .January 15.1999 4-3. . . . . . . . . . . . . . . . .21 . . . . . . January 15.1999
2-4 . . . . . . . . . . . . . . . . I 3. . . . . . .January 15.1999 4-3. . . . . . . . . . . . . . . . .22 . . . . . . January 15. 1999
2-4 . . . . . . . . . . . . . . . . I 4.. . . . . .January 15.1999 4-3. . . . . . . . . . . . . . . . . 23 . . . . . . January 15.1999
2-4 . . . . . . . . . . . . . . . . I 5. . . . . . .January 15. 1999 4-3. . . . . . . . . . . . . . . . .24 . . . . . . January 15. 1999
2-4 . . . . . . . . . . . . . . . . I 6.. . . . . .January 15,1999 4-3. . . . . . . . . . . . . . . . . 25 . . . . . . January 15.1999
2-4 . . . . . . . . . . . . . . . . I 7.. . . . . .January 15.1999 4-3. . . . . . . . . . . . . . . . .26 . . . . . . January 15.1999
2-4 . . . . . . . . . . . . . . . . I 8.. . . . . .January 15. 1999 4-3. . . . . . . . . . . . . . . . .27 . . . . . . January 15.1999
2-4 . . . . . . . . . . . . . . . . I 9. . . . . . .January 15.1999 4-3. . . . . . . . . . . . . . . . . 28 . . . . . . January 15.1999
2-4 . . . . . . . . . . . . . . . . 20.. . . . . .January 15. 1999 4-3. . . . . . . . . . . . . . . . .29 . . . . . . January 15.1999
2-5 . . . . . . . . . . . . . . . . 1 . . . . . .November 15.1995 4-3. . . . . . . . . . . . . . . . .30 . . . . . . January 15.1999
2-5 . . . . . . . . . . . . . . . . 2. . . . . .November 15.1995 4-3. . . . . . . . . . . . . . . . . 31 . . . . . . January 15. 1999
3-0 . . . . . . . . . . . . . . . . 1 . . . . . .November 15. 1995 4-3. . . . . . . . . . . . . . . . .32 . . . . . . January 15.1999
3-0 . . . . . . . . . . . . . . . . 2.. . . . .November 15.1995 4-3. . . . . . . . . . . . . . . . . 33 . . . . . . January 15.1999
4-1 . . . . . . . . . . . . . . . . 1 . . . . . .November 15. 1995 4-3. . . . . . . . . . . . . . . . . 34 . . . . . . January 15. 1999
4-1 . . . . . . . . . . . . . . . . 2. . . . . .November 15. 1995 4-3. . . . . . . . . . . . . . . . . 35 . . . . . . January 15.1999
4-1 . . . . . . . . . . . . . . . . 3. . . . . .November 15.1995 4-3. . . . . . . . . . . . . . . . .36 . . . . . . January 15.1999
4-1 . . . . . . . . . . . . . . . . 4.. . . . .November 15.1995 4-3. . . . . . . . . . . . . . . . . 37 . . . . . . January 15.1999
4-2 . . . . . . . . . . . . . . . . 1 . . . . . .November 15.1995 4-3. . . . . . . . . . . . . . . . . 38 . . . . . . January 15.1999
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4-3 . . . . . . . . . . . . . . . . 39 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 40 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 41 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 42 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 43 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 44 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 45 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 46 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 47 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 48 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 49 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 50 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 51 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 52 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 53 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 54 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 55 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 56 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 57 . . . . . . January 15. 1999
4-3 . . . . . . . . . . . . . . . . 58 . . . . . . January 15. 1999
5-0 . . . . . . . . . . . . . . . . 1 . . . . . . . January 15. 1999
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INTRODUCTION
This manual contains Start-up procedures, Functional Description, Operating lnstructions and
Maintenance information.
The Operation lnstructions are designed for new, or experienced operators, and fully describes
the Control Panel operation in a step-by-step sequence. The operator is also made aware of
normal operating indications, and indication of a defective unit.
A set-up preparation section show all necessary details on how the unit is prepared for
operation, and gives a basic introduction to the control circuitry.
The function description fully describes the system and can be used in conjunction with
maintenance and troubleshooting procedures. illustrations are provided to indicate various
component locations in the unit.
The Maintenance portion of this manual provides a Maintenance Schedule, and a
Troubleshooting chart to enable a quick location of defective components. Additionally provided
are manuals for various components plus schematic diagrams for the controlling circuitry.
July 15, 2000 Introduction

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Introduction July 15, 2000

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EQUIPMENT WARRANTY
GENERAL WARRANTY- All materials, workmanship and design features of Trilectron Ground
Support Equipment, which includes GPU's, Air starts and Air Conditioning units, shall be
guaranteed as follows:
a. For equipment shipped to destinations in the Continental United States, WARRANTY IS

ONE (I) YEAR FROM THE DATE OF SHIPMENT
b. For equipment shipped to destinations outside the Continental United States, WARRANTY
IS ONE (I) YEAR PLUS 90 DAYS (455) DAYS FROM DATE OF SHIPMENT, TO ALLOWFOR
SHIPPING AND START UP.
c. Failure to abide Trilectron Industries, Inc., recommended operation, maintenance, and
prescribed inspection procedures may void all warranties. Should investigation or inspection
reveal that the necessity for repair, replacement, etc, was caused by failure to follow the
procedures prescribed, claim will be declined.
2. COMPONENTS
Components of manufacturers, other than Trilectron Industries, Inc., such as engines,
generators, compressors, pumps, valves and other mechanical or electrical accessories, are
guaranteed only to the extend that installation in the end item. Trilectron Industries, Inc., will not
extend the guarantee of a purchased component beyond that extended by its manufacturers.
3. REFRIGERANT CASES
Trilectron Industries, Inc., warrants any closed refrigerant system to be leak free at the time of
shipment from Trilectron Industries, Inc. plant
Since Trilectron Industries, Inc., cannot control the manner in which the unit is handled while in
shipment or service, the qualifications of the operators, or the ability of people to properly
maintain the refrigerant system. The Company extends no warranty with respect to the loss of
refrigerant gases, or refrigerant oils.
4. EXCLUDED COMPONENTS
Ground hose fittings, hose adapter, air delivery hoses, cables and plugs are not included as part
of this warranty with exception that these components will comply with all applicable
specifications at the time of delivery of the unit.
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5. TERMS OF REPLACEMENT
Warranty with respect to all items, whether of Trilectron Industries, Inc., vendor manufacture, is
based on shipment of replacement parts ex-works with parts replaced under warranty returned
to Trilectron Industries. Inc.
6. This Warranty or Guarantee is expressly made in lieu of all other warranties expressed or
implied, and of all other obligations on our part and we neither assume, nor authorize any other
person to assume for us, any other liability in connection with the sale of this equipment. Under
no circumstances shall the Company be liable for the loss of profits, or any other consequential
damage.
7. If said replacement part is supplied prior to the return of the defective component, the
customer shall be invoiced for the full price of said part and appropriate credit issued promptly
upon receipt and examination of the returned part. Installation or operation of this machine in
any manner other than that recommended in the instructions, or operation beyond its rated
capacity will void this guarantee.
If this unit has malfunctioned during warranty period, and the defect cannot be located by the
user, in U.S.A. the user should contact Customer Service Department at (877) 874-5322 or
(941) 721-1 092 or fax at (877) 874-5321 or (941) 721-1091
Introduction July 15, 2000

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TABLE OF CONTENTS
SUBJECT CHAPTERISECTION PAGE

RECORD OF CHANGES ......................................... ROC........ I
LIST OF EFFECTIVE PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOEP ....... 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INTRO ...... 1
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INTRO . . . . . . 3
CHAPTER 1. GENERAL INFORMATION & OPERATING INSTRUCTIONS. . 1-1 ......... 1
SECTION 1. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 ......... 1
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . 1
2 . MAJORCOMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I - 1 . . . . . . . . . 1
3 . SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . 3
A . Engine: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . 3
B. Engine Electrical Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . 6
C. Engine Fault Protection Circuits . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 . . . . . . . . . 9
D. AC Generator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 . . . . . . . . 10
E. Generator Output Control Circuitry. . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . 13
F. AC Output Protective Circuits: . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 . . . . . . . . 13
G. AC Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 . . . . . . . . 15
H. DC Output Control Circuitry (Optional). . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . 16
SECTION 2. OPERATION ..................................... 1.2 ......... 1

1. CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . 1
2 . OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 . . . . . . . . . 1
A . Pre-Operational Inspection: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . 1
B. Engine Start Procedures: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . 4
C. Generator Operating Procedures: . . . . . . . . . . . . . . . . . . . . . . . .1-2 . . . . . . . . . 5
D. AC Fault Indicators: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 . . . . . . . . . 7
E. Fault LampTest: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I - 2 . . . . . . . . . 7
F. AC Fault Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . 7
G. DC Output Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . 8
H. Combined AC and DC Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . 8
SECTION 3. SPECIFICATIONS & CAPABILITIES ................. . I . 3 . . . . . . . . . 1

1. GENERAL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . 1
2 . ENGINE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . 1
3 . VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 . . . . . . . . . 2
4 . AC GENERATING SYSTEM: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . 2
5 . AC GENERATOR PROTECTIVE SYSTEM . . . . . . . . . . . . . . . . . . . I - 3 . . . . . . . . . 2
6. DC GENERATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . 2
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.
SECTION 4 SHIPPING AND RECEIVING......................... 1-4 ......... 1
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . . . . . 1
2 . PREPARATION FOR SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . . . . . 1
3. RECEIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . . . . . 1
A . Initial Inspection: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . . . . . 2
.
SECTION 5 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 ......... I
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . ...... 1
2 . PREPARATION FOR STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . ...... 1
A . Short Term Storage (less than 3 months) . . . . . . . . . . . . . . . . . . 1-5 . . . ...... 1
B. Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . ...... 1
CHAPTER 2. MAINTENANCE ..................................... 2 . . . . . . . . . . . 1

SECTION 1. SERVICING ...................................... 2-1 ......... 1
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 1
A . Equipment Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 1
B. Consumable Supplies Required for Normal Operation & . . . . . . 2-1 . . . . . . . . . 1
Scheduled Maintenance
2 . LUBRICATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 2
A . Engine Oil Change Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 2
B. Arctic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 3
3 . COOLANT SPECIFICATIONS & RECOMMENDATIONS . . . . . . . . 2-1 . . . . . . . . . 3
A . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 3
B. Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 3
C. Concentration Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 4
D. Coolant Change Recommendations . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 4
4 . FUEL RECOMMENDATlONSlSPEClFlCATlONS . . . . . . . . . . . . . . 2-1 . . . . . . . . . 4
5 . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 4
A . Preventive Maintenance Inspection Schedule . . . . . . . . . . . . . . 2-1 . . . . . . . . . 4
B. Initial Inspection and Preparation . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 6
C. Returning Unit To Service After Extended Storage . . . . . . . . . . . 2-1 . . . . . . . . . 7
D. Engine Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 7
6 . ENGINE FUEL FILTER REPLACEMENT-CUMMINSB . . . . . . . . . . 2-1 . . . . . . . . . 8
A . Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 8
B. Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . 8
7 . ENGINE OIL FILTER REPLACEMENT PROCEDURE-CUMMINSB 2-1 . . . . . . . . . 8
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8 . ENGINE FUEL FILTER REPLACEMENT-JOHN DEEREB . . . . . . . 2.1 . . . . . . . . 10
A . Rectangular Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . 10
B. Round Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . 10
9 . RACORB FUEL FILTER MAINTENANCE (Optional) . . . . . . . . . . . . 2-1 . . . . . . . . 12
10. CLEAN/RE[LACE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . 13
SECTION 2 . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 ......... 1

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2-2 . . . . . . . . . 1
2 . TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . 2
A . Use of the Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . 2 -2 . . . . . . . . . 2
B. Support Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . 2
3 . SCHEMATICS AND WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . .2-1 . . . . . . . . 17
SECTION 3. REMOVALIINSTALLATION ........................ . 2 . 3 . ........ 1

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2-3 . . . . . . . . . 1
2 . TORQUE VALUES FOR GENERAL ASSEMBLY . . . . . . . . . . . . . . . 2 -3 . . . . . . . . . 1
3 . ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 -3 . . . . . . . . . 2
A . Canopy Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -3 . . . . . . . . . 2
B. Adjacent Hardware Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -3 . . . . . . . . . 2
C. Engine IGenerator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 . . . . . . . . . 3
4 . ENGINE 1 GENERATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . 4
A . Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 . . . . . . . . 4
B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 . . . . . . . . . 5
C . Engine Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . 5
5 . GENERATOR REMOVALIINSTALLATION. . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . 5
A . Electrical Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . 5
B. Generator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . 6
C. Generator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -3 . . . . . . . . . 6
6. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -3 . . . . . . . . . 7
A . Radiator Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -3 . . . . . . . . . 7
B. Radiator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -3 . . . . . . . . . 8

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SECTION 4 . ADJUSTMENTS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 1
1. MAINTENANCEIREPAIR ELECTRONIC BOX ASSEMBLY . . . . . . 2-4 . . . . . . . . . 1
A . Disassembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 1
B . Gaining Access: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 1
2 . SYSTEM FAULT TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 1
A . Protective System Test Procedures . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 1
B. Fault Lamp Test (With Engine Not Operating). . . . . . . . . . . . . . . 2-4 . . . . . . . . . 4
C. Fault Lamp Test (With Engine Operating). . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 4
D. Testing Engine Fault Indicators Only. . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 4
3. CIRCUIT CARD ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 4
A . Automatic Voltage Regulator (AVR) module: . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 4
B. AC Overload Module: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 6
C. OverlUndervoltage Module: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 7
D. OverIUnder Frequency Module: . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . 7
E. DC Over Voltage Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . 10
F. DC Current Limiting and Line Drop Compensator Adjustment . . 2-4 . . . . . . . . 10
Procedure
4 . ELECTRONIC GOVERNOR ADJUSTMENTS . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . 12
A . Governors America Corporation@Unit . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . 12
B. Woodward Company@Governor Units . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . 16
SECTION 5. CLEANING AND PAINTING ......................... 2-5 ......... 1

1. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . . . . . 1
2 . PAINTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . . . . 1
CHAPTER 3. OVERHAUUMAJOR REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . 3-0 . . . . . . . . . I

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-0 . . . . . . . . . 1
CHAPTER 4 . ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

SECTION 1. LIST OF VENDORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ......... 1
SECTION 2 . NUMERICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . . . . I
SECTION 3 . DETAILED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ......... 1
1. EXPLANATION OF COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . 1
2 . INSTRUCTIONS FOR ORDERING PARTS . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . 1
CHAPTER 5. MANUFACTURERS' APPENDICES . . . . . . . . . . . . . . . . . . . . . 5-0 ......... I

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TABLE OF CONTENTS
LIST OF FIGURES

CHAPTER 1
SECTION 1
Figure 1.90T400SLN Side View . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . 2
Figure 2 . 90T400SLN Major Component Location . . . . . . 1-1 . . . . . . . . . . . . . . . . 5
Figure 3.Engine Controls and Indicators. . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . 7
Figure 4.Generator Controls and Indicators . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . 11
SECTION 2
Figure 1. Engine IGenerator Control Panel . . . . . . . . . . . 1-2 . . . . . . . . . . . . . . . . 2
SECTION 3
Figure 1.90T400SLN Outside Dimensions. Side View . . . 1-3 . . . . . . . . . . . . . . . . 3
CHAPTER 2
SECTION 1
Figure 1. PSA Oil Viscosity Recommendations . . . . . . . . 2-1 . . . . . . . . . . . . . . . .2
Figure 2 . CumminsB Engine Fuel and Oil Filter . . . . . . . 2-1 . . . . . . . . . . . . . . . .9
LocationIReplacement
Figure 3 . John DeereB Engine Fuel and Oil Filter . . . . . . 2-1 . . . . . . . . . . . . . . . . 11
LocationIReplacement
Figure 4 . RacorB Fuel Filter (Optional) . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . 12
Figure 5 . Air Filter Assembly . . . . . . . . . . . . . . . . . . . . . .2-1 . . . . . . . . . . . . . . . . 13
SECTION 3
Figure 1. Bridge Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . . . . 3
Figure 2 . Engine 1 Generator Lifting Arrangement . . . . . . 2.3 . . . . . . . . . . . . . . . . 4
Figure 3 . Generator Removal. . . . . . . . . . . . . . . . . . . . . . 2.3 . . . . . . . . . . . . . . . . 7
SECTION 4
Figure 1. Electrical Drawer Assembly Component Layout 2-4 . . . . . . . . . . . . . . . . 2
Figure 2 . Fault Push-Button Test Panel . . . . . . . . . . . . . 2-4 . . . . . . . . . . . . . . . . 3
Figure 3 . Automatic Voltage Regulator (AVR) Module . . 2-4 . . . . . . . . . . . . . . . . 5
Figure 4 . AC Overload Module . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . . . . . . . . 5
Figure 5 . OverIUnder Voltage Module . . . . . . . . . . . . . . 2-4 . . . . . . . . . . . . . . . . 6
~ i g u r e6 . OverlUnder ~ r e ~ u e Module
n c ~ . . . . . . . . . . . . 2-4 . . . . . . . . . . . . . . . . 8

Revision 6 Page 5
TABLE OF CONTENTS
LIST OF FIGURES

Figure 7 . DC Over Voltage Module . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . . . . . . . . 9
Figure 8 . DC Component Module . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . . . . . . . . 9
Figure 9. Current LimittLine Drop Compensator Board . . 2-4 . . . . . . . . . . . . . . . . 11
Figure 10. GAC Electronic Governor Control. . . . . . . . . . . 2-4 . . . . . . . . . . . . . . . . 12
Figure 11. Governor Linkage . . . . . . . . . . . . . . . . . . . . . . . 2 4 . . . . . . . . . . . . . . . . 13
Figure 12. Governor System Magnetic Pickup . . . . . . . . .2-4 . . . . . . . . . . . . . . . . 14
Figure 13. GAC Control Unit Adjustments . . . . . . . . . . . . . 2-4 . . . . . . . . . . . . . . . . 15
Figure 14. WoodwardB Governor System Components . . 2 4 . . . . . . . . . . . . . . . . 17
Figure 15. WoodwardB Control Adjustments . . . . . . . . . .2 4 . . . . . . . . . . . . . . . .18
Figure 16. Actuator Linkage Adjustment . . . . . . . . . . . . . .2-4 . . . . . . . . . . . . . . . .19
CHAPTER 4
SECTION 3
Figure 1. Illustrated Key Guide. 90T400SLN . . . . . . . . . .4-3 . . . . . . . . . . . . . . . .3
Figure 2 . Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . .4
Figure 3. Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . .4-3 . . . . . . . . . . . . . . . .6
Figure 4 . Handbrake Assembly . . . . . . . . . . . . . . . . . . . . 4-3 . ...............8
Figure 5 . GPU End t Side Views . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 10
Figure 6 . Window Assembly, Control Panel. . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 15
Figure 7 . Support, Canopy Pivot . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 16
Figure 8 . Engine Mounted Components . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 19
Figure 9 . Radiator and Associated Hardware . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 23
Figure 10. Engine Air Filter Assembly . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . .25
Figure 11. Engine Exhaust Assembly . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . .26
Figure 12. Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 29
Figure 13. Engine Battery Assembly . . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 30
Figure 14. Engine Speed Governor Assembly . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 31
Figure 15. Control Panel Assembly . . . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 35

Page 6 Revision 6
TABLE OF CONTENTS
LIST OF FIGURES

Figure 1. Electronic Drawer Assembly . . . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 39
Figure 2 . Electronic Contactor Assembly . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 43
Figure 3 . TransformerIRectifier Assembly . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 46
Figure 4 . Bridge Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 50
Figure 5 . Kim@ Hotstart Start System (Optional) . . . . . . . 4-3 . . . . . . . . . . . . . . . . 52
Figure 6 . Ether Start System-Quick Start@ (Optional) . . . 4-3 . . . . . . . . . . . . . . . . 53
Figure 7 . Ether Start System-KBI @ (Optional) . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . 54
Figure 8 . Tow Bar Slide Brake Assembly (Optional) . . . . . 4-3 . . . . . . . . . . . . . . . . 56

Revision 6 Page 7
a 90T400SLN
GROUND POWER UNIT
TABLE OF CONTENTS
LIST OF TABLES

CHAPTER 2
SECTION I
Table 1. Antifreeze Concentration Protection . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . 4
Table 2. Preventive Maintenance Inspection Schedule . . 2-1 . . . . . . . . . . . . . . . . 5
Table 3. Engine Fuels. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 . . . . . . . . . . . . . . . . 7
SECTION 2
Table 1. Engine Troubleshooting Chart . . . . . . . . . . . . . . 2-2. . . .............3
Table 2. AC Generator Troubleshooting Chart. . . . . . . . . 2-2. . . ............. 8
Table 3. DC System Troubleshooting Chart. . . . . . . . . . . 2-2. . . . . . . . . . . . . . . . 11
Table 4. Schematic Diagram Component Key and . . . . . 2-2. . . . . . . . . . . . . . . . 12
Description
CHAPTER 4
SECTION 1
Table I.List of Vendors . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . . . . . . . . . . . 1
July 15, 2000 Table of Contents

Revision 6 Page 8
4J-I GROUND POWER UNIT
CHAPTER
1
SECTION
1
DESCRIPTION
1. GENERAL
The 90T400SLN generator set is designed t o provide regulated 400 Hz, 115/200 VAC, 260
Amperes, three phase power for operation of aircraft electrical equipment when the
on-board generators are not running.
2. MAJOR COMPONENTS (See Figure 2)
The Ground Power Unit (GPU), designated as Model 90T400SLN. has the overall
dimensions of 130 inches (3302mm) i n length, 64 inches (1626mm) wide, and 64.5
inches (7638mm) i n height.
The Generator is directly coupled t o the diesel engine. An electrically controlled
governor regulates the engine speed. As protection against engine overspeed, an
engine speed sensing circuit automatically shuts-down the engine should engine
speed reach 2550 RPM.
The GPU is trailer mounted, self contained, requiring no external electrical or mechani-
cal sources of power. It may be towed at speeds u p t o 15 MPH. Rated efficiency of the
GPU is not affected by being o n an incline of u p t o 15 degrees, under an ambient
temperature range of -30 to 1 2 5 ' ~or ~ under relative humidity up t o 100%. The GPU
will operate efficiently at altitudes ranging f r o m sea level t o 6,000 feet (1829M). When
operating the power plant observe the safety precautions at the front of the manual.
Components of the GPU are protected by a weather resistant enclosure. This Clam
Shell enclosure consists of an arrangement of covers and access doors overthe welded
frame. The enclosure reduces the operational noise level in the immediate area of the
unit, and providesfor a cooling air passage. Additional see through doors are provided
for access t o controls and indicators. A slide control drawer allows access t o electronic
control components.
The standard GPU is equipped with one AC power cable, with a second cable optional.
The AC Cable is equipped with a remote sensing circuitfor loads which require precise
voltage regulation. Voltage regulation for the second optional AC cable (AC Cable #2),
if provided, is controlled by the Cable #Isensing circuit. AC Cables are normally
equipped with an industry standard connector for aircraft interface.
As an option, the unit may be equipped with a DC output cable. ATransformerIRectifier
assembly with protective circuitry is utilized for DC output power requirements. AC
and DC power can be used individually or simultaneously.
The chassis is equipped with a turntable steering front axle (5th wheel), and leaf type
suspension springs on the rear axle t o minimize vibration during transport. The rear
axle contains expanding shoe brakes that are operated b y a hand brake lever located
on the front right side. The running gear rides o n four pneumatic tires.
January 15, 1999 1-1
Revision 5 Page 1
GROUND POWER UN
t
w
: Cd
(nN
Figure 1A. 90T400SLN Side View

1-1 January 15, 1999
Page 2 Revision 5
GROUND POWER UNIT
O P T I O N A L L O W FUEL
1 - 3 5 0 / W' A R N&I N G m - P
1- 64"
1625mrn
,)
Figure 1B. 90T400SLN End View
3. SYSTEM DESCRIPTION
A. Engine: The engine manufacturer is customer choice. Standard models include Curn-
mins and John Deere. A six cylinder, four cycle, turbocharged, after cooled Diesel power
plant is utilized. Refer t o Section 1- 3 for the specific engine information. Engine controls
and indicators are located o n the instrument/control panel.
(1) As received f r o m the manufacturer, the engine includes the following equipment:
(a) Fuel filter assembly (b) Full flow oil filter (c) Fuel solenoid and pump
(d) Turbocharger
(2) A n Electronic Governor System is utilized t o control engine speed from idle speed
of 800 RPM t o run speed of 2000 RPM o n units equipped with Marathon@ generator
or 2400 RPM o n units equipped with KatoB generator. The electronic governor system
consists of the following sub-assem blies:
(a) Magnetic Pickup: This is mounted o n the flywheel housing, and feeds a signal
t o the Speed Control Unit for comparison with a preset frequency.
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Revision 5 Page 3
GROUND POWER UNIT
(b) Speed Control Unit: This solid state unit receives a signal from the Magnetic
Pickup, and provides a control signal to the Actuator. It also features a control signal
for Engine Overspeed shutdown capabilities.
(c) Actuator: The actuator receives a control signal f r o m the Speed Control Unit,
and moves the fuel control lever.
(3) The Engine Fault System is designed t o prevent o r reduce the possibility of engine
damage by shutting d o w n the engine and turning ON a specific trouble light. The engine
fault system consists of four safety devices, they are:
(a) Overspeed Shutdown: Fuel t o the engine is cutoff if the engine speed exceeds
2650 RPM.
(b)Low Fuel Engine Shut-down (optional): Shuts off fuel t o the engine during a l o w
fuel condition; preventing the fuel injector p u m p from cavitating.
(c) Temperature Sensing Switch: This switch is activated when engine water
temperature reaches 225' F. The fuel solenoid is de-energized, shutting off fuel t o
the engine.
(d) L o w Oil Pressure Switch: Shuts the engine d o w n if the oil pressure drops t o 10
psig or less.
(4) The Fuel Tank is located at the rear of the GPU (refer to Section 4-3). The fuel filler
port, with a captive cap, is located behind an access door at the rear of the unit. A
removable strainer (optional) located inside the filler neck should be periodically
removed and cleaned.
Fuel f l o w begins as the lift p u m p pulls fuel from the supply tank. The p u m p supplies
low-pressure fuel (21-34 kPa, [3-5psg to the fuel filter head, through the filter and then
t o the distributor injection pump. The distributor p u m p builds the high injection
pressures required for combustion, and routes the fuel through the individual high-
pressure fuel lines t o each injector. When the high pressure fuel reaches the injector,
the pressure lifts a needle valve against spring tension t o allow the fuel t o enter the
combustion chamber. Any leakage past the needle valve enters the fuel drain manifold.
The fuel drain manifold routes the controlled venting from the distributor injection
p u m p and leakage f r o m the injectors back into the fuel tank.
(5)Exhaust System (See Section 4-3): The exhaust system consists of a noise reducing
muffler connected by a pipe t o the exhaust outlet of the turbocharger.
(6) Radiator (See Section 4-3): The radiator is of the cross-flow design, with the filler
at the front, center of the unit. A n overflow tube is mounted o n the side of the filler port.
(7) Air Cleaner (See Section 4-3): The air cleaner is a dry cartridge type with a Filter
Minder indicator t o alert the operator when the cartridge should be replaced. The Filter
Minder Indicator is connected t o the air cleaner b y a rubber hose.
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Page 4 Revision 5
U-lGROUND POWER UNIT
Figure 2. 90T400SLN Major Component Location

January 15, 1999 1-1
Revision 5 Page 5
GROUND POWER UNIT
B. Engine Electrical Circuits (Refer to Section 2-2 for the Engine Electrical Schematic):
(1) All engine instruments, except the filter minder indicator, are located o n the engine
control panel. Engine instrument sensor locations are shown i n Section 4-3. Gauges
are shown i n Figure 3. The instruments are:
(a) Fuel level indicator - Controlled by the fuel tank sensor.
(b) Oil Pressure gauge - Engine sensor controlled.
(c) Water Temperature - Engine sensor controlled.
(d) Hour Meter - Shows engine run hours.
(e) Battery voltmeter - Shows battery voltage.
(f) Filter minder (Located on the air filter mounting bracket, See 4-3) - Engine air
filter change indicator.
(2) Instrument Lights: The engine instrument lights are controlled b y the Ignition
switch. The panel illumination light is controlled by the Panel Light switch located o n
the instrument panel.
(3) Engine Start: Power for the starter motor, and running circuits, is provided by the
battery circuit. The power is applied through the ignition switch S1. When switch S1 is
ON the following occurs:
" lgnition ON indicator is illuminated.
" DC power is applied t o the instrumentation, fuel solenoid, and the electronic
governor system.
The engine is started b y pressing the Start Button. This causes contacts o n the starter
solenoid t o close, energizing the starter motor. In addition, the Start Button energizes
a Timed Delay Relay which disables the l o w oil pressure fault circuit. Time Delay Relay
contacts close and will not open for approximately 14 seconds t o allow time for engine
starting and engine oil pressure to rise t o normal operating levels. Upon starting, the
engine will then go t o IDLE speed.
The engine is brought to RUN speed for generator operation b y placing the IDLEIRUN
switch on the Engine Control Panel in the RUN position (see Figure 3). This signals the
Electronic Governor Control (EGC) to bring the engine up to an operating speed of 2000
rpm o n units equipped with a Marathon@generator o r 2400 RPM o n units euipped with
a KatoB generator. In the RUN mode, the rated speed of the governor system is
controlled by the SPEED adjustment screw o n the EGC. The RUN position also applies
battery voltage t o the generator control system.
NOTE: An optional electrically controlled Ether Start System is available and is installed on
request. Refer to Chapter 5 for manufacturer information on this system, if installed.
When utilized, a push-button control switch is located to the left of the main control
panel.
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Page 6 Revision 5
unlts wth roof mounted

warnmg light.
I
Neutral Faun Option.
lnd~catesNeutral fault
detected
T d y
CIRCUIT B EAKLRS
Figure 3. Engine Controls and lndicators

Item - Description Item Description
1 Oil Pressure Gauge 8 Ignition Switch, "ONIOFF"
' 2 /Engine Fault Indicators 9 Circuit Breaker, CB 1, 10 Amp
3 ignition "ON" Indicator 10 Circuit Breaker, CB2, 5 Amp
4 water Temperature Gauge 11 Circuit Breaker, CB3, 15 Amp
5 j Battery Voltmeter 12 1 Switch, "RUNIIDLE"
6 ourm meter 13 Fuel Gauge
I 7 Start Push-button Switch 14 L o w Fuel or Neutral Fault Warning Light
(Optional)
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Revision 5 Page 7
U-J
GROUND POWER UNIT
(4) Engine Fault System: There are four engine fault systems which, when activated,
shut down the engine. Automatic switches on these systems de-energize the fuel flow
solenoid which shuts off fuel flow to the injectors. The fault systems are as follows:
(a) Low Oil Pressure: 10 psi
I (b) Engine Overspeed: 2650 RPM
(c) Engine Water Temperature (High): 2 2 5 ' ~
I (d) Low Fuel Quantity Engine:
NOTE: When referring to contact positions on relays, N.0. refers to normally open contacts,
N. C. refers to normally closed.
(5) Low Oil Pressure Fault System: The low oil pressure circuit is used to stop the
engine should oil pressure drop below 10 psi. The switch also prevents the starter
motor from being energized when the engine is already running. The Low Oil Pressure
circuit consists of the following:
(a) Low Oil Pressure switch and Oil Pressure sensor are mounted on the engine
block.
(b) A low oil lockout relay, and control diodes.
(c) A fault relay located on the Control Chassis Relay Board.
(d) Diodes located on the Diode Logic Board o n the Control Chassis.
(e) A Low Oil indicator light located on the Engine Control Panel (Figure 3).
(6) Low Oil Pressure Fault Function: During normal operation, engine oil pressure
opens the Low Oil Pressure switch. If the oil pressure drops below 10 psi, this switch
closes, completing a ground circuit to the Engine Fault Relay, which de-energizes the
fuel solenoid, stopping fuel flow and shutting down the engine.
( 7 )Low Oil Pressure Lockout: During initial engine cranking, no oil pressure exists and
the low oil pressure switch is closed completing a ground circuit t o the engine fault
relay. The engine fault relay receives battery power when the ignition switch is set to
ON. A ground to the negative side of the relay by any ofthe fault sensors, which includes
the low oil pressure switch, causes the relay to energize. When energized, it de-ener-
gizes the fuel solenoid, stopping fuel flow to the engine.
During initial starting, the low oil pressure fault circuit must be temporarily disabled.
When the start switch is pressed, in addition to the starter motor, a time delay relay is
energized which energizes the Low Oil Lockout Relay. Time delay relay contacts will
remain closed approximately 14 seconds after the start push button switch has been
released. Oil pressure builds as the engine rotates. After the start switch is released,
oil pressure must open the low oil pressure switch within 14 seconds. If oil pressure
does not reach 10 psi within 14 seconds, the time delay contacts will open, de-ener-
gizing the Low Oil Lockout Relay which will complete the circuit from ground through
the oil pressure switch t o the engine fault relay. The engine fault relay de-energizes the
fuel solenoid, stopping fuel flow and shutting down the engine.
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Page 8 Revision 5
GROUND POWER UNIT
C. Engine Fault Protection Circuits
(1) Overspeed Fault Function: Under normal operating conditions, the engine over-
speed switch contacts are open, preventing a ground path t o the fault relay. A n
overspeed condition causes the following:
" Overspeed switch N.O. contacts close, providing a ground path through the
overspeed fault diode for the fault relay.
" The fault relay is actuated, opening N.C. contacts t o de-energize the fuel solenoid.
" Fuel solenoid shuts off fuel t o engine.
" Current through the overspeed fault diode lights the engine overspeed indicator.
(a) Overspeed Fault Components - The Overspeed circuit consists of the follow-
ing:
* Overspeed circuit built into GAC or an extrenal overspeed switch when using
a Woodward governor.
* Fault relay
* Three diodes
* Engine Overspeed Indicator lamp
(2) High Water Temperature Fault Function: High water temperature (above 2 2 9 F)
causes the following t o occur:
" The engine mounted High Water Temperature switch contacts close, providing
a ground path through the high water temperature diode to the fault relay.
" The Fault relay is actuated, opening normally closed contacts in the fuel solenoid
circuit.
" The fuel solenoid is de-energized, shutting off fuel t o engine.
" Current path throeugh the high water temperature fault light diode lights the HIGH
TEMP indicator.
(a) High Water Temperature Fault Components: The High Water Temperature
circuit consists of the following:
* Engine mounted High Water Temperature switch (S77)
* Two Diodes
* Fault relay
* HIGH TEMP indicator lamp
(3) Low Fuel Fault Function Warning Light: The circuit is designed t o alert the operator
t o a l o w fuel quantity condition to prevent engine shut-down due to fuel starvation. The
l o w fuel level switch closes when approximately 3 inches of fuel remains i n the tank.
The circuit function is as follows:
" Low fuel level switch closes completing a ground circuit to the Low fuel engine
warning light, causing it to illuminate.
(4) Low Fuel Fault Function Engine Shut-Down (Optional): The circuit is designed to
prevent engine shut-down due to fuel starvation. The l o w fuel level switch closes when
approximately 2 inches of fuel remain in the tank. The circuit function is as follows:
" Low fuel level switch closes completing a ground circuit t o the engine fault relay.
January 15, 1999 1-1

Revision 5 Page 9
" The engine fault relay energizes, opening its contacts and removes voltage from
the fuel solenoid. The fuel solenoid de-energizes stopping fuel flow t o the injector
Pump.
" Low fuel level switch also completes the ground circuit t o the engine l o w fuel fault
indicator, causing it t o illuminate.
( 5 ) Fault Lamp Test: The indicators for the fault circuits can be tested by depressing
the FAULT LAMP TEST push-button switch located o n the Control Panel. Battery
voltage supplies the power to operate the engine fault lamp test. The fault lamp test
switch applies a ground t o each lamp when depressed. By placing the ignition switch
i n the ON position, the fault lamps may be tested without the engine running.
D. AC Generator System (See Figure 4 and the AC Generator Schematic, Section 2-2):
(1) Generator: The 400 HZ generator is a brushless, revolving field, three-phase,
alternating current type. The rotor assembly is mounted b y a single ball bearing race
located between the exciter rotor and main generator rotor. The bearing race is
mounted i n the stator housing which is bolted t o the engine housing. The front end of
the rotor shaft extendsforward beyond the stator and is attached to the engine flywheel
by a hub and flexible disc coupling assembly. The rear end of the rotor shaft extends
rearward beyond the bearing and into the exciter stator housing.
( 2 ) DC Control Power: With the engine at RUN speed, The engine 12VDC (or optional
24VDC) provides DC power t o the generator system through the IGNITION and
IDLEIRUN switches (located on the engine controlpanel). The following components
are DC powered:
" AC voltage regulator
" Protective circuits
" Fault Lamps
" Protective Circuitry
(3) Exciter: The brushless exciter is used t o provide excitation current t o the rotating
field assembly. The exciter consists of t w o basic component assemblies; the exciter
stationary field assembly; and the exciter rotor comprised of the rotating exciter and
a rotating rectifier bridge. The rectifier, with six diodes, converts exciter AC output to
DC for generator field excitation. The exciter rotor is mounted o n the shaft extension
with a Woodruff Key, and is secured by washer and cap screw.
(4) Generator Output: Generator output is controlled by the amount of DC current
supplied t o the exciter field by the field voltage regulator.
(5) Cooling Fan: A radial blade fan that is part of the h u b coupling assembly, draws
cooling air over all internal windings. Air enters the exciter end and is discharged
through the drive end.
1- 1 January 15, 1999

Page 10 Revision 5
ENGINE START
aT \
-
UNDER
VOLTS
- -
OVER UNDER
VOLTS FIFO
-
OVER
FRFP
-
OVER
LOAD
: YE1 RUN/IULE SWlrCH TO IULE POSITION.

R
I
2 SL1 ENGINE ICNlTlOIl SWITCH 10 ON PDSlTlON
3 PRESS LNClIML SiAR1 P U S P BUTTON SWITCH
L
1 - 2 SECONDS UNTIL ENGINE STARTS. E VOLTS AMPERES
2. ALLOH' ENGINE TO IDLE 2-3 MINUTES TO C
WARM PROPERLC.
T
/ 5 s t 1 D L E , / R ~ Nswncr TO RUN m s l r t o N FOR
UPCRATING SPEED
R
0
N
[FL
I.IEV€R CONNECT OR DISCONNECT OUTPUT
GARLE WHILE POWER IS BEING DELIVERED.
AMMETER
%3
A C OUTPUT
I WLlPGL M O iSEOUENC1 IfVELS LRL F X T O R I
SET 7 0 115 V K . W Hi
2 CVNNLLT JC MWER W i TO AlRCRlFl
3 PRES5 K LOP0 Oh PUSH B L m D l &C PDUlER
IS NU%' SUPPULS TO U R C M . PANEL
LIGHTS
A C OFF
/
I. m E S 5 AL L M OF' WW BUTTON 1 0 TURN
WFAC M R THE WAC MDEATOR &ILL
CU OUl
FAULT
TO STOP E N G I N E /
1 SCT lULL/RUN SWl7LH TO IDLL. ENCINE WLL
RETURN 10 IPLL SPEED
2 DKCONNCCT CABLE FRDM &Run LEI
ENGINL RUN PT lULE SPCCD FOR 2-3 FAULT
U l N U N TO COOL. THEN SET GMTlQN
ShllC* 1 0 C Y f
@ / / I G3
NOTE: POSITION OFAC CONTROL WHEN
ONLY ONE AC OUTPUT IS PROVIDED.
Figure 4A. Generator Controls and lndicators (Without DC Option)

Item Description Descri tion
1 AC Voltmeter Switch, Voltmeter Select
1 2 A C Fault lndicators
3 Ammeter Switch, Fault Reset
4 Switch, Ammeter Select Switch. Panel Liaht
5 'Switch, Push-button, AC Load OFF, Cable 1 12 Switch, Push-button, AC Load OFF, Cable 2
6 Switch, Push-button, AC Load ON, Cable 1 13 Switch, Push-button, AC Load ON, Cable 2
7 Freauencv Meter I
J a n u a r y 15, 1999 1-1

Revision 5 Page 11
-
WDER
-
OVER
-
UNDER
-
OVER
-
OVER
OLIS VOLE FUEO nro IDAD
VOLTS
AMPERES
Fiqure 4B. Generator Controls and lndicators (With DC O ~ t i o n )

1 ltem 1 Description ltem 1
i 1 IAC Voltmeter 11 /switch. Panel Liaht
1 2 A C Fault lnd~cators 12 iswitch, Push-button, AC Load OFF, Cable 2
j 3 Ammeter 13 Switch, Push-button, AC Load ON, Cable 2
4 Switch, Ammeter Select 14 Switch, Push-button, DC Load OFF
5 Switch, Push-button, AC Load OFF, Cable 1 15 Switch, Push-button, DC Load ON
6 Switch, Push-button, AC Load ON, Cable 1 16 Switch, Toggle, Soft Start ONIOFF
1 7 i~re~uenc~Meter 17 Potentiometer, DC Soft Start Amperes
1
8 /Switch, Voltmeter Select 18 DC Ammeter
1 9 S w ~ t c h Fault
, Lamp Test 19 DC Voltmeter
10 S w ~ t c h ,Fault Reset 20 DC Fault Indicators
1- 1 January 15,1999
Page 12 Revision 5
GROUND POWER UNIT
E. Generator Output Control Circuitry (See Figure 4 and the AC Generator Schematic,
Section 2-2) :
(1) Generator Control System: Controls, devices and modules for the AC system are
located in the Control Drawer, and on the Contactor Panel (Section 4-3).
(2) Frequency Regulation: Regulation of the 400 Hz output is controlled through the
Electronic Governor Control System (engine speed), and can be adjusted with the
voltage adjust potentiometer located on the Governor Control Panel.
(3) Generator Voltage Regulation: Generator output voltage is fed back to supply
power to the transformer T I primary. The secondary side of T1 provides AC voltage
to the rectifier assembly on the Automatic Voltage Regulator (AVR) board, which feeds
the generator exciter field through the voltage regulator.
" The AVR controls the current to the generator exciter field, which in turn controls
the output voltage. Power supplied from the battery provides an initial sufficient
field voltage to permit voltage build-up in the generator output. Generator output
voltage is fed to the Transformer T1 primary for voltage sensing.
" The Transformer T I secondary provides AC voltage to a rectifier assembly on the
AVR board. DC voltage from the rectifier bridge is supplied to the voltage regulator
pass transistor. The pass transistor regulates the current supplied to the generator
exciter field, to regulate generator output voltage.
(4)AVR Voltage Adjustment: Voltage adjustment for the Automatic Voltage Regulator
(AVR) is determined by the following:
" The setting of Voltage Adjustment potentiometers R5 and R32 on the AVR.
" Sensing transformer T I which senses the output voltage at the output contactor.
(5)Power Supply: The Power Supply is fed directly from the generator throug h a circuit
breaker, and provides voltage and current sensing input to the Fault Modules, Test
Push-buttons, and other low voltage devices. Load sensing transformers CTI-3, and
the Voltage Sensing transformer (Tl) also feed into the Power Supply. These sensing
transformers work in conjunction with the fault modules to shut-off power should an
overload condition occur, or overlunder voltage and over/underfrequency conditions.
The Fault Lamps and Fault Relays receive power from the DC battery circuit.
F. AC Output Protective Circuits: There are three AC modular protective circuits on the
contactor panel, all of which disconnect AC output power. The Overvoltage and Overload
circuits also shut off the voltage regulator and light the appropriate fault lamp(s).
(1) Protective Circuit Conditions: Conditions activating the protective circuits are as
follows:
" Overvoltage: 130 volts (adjustable)
" Undervoltage: 100 volts (3-5 second delay).
" Ovetfrequency: 415 Hz
" Underfrequency: 385 Hz (7- 10 second delay).
" Overload: Trips at 125% rated load within 5 minutes. Trips at 15O0/0 rated load
within 30 seconds.
January 15, 1999 1-1

Revision 5 Page 13
GROUND POWER UNIT
" Neutral Fault (Optional): Trips when any t w o phases out o u t o f balance b y more
than 2Vrms.
(2) Protective Circuit Functional Description: The protective circuitry is comprised of
the OverIUnder (OIU) Voltage, Over/Under (O/U) Frequency, Neutral Fault (optional)
and Overload modules. The O/U Voltage and O/U Frequency modules sense the
generator output voltage and frequency through the Power Supply module. In the case
of overload, load sensing transformers CT1-3 sense output current. W h e n activated
each o f these modules complete a ground circuit t o the AC fault relay. The protective
circuits operate as follows:
" Circuit closure is provided t o energize the fault relay (Closure is on pins 2 and 4
of these modules).
" When the fault relay is energized, its contacts open. DC voltage t a k e n f r o m bridge
rectifier is removed f r o m the output contactor causing it t o de-energized. AC
output voltage is n o w removed f r o m the load.
O n Over-voltage o r Overload conditions, only the Automatic Voltage Regulator (AVR)
is shut off; this is accomplished as follows:
" The overload and over-voltage modules provide a ground circuit t o t h e coil o f the
fault relay, causing it t o energize. When energized the fault relay removes the DC
operating p o w e r f r o m the automatic voltage regulator.
" When the AVR shuts off, current through the generator exciter is stopped and
generator output is halted.
(3) Fault Signal Events: W h e n a fault signal occurs, a circuit i n a protective module
latches ON. After the fault has been corrected, the protective circuit must be reset. The
module latching function serves t w o purposes:
" To maintain fault indication.
" To prevent t h e unit f r o m operating until the fault has been cleared.
(4) Protective Circuit Reset: Resetting o f the circuit is accomplished b y pressing the
FAULT RESET switch o n t h e control panel t o the RESET position. Resetting the circuit
does the following:
O Resets the protective circuit.
" Energizes t h e overload module reset relay (closes normally open contacts), which
grounds a capacitor o n the overload module. This capacitor must discharge t o
allow the overload module t o reset.
(5) Fault Lamps: These lamps are supplied voltage through a circuit breaker and the
Fault Reset switch. A ground path is supplied through steering diodes o n the protective
modules. The steering diodes allow the fault lamps t o be tested independently f r o m
fault circuit operation.
(6) Generator Fault L a m p Test: The fault lamp test circuit includes diodes and the fault
light push-button test switch. The diodes maintain separation o f all fault circuits.
Generator fault lamps are battery powered, and function w h e n the engine is at
operating (RUN) speed. A generator fault lamp test should ONLY b e performed when
1-1 January 15, 1999

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GROUND POWER UNIT
the engine is at RUN speed. The fault lamps are tested by pressing the generator FAULT
LAMP TEST switch.
(7) Ammeter Current Transformers: Ammeter Current Transformers are used for
metering purposes, and are connected to the control panel AMMETER selector switch
for appropriate line selection.
(8) Overload Current Transformers: These transformers are connected to a rectifier
bridge on the Power Supply board. They provide a voltage proportional to current for
purposes of overload sensing, this voltage is then supplied to the Overload module on
module input Pin number 8.
G. AC Output Power
(1) AC Output Contactor (KI) (K2 is utilized with dual A C output):
When energized, the primary output contactor (K1) provides AC power to Cable 1, and
and the secondary output contactor (K2) provides AC power to Cable2. Both contactors
are supplied voltage by the power supply module. The output contactors function only
when the engine IDLEIRUN switch is placed in the RUN position, and generator output
voltage is established. Circuit description is as follows:
The AC Output Contactors can only be energized when the engine IDLEIRUN switch is
placed to the RUN position and after generator voltage has been established. The
Power Supply, which receives its voltage from the "A" phase of the generator, energizes
the Load Control Relay which is located on the A13 relay assembly board.
(a) Generator output voltage is supplied through a 5 amp fuse to the Power Supply
module A5 (Pin J8-10). Output voltage (DC) from the Power Supply module (pin
J8-4) energizes the load control relay which closes its contacts, sending battery
voltage to the LOAD ON control switch(s).
(b) Power is applied to the aircraft through the appropriate cable with the closure
of the LOAD ON control switches to energize the output contactors.
(2) Remote Sensing: Remote voltage sensing uses the voltage level at the output end
of the cable connector for monitoring and regulation purposes. This system eliminates
the effect of voltage drop which may occur in the output cable, and maintains a constant
115 VAC supply at the aircraft.
Remote sensing is performed only on the main #I output cable. The #I
cable should
always be utilized first.
(3) Cable Interlock Switch: This switch, located in the control panel drawer, gives
aircraft ground support personnel the ability to control the manner in which the GPU
output contactors are energized. The Cable Interlock switch has two purposes:
(a) Interlock: This safety feature is selected by placing the switch to the "ON"
(INTERLOCK) position. The generator output contactors will not energize closed
unless the AC power cable is securely connected to the aircraft/load bank. The
aircraft or load bank must be capable of returning 28 VDC to the E-pin on the power
cable. This voltage is used to energize the GPU output contactor(s). Should the
January 15, 1999 1-1

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GROUND POWER UNlT
power cable disconnect during servicing, the generator output contactor will
immediately de-energize and remove power from the AC cable.
With the switch in the "ON" (INTERLOCW position and the Load ON push-button
switch pressed in briefly, battery voltage energizes the output contactors. With the
closure of the contactors, AC power is applied through the cable(s) t o the aircraft.
28 VDC returns from the aircraft o n E-pin and energizes a holding relay(s). This
relay(s), when energized, establishes another current path keeping the contactor(s)
energized when the LOAD ON push-button switch(s) is released.
THE USE OF THE CABLE INTERLOCK SWITCH I N THE "ON" (INTERLOCK)

POSITION IS RESTRICTED TO AIRCRAFT CAPABLE OF PROVIDING 28 VDC O N THE
CONNECTOR E-PIN. SERIOUS DAMAGE TO THE AIRCRAFT OR THE UNlT MAY
RESULT IF THE SWITCH IS IMPROPERLY USED. CONSULT THE AIRCRAFT TECHNICAL
MANUAL FOR PROPER USAGE OF THIS SWITCH.
NOTE: Both the interlock feature and the Neutral Fault Option will operate only with
aircraftlloadbanks that provide 28 VDC on the connector E pin
(b) Bypass: This feature is selected by placing the switch t o the BYPASS position.
It bypasses the cable interlock safety circuit and allows the operator t o power the
cable with or without the cable being connected t o the aircraft or loadbank.
H. DC Output Control Circuitry (Optional)
(1) TransformerIRectifier (T/R) System: The DC system consists of a transformer
rectifier assembly, protective circuits and a soft-start Current Limiting/Line Drop Com-
pensation board (CLILDC) module. The transformer is a 3 phase power transformer,
with the secondary connected t o the rectifier bridge. DC output power is applied t o the
service cable by the energizing of Input Contactor K11, which provides AC power t o
the T/R. Contactor K11 is energized by activating the DC Load "ON" switch, and
de-energized by activating the DC Load "OFF" switch.
(2) Protective Circuits: Protective circuits will automatically disconnect DC powerfrom
the output cable in the event of an Overload condition or a DC Over-voltage condition.
A "heat sink" Over-temperature condition will illuminate a warning light o n the control
panel, but will not disconnect DC output power.
(a) Protective Circuit Functional Description: The protective circuitry utilizes the
AC over-voltage module, along with the DC over-voltage module, DC overload, and
T/R over-temperature circuits.
* Overload: Protection is performed by the overload module in the AC system.
Load sensing is accomplished using current sensing transformers CTI, 2 and
3 o n the generator output.
* DC Over-voltage: The over-voltage module senses voltage from the DC
output line. When an over-voltage condition occurs, K1 contactor o n the DC
over-voltage module opens, disconnecting the ground side of the T/R contac-
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U-IGROUND POWER UNIT
t o r relay K11, de-energizing K11 and removing DC voltage f r o m the output
cable.
* Over-Temperature Switch: The heat sink over-temperature (HSOV switch is
mounted o n the rectifier. When activated b y an over-temperature condition,
this switch supplies a ground path t o the over-temperature indicator light
(DS26). The switch is reset b y load reduction o r removal, which will allow the
rectifier and heat sink assembly t o cool. It cannot b e reset using the Fault Reset
Switch.
NOTE: An over-temperature fault condition can be caused by lack of sufficient air flow to the
TransformerlRectifier assembly or by an actual electrical overload.
CAUTION
IN THE EVENT OF AN OVER-TEMPERATURE CONDITION, LOAD ON THE GENERATOR
MUST BE MANUALLY REDUCED OR REMOVED. IF LOAD IS NOT REMOVED, DAMAGE
TO THE TRANSFORMER/RECTIFIER, AC GENERATING SYSTEM, OR ENGINE WILL
RESULT.
(b) Fault Indicators: Protective circuit fault indicators are o n the AC and DC control
panels. AC Overload and Over-frequency (T/R input frequency) faults are indicated
o n the AC panel. Over-voltage and Over-temperature faults are indicated o n the DC
panel.
(c) Fault Reset: DC faults, with the exception o f the over-temperature fault, are reset
b y momentarily pressing the Fault Reset toggle switch. The over-temperature
switch will reset only when the heat sink has cooled t o nominal temperature.
(3) T/R lnput Contactor (Kl I ) : When energized closed, input contactor K11 delivers
AC voltage t o the transformer/rectifier assembly. The T/R reduces and rectifies AC
voltage t o 28 VDC. This contactor is activated b y the DC LOAD ON switch (S27). The
auxiliary contacts o n K11, between terminals 1 and 2, close causing the DC LOAD ON
push button switch t o illuminate.
(4) Current LimitingILine Drop Compensation (CLILDC) Module:
" Current limiting is used t o limit the output current t o a preset level. It is activated
b y the Current Limiting switch (S25) and adjusted b y the Soft Start adjust control
potentiometer (R10). When activated, t h e current applied to the aircraft is limited
and maintained according t o the setting o f t h e potentiometer. Current sensing for
the CL/LDC module is taken from the shunt resistor RSI. The CLILDC output for
current limiting is sent t o the Automatic Voltage Regulator (AVR) pin J3-11.
" Line Drop Compensation (LDC) is used t o maintain a constant output voltage at
any load. lnput is taken f r o m the voltage across the shunt resistor RS1. Output
f o r the LDC is sent t o the Automatic Voltage Regulator (AVR) o n pin J3-9.
( 5 ) Output Voltage Sensing: Due t o loading characteristics, only one o f the outputs,
AC o r DC, can b e regulated at one time. Relay K46 senses power output, and directs
the output sensing voltage source:
" Whenever AC power is being applied t o an aircraWloadbank, output voltage
sensing is sampled f r o m the AC output. Should DC power also b e applied while
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GROUND POWER UNIT
AC power is being applied, load sensing is based on AC output, and DC output
voltage may vary slightly based on DC load applied.
" Whenever DC power only is being applied to an aircraftlloadbank, output voltage
sensing is automatically sampled from the DC output. Should AC power then be
applied, sensing will automatically transfer to the AC output.
CALIFORNIA
Proposition 65 WARNING
DIESEL ENGINE EXHAUST AND SOME OF ITS CONSTITUENTS ARE KNOWN TO THE
STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS, AND OTHER
REPRODUCTIVE HARM. A
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GROUND POWER UNIT
CHAPTER
1
SECTION
2
OPERATION
1. CONTROLS AND INDICATORS
Prior t o operating t h e GPU, personnel must become thoroughly familiar with the operating
controls, indicators and procedures described in this section. Refer t o Figure 1 f o r control
location and a functional description.
2. OPERATING PROCEDURES
A. Pre-Operational Inspection:
A PRIOR-TO-USE INSPECTION MUST BE PERFORMED BEFORE EACH OPERATION TO

ENSURE SAFE AND RELIABLE OPERATION OF THE GPU. FAILURE TO PERFORM THE
PROCEDURES LISTED BELOW MAY RESULT I N SEVERE DAMAGE TO THE
EQUIPMENT.
(1) Enclosure: Visually inspect f o r obvious defects, i.e., security of c o m m o n hardware.
(2) Towbar: Excessive movement.
(3) Brakes: Check brakes f o r proper operation.
(4) Tires: lnspect tread wear, and check tire inflation (60 psig)
( 5 ) Engine hoses and clamps: lnspect f o r leaks and security.
(6) Radiator Coolant: For units with an over-flow tank, check that fluid level is between
the "minimum/maximum" markings. For units without an over-flow tank, and o n COLD
engines only, open radiator access door and remove radiator cap. Observe that coolant
is visible at the t o p o f radiator. Service as required (Refer to Section 2-7,Servicing).
(7) Oil level: Open left front access door. Check that oil level is at the full mark o n the
d i p stick (Refer to Section 2- 7, Servicing).
(8) Fuel level: Set IGNITION switch to O N position, observe reading o n fuel gauge.
Service with diesel fuel as necessary.
(9) Engine Assembly: Visually inspect fuel lines and fittings f o r evidence o f fuel leakage.
lnspect valve covers, oil pan, and cylinder block f o r evidence o f oil leakage.
(10) Fan Belt: Visually inspect f o r wear and cracking. Check belt f o r proper tension (3/8"
deflection of belt with hand pressure).
June 2, 1997 1-2

Revision 4 Page 1
Figure 1. EnginelGenerator Control Panel (Optional DC Controls Shown)
1-2 June 2 , 1997
Page 2 Revision 4
GROUND POWER UNIT
Figure 1. Control Panel Component Identification
Item Description
1 CONTROL PANEL ASSEMBLY: Mounted at the rear of the unit o n the Electrical Drawer Assembly.
1 2 1 AC VOLTMETER: Shows generator (L-N or L-L) output voltage (0-150 or 0-300 volts).
3 FAULT INDICATORS -GENERATOR: Fault indrcators will illuminate red when a fault has occurred. Each
fault removes voltage f r o m the aircraft. Overvolts & Overload stops all voltage generation.
4 AMMETER: lndicates generator (L-N) output current.
I
5 FUEL LEVEL GAUGE: lndicates amount of fuel remaining in fuel tank.
1 6 OIL PRESSURE GAUGE: lndicates engine oil pressure.
7 1 ENGINE
FAULT INDICATORS (Red): lndicates the protective system that caused engine shutdown.
I 8 IGNITION O N INDICATOR (Yellow): Lights when the IGNITION switch IS ON.
9 WATER TEMPERATURE GAUGE: lndicates engine water temperature ( 2 2 5 ' ~max.).
I 10 BATTERY VOLTMETER: lndicates battery voltage cond~tion.Do not start unit if voltage is less than 10
VDC o n 12VDC units. or 20VDC o n 24VDC units.
11 IHOURMETER: lndicates total engine run time.
12 !START SWITCH: Starts engine. Push-button, momentary contact switch.
13 'IGNITION SWITCH (ONIOFF): On position supplies starting and controlling voltages t o engine circuits.
14 GOVERNOR CIRCUIT BREAKER (CBI): Protects the electronic governor control (10 ampere).
15 INSTRUMENT CIRCUIT BREAKER (CB2): Protects the instrument electrical circuits (5 ampere).
1 16 IGNITION
CIRCUIT BREAKER (CB3): Protects engine ignition system (15 ampere).
! 17 'RUNIIDLE SWITCH: Controls engine speed. IDLE for starting. RUN position for generator operation.
18 LOW FUEL WARNING LIGHT: Location is optional, m a y b e roof mounted.
19 LOW FUEL or NEUTRAL FAULT WARNING LIGHT PLACARD: l d e n c 1
20 'AMMETER SWITCH (Rotary): Measures current of phases 1,2 or 3.
/ 21 'FREQUENCY METER: Shows aenerator o u t ~ ufreauencv
t 1360-440Hzl. 1
22 ~ A CLOAD CABLE #I OFF (Push-button):
- Removes output power f r o m Cable #I.
23 AC LOAD CABLE #I ON (Push-button): Supplies AC power t o Cable #I.
24 VOLTMETER SWITCH: Selects Line t o Line or Line t o Neutral voltage measurements for voltmeter.
25 FAULT LAMPTEST (Push-button): When pressed while unit is in the RUN mode, it lights all faults lamps.
26 FAULT RESET (Toggle switch): Clears fault indications, returns unit t o normal after protective lockout.
1 27 /PANEL LIGHTS SWITCH: Turns panel lights On for night time operation.
28 ETHER START SWITCH (Push-button): Optional equipment.
29 AC LOAD CABLE #2 OFF (Push-button): Removes output power f r o m Cable #2.
30 A C LOAD CABLE #2 ON (Push-button): Supplies AC power t o Cable #2.
31 GENERATOR FAULT INDICATORS (Red): lndicates ~ r o t e c t i v esvstem that caused aenerator shutdown.
1
I
32 D C VOLTMETER: Shows TIR output voltage (Only with DC Option)
i 33 DC AMMETER: Shows TIR output current (Only with DC Option)
34 SOFT START CURRENT ADJUST: Selects DC current high limit (Only with DC Option)
35 1 SOFT START ONIOFF TOGGLE SWITCH: Selects Soft Start DC function (Only with DC Option)
I
1 36 /DC LOAD CABLE ON (Pushbutton): Supplies power t o DC cable (Only with DC Option).
1 37 i DC LOAD OFF /Pushbutton): Removes DC ~ o w e from
r cable lOnlv with DC O ~ t i o n ) . 1
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u - l GROUND POWER UNIT
(11) Engine Air Filter: With engine running, check the reading on the Filter Minder
Indicator located to the left of the right front access door under the air filter assembly.
Replace air filter element if a reading of 20 is noted. Recheck the reading when the unit
is operating under load.
B. Engine Start Procedures: The following steps must be performed in the sequence in
which they are presented (See Figure I ) :
\YAItNI NG
DO NOT CONNECT LIVE POWER CABLE(S) TO AIRCRAFT. SEVERE ELECTRICAL
ARCING MAY CAUSE SERIOUS INJURY, DEATH AND OR DAMAGE TO THE
EQUIPMENT.
NOTE: Gauge lights automatically come ON when Ignition switch is ON. Turn Panel Lights
on using the Panel Light switch if required.
WAlt NI NC
PROLONGED EXPOSURE TO HAZARDOUS NOISE LEVELS MAY RESULT I N
PERMANENT HEARING LOSS. EAR PROTECTION DEVICES MUST BE WORN
7
WHEN WORKING IN CLOSE PROXIMITY TO THlS EQUIPMENT.
(1) Set ENGINE IGNITION SWITCH (13) to ON position. IGNITION ON indicator (8) will
be illuminated.
(2) Set IDLE/RUN switch (17) to IDLE.
CAIJ'I'ION
BAlTERY MUST BE FULLY CHARGED TO SUPPLY VOLTAGE FOR ENGINE
ST.ARTING AND CONTROL.
(3) Observe the VOLTMETER gauge (10) on the Engine Control Panel, charge battery
if a low voltage is indicated.
CRIJTION
DO NOT HOLD START B U l T O N DEPRESSED FOR LONG PERIODS OF TIME, AS
THlS DEPLETES THE BAlTERY AND COULD DAMAGE THE STARTER.
(4) Press START push-button (12) for 1 - 2 seconds to start engine. Engine will come
up to idle speed.
(3RIJTI0N
IF LOW OR NO OIL PRESSURE IS INDICATED AFTER 10-15 SECONDS OF
OPERATION, IMMEDIATELY STOP ENGINE BY PLACING ENGINE IGNITION
SWITCH (13) TO THE OFF POSITION. FAILURE TO COMPLY CAN RESULT IN
SEVERE ENGINE DAMAGE.
(5) OIL PRESSURE Gauge (6) should read 10 psi minimum pressure at idle speed, 30
psi minimum at run speed.
(6) WATER TEMPERATURE Gauge (9) should read 170-195'~water temperature when
engine has warmed.
1-2 June 2, 1997
Page 4 Revision 4
U-lGROUND POWER UNlT
(7) VOLTMETER Gauge (5): Voltage should be at least 12 VDC minimum o n a 12 volt
battery system or 24 volts minimum o n a 24 volt battery system.
1I CAIJTION
DO NOT ALLOW THE ENGINE TO IDLE FOR LONG PERIODS OF TIME. FAILURE
TO COMPLY COULD RESULT I N ENGINE DAMAGE. II
(8) Let the engine idle for 2-3 minutes to warm engine.
(9) Bring the engine t o operating speed by placing the engine RUNIIDLE switch (17) to
the RUN position.
(10) Turn VOLTMETER knob (24) t o L l - N (Line 1 to-Neutral).
DO NOT ATTEMPT TO PLACE UNlT INTO SERVICE IF VOLTAGE AND/OR

FREQUENCY CANNOT BE ADJUSTED TO REQUlRED OUTPUT. SHUT UNlT DOWN
AND SERVICE AS REQUIRED.
(11) Observe VOLTMETER (2) reading for 115 VAC (200 VAC Line-to-Line).
(12) Observe FREQUENCY (21) reading for 400 Hz.
CAIJTION
BATTERY MUST BE KEPT FULLY CHARGED FOR PROVIDING STARTING AND
CONTROL VOLTAGES. SHUT ENGINE DOWN IF LESS THAN 12 VOLTS ON 12VDC
UNITS, OR 24 VOLTS ON 24VDC UNITS.
(13) Observe VOLTMETER gauge (5) on the Engine Control Panel. If less than 12 volts
(on 12VDC units) is indicated (24 volts on 24VDC units), unit is not charging. Use the
normal engine shut d o w n procedure.
(14) After engine has warmed to operating temperature, place the engine RUN/IDLE
switch t o the IDLE position before connecting power cable t o the aircraft.
C. Generator Operating Procedures - AC Power: Controls and Indicators for AC Power
Output are located o n the AC section of the control panel (See Figure 1). Procedure for
operating the AC Power Output is as follows:
(1) Generator Operation
DO NOT CONNECT AN ENERGIZED POWER CABLE TO AIRCRAFT. SEVERE

ELECTRICAL ARCING COULD CAUSE SERIOUS INJURY, DEATH AND OR DAMAGE
TO THE EQUIPMENT.
June 2, 1997 1-2

Revision 4 Page 5
GROUND POWER UNlT
THE COMBINED LOADS OF CABLE 1 AND CABLE 2 CANNOT EXCEED 289 AMPERES
CONTINUOUS. FAILURE TO COMPLY WILL RESULT I N SERIOUS DAMAGE TO THE
GENERATOR.
REMOTE SENSING IS AVAILABLE ONLY ON CABLE 1. CONNECT CABLE 1 TO LOADS

THAT REQUIRE PRECISE VOLTAGE REGULATION. DO NOT CONNECT CABLE 2 TO
LOADS REQUIRING PRECISE VOLTAGE REGULATION.
(a) Connect AC Cable(s) to the aircraft.
(b) Set RUNIIDLE (17) switch o n Engine Control panel t o RUN. This will bring the
engine up to operating speed of 2000 RPM o n units equipped with Marathon0
generator or 2400 RPM o n units equipped with KatoB generator.
(c) Measure AC voltage o n all lines using the voltmeter (2) as follows:
I IF A READING OF LESS THAN 100 VOLTS

CAUTION 1
II OR MORE THAN 130 VOLTS IS SHOWN LlNE
TO NEUTRAL, OR LESS THAN 190 VOLTS OR MORE THAN 210 VOLTS LlNE TO LINE,
THE UNlT MUST BE SHUT DOWN AND SERVICED.
(d) Turn VOLTMETER knob to the riqht (24) t o L1-N, L2-N or L3-N for line t o neutral
voltage readings (1 15 VAC), or LI-~2, ~ 2 - for
~ 3each generator phase.
(e) Observe and note VOLTMETER (2) reading, 115 VAC Line-to-Neutral, or 200 VAC
Line-to-Line should be shown.
(f) Observe and notethe FREQUENCY METER (21) reading. 400 Hzshould beshown.
I CAUTION
THE CABLE INTERLOCK SWITCH IS USED ACCORDING TO AIRCRAFT SYSTEM
I/
REQUIREMENTS. CONSULT THE AIRCRAFT TECHNICAL MANUAL FOR PROPER
USAGE OF THlS SWITCH. THE SWITCH IS LOCATED IN THE GENERATOR
ELECTRICAL DRAWER ASSEMBLY. ONLY AUTHORIZED GROUND SUPPORT
PERSONNEL SHOULD CHANGE THE POSITION OF THlS SWITCH.
(g) Set the CABLE INTERLOCKIBY-PASS switch according t o aircraft requirements.
* INTERLOCK: In this position the AC power will not be available unless the
power cable is securely connected t o an aircraft or t o a loadbank that returns
28 VDC o n cable pin E. In this position aircrew personnel within the aircraft
may terminate GPU output.
* BY-PASS: Use this position to directly energize the GPU output contactor(s)
and energize the AC cable(s). Output power t o the aircraft may only be
terminated from the GPU control panel.
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GROUND POWER UNlT
\\rlmNIN(;
DO NOT PLACE THE AC LOAD SWITCH ON, OR MAKE ANY FURTHER SWITCH
ADJUSTMENTS UNTIL THE UNlT IS PROPERLY CONNECTED TO THE AIRCRAFT
OR LOADBANK. FAILURE TO COMPLY COULD RESULT I N SEVERE EQUIPMENT
DAMAGE, AND/OR INJURY TO PERSONNEL.
(h) Press AC LOAD ON push-button (23) t o provide AC power t o the aircraft on
power cable 1.
(i)Press AC LOAD ON CABLE 2 (29) to provide AC power t o the aircraft o n power
cable 2.
(j) To monitor load conditions at the unit perForm the following:
* Turn AMMETER knob (20) to position 1 for A phase, 2 for B phase and 3 for C
phase cable current readings.
* Observe reading shown on AMMETER (4).
(2) AC Fault Indicators: If the AC output reaches the protective limits, the appropriate
AC FAULT indicators (3) will illuminate, and the output contactor(s)will open t o remove
power from the output cable(s). Press the FAULT RESET (26) switch t o reset the
electrical system when the fault has been cleared.
D. Shut-down Procedures:
I NEVER DISCONNECT OUTPUT CABLES WHILE AC POWER IS BEING DELIVERED. 1

(a) Press AC LOAD CABLE 1 OFF (22) push-button.
(b) If applicable, press AC LOAD CABLE 2 OFF (30) push-button.
(c) Set engine RUNIIDLE switch (17) to IDLE.
(d) Disconnect cable(s) from aircraft.
(e) Allow engine t o run at Idle speed for 2-3 minutes t o cool down.
(f) Set the IGNITION switch (13) to OFF.
E. Fault Lamp Test: The AC, and Engine fault lamps are tested as follows:
(I)
Set the IGNITION (13) switch t o ON.
(2) Set the RUNIIDLE switch (17) on the Engine Control Panel t o RUN (the engine need
not be running).
(3) Press the FAULT LAMP TEST push-button (25). Fault lamps will be illuminated.
(4) Restore switches t o normal IDLE and OFF positions when test is completed.
F. AC Fault Indicators: If the AC output reaches the protective limits, the appropriate AC
FAULT indicator(s) (3) will illuminate, and the output contactor(s) will open t o remove the
load from the generator set. Press the FAULT RESET (26) switch to reset the electrical
system when the fault has been cleared.
June 2, 1997
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U-J
GROUND POWER UNIT
G. DC Output Operation (If Applicable) (See DC TransformerlRectifier Schematic, Section
2-2): Controls and indicators f o r DC voltage output are located o n the DC section of the
control panel. Procedures f o r operating the DC power output are as follows:
DO NOT CONNECT AN ENERGIZED POWER CABLE TO AIRCRAFT. SEVERE

ELECTRICAL SHOCK CAUSING SERIOUS INJURY. DEATH AND/OR DAMAGE TO THE
EQUIPMENT MAY RESULT. -
(1) Soft Start (See Figure
- 7): Due t o the current requirements o f various aircraft starter
motors, and the potential damage that may result i n excessive current application, the
Soft Start or Current Limiting feature is provided. When the Soft Start switch (ltem 35)
is placed i n the ON position, current available t o the p o w e r cablelaircraft is limited t o
the amount seclected b y the Soft Start Current Limit Adjustment Potentiometer (ltem
34). With the Soft Start switch i n the OFF position, current available t o the aircraft is
not regulated o r limited.
(a) Soft Start Operation:
* Set the Soft Start control knob (ltem 34) t o t h e required current. Consult the
aircraft technical manual f o r the correct setting.
* Place the Soft Start switch (ltem 35) t o the O N position.
I DO NOT USE SOFT START O N HARD STARTING ENGINES.

1
* Press the DC LOAD ON switch (ltem 36). The O N pushbutton will illuminate,
showing that p o w e r is being applied t o the p o w e r cablelaircraft.
* To disconnect p o w e r f r o m the DC cablelaircraft, press the DC LOAD OFF
pushbutton (ltem 37). The ON pushbutton indicator light (ltem 36) will extin-
guish.
(2) DC Fault Indicators (See Figure I ) :
" If the DC voltage output reaches the protective limits, t h e Over Voltsfault indicator
(ltem 37) will illuminate, and the output contactor will open t o remove the load.
" High Temp Fault conditions will automatically reset w h e n the temperature of the
heat sink returns t o normal operating temperature.
(3) Fault Reset Switch (Figure 7, ltem 26): For DC output, t h e Fault Reset switch is used
f o r resetting an Overvoltage condition only. It will have n o other effect o n DC system
faults.
H. Combined AC and DC Outputs: When both AC and DC outputs are applied simultane-
ously, voltage regulation is determined b y the AC voltage output. DC voltage may vary.
When DC output only is being applied, voltage regulation is determined b y DC voltage
output.
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U-J
GROUND POWER UNlT
DO NOT PRESS THE AC LOAD "ON" SWITCH OR THE DC LOAD "ON" SWITCH OR
MAKE ANY FURTHER SWITCH ADJUSTMENTS UNTIL THE UNlT IS PROPERLY
CONNECTED TO THE AIRCRAFT OR LOADBANK. FAILURE TO COMPLY COULD
RESULT IN SEVERE EQUIPMENT DAMAGE, AND/OR INJURY TO PERSONNEL.
(1) Power Output Procedure:
(a) Place the Cable Interlock switch t o the appropriate position. Consult aircraft
technical manual for applicability of this switch [Paragraph 2. C. (1) (g)].
(b) Start the GPU engine per instructions previously covered (Paragraph 2, Section
1-2, Page 4).
(c) Place IDLEIRUN switch to the RUN position. After the engine has reached its
rated operating speed, observe the generator frequency and voltage readings.
Adjust voltage and/or frequency as required.
(d) Press the AC LOAD ON pushbutton switch (Figure 1, ltem 23). The Load On
indicator light (ltem 23) will illuminate. Observe the frequency and voltage meters
for proper readings.
- --
WI~RNI
NG
DURING COMBINED AC AND DC OPERATION, DC VOLTAGE IS NOT REGULATED. DO
NOT USE DC ON LOADS THAT REQUIRE HARD START CAPABILITIES.
(e) Press the DC LOAD ON pushbutton (ltem 36). The DC LOAD On push button will
illuminate.
(2) Shut-Down Procedures (See Figure 1):
NEVER CONNECT OR DISCONNECT THE AC OR DC CABLES WHILE POWER IS BEING

DELIVERED.
(a) Press the AC and DC LOAD OFF pushbuttons (Items 37).
(b) Place the engine IDLEIRUN switch (ltem 17) t o the IDLE position.
(c) Disconnect power cables from aircraft.
(d) Allow engine t o run at idle speed for 2-3 minutes t o cool off
(e) Place the Ignition switch (ltem 13) t o the OFF position.
June 2,1997 1-2

Revision 4 Page 9
THIS PAGE INTENTIONALLY LEFT BLANK
1-2 June 2,1997

Page 10 Revision 4
fl90T400SLN
GROUND POWER UNIT
CHAPTER
1
SECTION
SPECIFICATIONS AND CAPABILITIES

NOTE: Refer to the Options check list on the cover of this manual for the options which
apply to your unit,
1. GENERAL (See Figure 7)
Length: 130" (3302 mm).
Width: 64" (7625 mm)
Height: 64.5" (7638 mm).
Weight: 3900 Ibs (7770 kg.) wlcables.
Operating Temperature: - 3 0 ' ~to + 1 2 5 ' ~( - 3 4 C to 57.6OC).
Storage Temperature: -40°F to + 150°F (-40°C to 65.gC).
Noise Level less than 79 DBA on 32.5 foot radius.
Static Discharge Grounding: 50 ft. with 100 Ampere grounding clamp.
2. ENGINE
Curnrnins Curnrnins
Engine Model Number 6BT5.9
1 Number of Cvlinders / 6
5882 cm3 (359 in3)

Usable Fuel Diesel (ASTM 0975 No. Diesel (ASTM 0975 No.
2-D), Jet-A
Oil Capacity, w1Filter "12-15.5 qt (1 1.5 - 14.5 "12-15.5 qt (1 1.5- 14.5
ltr) ltrl
Air Cleaner Drv cartridcie t v ~ e Dry cartridge type
Thermostat (Fully Open) 1 9 0 ' ~(880C)
Cooling System 5.5 gals (20.8 Liter) 5.5 gals (20.8 Liter)
Charging System 12 or 24VDC 12 or 24VDC 12 or 24VDC
Protective System High water temperature High water temperature High water temperature
-
(Auto Shut-Down) (2250F) Low oil pressure (2250~)Low oil pressure (2250F) Low oil pressure
I (10 psi) Engine (10 psi) Engine (10 psd Engine
i o v e r s ~ e e d(2000 ram) overspeed (2000 rpm) overspeed (2000 rpm)
Governor Operating 80012400 RPM, f 112% 80012400 RPM, i 1 / 2 % 80012400 RPM, f 112%
Speed (IdlelRun) from no load to full load. from n o load t o full load. from no load t o full load.
KatoB Generator Units
Governor Operating 80012000 RPM, 1112% 80012000 RPM, 1112% 80012000 RPM, +1/2%
Speed (IdlelRun) from no load t o full load. from n o load t o full load. from no load t o full load.
Marathon@ Generator
Units
/ *NOTE: Varies, refer to individual encrine manual.
January 15, 1999 1-3

Revision 5 Page 1
ILUGROUND POWER UNIT
VEHICLE
Frame and Running Gear
Welded steel
rn Leaf spring suspension on rear wheels
a Four steel wheels equipped with 6.9 x 9, 6 ply pneumatic tires.
rn Tire Pressure: 60 psi (414 kPa).
Brakes: Rear wheel mechanical drum parking brakes.
Towbar brake (Optional)
Enclosure (Engine 6 Generator):
a Aluminum
Hinged canopy for service access.
Fuel Tank Capacity: 60 gallons (227.12 ltr.)
AC GENERATING SYSTEM:
AC Output: 1201200 VAC 3-phase 4-wire, 100% duty cycle at 2000 RPM o n units
equipped with Marathon@ generator or 2400 RPM o n units equipped with KatoB
generator.
Output Power Rating: 90 kVA at 0.8 PF.
Output Kilowatts: 72 kW.
AC Rated Load Capacity: 260 Amperes
Overload Capacity: 325 Amperes (125% rated load).
Frequency: 400 Hz.
Field Excitation: Static type, automatic field flashing.
AC GENERATOR PROTECTIVE SYSTEM:
Overvoltage: Trips at 130 volts, i n 0.5 seconds, inverse time delay.
Undervoltage: Trips at 100 volts, with 3-5 second delay.
Overfrequency: Trips at 415 Hz, with 3-5 second delay.
Underfrequency: Trips at 385 Hz, with 7-10 second delay.
Overload: Trips within 5 minutes at 125% rated load. Trips within 30 seconds at
150% rated load, Inverse timed delay circuitry.
Neutral Fault: Trips within 150 msec., upon detection of faulty neutral with an un
balanced load.
DC GENERATING SYSTEM (Optional):
DC Overvoltage: Trips at 36 VDC
DC High Temperature: Indicator lights when the transformer rectifier (TIR) assem-
bly temperature exceeds 1 5 0 ~ ~ .
DC Output: Dependent upon the unit model. Refer t o the unit identification placard
located at the right front of the unit and the cover of this manual. DC output current
will be as indicated below:
Transformer-Rectifier Type ' Continuous Current Rating
(Amperes)
Infermitent Current Rating
(Amperes)
TR 1 800 2000
1
TR 1.5 I 1050 2000
I
I TR2 1500 2500
1-3 January 15, 1999

Page 2 Revision 5
fl90T400SLN
GROUND POWER UNIT
January 15, 1999 Figure 1A. 90T400SLN Outside Dimensions, Side View 1-3
Revision 5 Page 3
fl90T400SLN
GROUND POWER UNIT
O P T I O N A L LOW FUEL
WARNING L I G H T
/
Figure 1B. 90T400SLN Outside Dimensions, End View
1-3 January 15, 1999

Page 4 Revision 5
U-lGROUND POWER UNlT
CHAPTER
1
SECTION
4
SHIPPING AND RECEIVING
1. GENERAL
When shipped domestically, the GPU does not normally require crating, skidding or a solid
external container. It may be shipped completely assembled.
2. PREPARATION FOR SHIPMENT
To prepare the GPU for shipment, perform the following procedures:
(1) Disconnect battery cables.
(2) Ensure all doors are closed and securely fastened.
(3) Roll-up generator output cables, use rope to secure cable box(s).
(4) Inspect fuel tank cap for proper seal and security.
I UNDER NO CIRCUMSTANCES SHOULD THE POWER PLANT BE ANCHORED BY

PASSING BANDS OR CABLES OVER THE SUPERSTRUCTURE. I
(5) Use 1-114 inch steel banding (minimum) or 318 inch minimum steel cables and
secure the unit to the skid base. Attach cableslbanding to the front and rear axles, or
the FORE and AFT members of the frame may be used to secure the unit. On units so
equipped, tie down rings may be used to secure the unit to the skid base.
(IAIJTION
DO NOT USE FORK LIFT TO RAISE THE UNIT, AS THE CRANK CASE WILL BE
RUPTURED. UNlT M U S T BE LIFTED BY USE OF SPREADER BAR AND AlTACHED
I TO THE FORE AND AFT MEMBERS OF THE FRAME. l
When deemed advisable by the shipping activity, the GPU should be covered with water-
proof canvas or polyethylene material in such a manner as to prevent the entry of natural
elements into the electrical and instrument areas.
Application of the covering material should be accomplished in such a manner as to avoid
the formation of water pockets or interfere with the mobility of the unit. The covering material
should be of sufficient strength to preclude rupture or tearing when exposed to conditions
encountered during open transportation.
3. RECEIVING
The Ground Power Unit is shipped from the factory fully assembled and may be rolled or
towed into position. Local movement may also be accomplished by using an appropriate
lifting device utilizing a spreader bar attached to the fore and aft members of the frame.
November 15, 1995 1-4
Original Page 1
GROUND POWER UNIT
When transporting by lifting equipment, care should be taken that all housing doors are
securely closed. Do not t o w the unit any great distance before performing the initial
inspection procedures.
A. Initial Inspection:
(1) Remove any crating o r envelope of weather resistant material.
(2) Thoroughly inspect the exterior of the unit for any damage which may have occurred
during shipment. Open all doors and close, checking latches for proper operation.
(3) Inspect all indicator glass and indicator light lenses for evidence of cracks or
damage.
(4) Check towbar and front wheel assembly for evidence of damage, loose or missing
hardware.
(5) Check braking action o f rear wheels by positioning the brake handlefrom the vertical
t o the horizontal position. Brakes are applied when handle is in the horizontal position,
(6) Open access doors/canopies and inspect the interior of the unit.
O Check the fuel system for leakage.
" Check the electrical wiring for brakes or exposed wiring.
Check the entire unit f o r loose connections, parts, bolts, nuts or other hardware
that may have been loosened during t r a n s i t . ~ i ~ h t eorn repair all discrepancies.
CAIJTION
BEFORE ATTEMPTING TO CONNECT THE BATTERIES, MAKE SURE THE
IGNITION SWITCH ON THE ENGINE/GENERATOR CONTROL PANEL IS IN THE
OFF POSITION.
(7) Connect the batteries as follows:
(a) Open the forward (engine) access canopy. Batteries are located o n the right side
of the engine.
(b) Connect one positive terminal lead (Red) t o each battery and tighten.
(c) Connect one negative terminal lead (Black) t o each battery anddtighten.
(8) Check engine oil level. D o not operate the unit if the oil level is below the "L" (low)
mark o n the dip stick. Service with oil until the oil level is at the "H" (full) mark. Refer to
Chapter 2-1, Servicing, for proper oil grade.
(9) Remove the radiator cap and inspect the coolant level. Service as required t o bring
the level t o within one inch (25mm) of the filler neck. Refer t o Chapter 2-1, Servicing,
for the proper coolant mixture.
1-4 November 15, 1995

Page 2 Original
GROUND POWER UNIT
CHAPTER
1
SECTION
5
STORAGE
1. GENERAL
This section provides instructions for preparing the ground power generator for both short
and long term storage. When the unit is to be stored or removed from operation, use the
following procedures to protect the internal and external components from rust, corrosion,
and gumming in the engine fuel system.
2. PREPARATION FOR STORAGE
A. Short Term Storage (less than 3 months): The following steps are recommended if the
unit is to be placed out of service for three months or less. The unit should be prepared for
storage as soon as possible after being removed from service.
(1) Check that the thoroughly mixed coolant is adequate for the lowest anticipated
temperatures during time of storage.
(2) Add oil to the FULL mark level on the engine oil dip stick.
(3) Drain a small portion offuel from fuel tank by removing drain plug at bottom of tank.
This will remove any water that may have accumulated a t the bottom of the fuel tank.
NOTE: Do not drain the fuel system or crankcase.
(4) Install new fuel filters.
(5) Fill fuel tank to capacity. A full fuel tank prevents moisture laden air from entering
the tank during the cool periods and allowing rust or corrosion to form.
(6) Close all access doors and covers to minimize build-up of foreign particles in the
unit.
(7) Store unit in a building that is dry.
(8) If the storage area has high humidity levels, place moisture absorbing chemicals
inside the unit.
B. Long Term Storage: Special precautions are necessary to protect the Ground Power
Unit from rust and corrosion. It is recommended that the unit be stored in a building that
is heated during winter months. Moisture absorbing chemicals should be placed inside the
unit in climates where there is excessive dampness.
Parts of the diesel engine requiring special attention are given below. The unit should be
prepared for storage as soon as possible after being removed from service.
November 15, 1995 1-5

Original Page 1
u-!
GROUND POWER UNIT
(1) Drain the cooling system: Flush with clean water. Refill with 50150 mix of water and
antifreeze and add a rust inhibitor, or mix according t o ratio for temperature anticipated
per the product manufacturer's recommendation.
(2) Circulate the coolant by operating the engine to normal operating temperature.
(3) Drain the engine crankcase and fill with new lubricating oil (Shell code 66202, or
Texaco Preservative Oil 30 [MIL-L- 2 126OC Grade 21).
(4) Replace oil filter elements.
(5) Drain the fuel tank. Add additives, fill with fuel.
(6) Replace fuel filter elements.
(7) Operate the engine for about ten minutes.
NOTE: If the unit is stored where water or condensation may be a problem, add pure
waterless isopropylalcohol (isopropanol) to the fuel, at the rate of 7 pint to 125gallons of fuel
1.010% by volume). Where biological contamination may be a problem, add a biocidal such
as Biobor JF or equivalent to the fuel. Follow the Biocidal manufacturer's concentration
recommendations and observe all warnings and cautions.
(8) Remove and clean battery terminals and cables with baking soda-water solution,
rinse with fresh water. Do not allow the soda water to enter the battery. Add distilled
water to the electrolyte, if necessary fully charge the battery. Store the battery in a cool
dry place separate from the unit. Storage temperature should never be below 32' F (0'
C). Periodically inspect the batteries t o keep them fully charged and check the specific
gravity of the electrolyte regularly.
(9) Seal all engine openings, including the exhaust outlet, with moisture resistant tape.
Use cardboard, plywood, or metal covers where practical.
(10) Tag engine Control Panel "DO NOT RUN, STORAGE READY".
1-5 November 15, 1995

Page 2 Original
CHAPTER
2
SECTION
1
SERVICING
1. GENERAL
A. Equipment Service Life: Under normal operating conditions and with proper preventive
maintenance, the GPU will provide excellent service for a period of 20,000 to 30,000 hours
before major engine overhaul is normally considered (depending upon local conditions).
B. Consumable Supplies Required For Normal Operation & Scheduled Maintenance:
I Component I Description / Quantity I

l ~ u eTank
l ]Fuel oil, "Jet-A, Diesel (ASTM 0975 No. 2-0) 160 gal. (227.7 ltr)
Crankcase Lubricating oil **CC-CD 15W-40 10 qt.. (9.46 Itr)
Lube points Grease, General Purpose as required
Running gear Grease, General Purpose as required
Door Hinges Oil, OE30 as required
Radiator Antifreeze """Ethylene Glycol 5.5 gal. (20.8 ltr)
Filters, Fuel Filter Element, Primary 1 ea.
Filter Element, Secondarv 1 ea.
Filter, Oil Cartridge 1 ea.
Air Cleaner Cartridge 1 ea.
NOTES:
"Jet-A Fuel: Refer to options check list for your unit.
** While 15W-40 oil is recommended for most climates, refer to Figure 1 for oil viscosity recommendations for
extreme climates
"""Antifreeze concentration level should not exceed recommended levels. To do so can cause cooling system
failure.
a. A mixture of 50 percent antifreeze and 50 percent water is required for temperatures above -34' F
(-370 C).
b. A mixture of 60 percent antifreeze and 40 percent water is required for environments below - 3 4 ' ~
(-37OC)This provides protection to - 6 5 ' ~(-54'C). NEVER exceed a 60 percent antifreeze and 40 percent
water mix.
c. NEVER use 100 percent antifreeze for make-up coolant. 1
November 15, 1995 2-1

Original Page 1
Anticipated A m b i e n t T e m p e r a t u r e
Figure 1. PSA Oil Viscosity Recommendations
2. LUBRICATION INSTRUCTIONS
To ensure that the unit is kept in correct operating condition, it must be inspected and
maintained o n a regular basis. Proper replacement of filters, lubricating oil, etc., at recom-
mended intervals will prevent damage t o or failure of the unit, and provide optimum
performance. The use of quality engine lubricating oils combined with appropriate oil drain
and filter change intervals is a critical factor in maintaining the engine performance and
durability.
A. Engine Oil Change Schedule: Time schedules indicated in Table 2 are based o n average
operating conditions. It may be necessary t o change oil and airfilters more frequently under
severe operating conditions, such as operating in dry, hot, dusty climates (desert), areas
of high humidity (tropical), excessive periods of heavy load or frequent intermittent
operations. Checkthe oil level after every 8-10 hours of operation during the break-in period
(first 50 hours). A d d oil as necessary.
NOTE: Change oil and filter after first 50 hours of operation, then every 250 hours of
operation or every six months, which ever comes first.
(1) Always clean around oil filler openings before removing caps or plugs.
(2) Do not over-lubricate or overfill the engine crankcase. Use engine oil level dipstick
t o check oil level.
(3) Prevent dust, dirt or water from contaminating lubricants.
(4) Do not mix brands, weights or types of oil when servicing unit.
(5) A high quality SAE 15W-40 heavy duty engine oil, which meet the American
Petroleum Institute (APO performance classification CEISG, is recommended.
2-1 November 15, 1995

Page 2 Original
GROUND POWER UNIT
NOTE: CCICD or CDISF engine oils can be used in areas where CE oil is not yet available, but
the oil change interval must be reduced to one half the interval given in the maintenance
schedule.
B. Arctic Operation: If an engine is operated in ambient temperatures consistently below
- 1 0 ' ~ (-23'~) and there are no provisions to keep the engine warm when it is not in
operation, use a synthetic CC/CE engine oil with adequate low temperature properties such
as: 5W-20 or 5W-30. The oil supplier must be responsible for meeting the performance
service specifications.
I CAIJTIOM
THE USE OF A SYNTHETIC BASE OIL DOES NOT JUSTIFY EXTENDED OIL CHANGE
1
INTERVALS. EXTENDED OIL CHANGE INTERVALS CAN DECREASE ENGINE LIFE DUE
TO FACTORS SUCH AS CORROSION, DEPOSITS AND WEAR.
CAIJTION
A SULFATED ASH LIMIT OF 1.85% HAS BEEN PLACED ON ALL ENGINE LUBRICATING
OlLS RECOMMENDED FOR USE I N THE ENGINE. HIGHER ASH OlLS MAY CAUSE
VALVE AND/OR PISTON DAMAGE AND LEAD TO EXCESSIVE OIL
CONSUMPTION.
NOTE: Additional information regarding lubricating oil availability throughout the world is
available in the "E.M.A. Lubricating Oils Data Book for Heavy Duty Automotive and Industrial
Engine." The data book may be ordered from the Engine Manufacturers Association, One
Illinois Center, 1 1 1 East Wacker Drive, Chicago, 11 U.S.A. 6060 1.
3. COOLANT SPECIFICATIONS & RECOMMENDATIONS
A. Specifications: Use low silicate antifreeze which meets ASTM4985 test (GM6038M
spec.) criteria.
B. Concentration: Antifreeze must be used in any climate for both freeze and boiling point
protection. A 50 percent concentration level (40 to 60 percent range) of ethylene glycol
propylene glycol is recommended in most climates. Antifreeze at 68 percent concentration
provides the maximum freeze protection and must never be exceed under any condition.
Antifreeze protection decreases above 68 percent.
November 15, 1995 2-1

Original Page 3
GROUND POWER UNIT
Table 1
ANTIFREEZE CONCENTRATION PROTECTION
Antifreeze Type Percentage of Protection to
Antifreeze Temperature
Ethylene Glycol 40 O/O -1 OOF (-23OC)
50% -34OF (-3PC)
60% -65OF (-54OC)
68% 9 0 ' ~1-77Oc1
C. Concentration Testing: Antifreeze concentration must be checked using a refractometer

(such as Fleetguard Part No. CC2800). "Floating ball" type density testers or hydrometers
are NOT accurate enough for use with heavy duty diesel cooling systems.
D. Coolant Change Recommendations: Trilectron recommends the cooling- system . be
drained and replaced every 3000 hours or yearly (whichever occurs first) t o eliminate
build-up of harmful chemicals.
Cooling System Capacity: 5.5 U.S. gal. (20.8 liters).
4. FUEL RECOMMENDATIONS/SPEClFlCATlONS
Cummins Engine Company Inc., recommends the use of ASTM No. 2 Dfuel. The use of No.2
diesel fuel will result in optimum engine performance. A t operation temperatures below
- blends of No.2 D and No.1 D.
3 2 ' ~(OOC), acceptable performance can be obtained b y using
The use of lighter fuels can reduce fuel economy.
DO NOT M I X GASOLINE OR ALCOHOL WITH DIESEL FUEL, THIS MIXTURE CAN

CAUSE AN EXPLOSION.
UNLESS THE ENGINE IS SPECIFIED AS BEING JET-A FUEL COMPATIBLE, THE FUEL'S
VISCOSITY MUST BE KEPT ABOVE 1.3 CST TO PROVIDE ADEQUATE FUEL SYSTEM
LUBRICATION.
5. INSPECTION (See Table 2):
A. Preventive Maintenance Inspection Schedule: A periodic inspection schedule should
be established and maintained. A suggested inspectionlcheck schedule is provided below.
The criteria listed meets the minimum requirements necessary t o ensure safe reliable
service under normal operating conditions. It should be modified as required to meet
varying operating and environmental conditions.
2-1 November 15, 1995

Page 4 Original
ENGINE COOLING SYSTEM
I . Inspect for leaks. X
2. Inspect Radiator core for cleanliness X X X X X X
3. Condition of belts. X
4. Check Coolant level add coolant as required. X
5. Change antifreeze solution each 3000 hours or yearly (whichever occurs first).
AIR INTAKE SYSTEM
TURBOCHARGER
ENGINE ELECTRICAL SYSTEM

1. Inspect battery electrolyte level covers plates. X
2. Check battery state of charge. X X X X X X
3. Inspect battery hold-down. X
CHASSIS & RUNNING GEAR

1. Inspect doors and hinges for defects. Lubricate hinges. ~ x ~ x I X ~ X -~
2. Inspect unit for loose nuts, bolts and missing hardware. X
3. Inspect drawbar for cracks, corrosion and excessive wear. X
4. Inspect drawbar latch for proper operation. X
5. Inspect axles for security. X X X X X X
6. Inspect tires for wear and inflation X
November 15, 1995 2-1
Original Page 5
9OT40OSLN
f i G R O U N D POWER UNIT
7. Inspect wheel bearings for looseness. ] X l X l X l X l X l X

8 R e p a c k s yearly or 750 hours whichever comes first. -
GENERATOR/ELECTRICAL SYSTEM
1. lnspect generator air inlet screen and air outlet louver for obvious X
obstructions. -
2. Inspect all wiring for cuts, excessive bends and chaffing. X
3. Inspect generator mount bolts for tightness. X
4. Relays and Contactors:
a. Loose w ires and evidence of over-heat ing x
b. Contact or for loose w ires x
5. GeneratorIEngine Panel. Inspect:
a. Gauges for proper operat ion, cracked glass. x
b. Switches for proper operat ion X
c. Panel lights for proper operat ion x
d. Printed circuit boards for security. X
e. Electronic Governor module for security, x
loose terminals.
B. Initial Inspection and Preparation:
(1) Remove all packaging material from unit.
(2) lnspect exterior of unit for damage that may have occurred during shipment.
(3) Open the canopy by unlatching and lifting the rear half until it comes to rest at a full
vertical position. lnspect interior of unit for foreign material.
(4) lnspect all wiring connections for security.
(5) Lower and latch the rear half of the canopy.
(6) Lift open the front canopy inspection cover located over the radiator. Remove
radiator cap. Check to make certain that the coolant level is one inch below the filler
neck.
(7) Inspect battery electrolyte level. Service batteries as necessary, using distilled water.
(8) Connect battery.
(IAIJTION
BEFORE ATTEMPTING TO START UNIT, PERFORM A PRE-OPERATIONAL
1 INSPECTION (CHAPTER 7). l
(9) Check fuel level by turning on the ignition switch (Refer to Section 7-2).Observe
fuel gauge. Service as necessary with diesel fuel.
2-1 November 15, 1995

Page 6 Original
C. Returning Unit To Service After Extended Storage:
( 1 ) Remove covers and tape from all engine, exhaust and fuel tank openings.
( 2 ) Remove covers and tape from electrical system components.
( 3 ) Drain and refill radiator with a mixed solution of water and antifreeze (ethyl glycol)
or according t o a ratio for temperature as described in Para. 3,B. Coolant capacity is
5.5 gallons (20.8 ltr).
(4) Drain and refill engine crankcase. Change oil filter.

( 5 ) If isopropyl alcohol (isopropanol) was added to fuel for storage, drain and refill fuel
tank with diesel fuel.
D. Engine Fuels (See Table 3): The diesel engine uses #2 diesel, or fuels meeting ASTM
D975 Standard Specification of Diesel Fuels, or the following lighter fuels: No. 1 Diesel;
kerosene; *Jet A fuel, o r blends of these fuels.
*If specified as an option for your unit.
Table 3. Engine Fuels

Viscosity (ASTM 0-445) 1.3 - 5.8 CentiStroke (7.3 to 5.8 m m Per Second) at 104'F (40°C).
Cetane Number 40 minimum. In cold weather or prolonged low (ASTM 0-445) load (ASTM
0-613) service, use higher cetane number.
Sulfur Content Not to exceed 1OO/ by weight.
(ASTM D- 129 or 1552)
Carbon Residue (Ransbottom Not to exceed 0.25% by weight on 10% residue.
ASTM 0-524 D 189)
Flash Point (ASTM 0-93) 1 2 5 ' ~(52OC) min. Certain marine registries require higher flash points.
Density (ASTM 0-287) 30 to 4 2 ' ~(-7 to 60C) A.P.I. at 6 0 ' ~(760C) 1.816to .876Sp. Gr).
Cloud Point 1 0 ' ~(-12'C) below lowest temperature expected to operate.
IASTM 0-971
Active Sulfur-Copper Strip- Not to exceed No. 2 rating after 3 hours at 1 2 2 ' ~(50°C).
Corrosion (ASTM D-130)
Ash (ASTM 0-482) Not to exceed 0.02% by weight.
Distillation (ASTM D-86) Curve should be smooth and continuous. Minimum 90% of fuel should evaporate
at less than Ash (ASTM 0-482). Not t o exceed 0.02% by weight.
MT1lIINING
ESCAPING FLUID UNDER PRESSURE CAN PENETRATE THE SKIN CAUSING SERIOUS
INJURY. RELIEVE PRESSURE BEFORE DISCONNECTING FUEL OR OTHER LINES.
TIGHTEN ALL CONNECTIONS BEFORE APPLYING PRESSURE. KEEP HANDS AND
BODY AWAY FROM PINHOLES AND NOZZLES WHICH EJECT FLUIDS UNDER HIGH
PRESSURE. USE A PIECE OF CARDBOARD OR PAPER TO SEARCH FOR LEAKS, DO
11 NOT USE YOUR HANDS.
November 1 5 , 1995 2-1

Original Page 7
GROUND POWER UNIT
-
6. ENGINE FUEL FILTER REPLACEMENT CUMMINS (Figure 2)
Both the primary and secondary fuel filters should be replaced after every 125 hours of
engine operation. Both filters are of the screw-off canister design.
A. Secondary Fuel Filter
Remove (unscrew) the secondary fuel filter. Discard the filter and the contaminated
fuel located within the filter.
Fill the replacement filter with fuel. Lubricate the rubber seal o n the mating end of the
filter with fuel.
Screw the filter onto the filter base hand tight. Using the proper size filter wrench,
tighten the filter an additional one-quarter turn.
B. Primary Fuel Filter
Remove (unscrew) the secondary fuel filter. Discard the filter and the contaminated
fuel located within the filter.
Fill the replacement filter with fuel. Lubricate the rubber seal o n the mating end of the
filter with fuel.
Screw the filter onto the filter base hand tight. Using the proper size filter wrench,
-
7. ENGINE OIL FILTER REPLACEMENT PROCEDURE CUMMINS (Figure 2)
Replace the engine oil filter after every 250 hours of engine operation.
(1) Remove (unscrew) the engine oil filter. Discard the filter and the contaminated oil
located within the filter.
(2) Fill the replacement filter with engine oil. Lubricate the rubber seal o n the mating
end of the filter with oil.
(3) Screw the filter onto the filter base hand tight. Using the proper size filter wrench,
(4) Check the engine oil level. A d d oil as necessary to bring the oil level to the full mark.
(5) Start the engine, watching the engine oil pressure indication. Engine oil pressure
should be above 10 psi within five seconds of starting the engine. If not, the engine will
automatically shut-down. Turn ignition switch OFF, then back t o ON and retry engine
start. Allow engine t o run for 2 to 3 minutes, then shut-down engine.
(6) Allow the engine t o set for five minutes, then recheck the engine oil level, adding
oil as required.
2-1 November 15,1995

Page 8 Original
~ G R O U N POWER
D UNIT
SEPARATOR
RAIN THE WATER

ND SEDIMENT DAILY
OIL DRAIN
PLUG
O I L FILTER
LEETGUARD FL3349
MMlNS #3908615
Figure 2. Cummins Engine Fuel and Oil Filter Location/Replacement
November 15, 1995 2-1

Original Page 9
UGROUND
POWER UNIT
8. ENGINE FUEL FILTER REPLACEMENT -JOHN DEERE (Figure 3)
A. Rectangular Fuel Filter: Daily, check the glass sediment chamber of the rectangular fuel
filter for water or debris. If present, drain the filter. To replace the filter:
(1) Loosen bleed plug o n the side of the filter base. Remove drain plug from bottom of
filter base t o drain fuel f r o m filter.
(2) At the t o p of the filter, use the palm of the hand t o press i n o n the retaining spring
t o p tab while using the fingers t o pull upward o n the bottom tab of the retaining spring.
(3) Pull the fuel filter off the filter base.
(4)To install new filter, ensure that the three pins o n the filter base enter the grommeted
holes o n the filter. Hook the bottom end of the retaining spring first, then hook the top
end.
(5) To bleed the air f r o m the filter/system, loosen the air bleed plug o n the fuel filter
base.
(6) Operate the supply pump primer lever located o n the bottom of the mechanical
engine mounted fuel pump. On units with electric fuel pump, simply turn o n the ignition
switch.
(7) When fuel f l o w f r o m air bleed plug is free of bubbles, tighten the bleed plug securely.
( 8 )Continue operating hand primer until pumping action is not felt. Push hand primer
inward (toward engine) as far as it will go.
B. Round Fuel Filter: Daily, drain the filter sediment chamber of water or debris. Open the
drain plug at the bottom of the filter and drain into a clear container until only clean fuel is
present. To replace the filter:
(1) Close fuel system shut-off valve (if so equipped).
(2) Loosen the locking collar and remove and discard the old filter element. Use the
plug provided with the n e w filter t o plug the used one.
(3) Align keys o n new filter element with slots in filter base.
(4) Position the locking collar over the filter and hand tighten until the locking collar fits
into the lock position, a click will be heard and a release of the locking collar is felt.
(5) If the engine is equipped with a water separator, remove the filter element from the
glass sediment bowl, clean the sediment bowl and reinstall a new element onto the
bowl.
(6) Open the fuel shut-off valve (if so equipped), and bleed the fuel system. Tighten the
bleed plug.
(7) To bleed the air f r o m the filter/system, loosen the air bleed plug o n the fuel filter
base.
2-1 November 15, 1995

Page 10 Original
FUEL FILTER \,
HOUSING
CODE
FUEL
DRAIN PLUG
FUEL FILTER
PLUG
1
LOCKING COLLAR
Figure 3. John Deere Engine Fuel and Oil Filter Location/Replacement

November 15, 1995 2-1
Original Page 11
UGROUND
POWER UNIT
(8) Operate the supply pump primer lever located o n the bottom of the mechanical
engine mounted fuel pump. On units with electric fuel pump, simply turn o n the ignition
switch.
(9) When fuel f l o w from air bleed plug is free of bubbles, tighten the bleed plug securely.
(10) Continue operating hand primer until pumping action is not felt. Push hand primer
inward (toward engine) as far as it will go.
9. RACOR FUEL FILTER MAINTENANCE (If installed) (Figure 4)
For best results and more dependable service, drain water condensation and other contami-
nates from the filter daily. Turn drain knob counter-clockwise t o drain, clockwise to tighten.
If necessary t o reprime the filter, remove the lid and fill with clean fuel. Replace the lid and
tighten by hand t o approximately 10 ft. Ibs., maximum.
Replacing Element: Remove the lid and then remove the element by slowly pulling upward
o n the molded handle with a turning motion.
Install new element.
Replace the lid gasket with the one supplied with the new element. Apply a coating of
clean fuel t o the seal prior t o reassembly.
Fill the unit with clean fuel, then replace the lid and tighten b y hand t o approximately
10 ft. Ibs., maximum.
Start the engine and check for leaks. Correct any leaks with the engine off.
z UD ASSEMBLY
flLTER ELEMENT
RACUK PART NO.
2040TMOR (1 0 Micron)
CONTAMINATION
DUAIN
Figure 4. Racor Fuel Filter (Optional)

2-1 November 15, 1995
Page 12 Original
~ G R O U N D
POWER UNIT
10. CLEANIREPLACE AIR FILTER ELEMENT (Figure 5)
Whenever the air Filter Minder gauge reads 20 or high while the engine is running, the air
filter requires service.
On units with only a replaceable element, remove the old element, clean the interior of the
housing and cover plate prior t o installing the new element.
On units with a reusable pre-filter, remove and clean the prefilter.
Gently pat the sides of the pre-filter with the palm of the hand to loosen dirt.
Insert a cleaning air gun into the element, holding the air nozzle about one inch from
the perforated metal retainer and force air through the filter from the inside. Move air
gun u p and d o w n the pleats t o remove as much dirt as possible. Repeat this procedure
until filter element is clean.
Inspect element for damage after cleaning, if any damage is found, replace element.
AIR FILTER AIR FILTER HOUSING

SECONDARY
DISPOSABLE ELEMENT
PRIMARY REUSEABLE
FlLTER ELEMENT
WING NUT
0
m-DUST UNLOPDER VALVE

Figure 5. Air Filter Assembly
Novem ber 15, 1995 2-1

Original Page 13
GROUND POWER UNIT
2-1 November 15, 1995

Page 14 Original
a 90T400SLN
GROUND POWER UNIT
CHAPTER
2
SECTION
2
TROUBLESHOOTING
1. GENERAL
This section contains troubleshooting information to assist in locating and correcting
operating troubles which may develop in the generator set. Each malfunction for an
individual component, unit or system is followed by a list of tests or inspections which will
help the technician to determine probable causes and corrective action to take.
The tests/inspections and corrective actions should be performed in the order listed.
Troubleshooting is a logical and systematic process of determining and correcting the cause
of a malfunction. The process begins with verification of the malfunction. This may often
involve an operational checkout of the GPU. After the trouble has been verified, identify all
components in the circuit whose failure could cause the symptoms observed during the
operational checkout. The technician should start by checking those items which are highest
in probability of causing the problem. Inspect and test each component, until the exact cause
of the problem is determined and corrected.
WARNING II
EXERCISE EXTREME CARE TO AVOID CONTACT WITH HIGH VOLTAGE LEADS.
REMOVE ALL JEWELRY, SUCH AS RINGS, WATCHES, CHAINS, ETC., THAT COULD
COME INTO CONTACT WlTH EXPOSED POINTS. FAILURE TO COMPLY MAY RESULT
IN SERIOUS INJURY OR DEATH TO PERSONNEL AND/OR DAMAGE TO THE
EQUIPMENT.
I EAR PROTECTION DEVICES MUST BE

WARNING
WORN WHEN IN THE IMMEDIATE VICINITY OF
1
THIS UNIT DURING OPERATION. REPEATED EXPOSURE TO HAZARDOUS NOISE CAN
CAUSE PERMANENT HEARING LOSS.
/II FUEL, OILS AND OTHER PETROLEUM PRODUCTS CAN READILY BE ABSORBED
THROUGH THE SKIN AND INTO THE BLOOD STREAM. WASH IMMEDIATELY AFTER
COMING INTO CONTACT WlTH THESE PRODUCTS.
January 15, 1999 2-2

Revision 5 Page 1
a 90T400SLN
GROUND POWER UNIT
ESCAPING FLUID UNDER PRESSURE CAN PENETRATE THE SKIN CAUSING SERIOUS
INJURY. RELIEVE PRESSURE BEFORE DISCONNECTING FUREL OR OTHER LINES.
TIGHTEN ALL CONNECTIONS BEFORE APPLYING PRESSURE. KEEP HANDS AND
BODY AWAY FROM PINHOLES AND NOZZLES WHICH EJECT FLUIDS UNDER HIGH
PRESSURE. USE A PIECE OF CARDBOARD OR PAPER TO SEARCH FOR LEAKS, DO
NOT USE YOUR HANDS.
2. TROUBLESHOOTING CHART
This troubleshooting chart (See Table I)lists information under three headings as follows:
Problem
Cause
Remedy
A. Use of the Troubleshooting Chart: If the cause of a trouble is uncommon and cannot
be located using the chart, a good place t o start your checks is at the last known source of
power. Then proceed b y checking each component in the circuit/system thoroughly. Use
the schematics and diagrams. Electrical components in the troubleshooting chart (such as
SI, TI, etc.), are identified b y a noun name an a corresponding symbol t o identify the item
on schematic diagrams. It is assumed that wiring and connections in defective circuits have
been thoroughly checked before condemning any component(s).
B. Support Test Equipment Required:
Multimeter (Simpson 260 V O M o r equivalent)
Tachometer
See Engine Shop Manual for tool requirements
C. Component Failure: Stop the engine immediately should any component fail. Practically
all engine failures give some warning to the operator before the component fails and ruins
the engine. Many engines have been saved because alert operators heed warning signs
such as a sudden drop in oil pressure, unusual noises, etc., and immediately shutdown the
engine.
2-2 January 15, 1999

Page 2 Revision 5
Fault Er Condition
a 90T400SLN
GROUND POWER UNIT
Table 1. Engine Troubleshooting C
Probable Cause Test, Check, Remedy
--
:heck/correct the source of the leak.

2. Additional loading from lhecklrepair accessories and vehicle
malfunctioning accessories. :omDonents.
3. Poor quality fuel. :heck that proper fuel is being used.
:heck for contaminates.
4. Inadequate intake air or exhaust :heck/change air intake filter, and
restriction. emove any restrictions found in the
I txhaust.
5. Fuel p u m p timing. Zheckltime the pump.
i 6. Worn or malfunctioning injectors. :heck and/or redace iniectors.
7. Valves not seating. lhecktadiust valves.
Engine hard t o start or will 1. Engine cranking speed t o o slow. :heck engine cranking RPM. Refer t o
not start (exhaust smoke pre- mgine will not crank or cranks slowly.
sent). 2. Starting aid needed for cold :heck and repair or replace cold
weather or not working properly. itarting aid, if necessary.
3. Air in the fuel svstem. 3leed the fuel system.
4. Fuel supply restricted. :lean or replace prefilters and
xreens. Check fuel lines for
estrictions.
I 15. Intake air system restricted. :heck intake svstem.
' ~ n ~ i cranks
ne but will not 4dd fuel.
start (no smoke from ex- 2. Fuel solenoid not energized open. :heck for loose wires. Verify that the
haust). ;olenoid is functioning.
3. Fuel filter clogged with water or )rain fuel - water separator or replace
uel filter.
4. Worn or malfunctioning injector .oosen high pressure line at t w o
njectors and visual check fuel
lelivery while cranking the engine.
3eplace the p u m p if fuel is not being
lelivered.
5. Injection p u m p timing incorrect. /erify timing; time injection p u m p if
eauired.
1 ~ n ~ i starts
n e but will not Adjust governor linkage.
I keep running. 2. Air in the fuel system. 3leed the fuel system and check for
;uction leaks.
)rain fuel-water separator or replace
due t o cold weather. ilter.
January 15, 1999 2-2

Revision 5 Page 3
I
r---K&
Condition
a%-
I
-
9OT40OSLN
GROUND POWER UNIT
Table 1. Engine Troubleshooting Chart (Continued)
Engine starts but will not 14. Fuel supply restricted. Clean or replace pre-filters and
I keep running. screens and check for fuel line
(Cont~nued) restrictions.
5. Fuel contaminated. Verify b y operating engine from a
temporary supply tank.
---
I
6. Injection pump out of time. Checklcorrect pump timing.
3ough idle, warm engine. I.Idle speed set too low. ' ~ d j u sgovernor
t linkage.
2. Air fuel system. Bleed fuel system and check for
suction leaks.
3. Injection
-. timing incorrect. Check/correct injection timing.
4. Injector nozzles clogged or Replace injectors.
inoperative.
5. Broken engine mounts. Checklreplace mounts.
6. Malfunctioning injector pump. Checklreplace pump.
/Engine surges at idle. 1. Low fuel level in tank. Fill surs~lvtank.
2. Idle speed set too low. Checkladjust governor linkage.
3. Air in the fuel system. Bleed fuel system and check for
suction leaks.
4. Restricted fuel supply. Cleanlreplace prefilters and screens
and check fuel lines for restrictions.
5. Malfunctioning or worn injector Remove pump. Have pump re-
,- - 1 pump. calibrated or replace pump.
Fuel or 011leaking from ex- 1. Intake air restriction. Checklreplace filter element. Review
: haust manifold. operation for excessive idling.
2. lnjector needle valve stuck open. Locate and replace malfunctioning
I injector.
I
I 3. Obstructed turbocharger drain line. Checklclean line.
~ 4. Turbocharger seals leaking oil. Checklreplace turbocharger.
,Engine w ~ lnot
l reach rated 1. Throttle linkage incorrectly Check throttle linkage adjustment for
speed when loaded. adjusted. full travel t o the high idle stop screw.
2. Fuel supply restricted. Change the fuel filter and check fuel
I
line, pre-filter and screens for
restrictions.
3. Electronic governor incorrectly Adjust governor speed screw.
I
I adjusted.
I 4. Malfunctioning injection pump. Replace injection pump.
Low 1. Lubricating oil level too high.

2. Throttle linkage adjustment wrong.
Drain oil to proper level.
Check and adjust throttle for full travel
of the fuel control lever.
3. Low intake air temperature (below Allow engine t o warm up to proper
0"C [32' F]l . temperature before attempting to
Engine m~sfirtng.
1 1. Contammated fuel. bring it up t o RUN speed.
Verify by operating from a temporary
lSUPPIY
tank.
2-2 January 15, 1999

Page 4 Revision 5
Fault & Condition
- 1
a 90T400SLN
GROUND POWER UNIT
Probable Cause
Lngine misfiring (Continued). 2. Air in the fuel system.
Test, Check, Remedy
Bleed fuel system and check for
suction leaks.
3. Fuel injection lines leaking. Inspect and replace broken lines.
4. Incorrect valve adjustment. Inspect push rods, springs and adjust
valves.
5. Injector nozzles clogged or Replace injectors.
inoperative.
6. Injector pump timing incorrect. Checkhime injection pump.
Iuel knock. 1. Poor quality fuel. Drain tank, fill with correct fuel.
12. Air in fuel system. Bleed fuel system and check for
suction leaks.
'3. lncorrect injection pump timing. Check pump timing.
4. Injection nozzles malfunctioning. Remove nozzles. Test and repair.
Engine will not crank or 1. Battery voltage low. Remove and load test battery.
,ranks too slowly. Recharge battery.
2. Defective fuse (F2) or circuit Check fuse (F2) and circuit breaker
breaker CB2. CB2 for open. Replace if defective.
3. Starting circuit connections loose Check and tighten connections.
or corroded.
4. No voltage to solenoid. Check wiring, perform voltage check
at solenoid.
5. Solenoid or starting motor Replace starting motor.
malfunctioning.
6. Starting motor operating but not Remove the starting motor and check
cranking the engine. for broken teeth on the flywheel or
starting motor spring.
Alternator not charging or 1. Loose or corroded battery Cleanttighten battery connections.
charging is not sufficient. connections.
2. Alternator belt slipping. Checklreplace belt tensioner.
3. Alternator pulley loose on shaft. Tighten pulley.
4. Malfunctioning alternator. Replace alternator.
Engine will not start. No fault 1. Low battery voltage. Check battery connections. Tighten if
indicators ON. necessary. Perform load test on
battery, recharge if necessary.
2. Defective ignition
- switch (. S l.) . With switch at ON position, check
voltages at switch i12 VDC), replace if
defective.
3. Defective RUNIIDLE switch (S14). /check switch, replace if defective.
4. Defective starter solenoid. c h e c k starter solenoid, replace if
ldefective.
5. Defective starter. Check starter, replace if determined it
is defective.
6. Defective fuel solenoid. Check fuel solenoid.
7. Defective K7 relay. Check N.C. contacts to open when
energized.
January 15, 1999 2-2

Revision 5 Page 5
I
Fault & Condition
a 90T400SLN
GROUND POWER UNIT
IEngine will not start. No fault 8. Defective time delay relay K8. Check relay K3 for fused N.O.
!i:li;I= ON (Continued). contacts. Replace if defective.
Engine will not start. Control 1. Ignition circuit breaker (CB3) Reset circuit breaker CB3.
p o w e r ON indicator not illu-
Engine will not start, no read- 1. Low fuel.

ing on fuel gauge.
!
tripped.
2. Defective fuse (F2).
2. Defective fuel level sending unit.

I Check fuse F2, replace if defective.
Check fuel gauge. Fill fuel tank if
required.
Check sending unit. 35+/- 10 ohms
full, 250 +I -ohms empty.
10
,High water temperature indi- 1. High water temperature. Check water temperature level gauge
cator ON. & fluid level in radiator.
2. High water temperature switch Check high water temperature switch
I
I
-- --
Overspeed ~ n d ~ c a t ON.
or
defective.
I.Overspeed condition, governor
needs adjustment.
S3 for short, replace if defective.
/Reset overspeed switch and adjust
governor to: 2000 RPM if using Mara-
thon@ generator or 2400 RPM if using
KatoB generator.
I 2. Defective overspeed switch circuit Perform continuity check on terminals
I
in the electronic governor control 1 and 2. Circuit should be open below
I module. 2800 RPM.
Low oil pressure indicator 1. Low oil pressure. Check oil dip stick. Add oil as required.
/2;w oil pressure switch defective. Check l o w oil level pressure switch
for binding or short. Replace if defec-
I tive.
~ n ~ i will
n enot go to RUN I I.Defective RUNIIDLE switch (S14). / w i t h S14 in the RUN position, check
I
speed. I lfor continuity. If switch contacts are
open, replace switch.
3. Defective K47 relay control box. Check relay coil for open and contacts
14. Defective actuator. lI ~ h e c kactuator for freedom of

movement. Check coil for open or
shon.
5. Maladjusted or defective /a. With engine off, turn MPU
magnetic pickup (MPU). clockwise until contact with flywheel
is made, then turn CCW one (I) full
turn.
openlshorted coil. Replace MPU if
!
1 /c. CheckJadjust clearance, check coil
I
r-
I Ifor open, replace if defective.
1 Eng~neshuts off. Fault condl- / 1. Open diode CR21 on Diode 'Replace Diode Logic board.
ltlon ex~sts,but fault indicator Logic Board.
not light Indicators 2. Defective overspeed indicator Replace ind~catorif defective.
lcheck OK with test push but- (DS76).
tons.Overspeed ind~cator
;does not I~ght.
I
2-2 January 15, 1999

Page 6 Revision 5
-
I
\
f a u l t b Condition
High temperature indicator
a 9OT40OSLN
GROUND POWER UNIT
I
Probable
- Cause
/ 1. Open diode CR22 located on diode
Test, Check, Remedy
Replace diode logic board.
I does not light logic board.
2. Defective high temperature Replace indicator if defective.
I (indicator (DS 75).
1 Low oil pressure indicator 1. Open CR20 on diode logic board. Replace diode logic board.
d o e s not light. 2. Defective low oil pressure indicator Replace indicator if defective.
Fuel level gauge inoperative. 1. Defective fuel level gauge. Check for 24VDC at gauge. Check fuel
level sender. Replace gauge if 24VDC
is available and sender checks OK.
2. Defective fuel level sender. Check wiring t o the sender.
Engine will not shut off, fault 1. Defective fault relay K7. Check K7 coil for open. Replace if
indicator ON. defective.
2. Defective relay K48. Check coil for open. Check contacts
Engine will not shut off. No -

1. Overspeed condition Defective Check contacts on overspeed switch.
fault indicator lights, but fault contacts on overspeed switch (S5). Replace if defective.
condition observed. 2. Over temperature - Defective high Check high temperature switch,
temperature switch. replace if defective.
3. Low oil pressure condition - Check low oil pressure switch, replace
Defective low oil pressure switch. if defective.
January 15, 1999 2-2

Revision 5 Page 7
-
1 Fault & Condition

-
iNo AC voltage. Engine at
a 9OT40OSLN
GROUND POWER UNIT
Table 2. AC Generator Troubleshooti
Probable Cause
1. Voltmeter selector switch in
1 Chart
Test, Check, Remedy
'lace switch in L1, L2 or L3 position.
l RUN speed, no fault indica- OFF ~ o s i t i o n .
/tors ON, frequency at 400 Hz. 2. Defective voltmeter Sheck voltage at meter, if 115VAC is
3btained. redace meter.
I No AC voltage. Engine at 1. Defective RUNIIDLE switch. rllrith ignition switch in ON position,
R U N speed, no fault indica- dace S14 to RUN position. Check S14
'tors ON. ire # I 6 3 for 12VDC. Check wire
# I 7 0 for 12VDC. Replace S14 if
~ o l t a g eis on wire # I 6 3 and NOT on
ire #170.
2. Automatic Voltage Regulator (AVR) :heck fuse on AVR. Check 24VDC to
fuse blown or AVR defective. 4VR. Check generator field windings.
qeplace AVR if fuse and generator
field checks OK and 24VDC is
3btained at AVR.
3. Defective generator exciter field. 'erform continuity test between F1 -
f2.
4. Defective power supply. Zheck condition of transformer TI,
lerminals 1 thru 9. If transformer
2hecks OK, change power supply.
5. Defective supply transformer T I . Inspect T I for loose, burned, or
shorted wiring, terminals 1 thru 9.
6. Defective diodes in generator field Check diodes for open, replace if
exciter. defective.
~LowIHighAC voltage, no con. 1. Defective fuse(s1. Check fuses F3-F5. F6-F8.
trol. Engine at RUN speed, 2. Defective or maladjusted R32 on 4djust R32. Counterclockwise
1 undervoltage indicator ON. the Automatic voltage Regulator increases output. If no change in
(AVR) board. o u t ~ u t replace
, AVR.
3. Defective supply transformer T I . a. Inspect T I for open, loose or
burned wiring.
b. Check fuses F3 - F8.
4. Defective volts adjust Measure R5 for 0 to 1.5K ohms.
potentiometer.
5. Defective generator exciter field Check diodes for open.
diodes.
6. Defective sensing relay K1 on a. With unit running, S40 in REMOTE
remote sensing assembly. position and K1 OFF, measure voltage
on terminals 3,6, & 9 on the remote
sense board. Record readincls.
b. Connect AC output to 30KVA
c. Apply load (KI ON), observe

voltmeters on loadbank for voltages
d. Verify voltages on terminals 3,6,9

on the remote sense board.
2-2 January 15, 1999

Page 8 Revision 5
Fault & Condition
a 90T400SLN
GROUND POWER UNIT
Table 2. AC Generator Troubleshootina Chart (Continued)
LowIHigh AC voltage, no con- 5. Defective sensing relay K1 on (1) If remote sense is working, meter
trol. Engine at RUN speed, remote sensing assembly (Continued). readings will equal voltmeter readings
undervoltage indicator ON. on loadbank. Terminals 3=A, 6=B,
(Continued) 9=C phase.
(2) If remote sense is not working,
voltage measured at terminals 3,6,9
will equal measurements taken in
step a and voltage observed on
loadbank meters will be low.
AC output voltage high. No 1. R32 on the AVR board defective or Adjust R32. Clockwise decreases
control. Shuts down on over- adjusted incorrectly. output.
voltage. 2. Defective R5 potentiometer. Check R5 0 to 1.5K ohms.
3. Defective supplylsensing Check T I output for 8 to 9 VAC,
transformer T I . terminals 7, 8, 9. Replace if low.
No AC output voltage at ca- 1. Defective K1 output contactor Check for 12VDC at coil. If volts good,
ble connector. AC voltage at relay. change coil.
panel meter. 2. Defective K2 relay. Check for 12VDC at coil, and for
closing of contacts.
3. Defective K4 relay. Check N.C. contacts of K4.
No AC output voltage at ca- 1. Overload indicator ON. Overload Check GPU for overload. Remove
ble connector. condition.
-
overload and reset.
2. Overload indicator ON. Defective If indicator stays ON with overload
AC overload module. removed, replace overload module.
3. Overload indicator ON. Check relay K5. Replace if
Defective relay K5. defective.
Over or Under (O/U) fre- 1. O/U frequency condition exists. R8 Adjust frequency adjust
quency indicator ON. not properly adjusted. potentiometer R8 t o obtain 400 Hz on
-
meter. -
2. Defective or binding actuator. Check actuator for binds. Replace if
defective.
3. Defective over frequency module. If indicator stays ON, but frequency is
correct, replace overlunder frequency
module.
Over voltage indicator ON. 1. Overvoltage condition. voltage Adjust R5 to obtain proper voltage.
adjust potentiometer (R5) not
properly adjusted.
2. Potentiometer R32 on AVR not /Adjust R32. If no change in output,
adjusted properly or is defective. change AVR.
3. OverIUnder voltage module Reset AC. If voltage stabilizes at
defective. 115VAC and after 5 to 7 seconds the
overvoltage indicator turns ON,
,change the module.
power supply. Check condition of transformer TI,
terminals I,2, 3, 4, 5, and 6. If
transformer checks good, change
power supply.
(5. Defective voltage regulator. 1 Replace voltage regulator.
January 15, 1999 2-2
Revision 5 Page 9
a 90T400SLN
GROUND POWER UNIT
Table 2. AC Generator Troubleshooting Ch, t (Continued)
Test, Check, Remedy
Replace supply/sensing transformer
(Cont~nued). TI.
Replace voltage adjust
potentiometer R5. potentiometer R5.
8. Defectrve generator exciter f ~ e l d Check diodes.
I -
diodes.
t- -
Under voltage rndrcator ON. 1. Undervoltage condition exrsts. Adjust R5 t o correct voltage.
Voltage adjustment potentiometer R5
is rncorrectly adjusted.
2. OverIUnder voltage (O/U) module Reset AC. If AC voltage stabilizes at
-
115VAC and after 5 7 seconds the
indicator illuminates, change O/U
voltaae module.
A C output voltage adjust- Check R5 for opens or intermittent
/ rnent range limited. Voltage readings. Replace if defective.
'cannot be adjusted t o Set voltage adjust potentiometer R5
o n control panel at m i d point. Adjust
200VAC line t o line. potentiometer R32 o n voltage
regulator board for a reading of
2OOVAC line t o line o n the AC output
I voltmeter.
1
Panel llghts and~nstrument 1. Instrument circuit - Open circuit Reset circuit breaker.
llghts do not I ~ g h t . breaker.
2, Individual panel lights d o not light - Replace lamp.
Blown lamp.
lndlvrdual fault lamp does 1. Blown lamp. Replace lamp.
Ilnot .
llght when Fault Lamp / 2. Defective diode. Check diode for open: CR6 = U N ;
Test pushbutton IS pressed. CR8 = O N ; CR5 = O/F; CR4 = U/F;
CR7 = OIL; CR 1 1 = H i Temperature;
I
CRlO = Overspeed; CR9 = L o w oil
I pressure. Replace diode logic board.
I -.
lndrv~dualfault l ~ g h does
t Check diode for open: CR17 = U N ;
light. CR19 = O N ; CR16 = O/F; CR15 =
I
U/F; CR18 = OIL; CR22 = Hi
Temperature; CR21 = Overspeed;
CR20 = L o w oil pressure.
2-2 January 15, 1999

Page 10 Revision 5
Fault & Condition
a
Voltage. AC voltage at
90T400SLN
GROUND POWER UNIT
Table 3. DC System Troubleshooting Chart
Probable Cause
1. Defective over voltage
Test, Check, Remedy
Press FAULT RESET pushbutton. If
I 115 VAC, Line to Neutral. AC fre- module. indicator stays ON, replace over
lquency 400 Hz. DC Overvoltage 1 /voltage module.
I indicator ON. 2. Defective Kl 1 relay. Replace relay K11.
3. Shunt resistor open. Replace shunt resistor.
Overload indicator (AC panel) 1. Unit overloaded. Remove load from power plant.
lit. Over Temperature indicator Allow unit to cool down, the Over
lit. Temperature indicator should go
2. Air flow through TIR unit blocked. Check air passage for obstruction.
Fan not working. Replace fan blower if required.
3. Defective Current LimitILine Drop Replace CLILDC module.
Compensation (CLILDC) module.
OVERLOAD indicator lit. OVER- 1. Defective overload module. Replace overload module.
TEMPERATURE indicator OFF. 2. ~ ~
power supply.
f ~ ~
Replace ~ supply.i
power ~ ~
3 . Defective Current Sense module. I ~ e ~ l a module.
ce
4. Defective Automatic Voltage Replace AVR.
Regulator (AVR).
No increase in DC voltage with 1. Defective Current LimitILine Drop Replace CLILDC module.
3. Defective DC Power Supply Replace DC Power Supply module.

module.
14. Defective Current Sense module. l ~ e a l a c eCurrent Sense module. 1
Current not limited in Soft Start 1. Defective CLILDC module. Replace CLILDC module.
mode. 2. Defective Automatic Voltage Replace AVR,
-
Regulator (AVR).
13. Defective Current Sense Module. l ~ e ~ l a Current
ce Sense module.
January 15, 1999 2-2

Revision 5 Page 11
I
)
Item I
No. 1 Nomenclature
a 9OT40OSLN
GROUND POWER UNIT
Table 4. Schematic Diagram Component Key A n d Description
Location Functional description

A1 ~ u t o m a t l cVoltage Electrical Drawer Assy Maintains voltage at preset level under all
Regulator (AVR) load conditions.
A2 Over/Under Voltage Electrical Drawer Assy Protects aircraft and generator f r o m
- -
Module over/undervoltage conditions.
A3 ~ v e r l ~ n d Frequency
er Electrical Drawer Assy I ~ r o t e c t saircraft and generator f r o m an
I Module lover/under frequency condition.
1 A4 Overload Module Electrical Drawer Assy 1 protects generator f r o m overload condition.
~
I A5 Power Supply Module Electrical Drawer Assy :provides control voltage for protective circuit
1 card operation and rectifies voltage for
I
4
I
I 1 i aenerator field o ~ e r a t i o n . 1
A6 I r i o d e Logic Board Electrical Drawer Assy l ~ r r i diodes
n~
A7 Remote Sense Module Electrical Drawer Assy Allows voltage regulator t o sense load
conditions at the end of the cable. Precise
voltage regulation is maintained at the cable
end under all load conditions.
A8 j ~ l e c t r o n i cGovernor Electrical Drawer Assy Provides engine speed control, gain and
1 control stability.
A13 ~ e l a Module
y Board Electrical Drawer Assy Mounts relays K2, K4, K5, K6, K7, K10
ACT over nor Actuator Engine Fuel control actuator. Receives signal from A8
and moves throttle linkage t o control engine
l s~eed.
1 ALT ~ l t e r n a t o r En
1 B1.2 Batterv Frame 12 VDC source for enaine startina and control.
1 CB1 c i r c u i t Breaker
,
' ~ n ~ i Control
ne Panel Protects governor control unit and harness.
10 A m p
I
CB2 Circuit Breaker - Engine Control Panel Instruments and harness protection. 5 A m p
CB3 ,Circuit Breaker Engine Control Panel Engine ignition and harness protection. 15
I .
i Amp
t ~ 4 - ~
I 8iode
Diode Logic PC Board Lamp Test Circuit, provides for 1 point
ground t o lamps test DS7,8,9, 10, and 11.
I
CR9, Diode Diode Logic PC Board Lamp Test Circuit, provides for 1 point
10,ll -. -
ground t o lamps test DS14, 15, and 16.
CR15 Diode Diode Logic PC Board Generator fault circuit - Isolates A2,A3 and A4
- -19 I during lamp test of DS7 thru 10.
CR20 Diode Diode Logic PC Board Engine fault circuit - Isolates K7 during lamp
test of DS 14.
~ ~ lode
2 1 ~ i o d Logic
e PC Board Engine fault circuit - Isolates K7 during lamp
I test of DS 16.
Diode Logic PC Board n e circuit - lsolates K7 during lamp
~ n ~ i fault
/test of DS 15.
I
CR29 Diode Diode Logic PC Board Blocking diode. Prevents power back feed
f r o m S6 t o A4,5.
1 ~ ~ 3Diode
0 Diode Logic PC Board Blocking diode. Provides isolated ground
path for fault relay K7 during l o w fuel quantity
~
I
I I fault conditions.
2-2 January 15, 1999

Page 12 Revision 5
Item
No. 1 Nomenclature
a 90T400SLN
GROUND POWER UNIT
Table 4. Schematic Diagram Component Key And Description (Continued)

3R31 Diode Diode Logic PC Board Blocking diode. Prevents power back feed t o
pin E of the output cable when S6 is i n the
interlock/bypass position.
3R32 Diode Diode Logic PC Board Steering diode.
3R33 Diode Logic PC Board Steering diode.
3R34 Diode Diode Logic PC Board Engine fault circuit. Isolates l o w oil pressure
switch from other fault indicators.
3R35 ' ~ i o d e Diode Logic PC Board Engine fault circuit. Isolates overspeed switch
f r o m other fault indicators.
3R36 / ~ i o d e Diode Logic PC Board Engine fault circuit. Isolates high temperature
circuit f r o m other fault indicators.
2R41 Diode Diode Logic PC Board Arc suppression diode.
CT1 /Current Transformer Contactor Panel Provides current signal (A phase) t o power
I supply module then t o overload module.
CT2 Current Transformer Contactor Panel Provides current signal (Bphase) t o power
supply module then t o overload module.
CT3 ;Current Transformer Contactor Panel Provides current signal (Cphase) t o power
supply module then t o overload module.
CT4 Meter Transformer Contactor Panel Provides current signal for A phase ammeter
readinas.
CT5 /Meter Transformer Contactor Panel Provides current signal for B phase ammeter
I
readings.
CT6 M e t e r Transformer Contactor Panel Provides current signal for C phase ammeter
readings.
DS1 Indicator, AC Load ON Generator Control Panel Illuminates when load contactor is energized
and generator voltage is applied t o load.
DS4 !Lamp Engine Control Panel Illuminates oil pressure gauge (M9).
DS5 lLamp Engine Control Panel Illuminates water temp. gauge (MIO).
DS7 /indicator, Overload Generator Control Panel Illuminates when overload fault has occurred.
DS8 'lndicator, Overvoltage Generator Control Panel llluminates when an overvoltage condition
has occurred.
DS9 Indicator, Undervoltage Generator Control Panel llluminates when an undervoltage condition
has occurred.
3S10 lndicator Underfrequency Generator Control Panel llluminates when an underfrequency
,condition has occurred.
D S l 1 Indicator, Overfrequency Generator Control Panel llluminates when an overfrequency condition
has occurred.
DS14 ' ~ a u lIndicator,
t L o w Oil Engine Control Panel Illuminates when a l o w oil fault condition has
occurred.
DS15 Fault lndicator Water Engine Control Panel Illuminates when high water temperature fault
I T e m ~ eature
r condition exists.
I
DS16 Fault lndicator, Over Engine Control Panel IEngine Panel: Illuminates when an overspeed
Speed fault condition occurs.
January 15, 1999 2-2

Revision 5 Page 13
-- a 90T400SLN
GROUND POWER UNIT
Table 4. Schematic Diagram Component Ke A n d Description (Continued)
Nomenclature Location Functional description

lDS17 Lamp Canopy, over control Illuminates control panel.
ane el.
Illuminates when ignition switch S1 is placed
to ON.
I
DS30 Lamp Engine Control Panel Illuminates battery volt meter.
DS31 Lamp ~ n ~ i Control
n e Panel Illuminates fuel aauae lM81.
EXC Generator winding Generator Exciter winding of generator.
Contactor Panel Main power/Harness protection.
Electrical Drawer Assy. Harness instrumentation protection (A phase).
F4 ~ u s e 5 A Electrical Drawer Assv. Harness instrumentation protection (B phase).
I F5 use 5A ! ~ l e c t r i c aDrawer
!
l Assy. Harness instrumentation ~ r o t e c t i o n/C ahasel.
F6 Fuse 5A ;Electrical Drawer Assy. Remote sensina A ~ h a s e
~rotection.
F7 Fuse 5A Electrical Drawer Assy. Remote sensing, B phase protection.
F8 Fuse 5A - Electrical Drawer Assy. Remote sensing, C phase protection.
F9
L-
F u s e 5A 4Electrical Drawer Assy. Generator fault circuitry protection.
F10 ~ u s e 5 ~ i Electrical Drawer Assv. Circuit protection, power supply board.
/ ~ o n t a c t o Panel
r Circuit protection, K1 output contactor coil.
FLS Sender, Fuel Level Fuel Tank Fuel Tank level sianal for M8.
FS Fuel
- Solenoid Engine Controls fuel supply t o injector pump.
G 1 1 Generator
-A- Frame Produces 115/200VAC 400 Hz.
K1 / o u t p u t Contactor Contactor Panel Applies or disconnects generator output
I power t o load.
K2 ,Relay, Hold-in Relay Module Board Hold-in relay for K1 contactor.
K4 ~ e l a ~ Relay Module Board Disconnects output contactor f r o m load
I during any detected generator fault condition.
K5 Relay Relay Module Board Provides discharge path for capacitor o n
overload module durinq Fault Reset function.
-Relay Relay Module Board Disconnects voltage regulator (AVR) during
overvoltage and overload conditions.
K7 ~ n ~ i Fault
n e Relay j~ e l Module
a ~ Board Provides voltage t o fuel solenoid through
N.C. contacts. lnterrupts power t o fuel
solenoid when energized b y any engine fault
detection circuit.
1 ~ o n t a c t o Panel
r Low oil pressure fault delay. lnterrupts l o w oil
pressure fault circuit when energized, enables
fault circuit in N.C. position.
1
K10 lnterlock Relay 1 ~ e l Module
a ~ Board Provides ground for K2 relay when Generator
I InterlockIBypass switch is placed in the
Interlock position.
1 ~ o n t a c t o rPanel Provides power t o hourmeter M I 2 when
energized. K42 is energized whenever engine
oil pressure is more than 10 psi.
2-2 January 15, 1999

Page 14 Revision 5
I
I
a 9OT40OSLN
GROUND POWER UNIT
Table 4. Schema c Diagram Component Kev And Descri~tionKontinuedl

I
K45 Ether Start Solenoid Ither Start Assembly When energized, provides ether to injector
pump assembly.
K48 solenoid :ontactor Panel Provides power to engine mounted starter
solenoid.
:ontactor Panel Provides power to low fuel warning light
when activated by low fuel switch S39A.
M1 / Meter, Amperage Senerator Control Panel lndicates amount of current being drawn by
load.
M2 / Meter, Voltase Senerator Control Panel lndicates generator output voltage.
M7 Meter, Frequency Senerator Control Panel Frequency of generator output.
M8 Gauge, Fuel Level f ngine Control Panel Displays fuel level in fuel tank.
M9 Gauge, Oil Pressure E ngine Control Panel Displays engine oil pressure.
M I 0 'Gauge, Water Engine Control Panel Displays engine coolant temperature.
!TernDerature - -
M 11 voltmeter Engine Control Panel Displays BatteryIAlternator voltage when

ignition switch in in ON position.
Engine Control Panel Records engine operating time.
Engine Governor System - Provides engine speed
signal t o governor control from engine
1 flywheel.
OPS /pressure Sender Engine Engine Oil Pressure Sender signal for oil
pressure gauge (M9)
R5 potentiometer Electrical Drawer Assy. Voltage adjust potentiometer 1.5K, 2W
R9 l ~ e s i s t o r Contactor Panel, on TDI Low oil pressure fault delay relay, current
limiting resistor to set length of time delay.
S1 iswitch, lsnition Engine Control Panel Main Power ONIOFF.
S2 /Switch, Ammeter Phase Generator Control Panel Selects desired phase for amperage
1 Selector monitorina.
S3 Switch, Volt Phase Generator Control Panel Selects desired phase for voltage monitoring.
Selector
S4A l ~ o a d
ON Pushbutton Generator Control Panel L o a d ON switch to control AC output.
Switch, N.O.
S4B Load OFF Pushbutton Generator Control Panel Load OFF switch to control AC output.
Switch, N.C.
S6 ;Toggle Switch SPDT Electrical Drawer Assy. InterlocWBypass select switch for power
output control.
S11 T o s s l e Switch. Fault Reset Generator Control Panel Resets generator fault circuits.
S13 /pushbutton Switch , Engine Control Panel Pushbutton switch engages starter motor.
I ~ n ~ i Start
n e
S14 Toggle Switch, IDLEIRUN Engine Control Panel GovernorIGenerating System - Two position
switch, IDLE position = 800 RPM, RUN
position = 2000 RPM if using Marathon@ gen-
erator or 2400 RPM if using KatoB generator.
January 15, 1999 2-2

Revision 5 Page 15
-
-
.
-
I
I
I Item
! No. ! Nomenclature
-.
a
Table 4. Schematic Diagram
--
9OT40OSLN
GROUND POWER UNIT
Component Key A n d Description (Continued)
I
S 16A, Switch, Oil Pressure
I
Engine Low oil pressure fault circuit. N.C. switch
opens o n rise of oil pressure t o above 6 psi.
Closes below 10 psi and activates l o w oil fault
circuit.
S17 Sw~tch,Engine Engine Engine fault circuit - N.O. switch closes when
Temperature engine water temperature rises above 225OF
I activatmg the engine high water fault
temperature circuit.
S18 ,Switch, Panel lights 1 Engine Control Panel
i I
S21 Fault Lamp Test,
Pushbutton S w ~ t c h
1 en era tor Control Panel
Operates control panel lamp DS 17.
Press-to-test fault lights.
1 S32 /switch, Pushbutton N.O. l ~ i d of

e Electrical Drawer l ~ i m u l a t e soverload condition.
I I I, Assemblv 1
I S33 :switch, Pushbutton N.O. / s i d e of Electrical Drawer /simulates Underfrequency condition.
1 534 s w i t c h , Pushbutton N.O.

I
S35 Switch, Pushbutton N.O.
1 Side of Electrical Drawer
Assemblv
Side of Electrical Drawer
s i m u l a t e s Overfrequency condition.
Simulates Overvoltage condition.

Assembly
S36 Switch, Pushbutton N.O. Side of Electrical Drawer Simulates Undervoltage condition.
- i Assembly
S37 switch, Pushbutton Side of Control Panel Ether start pushbutton switch.
538 Switch, Temperature Engine Temperature switch. Opens w h e n warm,
disconnecting ether start system.
S39A Switch, Fuel Level ,Fuel Tank Fuel level switch, when level is low, lights
1
warning light. A t lower level, creates fault and
shuts-down engine.
S40 Switch, Toqqle Electrical Drawer Assv. LocalIRemote Sense select switch.
SM1 Starter Motor Engine Engine mounted starter motor.
SS 1 Starter Solenoid Engine Starter Engine starter mounted control solenoid.
TI Transformer Electrical Drawer Assy. Transformer, voltage sense and power supply.
TBI Terminal Board, 18 Point Electrical Drawer Assy. Terminal board, 18 point.
TBI Terminal Board. 5 Pt. Left Side of Enaine. Terminal board. 5 ~ o i n t .
TB2 l ~ e r r n i n aBoard,
l 4 Point Left Side of Engine. Terminal board, 4 point, generator output
connections.
TB3 ~ e r m i n aBoard,
l 18 Point icontactor Panel p
terminal
I
board, 22 point
TB10 Terminal Board, 3 Point Contactor Panel (on edge) Terminal board, 3 point, John Deere engine
onlv. I
' TD1 Relay, Time Delay 1 contactor Panel Time delay relay used t o lock out l o w engine
Engine Engine water temperature signal for water

Temperature temperature gauge (M70).
2-2 January 15, 1999

Page 16 Revision 5
'tom
I
Nome"clature
a 90T400SLN
GROUND POWER UNIT
Table 4. Schematic Diagram Component Key And Description (Continued)

21 Metal Oxide Varistor Mounted o n Relay K 1 Metal Oxide Varistor (MOV). Protects control
(MOv) winding of K1.
3. SCHEMATICS AND WIRING DIAGRAMS

This troubleshooting section incorporates schematics and associated wiring diagrams for
use by the technician. They should be used in conjunction with the Troubleshooting Chart
(Table I ) . When troubleshooting the diesel engine, the troubleshooting chart (Table I )
should be used in conjunction with the Engine Troubleshooting and Repair Manual. The
engine manual supplies an in-depth and comprehensive troubleshooting guide with repair
instructions. The schematic and wiring diagrams include:
Figure 1 - Schematic Ground Power Unit
Figure 2 - GPU Wiring Diagram
January 15, 1999 2-2

Revision 5 Page 17
GROUND POWER UNIT
2-2 January 15, 1999

Page 18 Revision 5
UGROUND
POWER UNIT
CHAPTER
2
SECTION
3
1. GENERAL
This section contains instructions for removal and installation of ground power unit major
components. All major components can be unbolted and removed from the GPU. Compo-
nent boards can be unplugged, and mounting hardware removed.
Remova1/1nstallation instructions for engine subassemblies i.e., water pump, fuel pump
injectors etc., can be found i n the engine Operation and Maintenance Manual for the engine
utilized.
2. TORQUE VALUES FOR GENERAL ASSEMBLY
The torque chart value (Chapter 5) is provided f o r reference when performing general
assembly of various components. These values should be used only if torque values are not
otherwise specified for a particular assembly. For an example refer t o Chapter 5, Manufac-
turers' Appendices for engine assembly or other components assemblies which may require
special torque specifications.
The following conditions must be observed when using the general assembly torque values:
Joints are assumed t o be metal and rigid. Do not use these values where gaskets or
compressed material may be damaged by over-torquing .
During disassembly, note bolt head marking and always reassemble the same hard-
ware or equivalent new hardware in the correct locations.
As a general, when reusing previously removed hardware, apply the minimum values
from the table.
Reduce the Table values by 20% when assembling plated hardware or phosphate
coated hardware.
Reduce Table values by 30% when molykote, white lead, or similar mixtures are used
t o lubricate threads.
Reduce the Table values by 35% when torquing jam nuts (thin nuts).
Special use column values in the Table are for capscrews in gray iron castings when
threads length engagement is at least 1.5 times the capscrew diameter.
November 15, 1995 2-3

Original Page 1
UGROUND
POWER UNIT
\\rRltNING
BEFORE STARTING ANY INSTALLATION OR REMOVAL PROCEDURES, TURN THE
ENGINE OFF BY PLACING THE IGNITION SWITCH TO THE OFF POSITION.
DISCONNECT BATTERY LEADS FROM THE BATTERY (NEGA TIVE GROUND LEAD
DISCONNECTED BEFORE THE POSITIVE LEAD).
3. ENGINEIGENERATOR REMOVAL
A. Canopy Removal (Refer to illustrations in Chapter 4) :
(1) Open rear canopy half and support canopy by placing a suitable brace of at least
46 inches (7 168mm) in height under canopy. This will prevent the canopy from falling
once the canopy retaining rods are removed.
(2) Remove bolt and nut and remove retaining rods.
(3) The canopy pin hinges are of the separating type. Lift the canopy roof off of the
support brace and slide the entire assembly t o the left until hinge assembly separates.
(4) Disconnect engine exhaust pipe from muffler.
(5) Unbolt and remove the front canopy half.
B. Adjacent Hardware Preparation
(1) Loosen radiator shroud.
(2) Drain engine coolant (5.5gals [20.8ltr]).
(3) Disconnect upper and lower radiator hoses from the engine.
(4) Disconnect engine coolant heater hoses (If applicable). One o n each side of the
engine.
(5) Disconnect and cap fuel pressure and return lines.
(6) Disconnect engine ground wire.
(7) Referring t o the Engine Wiring Diagrams in Section 2-2, disconnect electrical wiring
and harnesses which connect t o the enginelgenerator. Taglidentify all leads required
for disassembly. Disassemble only to the extent necessary t o accomplish the re-
movallrepair.
" Disconnect AC output cable from K1 contactor and Terminal Board 2 (TB2).
O Disconnect generator output wires from TBI o n the Power Panel Assembly
Bridge.
(8) Remove bolts attaching generator bridge to frame (Figure I ) .
(9) Using a suitable lifting device and lift chain, lift bridge assembly u p and away from
the generator.
(10) Install generator lifting eyebolt into stator housing (Figure 2).
2-3 November 15, 1995

Page 2 Original
C. EnginelGenerator Removal: (Refer to Figure 2)
(IAIJTION
WHEN LIFTING THE ENGINE AND GENERATOR, USE A HOIST WITH LIFTING
CAPABILITY OF AT LEAST 3000 LB. (7367 kg).
MAKE SURE THE LIFTING CHAINS ARE POSITIONED TO ALLOW THE ENGINE1
GENERATOR TO BE LIFTED VERTICALLY FROM THE UNIT.
(1) Using a lifting hoist and chains, attaching chains t o the front engine lifting eyelet
and the generator lifting eye bolt.
BEFORE REMOVING THE ENGINEIGENERATOR MOUNTING BOLTS, REMOVE ALL

SLACK IN THE LIFT CHAINS. APPLY ENOUGH LIFTING FORCE TO PREVENT THE
GENERATOR FROM SHIFTING BACK ONTO THE FUEL TANK WHEN THE MOUNTING
BOLTS ARE LOOSENED.
Figure 1. Bridge Assembly
November 15, 1995 2-3

Original Page 3
UGROUND
POWER UNIT
Figure 2. EnginelGenerator Lifting Arrangement
(2) Remove front and rear mounting bolts securing enginelgenerator to the frame. Refer
to Section 4-3 for illustration.
(3) Lift engine and generator from unit.
DO NOT PLACE ENGINEIGENERATOR DIRECTLY ONTO GROUND OR FLAT SURFACE.

DAMAGE TO ENGINE OIL PAN WILL RESULT. PLACE AN 8 112 INCH (276mm)
WOODEN BLOCK UNDER THE FRONT ENGINE MOUNT BRACKET AND AT LEAST
A 3 INCH (76mm) BLOCK ON EACH SIDE OF THE GENERATOR, BENEATH THE
WELDED GENERATOR SUPPORT BRACES.
4. ENGINEIGENERATOR INSTALLATION
(:RIJTION
UTILIZE TORQUE VALUES FOR GENERAL ASSEMBLY WHEN INSTALLING
ENGINEIGENERATOR MOUNTING BOLTS AND OTHER AlTACHING HARDWARE. -
A. Preparation:
(1) Install front engine mount t o engine (if previously removed).
(2) Attach the two rear engine mounts to fly wheel housing (if previously removed).
(3) Install generator lifting eye bolt to stator housing.
2-3 November 15, 1995

Page 4 Original
GROUND POWER UNIT
(4) Attach a suitable hoist to front engine lifting eyelet and t o generator lifting eye bolt.
B. Installation:
BEFORE INSTALLING ENGINEIGENERATOR, INSPECT EACH SNUBBER WASHER FOR

SERVICEABILITY. REPLACE IF CRACKED OR FOUND TO BE OTHERWISE DEFECTIVE.
(1) Align engine mounts with snubber washers installed o n frame.
(2) lnstall engine mounting bolts and torque.
C. Engine Attachments:
(1) Attach fuel pressure and return lines.
(2) lnstall exhaust system.
(3) lnstall radiator shroud.
(4) Attach upper and lower radiator hoses.
(5) Attach heater hoses, one o n each side of engine block (if applicable).
(6) A d d engine coolant (Refer to Servicing, Chapter 2- 7).
(7) lnstall engine ground wire.
(8) lnstall Assembly Bridge.
(9) Attach all electrical wiring (Refer to wiring diagrams, Chapter 2-2).
5. GENERATOR REMOVALIINSTALLATION
To Remove only the generator proceed as follows:
A. Electrical Disassembly (Refer to wiring diagrams in Chapter 2-2):
NOTE: Taglidentiw aN electrical leads disconnected for disassembly. Disassemble only to the
extent necessary to accomplish the repair.
(1) Disconnect AC output cable from K1 contactor and Terminal Board 2 (TB2).
(2) Disconnect generator output wires from TB1 o n the Power Panel Assembly Bridge.
(3) Disconnect engine ground wire from frame.
(4) Disconnect the three (3) electrical connectors and slide the control panel component
drawer assembly completely out of the enclosure.
(5) Disconnect and cap the fuel pressure and return lines.
(6) Remove Assembly Bridge (Refer Figure 7).
" Remove bolts attaching bridge t o frame.
" Using a suitable lifting device and lifting chain, lift bridge assembly up and away
from the generator.
November 15, 1995 2-3

Original Page 5
UGROUND
POWER UNIT
B. Generator Removal (Figure 3) :
(1) Install lifting eye bolt (Figure 2.) into generator stator housing and attach lift chain
to eye bolt. Remove all slack in chains to prevent the generator from dropping when
unbolted from engine.
(2) Remove the generator ventilation screen.
(3) Loosen the internal generator fan (2 bolts).
(4) Slide fan assembly back towards generator to gain access to flex coupling.
(5) Remove 8 bolts that secure the flex coupling to the flywheel.
(6) Uncouple the engine and generator by removing the 12 bolts around the generator
casing.
(7) Remove fan and coupling from generator. Clean and inspect fan, coupling and all
attaching hardware for serviceability prior to installing on new generator.
C. Generator Installation:
1I (~1NJ'l'I~~N
UTILIZE TORQUE VALUES FOR GENERAL ASSEMBLY WHEN INSTALLING
ENGINEIGENERATOR MOUNTING BOLTS AND OTHER ATTACHING HARDWARE. 1
(1) Install generator lifting eye bolt into generator stator housing and attach lifting hoist
(Refer to Figure 2).
(2) Position the fan around the flex coupling and loosely install the 2 fan bolts.
(3) Using lifting hoist, align the generator to the engine flywheel housing. Attach
generator to engine using 12 bolts.
(4) Side the fan assembly toward the generator to gain access to the engine flywheel
and flex coupling.
(5) Align the holes in the flex coupling plate with the holes in the flywheel and attach
with 8 bolts.
(6) Slide the fan assembly toward the engine and tighten the 2 bolts already installed
in the fan assembly.
(7) Install the generator ventilation screen.
(8) Remove generator lifting eye bolt and secure to stator housing using 3 x 3/4 inch
bolt provided.
(9) Install Assembly Bridge and attach all wiring.
2- 3 November 15, 1995

Page 6 Original
BEFORE MOVING GENERATOR
RETURN SHAFT TO PROPER
POSITION TO PREVENT DAMAGE
TO ROTOR OR STATOR. THIS
UNIT IS SINGLE BEARlNG TYPE.
PROP-UP FLEX END.
R e m o v e 12 o u t e r
f r o m flywheel h o
Remove 8 flex
plate bolts
II ENGINE FLYWHEEL
ENGINE
CRANK
SHAFT
ENGINE REMOVE FAN SCREEN

FLYWHEEL TO ALLOW ACCESS
HOUSING TO FLYWHEEL BOLTS
Figure 3. Generator Removal

6. COOLING SYSTEM
A. Radiator removal (Refer to illustration Chapter 4-3)
(1) Open Radiator access door, remove radiator cap.
(2) Open radiator petcock and drain coolant into container.
(3) After coolant has been completely drained f r o m t h e enginelradiator, close petcock.
(4) Remove canopy shell t o gain access t o radiator and engine.
(5) Loosen hose clamps and disconnect both hoses (Top and Bottom) f r o m radiator.
CAIJTION 1
THE RADIATOR IS HELD I N PLACE BY SIX MOUNTING BOLTS (THREE ON EACH SIDE).
SELECT A SUITABLE HOIST TO SUPPORT RADIATOR WHEN REMOVING THE
MOUNTING BOLTS. BE CAREFUL NOT TO DAMAGE FAN BLADES OR SHROUD WHEN
REMOVING RADIATOR.
November 15, 1995 2-3

Original Page 7
-GROUND POWER UNIT
(6) Remove six bolts, three on each side, and carefully pull the radiator and shroud
straight away (towards drawbar) until shroud clears the fan blades.
B. Radiator installation (Refer to illustration Chapter 4-3):
(1) Position shroud on radiator and secure with eight (8) screws, lock washers and flat
washers.
CAIJTION
BE CAREFUL N O T TO DAMAGE FAN BLADES OR SHROUD WHEN INSTALLING
RADIATOR.
(2) Select a suitable hoist to lift radiator.
(3) Carefully position radiator between the two vertical braces.
(4) Secure Radiator into position using six bolts, lock washers and flat washers.
(5) Attach hoses to radiator (Top and Bottom), position and tighten both hose clamps.
(6) Make sure petcock is closed before adding coolant to cooling system.
2-3 November 15, 1995

Page 8 Original
GROUND POWER UNlT
CHAPTER
2
SECTION
4
ADJUSTMENTS AND TEST
1. MAINTENANCEIREPAIR GENERATOR ELECTRICAL DRAWER ASSEMBLY

A. Disassembly:
(1) Open generator control electrical drawer assembly by loosening the t w o draw down
latches, one located above each pull handle o n the control panel face of the drawer
(Figure 2).
(2) Remove the electrical drawer assembly b y disconnecting the three electrical
connectors located at the rear of the drawer assembly (J7, J12, J13).
(3) Press the tabs inward o n the drawer assembly slides (one each side of the drawer)
and pull the drawer assembly away from the enclosure. Place the drawer assembly o n
work bench.
(4) Disconnect the electrical connector or wiring attached to the component that is t o
be replaced.
(5) Remove screws securing component assembly, then remove component.
B. Reassembly: Reassemble drawer and components i n the reverse order of disassembly.
2. SYSTEM FAULT TEST PROCEDURES
A Test Panel with 5 test push-buttons (located on the right side panel of the generator
control box drawer) is provided to check the AC protective circuits and the DC protective
circuit if applicable. See Figure 2.
The AC Test push-button switches are:
" UNDER-VOLTS
" OVER-VOLTS
" UNDER-FREQUENCY
" OVER-FREQUENCY
" OVERLOAD
" DC OVER-VOLTS (Optional)
CAUTION
DO N O T PERFORM FAULT CIRCUIT CARD TEST WHILE U N I T IS OPERATING
UNDER LOAD.
A. Protective System Test Procedures
(1) AC Overload Test:
O Push and hold the Overload Test switch.
O The Overload fault indicator will illuminate.
January 15, 1999 2-4

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Figure 1. Electrical Drawer Assembly Component Layout

2-4 January 15,1999
Page 2 Revision 5
GROUND POWER UNIT
" The Frequency meter will move to the extreme left.
" AC Voltmeter will indicate approximately 10 Volts.
( 2 )AC Over Frequency Test:
" Push and hold the Over Frequency Test switch.
NOTE: Circuit may take u p to 5 seconds to actuate.
" Frequency and Voltage meters should continue t o indicate 400 Hz and 115 VAC
Line-to-Neutral (200 VAC Line-to-Line) respectively.
" Over Frequency Fault indicator should illuminate.
(3) AC Under Frequency Test:
" Push and hold the Under Frequency Test switch.
NOTE: Circuit may take u p to -5seconds to actuate.
" Frequency and Voltage meters should continue t o indicate 400 Hz and 115 VAC
Line-to-Neutral (200 VAC Line-to-Line) respectively.
" The Under Frequency Fault indicator should illuminate.
(4) AC Over Voltage Test:
" Push and hold the Over Voltage Test switch.
NOTE: Circuit may take u p to 5 seconds t o actuate.
" Frequency meter will move t o the extreme left.
" Voltage meter will indicate approximately 10 volts (residual magnetism).
1 RIGHT SIDE, ELECTRICAL DRAWER ASSEMBLY

Figure 2. Fault Push-button Test Panel
January 15, 1999 2-4
Revision 5 Page 3
GROUND POWER UNIT
" Over Voltage Fault indicator will illuminate.
(5) AC Under Voltages Test:
" Push and hold the Under Voltage Test switch.
" Frequency and voltage meters should indicate 400 Hz and 115 VAC Line-to-Neu-
tral (200 VA C Line-to-Line) respectively.
" the Under Voltage indicator will illuminate.
(6) DC Over Voltage Test (If applicable)
" Push and hold the Over Voltage Test switch.
NOTE: Circuit may take u p to .5seconds to actuate.
" DC Voltage meter will drop t o "0" volts.
" DC Over Voltage Fault indicator will illuminate.
B. Fault Lamp Test (With Engine Not Operating): The fault lamps may be tested when the
unit is either operating at run speed or with the engine stopped.
Set lgnition switch t o ON, then set IDLEIRUN switch t o RUN.
Press the Fault Lamp Test switch and observe that all fault indicators illuminate red.
Release Fault Lamp Test switch; all indicators should turn off.
C. Fault Lamp Test (With Engine Operating):
Set IDLEIRUN switch t o RUN.
Press the Fault Lamp Test switch and observe that all the fault indicators illuminate red.
Release Fault Lamp Test switch; all indicators should turn off.
D. Testing Engine Fault Indicators Only:
Set lgnition switch t o ON. Ensure the IDLEIRUN switch is set t o IDLE.
Press the Fault Lamp Test switch. Only the engine fault indicators will illuminate.
3. CIRCUIT CARD ADJUSTMENTS
All circuit cards are preset at the factory. In most instances adjustments will not be necessary
after installation of the circuit card. If, after installation, fine tuning of the circuit card is
necessary t o obtain optimum performance, follow procedures listed for each circuit card.
NOTE: Units with a line-to-line voltage selector switch will read a normal output voltage to
200 VAC. Units with a line-to-neutral voltage selector switch willread a normal output voltage
of 7 75 VAC. Both line-to-line and line-to-neutral voltages are given the the following instruc-
tions.
A. Automatic Voltage Regulator (AVR) module (See Figure 3):
(1) Pull out the Electrical Drawer Assembly to the maintenance position to have access
to the required adjustments (Figure I ) .
(2) Start unit in accordance with normal start procedures.
(3) Set RUNIIDLE switch t o RUN.
2-4 January 15, 1999

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GROUND POWER UNIT
Figure 3. Automatic Voltage Regulator (AVR) Module
L \
\
"C"
Figure 4. AC Overload Module

January 15, 1999 2-4
Revision 5 Page 5
(4) The voltage adjustment potentiometer (R5) is located at the rear of the electrical
drawer assembly (Figure 7). Adjust the potentiometer to mid range between minimum
and maximum settings.
(5) **Adjust R32 on the AVR board obtain 200 VAC line-to-line (7 75 VAC Line-to-Neu-
tral). Counterclockwise rotation (R32) increases voltage.
NOTE: For 72V units with a TR (DC) option, adjust R32 on the AVR board to obtain 796 VAC
line-to-line (7 73 VAC line-to-neutral). Then adjust voltage adjustment potentiometer R5 to
obtain 115VAC line-to-neutral (2OOVAC line-to-line).
For 24V units with a TR (DC) option, adjust R5 full clockwise, then adjust R32 on the A VR
board to obtain 198 VAC line-to-line (7 76 VAC line-to-neutral), Then adjust voltage adjustment
potentiometer R5 to obtain 7 75VAC line-to-neutral (2OOVAC line-to-line).
B. AC Overload Module (See Figure 4):
(2) Set RUNIIDLE switch to RUN and verify 200 VAC Line-to-Line on the voltmeter (7 75
VAC Line-to-Neutral).
(3) Check test point "A" for 24 VDC.
TEST
POINT'
C
TEST/
POINT
8"
Figure 5. OverIUnder Voltage Module

2-4 January 15, 1999
Page 6 Revision 5
UJGROUND POWER UNIT
NOTE: Use P I pin 7 as the test point reference ground for the voltmeter.
(4) Place voltmeter at Test Point "B" and measure for 15 k2 VDC.
NOTE: If 15 i2 VDC is not present, replace circuit card.
(5) Place voltmeter at Test Point "C" and adjust R13 t o obtain 8 VDC.
(6) R9 and R7 are factory set at fully clockwise, and should be left in that position.
(7) Place voltmeter at Test Point "D" and adjust R4 to obtain .85 VDC.
(8) Apply a 125O/0 load to unit. Overload fault protection should activate between 3 to
5 minutes.
C. Over/Undervoltage Module (See Figure 5):
(2) Set RUN/IDLE switch t o RUN and verify 200 VAC Line-to-Line (7 15 VAC Line-to-Neu-
tra1)on the voltmeter.
NOTE: Use P7 pin 5 as the test point reference ground for the voltmeter.
(3) Place voltmeter at Test Point (TP) A and measure for 24 rt2 VDC.
NOTE: If 24 i2 VDC is not present, Check the power supply module.
(4) Place voltmeter at TPB and measure for 15 rt2 VDC.
NOTE: If 15 k2 VDC is not present, Replace circuit card.
(5) Adjust R32 o n voltage regulator circuit card t o obtain 155 VAC line-to-line (87.5 VAC
Line-to-Neutral) indication on instrument panel voltmeter.
(6) Measure voltage at TP2 on the circuit card and record the voltage reading.
(7) Place voltmeter at TP3. Adjust R10 to obtain the same voltage as TP2 (step "fy.
(8) Adjust R32 on the Voltage Regulator Circuit card t o obtain 200 VAC line-to-line (1 15
VAC Line-to-Neutral) indication on the GPU voltmeter.
(9) Clear faults by pressing fault reset switch (SI I).
(10) Adjust R32 on the voltage regulator circuit card to obtain 225 VAC line-to-line (130
VAC Line-to-Neutral) indication reading on the GPU voltmeter.
(11) Measure voltage at TP2.
(12) Place voltmeter at TPI. Adjust R9 to obtain the same voltage as TP2 in step (11).
NOTE: Because the over-voltage condition will cause the voltage regulator to shut off, it may
be necessary to press the fault switch S 17 during the adjustment procedure.
(13)Adjust R32 on the voltage regulator circuit card t o obtain 200 VAC line-to-line (1 15
VAC Line-to-Neutral) on the GPU voltmeter.
D. Over/Under Frequency Module (See Figure 6):
(1) Start unit in accordance with normal start procedures,
(2) Set RUNIIDLE switch to RUN and verify 200 VAC line-to-line (1 15 VAC Line-to-Neu-
tral) on the GPU voltmeter and 400 Hz on the GPU frequency meter. Adjust if necessary.
NOTE: Use P I pin 5 as the test point reference ground for the voltmeter.
January 15, 1999 2-4
Revision 5 Page 7
GROUND POWER UNIT
QT
TEST
F'Plti?
A"
Figure 6. OverIUnder Frequency Module

(3) Place voltmeter at Test Point "A" and measure f o r 2 4 +2 VDC.
NOTE: If 24 VDC is not present, check power supply module.
(4) Place voltmeter at Test Point 1 (TPI) and adjust R12 t o obtain 3 VDC.
(5) Adjust governor control speed adjustment t o obtain 380 Hz indication o n the GPU
frequency meter.
(6) Place voltmeter at Test Point 3 (TP3) and measure f o r 2.89 VDC. Adjust R 6 if
necessary t o obtain correct measurement.
(7) Adjust governor control speed adjustment t o obtain 400 Hz indication o n GPU
frequency meter.
(8) Clear fault b y pressing Fault reset switch S11 o n t h e GPU instrument panel.
(9) Adjust governor control speed adjustment t o obtain 420 Hz indication o n GPU
frequency meter.
(10) Place voltmeter at Test Point 2 (TP2) and measure f o r 3.11 VDC. Adjust R7 if
necessary.
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Page 8 Revision 5
Figure 7. DC Over Voltage Module
Figure 8. DC Component Module

January 15, 1999 2-4
Revision 5 Page 9
(11) Adjust governor control speed adjustment to obtain 400 Hz.
(12) Clear faults by pressing Fault Reset switch (SI I ) on the GPU instrument panel.
E. DC Over Voltage Module (See Figure 7):
(1) Start the unit in accordance with normal start procedures.
(2) Set RUNIIDLE switch to RUN.
(3) Press the DC LOAD pushbutton switch to the ON position.
(4) Observe the DC voltmeter on the GPU control panel. Adjust R2 on the DC Compo-
nent Module Board (A 7 1) (Figure 8) circuit card to obtain 34.0 VDC.
(5) Adjust R3 on the DC overvoltage module until the DC Overvoltage Fault Light
illuminates.
(6) Press the fault reset switch and then adjust R2 on the DC Component Module Board
(A1 7) (Figure 8) to obtain a 28.5 VDC indication on the GPU DC voltmeter.
(7) Set IDLEIRUN switch to IDLE. Allow engine to idle for 3 to 5 minutes to cool.
(8) Set ENGINE ONJOFF switch t o OFF.
F. DC Current Limiting (CL) and Line Drop Compensator (LDC) Adjustment Procedure (If
Applicable - Units with optional DC output only)
NOTE: Make Line Drop Compensator adjustments before making Current Limiting Adjust-
ments.
(1) Line Drop Compensator (LDC) Adjustment Procedure (Units with DC output only)
(a) Connect the DC cable to a 28VDC, 2000 ampere load tester.
(b) Start the unit in accordance with normal start procedures, allowing the engine
to idle for 3-5 minutes to warm.
(c) Set IDLEIRUN switch to RUN.
(d) Press the DC LOAD ON switch.
(e) Adjust the DC loadbank to the continuous rating of the DC output, i.e., 1000
amperes.
(f)Apply load to unit and observe the DC voltmeter on the loadbank. If voltage rose
when the load was applied, adjust the voltage to 28.5 VDC by turning R13 (Figure
9) on the CLILDC board.
(g) Press the DC LOAD OFF switch.
(h) Set IDLEIRUN switch to IDLE. Allow engine to idle for 3 to 5 minutes to cool.
(i) Place the ENGINE ONIOFF switch to OFF and disconnect the power cable from
the load tester.
( 2 ) Current Limiting Board (CL) (A9) Adjustment (Figure I and 9): The load current
limit value will correspond to the value found on the CURRENT LIMIT ADJust dial on
the instrument panel assembly. In order to provide for a constant limiting current at
the load, the voltage regulator will reduce AC voltage, and consequently DC output
voltage, to a value required which will limit the DC load current to its preset value.
Current limit adjustment procedure is:
2-4 January 15, 1999
Page 10 Revision 5
TRILECTRON IND. 0376-2407
REV. D
n
LIMIT
ADJUST
LINE DROP
COMPENSATION
ADJUST
Figure 9. Current LirnitILine Drop Compensator Board (CLILDC)

(a) If DC volt meter is not currently indicating 28.5 VDC output, adjust the DC Over
Voltage Module and DC output voltage in accordance with Para. 3,E before continu-
ing.
(b) With the unit shut-down, connect the DC output power cable to a 28 VDC, 2000
ampere loadbank tester.
(c) Start the unit i n accordance with normal start procedures, allowing the engine
t o idle for 3-5 minutes t o warm.
(d) Place the IDLEIRUN switch t o RUN.
(e) Adjust the Current Limit Adjust Potentiometer R7 (Figure 9) o n the Current Limit
Board (A9) fully clockwise.
(f) Turn the CURRENT LIMIT ADJust knob o n the instrument panel t o 1000 o n the
dial.
(g) Place the SOFT START ONIOFF switch t o ON.
(h) Adjust the DC loadbank t o apply a 2000 ampere load.
(i) Press the DC LOAD ON switch.
(j) Adjust R7 (Figure 9) t o obtain a 1000 ampere reading o n the instrument panel DC
ammeter.
(k) Press the DC LOAD OFF switch, then place the SOFT START ON/OFF switch to
OFF.
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(I) Set IDLEIRUN switch t o IDLE. Allow engine t o idle for 3 t o 5 minutes t o cool.
(m) Set ENGINE ONIOFF switch to OFF and disconnect the power cable from the
load tester.
4. ELECTRONIC GOVERNOR ADJUSTMENTS
I WARNING
TO PROTECT AGAINST POSSIBLE PERSONAL INJURY, LOSS OF LIFE, AND/OR
PROPERTY DAMAGE WHEN STARTING THE ENGINE, BE PREPARED TO MAKE AN
EMERGENCY SHUTDOWN TO PROTECT AGAINST OVERSPEED SHOULD A
COMPONENT OF THE GOVERNOR OR ENGINE SPEED CONTROL SYSTEM FAIL.
A. Governors America Corporation (GAC) unit:
(1) Magnetic Pickup: With engine stopped, adjust magnetic pick-up (Figure 12) t o
between .020 inches (0.45mm) from flywheel ring teeth. Usually, backing out the speed
sensor 314 turn after touching the ring gear teeth will achieve a satisfactory air gap. The
magnetic pickup voltage should be at least 1 VAC RMS during cranking.
(2) Electronic Governor (EG), (See Figure 10,7 7,73):
" Adjust all potentiometers o n the EG t o center position.
" Start engine. As engine cranks, the actuator should move t o the maximum fuel
position until the engine fires. The governor should control the engine at low idle
speed.
OVERSPEED
Figure 10. GAC Electronic Governor Control

2-4 January 15,1999
Page 12 Revision 5
GROUND POWER UNIT
" Start engine. As engine cranks, the actuator should move t o the maximum fuel
position until the engine fires. The governor should control the engine at low idle
speed.
" If the engine is unstable after starting, turn the GAlN and STABILITY adjustment
potentiometers counterclockwise until the engine is stable.
" set IDLEIRUN switch o n engine panel to RUN. Adjust governor speed to 2000 RPM
if using Marathon@ generator or 2400 RPM if using KatoB generator by turning
the SPEED adjustment CLOCKWISE to INCREASE engine RPM, or COUNTER-
CLOCKWISE t o DECREASE engine RPM.
" With engine at 2000 RPM if using Marathon@ generator or 2400 RPM if using
KatoB generator and NO LOAD, rotate the GAlN adjustment until instability
develops. Gradually move the adjustment counterclockwise until stability returns.
Move the adjustment one division further counterclockwise t o insure stable
performance.
ENGINE N E L WMP'
THROTTLE LEVER
IDLE
Figure 11. Governor Linkage

January 15, 1999 2-4
Revision 5 Page 13
" With engine at 2000 RPM if using Marathon@ generator or 2400 RPM if using
KatoB generator and NO LOAD, rotate the STABILITY adjustment clockwise until
instability develops. Gradually move the adjustment counterclockwise until sta-
bility returns. Move the adjustment one division further counterclockwise t o
insure stable performance.
NOTE: Gain and stability adjustments may require minor changes after engine load is applied.
Normally, adjustments made at no load achieve satisfactory performance. If instability cannot
be corrected and further performance improvements are required, refer to Troubleshooting
section.
" After the governor speed setting has been adjusted, set IDLEIRUN switch t o IDLE.
The IDLE speed set point is INCREASED by CLOCKWISE rotation of the IDLE
adjustment control. Adjust idle speed t o 800 RPM.
(3) Overspeed Adjustment (See Figure 10,13): The electronic governor performs over
speed sensing and will shut d o w n the engine should RPM exceed approximately2550.
Adjustment for overspeed is located o n the electronic governor.
" Start unit in accordance with normal starting procedures.
" Set IDLE/RUN switch t o RUN.
" Rotate SPEED adjustment potentiometer clockwise until engine speed reaches
2550 RPM or engine speed no longer increases.
O Rotate OVERSPEED adjustment counterclockwise until engine shuts down. The
OVERSPEED indicators located on the Electronic Governor module (Upper left
MAGNETIC PICKUP
2-4 Figure 12. Governor System Magnetic Pickup January 15,1999

Page 14 Revision 5
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January 15, 1999 Figure 13. GAC Control Unit Adjustments 2-4
Revision 5 Page 15
4J-l GROUND POWER UNIT
corner) and the indicator o n the control panel will illuminate. Rotate OVERSPEED
adjustment clockwise one half turn. The overspeed circuit is now adjusted.
" Reset the governor b y pressing the RESET push-button located o n the Electronic
Governor. The Overspeed indicator o n the Electronic Governor and the indicator
o n the control panel will go out.
" Rotate the speed potentiometer counterclockwise one turn to prevent the engine
f r o m reaching overspeed RPM the next time the engine is started.
" Start the engine, place the IDLE/RUN switch t o RUN then adjust engine speed
down to 2000 RPM if using Marathon@ generator or 2400 RPM if using KatoB
generator.
(4) Governor Linkage Installation and Adjustment (See Figure 7 I ) :
" Move the actuator lever forward and rearward t o assure freedom and proper
travel.
" Attach governor linkage t o both the actuator lever and t o the fuel control rod.
" Hold fuel control lever t o MIN position and adjust the actuator lever to vertical or
118 inch clockwise.
" Move linkage back and forth t o assure full fuel travel and that there are no points
of binding.
" Additional adjustments t o the electronic governor may be required t o ensure
satisfactory operation under load. Adjust the electronic governor as required
(Gain/Stability) .
B. Woodward Company Governor Units (See Figure 74,75,76 & Chapter 5):
(1) Magnetic Pickup: With engine stopped, adjust magnetic pick-up (Figure 72) t o .020
inches (0.45 mm) from flywheel ring teeth. Usually, backing out the speed sensor 314
turn after touching the ring gear teeth will achieve a satisfactory air gap. Do not
decrease t o below .010 inches (0.25 mm).The magnetic pickup voltage should be at
least 1.5 VAC RMS during cranking. The magnetic pickup will have a measurable
resistance of 50-350 ohms.
(2) Electronic Governor (EG) (See Figure 14,15): To verify correct system operation
any time trouble occurs, perform the following checks in the order given. Disconnect
all Accessories, but leave the IDLEIRATED switch or jumper connected.
Jumper terminal 7 t o terminal 8, and terminal 11 to terminal 12. If system does not
respond as indicated, find and correct the fault.
" Turn ignition switch ON, do not s t i r t engine. Actuator shaft settles in minimum
fuel position.
" Set IDLE potentiometer t o mid-position.
" Set RATED speed pot fully counterclockwise (minimum speed setting) then turn
back clockwise 10 turns.
" Set GAIN and STABILITY pots t o mid-position.
" Start the engine.
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Figure 14. Woodward Governor System Components
January 15, 1999 2-4

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u - l GROUND POWER UNIT
COUNTER-CLOCKWISE
TODECREASE STARTSPEED
CLOCKWlSE TO INCREASE
START SPEED
2-4 January 15, 1999

Page 18 Figure 15. Woodward Control Adjustments Revision 5
GROUND POWER UNIT
TO PROTECT AGAINST POSSIBLE PERSONAL INJURY, LOSS OF LIFE, AND/OR
PROPERTY DAMAGE WHEN STARTING THE ENGINE, BE PREPARED TO MAKE
AN EMERGENCY SHUTDOWN TO PROTECT AGAINST OVERSPEED SHOULD A
COMPONENT OF THE GOVERNOR OR ENGINE SPEED CONTROL SYSTEM FAIL.
FUEL INJUECTION
PUMP
\
-
i
FUEL PUMP
LEVER
ACTUATOR
W R O T L E ,-LINKAGE
Figure 16. Actuator Linkage Adjustment

NOTE: Magnetic Pickup Unit (MPU) voltage between terminals 5 and 6 should be at least 1.5
Vrms while cranking.
" Actuator should go to the maximum fuel position when the starter turns engine.
If, during cranking, the actuator stays a minimum fuel, check cranking speed
(cranking speed should be at least 2% of rated speed).
" When the engine starts and comes up to speed, the actuator arm should move
toward the minimum fuel position.
" Adjust the GAIN pot to the stable region between low-frequency and high-fre-
quency oscillation.
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Revision 5 Page 19
U-IGROUND POWER UNIT
" If there is a low-frequency oscillation which does not stop when the GAlN pot is
adjusted, turn the STABILITY pot slightly clockwise and try the GAlN pot adjust-
ment again. Continue adjusting the STABILITY pot slightly clockwise, then read-
justing the GAlN p o t until the engine runs at a steady speed.
NOTE: If there is a high-frequency oscillation which will not stop, even when the GAIN pot
is turned fully counterclockwise, adjust the STAB11I N p o t slightly counterclockwise until the
high-frequency oscillation stops.
(3) Speed Settings: With the engine idling smoothly, move the engine control
IDLEIRUN switch t o RUN.
" Adjust the RATED SPEED pot for the desired rated speed of: 2000 RPM if using
Marathon@ generator or 2400 RPM if using KatoB generator.
" Move the engine control IDLE/RUN switch t o IDLE. Set the IDLE SPEED pot for
the desired idle speed.
" Move the engine control IDLEIRUN switch t o RUN. Adjust the transient response.
A transient response can be simulated by manually bumping the actuator linkage.
* T o decrease settling time (may increase oscillation) after a transient, turn the
GAlN pot clockwise slightly, then turn the STABILITY pot counterclockwise as
required t o eliminate oscillation and to obtain desired response.
* To decrease oscillation (will increase settling time), after a transient, turn the
STABILITY pot clockwise slightly, then turn the GAlN pot counterclockwise t o
eliminate oscillation and t o obtain desired response.
(4) Governor Linkage Installation and Adjustment (See Figure 16):
" Move the actuator lever forward and rearward t o assure freedom and proper
travel.
" Attach governor linkage t o both the actuator lever and t o the fuel control rod.
" Hold fuel control lever t o MIN position and adjust the actuator lever t o vertical or
118 inch clockwise.
" Move linkage back and forth t o assure full fuel travel an that there are n o points
of binding.
" Additional adjustments t o the electronic governor may be required t o ensure
satisfactory operation under load. Adjust the electronic governor as required.
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a 90T400SLN
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CHAPTER
2
SECTION
5
CLEANING AND PAINTING
1. CLEANING
Cleanliness o f the unit not only adds to the general appearance, but it is also a factor in
reducing the maintenance upkeep. A unit maintained with periodic cleaning will require less
repainting and will also help prevent the accumulations o f abrasive grit o n moving parts and
surfaces. Cleaning schedules should be devised b y the user according to his environmental
and operating conditions. Painted surfaces require washing with a mild detergent and
rinsing with clean water. A bristle brush (never wire) or spray gun may be used. Unpainted
surfaces are cleaned using plain water and brush, approved solvents, or steam cleaning
equipment. Degreasers may be used to remove grease accumulations from non-lubricated
metal parts. Care should be taken with degreasers, as some brands will also remove or
damage painted surfaces. Clean electrical parts with a lint-free cloth, moistened with
approved solvents for electrical equipment.
CAUTION
DO N O T ALLOW SOAKING, SPRAYING OR STEAM CLEANING TO AFFECT
ELECTRICAL COMPONENTS OR WIRING. RUBBER COMPONENTS SHOULD NOT BE
CLEANED WITH SOLUTIONS HAVING A PETROLEUM BASE SUCH AS KEROSENE,
11 MINERAL SPIRITS, STODDARD SOLVENT OR DRY CLEANING SOLVENTS. 11
2. PAINTING
Painted surfaces, i n addition t o presenting a good appearance, etc., protect the unit from
deterioration. Paint should be maintained o n a non-scheduled, as required, basis. Depending
o n environmental and operational conditions, repaint the entire unit whenever it becomes
necessary. The unit is painted t o user specifications and will be repainted at their mainte-
nance facilities.
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CHAPTER
3
OVERHAUUMAJOR REPAIR
1. GENERAL
Under normal operating conditions and proper preventive maintenance, the GPU should
provide excellent service for a period of 20,000 t o 30,000 hours (depending on local
conditions) before considerat ions should be given t o major repair or overhaul.
Overhaul or major repair of the GPU power plant, i.e., the engine, should be accomplished
in accordance w it h the maint enanceloverhaul recommendat ions of the manufacturer or
their authorized agents.
The generator w ill normally require no overhaul other than normal maintenance or repair
procedures. If a rebuild is found t o be advisable, the manufacturer should be contacted for
their recommendat ions andlor procedures.
The Trilectron built and mounted equipment requires no scheduled overhaul. Normal
maintenance and repair of the unit and subsystems will maintain the equipment in proper
working order.
November 15, 1995 3-0

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CHAPTER
4
SECTION
1
LIST OF VENDORS
FVC VENDOR NAME/ADDRESS
OAGK2. . . ARTISAN CONTROLS CORP., P.O. Box 233, Parsipany, N J 07054
OAT39 . . . BRIERTON ENGINEERING, INC., Rt.2, 1200 S. Buckeye, Abilene, KS 67410
OBE70 ... SAGER ELECTRONIC CORP., 100 Nancy St., West Babylon, NY 11704
OBXW5 . . GOVERNORS AMERICA CORP., 720 Silver St., Agawam, M A 01001

OFREO ... STANCOR, INC., 515 Fan Hill Rd., Monroe, CT 06468
0G852 . . . WEATHERHEAD (DANA), 203 Weatherhead St., Angola, IN 46703-1024

OKKK7. .. SPENCER PRODUCTS CO., P.O. Box 39100, Indianapolis, IN 46239
OKVE6 . . . McMASTER-CARR SUPPLY, 6100 Fulton Ind. Blvd., Atlanta, GA 30336
12697 ... CLAROSTAT MFG. CO., P.O. Box 1507, Dover, NH 03820
01276 . . . AEROQUIP CORP., 1225 W. Main St., Van Wert, OH 45891

01364 ... RUTCO, 2602 E. Hwy 674, Ruskin, FL 33570
03486 . . . WESCO, 820 Washington Blvd., Pittsburgh, PA 15206-41460

04034 ... IMO INDUSTRIES (GEMS), 1 Cowles Rd., Plainville, CT 06062-1107
04061 . . . ALLEN BRADLEY CORP., 1201 S. 2nd St., Milwaukee, WI 53204

04729 . . . UNICORP, 291 Cleveland St., Orange, N J 07050
06666 ... GENERAL DEVELOPMENT, P.O. Box 39100, Indianapolis, IN 46239
09214 . . . GENERAL ELECTRIC CO., W. Genesse St., Auburn, NY 13021

lFJl5.. . . AMATOM ELECTRONIC HARDWARE, 445 Blake St., New Haven, CT 06515
10983 ... AMERICAN SOLENOID, 245 E. lnrnan Ave., Rahway, NJ 07065
12867 . . . TRILECTRON INDUSTRIES, INC., 12297 US Hwy. 41 North, Palmetto, FL 34220
15434 . . . CUMMINS ENGINE CO., P.O. Box 3005, Columbus, IN 47202-3005

15605 ... CUTLER HAMMER, 4201 N. 27th St., Milwaukee, WI 532 16
16476 ... DATCON INSTRUMENTS CO., P.O. Box 128, East Petersburgh, PA 17520
November 15, 1995 4-1

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FVC
a 9OT40OSLN
GROUND POWER UNIT
VENDOR NAMEIADDRESS (Continued)
2P016 . . . . CONTACT INDUSTRIES. 641 Dowd Ave.. Elizabeth. NJ 07201
2V507 . . . . McMASTER-CARR SUPPLY. P.O. Box 440. New Brunswick. NJ 08810-0440
22938 . . . . PROTOTYPE DEVELOPMENT INC.. 7750 Hub Parkway. Cleveland. OH 44125-5709
24161 . . . . GATES RUBBER CO.. P.O. Box 5887. Denver. CO 80217
29771 . . . . DELTROL CORP.. 3001 Grant St.. Bellwood. IL 60104-1251
3A934 . . . . PEERLESS RADIO CORP.. P.O. Box 7025. Lynbrook. NY 11563
31361 . . . . WOODWARD GOVERNOR CO.. 1000 E. Drake Rd.. Ft. Collins. CO 80525
32770 . . . . KATO ENGINEERING. 1415 1st. Ave.. Mankato. M N 56001
39732 . . . . CROMPTON INSTRUMENTS. 26B Worlds Fair Dr.. Somerset. NJ 08873
46366 . . . . CUMMINS SOUTHEASERN POWER INC.. 5910 E . Hillsborough Ave.. Tampa. FL 33610
4L990 . . . . RACOR INDUSTRIES. P.O. Box 3208. Modesto. CA 95353
4W042 . . . PAN AMERICAN ELECT.. P.O. Box 256. Pompton Lakes. NJ 07442
54388 . . . . IMLAC CORP.. 150 A St.. Needham Heights. M A 02194-2807
55566 . . . . RAF ELECTRONICS HARDWARE.. 95 Silvermine Rd.. Seymore. CT 06483
56289 . . . . SPRAGUE ELEC. CO.. 61 Spit Brook Rd.. Suite 305. Nashua. NH 03060
59150 . . . . ENGINEER PRODUCTS CO.. P.O. Box 598. Waterloo. IA 50704-0598
59270 . . . . SELCO PRODUCTS CO.. 7580 Stage Rd.. Buena Park. CA 90621
6S431 . . . . COASTAL POWER PRODUCTS INC.. 841 1 Adams Dr.. Tampa. FL 33619-3517
6U290 . . . . GENERAL BAlTERY
6V625 . . . . NAPA AUTOMOTIVE PARTS CO.. 3389 E. Main St.. Columbus. OH 43213-2744
65453 . . . . WHITNEY W.A. CORP.. 650-54 Race St.. Rockford. IL 61 105
71400 . . . . BUSSMAN. DIV.. COOPER INDUSTRIES. P.O. Box 14460. St . Louis. MO 63178
71744 . . . . CHICAGO MINIATURE LAMP INC.. 1080 Johnson Dr.. Buffalo Grove. IL 60089
72794 . . . . DZUS FASTENER CO . INC.. 425 Union Blvd.. W . Islip. NY 11795

73559 . . . . CARLING SWITCH INC.. 60 Johnson Ave.. Plainville. CT 06062-1 156
73752 . . . . GENERAL AUTOMOTIVE SP.. P.O. Box Blue 15178. Newark. NJ 07102
75160 . . . . DEERE & CO.. 8601 John Deere Rd.. Moline. IL 61265-9874
75382 . . . . KULKA ELEC. CORP.. 520 S . Fulton Ave.. M t. Vernon. NY 43050

4- 1 November 15. 1995
Page 2 Original
FVC
a 9OT4OOSLN
GROUND POWER UNIT
7591 5 . . . L l l T L E FUSE TRACOR INC., 800 E. Northwest Hwy, Des Plaines, IL 60016-3049 '
76225 . . . McCORD CORP., 2850 W. Grand Blvd., Detroit, MI 48202-2643
76385 . . . MINOR RUBBER CO. INC., 49 Ackerrnan St., Bloomfield, NJ 07003

76474 . . . MORSE INDUSTRIAL CORP., 620 S. Aurora St., Ithaca, NY 14850-5726
76700 . . . NELSON DIVISION, P.O. Box 428, Stoughton, WI 52589
77342 ... POTTER & BRUMFIELD INC., 200 S. Richland Creek Rd., Princeton, IN 47671
78280 . . . QUICK START PRODUCTS LTD., Hwy 251 South, Rochelle, IL 61068
78422 . . . SPEAKER, J.W., CORP., MB Unit 6171, Milwaukee, W1 53266

79260 . . . WALKER MFG. CO., 1201 Michigan Blvd., Racine, Wl35402-4963
7L243 . . . ANTHEM ELECTRONICS, 25555 Enterprise Rd., Suite 11-2, Clearwater, FL 34623
7R617 . . . WEICO, 45 Sarah Drive, Farmingdale, NY 11735
. . GOODYEAR RUBBER PRODUCTS, 329 McCarter Hwy, Newark, NJ 071 14

7\1\1514.
8E125 . . . MOTION INDUSTRIES, P.O. Box 1165, Pensacola, FL 32505
8K5ll . . . RAYBRO ELEC. SUPPLIES, P.O. Box 1351, Tampa, FL 33601

8P940 . . . DRAKE ELECTRICAL SUPPLY CO., 421 0 Grove Ave., Gurnee, IL 60031-2135
8W008. . . PREClSlONAlRE INC., P.O. Box 2390, St. Petersburg, FL 33734
80019 . . . K-D LAMP CO., P.O. Box 5374, Cincinnati, OH 45201-5374
81073 . . . GRAYHILL INC., P.O. Box 10373, La Grange, IL 60525

81860 . . . BARRY DIV., BARRY-WRIGHT CORP., 700 Pleasant St., Watertown, MA 02172
81861 . . . BURTON ELECTRICAL ENGINEERING CO., 111 Maryland St., El Segundo, CA 90245-41 16
83330 . .. DlALlGHT CORP., 1913 Atlantic Ave., Mannasquan, NJ 08736
85814 ... NASON CO., P.O. Box 505, West Union, SC 29696
9A611 . . . EIL/TROlT INSTRUMENTS, INC., 1914 Canada St. E., Palm Bay, FL 32909
91-1249 . . . PROTECTOSEAL, P.O. Box 95588, Chicago, IL 60694
9L773 . . . SIEMENS AMERICAN, Park Ridge, IL
9R569 . . . DEERE & CO. (PARTS), 1601 E. 1st Ave., Milan, IL 61264-2606
91577 . . . CANNON CORP., 666 E. Dyer Rd., Santa Ana, CA 92702
November 15, 1995 4-1

Original Page 3
g u GROUND POWER UNIT
FVC
p- --
- - - - -- - -
94222 . . . SOUTHCO FASTENERS, 210 N. Brinton Lake Rd., Concord, PA 19182

95408 . . . . KIM HOTSTART MFG. CO. INC., P.O. Box 42, Spokane, WA 99210-0042
ALCOC . . . ALCO CONTROLS DIV., P.O. Box 102057, Atlanta, GA 30368-0057
LPA. . . . . . LPA INDUSTRIES PLC., Tudor Works, Debden Rd., Saffron Walden, Essex CB11 4AN England
MlLWA . . . MILWAUKEE RESITOR CO.
PRECl . . . PRECISION GOVERNORS, 2322 7th Ave., Rockford, IL 61 104

SlERR . . . SIERRA PACIFIC, 1707 E. Cel Amo Blvd., Carson, CA 90746
THERM. . . THERMO-TEC, P.O. Box 946, Berea, OH 44017
4-1 November 15, 1995

Page 4 Original
a 90T400SLN
GROUND POWER UNIT
CHAPTER 4
SECTION 2
NUMERICAL INDEX
November 15, 1995 4-2

Original Page 1
PART NUMBER
a
--
90T400SLN
GROUND POWER UNIT
PART NUMBER
4-2 November 15, 1995

Page 2 Original
90T400SLN
GROUND POWER UNIT
PART NUMBER PART NUMBER
AGC 20 17-7A
. AGC 5 17-16A
AGC 5 17-19A
November 15, 1995 4-2

Original Page 3
I PART NUMBER
a
90T400SLN
GROUND POWER UNIT
4-2 November 15, 1995

Page 4 Original
PART NUMBER
a 9OT4OOSLN
GROUND POWER UNIT
November 15, 1995 4-2

Original Page 5
PART NUMBER
a
90T400SLN
GROUND POWER UNIT
PART N U M B E R
EB53l2
EB5314
COO
EC0044 8-7
HFH063 9-8
HGG 100 14-3
HGG 100 14-9
HGG200 14-13
, HGG200 14-13
HGH088 19-4
HGH 100 9-9

Page 6 Original
a
PART NUMBER
90T400SLN
GROUND POWER UNIT
FIGURE1
ITEM PART NUMBER
HHG 108 14-3

HHG108 14-9
HRECAI 15-108
HRECAI 15-5A
HRECAI 15-6B
HRECAI 15-9C
HRFCAI 19-10
HRFCAI 19-22
HRFCAI 6-10
- HRFCB1 11-23
HRFCB I 19-2 1
HRFCBI 19-9
HRFCB I 6-9
1 HRFCCI 1 11-22 - JI
', HRFCCI 19-20 Y
H RFCC 1 19-8
HRFCCl
--
6-8
HRGBAI 14-7
HRGBAI 19-26
HRGBAI 7-8
HRGBBI 12-10
HRGBBI 19-75
HRGBCI 12-9
HRHBBI 19-6
HRHBBI 8-39
HRHBBl 9-1 1
HRHBCl 10-12
November 15, 1995 4-2

Original Page 7
90T400SLN
GROUND POWER UNIT
PART NUMBER PART NUMBER
KH5 102 16-22 MS600-18 17-13A

KH5 102 5-9 MS600-6 19-14A
KH5112
KH5112
5-17A
5-7A 1 MSP-6718 14-15 - -
QS- 1 197- 1 21-7

QS- 1194- 1 21-5
QS4-3TC 21-4
4-2 November 15, 1995

Page 8 Original
a
PART NUMBER
90T400SLN
GROUND POWER UNIT
PART NUMBER
RE0012
RE0043
November 15, 1995 4-2

Original Page 9
PART NUMBER
a
9OT4OOSLN
GROUND POWER UNIT
I PART NUMBER
4-2 November 15, 1995

Page 10 Original
TECHNICAL MANUAL
SUPPLEMENT FOR
GROUND POWER UNITS
WlTH
PDI GROUND SUPPORT SYSTEMS, INC.
RUNNING GEAR
THIS SUPPLEMENT IS AN
INSERT TO YOUR TECHNICAL MANUAL
PDI BRIERTON
DRA WBAR DRA WBAR
UNITS EQUIPPED UNl TS EQUIPPED

WITH PD1 WlTH BRIERTON
RUNNING GEAR RUNNING GEAR
HOW TO DETERMINE YOUR UNIT'S RUNNING GEAR.
a 11001 Hwy. 41 North Palmetto, FL 34221

TRILECTRON INDUSTRIES, INC.
a HElCO company
TEL.
(941) 721-1000
FAX
(941) 723-3160
March 15, 1999

I
SUPPLEMENT - FS2
a Technical Manual Supplement
UNITS WITH PDI RUNNING GEAR
4-3 March 15, 1999

Page 2 SUPPLEMENT - FS2
SUPPLEMENT TO
CHAPTER 4
ILLUSTRATED PARTS LlST
SECTION 3
DETAILED PARTS LlST
EXPLANATION OF COLUMNS
A. Figurelltem No. column:
Figurelltem No. column lists the figure on which the item is shown and the item number
assigned to the detailed part. Items listed but not illustrated are preceded by a dash (-).
B. TI Part Number column:
TI Part Number column lists the Trilectron, Ind., Inc., part number assigned and required
to procure the part from Trilectron.
C. FVC Column:
The Federal Vendor Code Number (FVC) is a cross reference number used to identify
the manufacturer of the listed part by name and address. Only two vendor codes are
listed in this supplement, they are:
12867- Trilectron Industries, Inc.
11001 US Hwy. 41 North
Palmetto, Florida 34221 U.S.A.
0W357- PDI Ground Support Systems Inc.

5905 Grant Ave.
Cleveland, OH 44105 U.S.A
D. Nomenclature column:
Nomenclature column presents the complete item name required for identification or pro-
curement.
E. Units Per Assembly column:
Units Per Assembly column provides the total quantity of the listed component utilized for
that assembly.
March 15, 1999 4-3

SUPPLEMENT - FS2 Page 3
2. INSTRUCTIONS FOR ORDERING PARTS - Direct all inquires to:
Trilectron Industries, Inc.

Palmetto, Florida 34221 U.S.A.
Telephone (941) 721-1000; Toll Free (877) 874-5322
Fax (941) 723-3160; Toll Free (877) 874-5321
E-Mail: cs@trilectron.com
Important Facts: When ordering, give the serial number of the unit; model number; full descrip-
tion of the part and the quantity required; and the Illustrated Parts List Figure and Item number
from this manual. Give shipping method preferred.
4-3 March 15, 1999

March 15, 1999 4-3

(9
Figure 1. Four Wheel Running Gear
4-3 March 15, 1999

Parts List for Figure I.

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY
12867. . . . . ....... FOUR WHEEL RUNlNG GEAR . . . . . . . . . . . . . . I

OW357. . . . . . . . FRONT AXLE ASSY (SEE FIG 5 ) . . . . . . . . 1
OW357. . . . . . . . REAR AXLE ASSY (SEE FIG 2). . . . . . . . . 1
OW357. . . . . . . . DRAWER BAR ASSY . . . . . . . . . . . . . . 1
OW357. . . . . . . . PIVOT SUPPORT . . . . . . . . . . . . . . . . I
0W357. . . . . . . . HANDBRAKE & CROSS SHAFT ASSY . . . . . 1
(SEE FIG 3)
0W357. . . . . . . . SPRING BRACKET . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . BOLT, HEX HD, 9116-12 X 3-314. . . . . . . . . 2
OW357. . . . . . . . NUT, LK, 9/16-12. . . . . . . . . . . . . . . . . 2
OW357. . . . . . . . SPRING BRACKET . . . . . . . . . . . . . . . 2
OW357. . . . . . . . COTTER PIN, 118 X 1 . . . . . . . . . . . . . . 2
0W357. . . . . . . . RIVET. . . . . . . . . . . . . . . . . . . . . . 2
March 15, 1999 4-3

Technical Manual Supplement
Figure 2. Rear Axle

4-3 March 15, 1999
Parts List For Figure 2.

OW357. . . . . . . . . . . REAR AXLE ASSEMBLY (SEE FIG 1) . . . . . . REF

OW357 . . . . . . . .
REAR AXLE WELDMENT . . . . . . . . . . . . 1
OW357 . . . . . . . .
BRAKE ASSEMBLY. 7 X 10 . . . . . . . . . . . 2
OW357 . . . . . . . .
HUB & DRUM ASSEMBLY . . . . . . . . . . . 2
OW357 . . . . . . . .
SPINDLE KEY WASHER . . . . . . . . . . . . 2
OW357 . . . . . 1-14. HEX SLOTTED JAM . . .
. . . . . . . . . . . . 2
OW357 . . . . . COTTER PIN (MS24665-360) .
. . . . . . . . . . . . 2
OW357 . . . . . LEAF SPRING . . . . . . . . .
. . . . . . . . . . . . 2
OW357 . . . . . . . . AXLE CLAMP . . . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . U-BOLT . . . . . . . . . . . . . . . . . . . . . 4
OW357 . . . . . . . . LOCKNUT, D-20 (MS51922-37 . . . . . . . . . 8
March 15. 1999 4-3

SUPPLEMENT .FS2 Page 9
Figure 3. Mechanical Brake Detail
4-3 March 15, 1999


NO. NO. NO. FVC PART NO . NOMENCLATURE ASSY
.
OW357. . . . . . . . . . . MECHANICAL BRAKE ASSY . . . . . . . . . . . . . REF

(SEE FIG 6)
OW357 . . . . . . . . DUST SHIELD . . . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . BRAKE ASSY . . . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . BOLT . . . . . . . . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . CONE. BEARING . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . WASHER. LK . . . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . NUT. HEX . . . . . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . JAM NUT. HEX SLOTTED . . . . . . . . . . . . 2
OW357 . . . . . . . . GREASE CAP . . . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . SPINDLE KEY WASHER . . . . . . . . . . . . 2
OW357 . . . . . . . . CONE BEARING. . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . HUB & DRUM ASSY . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . GREASE SEAL . . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . COTTER PIN . . . . . . . . . . . . . . . . . . 2
March 15. 1999 4-3

HOLES FOP 2
el BOLTS (REF )
1 BRAKE "ON"
1
2 8 OC
' BRAKE "OFF" RCF
HAND L E M P 10 EL
MOUNTED INVERTED
B Y CUSTOMEP VIE'& k - A
HOLES FOR --
.a BOLTS (REF.)
Figure 4. Handbrake Lever & Cross Shaft Assembly
4-3 March 15, 1999

Parts List For Figure 4 .

OW357. . . . . . . . . . . HANDBRAKE LEVER & . . . . . . . . . . . . . . . . .REF

CROSS SHAFT ASSY (SEE FIG 1)
OW357 . . . . . . . . HANDBRAKE LEVER . . . . . . . . . . . . . . 1
OW357 . . . . . . . . CROSS-SHAFT, 48" . . . . . . . . . . . . . . . 1
OW357 . . . . . . . . SHAFT BEARING . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . SHAFT LEVER . . . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . ROLL PIN . . . . . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . BRAKE -ROD, 100" . . . . . . . . . . . . . . . 1
OW357 . . . . . . . . BRAKE ROD, 20" . . . . . . . . . . . . . . . . 6
OW357 . . . . . . . . YOKE (MS35812-4) . . . . . . . . . . . . . . . 6
OW357 . . . . . . . . YOKE NUT . . . . . . . . . . . . . . . . . . . . 5
OW357 . . . . . . . . YOKE PIN (MS35810-4) . . . . . . . . . . . . . 5
OW357 . . . . . . . . COTTER PIN, 3/32 X 0 . . . . . . . . . . . . . 2
OW357 . . . . . . . . LUBE FITTING, E-27 NPT . . . . . . . . . . . . 2
OW357 . . . . . . . . SHAFT COLLAR . . . . . . . . . . . . . . . . . 2
March 15. 1999 4-3

Figure 5. Front Axle Assembly
4-3 March 15, 1999

OW357. . . . . . . . . . . FRONT AXLE ASSEMBLY (SEE FIG 1) . . . . . REF

OW357 . . . . . . . . AXLE BEAM WELDMENT . . . . . . . . . . . . 1
OW357 . . . . . . . . HUB SUB-ASSEMBLY . . . . . . . . . . . . . . 2
OW357 . . . . . . . . HUB SUB-ASSEMBLY . . . . . . . . . . . . . . 1
OW357 . . . . . . . . BEARING CONE (INNER) . . . . . . . . . . . . 2
OW357 . . . . . . . . BEARING CONE (OUTER) . . . . . . . . . . . 3
OW357 . . . . . . . . BEARING CONE (INNER) . . . . . . . . . . . . . 1
OW357 . . . . . . . . GREASE SEAL . . . . . . . . . . . . . . . . . 2
OW357 . . . . . . . . GREASE SEAL . . . . . . . . . . . . . . . . . 1
OW357 . . . . . . . . GREASE CAP . . . . . . . . . . . . . . . . . . 3
OW357 . . . . . . . . HEX NUT . . . . . . . . . . . . . . . . . . . .16
OW357 . . . . . . . . 0-D LOCK WASHER . . . . . . . . . . . . . . 16
OW357 . . . . . . . . LATCH PEDAL . . . . . . . . . . . . . . . . . . 1
OW357 . . . . . . . . COIL. SPRING . . . . . . . . . . . . . . . . . . 1
OW357 . . . . . . . . ROLL PIN . . . . . . . . . . . . . . . . . . . . 1
OW357 . . . . . . . . HEX SLOTTED JAM NUT. 1-14 . . . . . . . . . 3
OW357 . . . . . . . . SPINDLE KEY WASHER . . . . . . . . . . . . 3
OW357 . . . . . . . . COTTER PIN . . . . . . . . . . . . . . . . . . 3
March 15. 1999 4-3

4-3 March 15, 1999

a 9OT4OOSLN
GROUND POWER UNIT
CHAPTER
4
SECTION
3
DETAILED PARTS LIST
1. EXPLANATION OF COLUMNS
A. Figurelltem No. column lists the figure on which the item is shown and the item numberassigned to the detailed
part. Items listed but not illustrated are preceded by a dash (-).
B. TI Part Number column lists the Trilectron, Ind., Inc., part number assigned and required to procure the part
from Trilectron. The abbreviation "COMM" (Commercial) indicates several manufacturers make the part and it is
usually available from local sources, i.e., standard fittings, bolts, etc.
C. Vendor Part Number column is lists the Vendor's part number for purchased components.
D. FVC column lists the Federal Vendor's Code for the vendor/manufacturer of purchased components.
E. Airline Part Number column is provided for the user to insert their system part number.
F. Nomenclature column presents the complete item name required for identification or procurement.
G. Units Per Assembly column provides the total quantity of the listed component utilized for that assembly.
2. INSTRUCTIONS FOR ORDERING PARTS - Direct all inquires to:

Trilectron Industries, Inc.
Palmetto, Florida 34220-2109 U.S.A.
Telephone (941) 723-1841
Fax (941) 723-3160
Important Facts: When ordering, give the serial number of the unit; model number; full description of the part and
the quantity required; and the Illustrated Parts List Figure and Item number from this manual. Give shipping method
preferred.
January 15, 1999 4-3

Revision 5 Page 1
a
90T400SLN
GROUND POWER UNIT
4-3 January 15, 1999

Page 2 Revision 5
CONTROL PANEL
1
SECTION 4 - 3 , F I G U R E 15
FRONT CANOPY REAR CANOPY

SECTION 4 - 3 , F I G U R E 5 CONTACTOR P A N E L
SECTION 4 - 3 ,
OPTIONAL
/ SECTION 4 - 3 .
FIGURE 5
TRANS~ORMER/RECTIFIER
COOLING SYSTEM ASSEMBLY. SECTION 4 - 3
FIGURE 9
EXHAUST
SYSTEM
FIGURE1 1
HANDBRAKE
FIGURE 4
DRAWBAR ASSEMBLY
J u I1
CONTROL P A N E L
ACCESS DOOR
SECTION 4-3.
I
C ~ N O P YSUPPORTS
FRONT AXLE SECTION 4-3,FIGURE 7
ASSEMBLY SECTION 4-3,
SECTION 4-3,
FIGURE2 FIGURE 3
a
9OT4OOSLN
GROUND POWER UNIT
Figure 2. Front Axle Assembly

4-3 January 15, 1999
Page 4 Revision 5
a 9OT4OOSLN
GROUND POWER UNIT
Figure 2 . Front Axle Assembly
2- . . . TA5246 . 03-30242 . . . OAT39 . . . . . . . . . AXLE ASSEMBLY. With Hubs . . . . . . . . 1
1 . . TA5243 . 02-20K13 . . . OAT39 . . . . . . . . . DRAWBAR Assembly . . . . . . . . . . . . . . 1
2 . . TA5244 . 02-02370 . . . OAT39 . . . . . . . . . BOLT. Queen. 1"-14 . . . . . . . . . . . . . . . 1
3 . . TA5522 . 321700140 . . OAT39 . . . . . . . . . LKNUIT. 1"-14 . . . . . . . . . . . . . . . . . . 1
4 . . TA5247 . 03-30241 . . . OAT39 . . . . . . . . . WELDMENT. Front Axle . . . . . . . . . . . . . 1
5 . . TA5150 . 6251-13 . . . . 22938 . . . . . . . . . BOLT. Lug. 112"-20 . . . . . . . . . . . . . . . . 15
6 . . TA5254 . 02-20212 . . . OAT39 . . . . . . . . . HUB. WlCups . . . . . . . . . . . . . . . . . . . 2
7 . . TA5088 . 204601-6 . . . 22938 . . . . . . . . . NUT. Hex. NF 112"-20 . . . . . . . . . . . . . . 15
8 . . HRKB4B . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. 112" . . . . . . . . . . . . . . . . 15
9 . . TA5251 . 06-60478 . . . OAT39 . . . . . . . . . SEAL. Grease . . . . . . . . . . . . . . . . . . . 3
10 . TA5252 . 130580500 . . OAT39 . . . . . . . . . CONE. Inner . . . . . . . . . . . . . . . . . . . 3
11 . TA5253 . 130581 100 . . OAT39 . . . . . . . . . CUP. Inner . . . . . . . . . . . . . . . . . . . . 3
12 . TA5255 . 130581200 . . OAT39 . . . . . . . . . CUP. Outer . . . . . . . . . . . . . . . . . . . . 3
13 . TA5256 . 130355100 . . OAT39 . . . . . . . . . CONE. Outer . . . . . . . . . . . . . . . . . . . 3
14 . TA5237 . 06-60295 . . . OAT39 . . . . . . . . . WASHER. Spindle . . . . . . . . . . . . . . . . 3
15 . TA5238 . 321451 40 . . . OAT39 . . . . . . . . . NUT. Spindle . . . . . . . . . . . . . . . . . . . 3
16 . TA5258 . 06-60479 . . . OAT39 . . . . . . . . . CAP. Grease . . . . . . . . . . . . . . . . . . . 3
17 . TA5239 . COMM . . . . . 12867 . . . . . . . . . KEY. Cotter. 118" x 1-112" . . . . . . . . . . . . . 3
18 . TA5035 . 1-3712 . . . . . 22938 . . . . . . . . . RIM. 6 . 9 0 ~ 9NHS. Five Bolt . . . . . . . . . . . . 2
19 . TA5168 . 6555-3 . . . . . 22938 . .... . . . . FLAP. Wheel. 6 . 9 0 ~ 9. . . . . . . . . . . . . . . 2
20 . TA0124 . 6555-2 . . . . . 22938 . . . . . . . . . TUBE. 6 . 9 0 ~ 9. . . . . . . . . . . . . . . . . . . 2
21 . TA0027 . 6555-1 . . . . . 22938 . . . . . . . . . TIRE. 4 Ply Nylon. 6.90-9 . . . . . . . . . . . . . 2
-ITEM NOT ILLUSTRATED
January 15. 1999 4 .3

Revision 5 Page 5
a
90T400SLN
GROUND POWER UNIT
4-3 Figure 3. Rear Axle Assembly January 15, 1999

Page 6 Revision 5
a 9OT4OOSLN
GROUND POWER UNIT
Figure 3. Rear Axle Assembly
3- . . . TA5262 . 02-20278 . . . OAT39 . . . . . . . . . ASSEMBLY. Rear Axle . . . . . . . . . . . . REF
. 02-20073 . . . OAT39 . . . . . . . . . BRACKET. Spring. Front . . . . . . . . . . . . . 2
. 6555-1 . . . . . 22938 . . . . . . . . . TIRE. 4 Ply Nylon. 6.90-9 . . . . . . . . . . . . . 2
. 322400100 . . OAT39 . . . . . . . . . NUT. Self LKing. 9116"-18 . . . . . . . . . . . . 4
. 06-60168 . . . OAT39 . . . . . . . . . BOLT. 9116"-18~3.69"Shackle . . . . . . . . . . 4
. 02-20074 . . . OAT39 . . . . . . . . . BRACKET. Spring. Rear . . . . . . . . . . . . . 2
. 06-60496 . . . OAT39 . . . . . . . . . U-BOLT. 112"-13x3.03"Xx6" Long . . . . . . . . 4
. 01-10018 . . . OAT39 . . . . . . . . . SPRING ASSEMBLY. 4 Leaf. .360" x 2.00" . . . 2
. 06-60495 . . . OAT39 . . . . . . . . . PLATE. Spring Axle . . . . . . . . . . . . . . . . 2
. 321610090 . . OAT39 . . . . . . . . . NUT. Self LKing. 1/2"-13 . . . . . . . . . . . . . 8
. 02-20278 . . . OAT39 . . . . . . . . . BEAM AXLE . . . . . . . . . . . . . . . . . . . 1
. 06-12101 . . . OAT39 . . . . . . . . . NUT. Plain Hex. 318"-24 . . . . . . . . . . . . . 4
. 06-12102 . . . OAT39 . . . . . . . . . WASHER. LK. 3/8" . . . . . . . . . . . . . . . . 4
. 3201 12060 . . OAT39 . . . . . . . . . SCREW. Cap. Hex HD 318"-24 x 1 . . . . . . . . 4
. 6251-13 . . . . 22938 . . . . . . . . . BOLT. Lug. 1/2"-20 . . . . . . . . . . . . . . . . 15
. 06-17450 . . . OAT39 . . . . . . . . . DRUM. Brake. 7" . . . . . . . . . . . . . . . . . 2
. 390800056 . . OAT39 . . . . . . . . . BRAKE ASSEMBLY . . . . . . . . . . . . . . . 2
. 5904 . . . . . . 22938 . . . . . . . . . LEVER ASSEMBLY. Brake . . . . . . . . . . . . 2
. 8209-5 . . . . . 22938 . . . . . . . . . SPRING. Hold Down . . . . . . . . . . . . . . . 2
. 8210 . . . . . . 22938 . . . . . . . . . SHIELD. Dust . . . . . . . . . . . . . . . . . . . 2
. 8209-3 . . . . . 22938 . . . . . . . . . PLATE. Backing . . . . . . . . . . . . . . . . . 2
. 8209-11 . . . . 22938 . . . . . . . . . SHOE AND LINING . . . . . . . . . . . . . . . . 4
. 8209-6 . . . . . 22938 . . . . . . . . . SPRING. Return . . . . . . . . . . . . . . . . . 2
. 8209-7 . . . . . 22938 . . . . . . . . . CAMSHAFT. Brake . . . . . . . . . . . . . . . . 2
. 06-60478 . . . OAT39 . . . . . . . . . SEAL. Grease . . . . . . . . . . . . . . . . . . . 3
. 130580500 . . OAT39 . . . . . . . . . CONE. Inner . . . . . . . . . . . . . . . . . . . 3
. 130581100 . . OAT39 . . . . . . . . . CUP. Inner . . . . . . . . . . . . . . . . . . . . 3
. 02-20212 . . . OAT39 . . . . . . . . . HUB. W/Cups . . . . . . . . . . . . . . . . . . . 2
. 130581200 . . OAT39 . . . . . . . . . CUP. Outer . . . . . . . . . . . . . . . . . . . . 3
. 130355100 . . OAT39 . . . . . . . . . CONE. Outer . . . . . . . . . . . . . . . . . . . 3
. 06-121 02 . . . OAT39 . . . . . . . . . WASHER. LK. 112" . . . . . . . . . . . . . . . . 15
. 06-12103 . . . 22938 . . . . . . . . . NUT. Hex. NF 112"-20 . . . . . . . . . . . . . . 15
. 06-60295 . . . OAT39 . . . . . . . . . WASHER. Spindle . . . . . . . . . . . . . . . . 3
. 324602100 . . OAT39 . . . . . . . . . KEY. Cotter. 118" x 1-112" . . . . . . . . . . . . . 3
. 32145140 . . . OAT39 . . . . . . . . . NUT. Spindle . . . . . . . . . . . . . . . . . . . 3
. 06-60479 . . . OAT39 . . . . . . . . . CAP. Grease . . . . . . . . . . . . . . . . . . . 3
. 1-3712 . . . . . 22938 . . . . . . . . . RIM. 6 . 9 0 ~ 9NHS. Five Bolt . . . . . . . . . . . . 2
. 6555-3 . . . . . 22938 . . . . . . . . . FLAP. Wheel. 6 . 9 0 ~ 9. . . . . . . . . . . . . . . 2
. 6555-2 . . . . . 22938 . . . . . . . . . TUBE. 6 . 9 0 ~ 9. . . . . . . . . . . . . . . . . . . 2
January 15. 1999 4-3

Revision 5 Page 7
a 9OT4OOSLN
GROUND POWER UNIT
.
Figure 4A Handbrake Assembly. Standard Configuration
NO. NO . NO. FVC PART NO . NOMENCLATURE ASSY
4A- . B02590 . 730-5901 . . . 22938 . . . . . . . . HANDBRAKE ASSEMBLY . . . . . . . . . . REF
1 . TA5044 . 5205 . . . . . YOKE . . . . . . . . . . . . . . . . . . . . . . . 6
2 . TA5046 . 5206 . . . . . PIN. Yoke . . . . . . . . . . . . . . . . . . . . . 5
3 . TA5036 . 8300-220 . . . ROD. Brake. 3/8"x22" Long . . . . . . . . . . . . 2
4 . TA5047 . 4800-2 . . . . PIN. Cotter . . . . . . . . . . . . . . . . . . . . . 5
5 . TA5045 . 4601-5 . . . . NUT. Yoke . . . . . . . . . . . . . . . . . . . . . 6
6 . TA5040 . 5909 . . . . . LEVER. Shaft . . . . . . . . . . . . . . . . . . . 2
7 . TA5041 . 5000-2 . . . . PIN. Roll . . . . . . . . . . . . . . . . . . . . . . 3
8 . TA5176 . 5910 . . . . . LEVER. Cross Shaft . . . . . . . . . . . . . . . . 3
9 . COMM . . . . . . . . . . SCREW. Cap. Hex Hd. 318"-16 x 2" . . . . . . . . 2
10 . TA5058 . 5910-730 . . . SHAFT. Cross . . . . . . . . . . . . . . . . . . . 1
11 . HG1125 . COMM . . . . BOLT. Hex Hd.. 318"-16 x 1-114" . . . . . . . . . 2
12 . TA5043 . 8300-1 070 . . ROD. Brake Link. 318" x 107" Long . . . . . . . . 1
13 . TA5037 . 1-5904 . . . . LEVER ASSEMBLY. Hand Brake . . . . . . . . . 1
14 . TA5039 . 5908 . . . . . BEARING. Shaft . . . . . . . . . . . . . . . . . . 2
15 . HBIBBI . COMM . . . . WASHER. LK. 318" . . . . . . . . . . . . . . . . 2
16 . HRlBAl COMM . . . . NUT. Hex. 318"-16 . . . . . . . . . . . . . . . . . 2
17 . TR5121 . . . . . . . . . . PLATE. Mounting . . . . . . . . . . . . . . . . . 1
4 .3 January 15. 1999

Page 8 Revision 5
a 9OT4OOSLN
GROUND POWER UNIT
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Figure 4B Handbrake Assembly. Spring Return
.....

NO . NO. NO. FVC PART NO. NOMENCLATURE ASSY
4- . . . B08180-B . . . . . . . . 12867 . . . . . . . . . HANDBRAKE ASSEMBLY. Sprinn . . Return . . REF
1 . . TA5037 . 1-5904 . . . . . 22938 . . . . . . . . . LEVER. Orscheln . . . . . . . . . . . . . . . . . 1
-1 . B07506 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Brake Lever . . . . . . . . . . . . . 1
2 . . TA5044 . 5205 . . . . . . 22938 . . . . . . . . . YOKE. #4 . . . . . . . . . . . . . . . . . . . . . 4
3 . . . . . . . . 06-60577 . . . OAT39 . . . . . . . . ROD. Brake . . . . . . . . . . . . . . . . . . . . 2
4 . . HRlBAl . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. 318"-NF . . . . . . . . . . . . . . . . 4
5 . . TA5046 . 5206 . . . . . . 22938 . . . . . . . .
. . PIN Clevis. 318" x 1-118" . . . . . . . . . . . . . 4
6 . . TA5047 . 4800-2 . . . . . 22938 . . . . . . . . . PIN. Cotter. 3/32" x 314" . . . . . . . . . . . . . 4
7 . . . . . . . . 06-60576 . . . OAT39 . . . . . . . . . CROSS SHAFT . . . . . . . . . . . . . . . . . . 1
8 . . . . . . . . 06-60162 . . . OAT39 . . . . . . . . . BLK. Bearing . . . . . . . . . . . . . . . . . . . 2
9 . . TA5040 . 5909 . . . . . . 22938 . . . . . . . . . LEVER. Forging . . . . . . . . . . . . . . . . . . 2
10 . COMM . . . . . . . . . . . 12867 . . . . . . . . . BOLT. Hex. 114"-NC x 1-314". Dd. #5 . . . . . . . 3
11 . COMM . . . . . . . . . . . 12867 . . . . . . . . . NUT.LK. Hex. 114"-NC . . . . . . . . . . . . . . 3
12 . . . . . . . 012 . . . . . . OAT39 . . . . . . . . . FITTING. Conduit End. Grooved . . . . . . . . . 1
13 . . . . . . . 161-010-2 . . . OAT39 . . . . . . . . . U-BOLT. With Nuts . . . . . . . . . . . . . . . . 1
14 . C8180-1 . . . . . . . . . . 12867 . . . . . . . . . CABLE. Handbrake Assy.. 101" . . . . . . . . . 1
15 . COMM . . . . . . . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 5116"-18 x 1-114" . . . . . . . . 2
16 . B08349 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Brake Cable. Front Mounting . . . . 1
17 . . . . . . . 01 1 . . . . . . OAT39 . . . . . . . . . FITTING. Conduit. Threaded End . . . . . . . . 1
18 . B08182 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Brake Cable Mounting. Rear . . . . . 1
19 . COMM . . . . . . . . . . . 12867 . . . . . . . . . NUT. Hex. 5116"-NF . . . . . . . . . . . . . . . 5
20 . B08180-1 . . . . . . . . 12867 . . . . . . . . . CABLE. Intermember. 1 x 19 Stranded x 123" . . 1
21 . B010255 . . . . . . . . . . 12867 . . . . . . . . . SEAT. Spring. Parking Brake Return . . . . . . . 1
22 . TA5460 . COMM . . . . . 12867 . . . . . . . . . SPRING. 1" Dia.. 3.8" lg. .135" Dia. Wire. . . . . 1
23 . . . . . . . CS541-3 . . . . OAT39 . . . . . . . . . FITTING. Clevis. Open End . . . . . . . . . . . . 1
24 . . . . . . . CS551-2 . . . . OAT39 . . . . . . . . . FITTING. End. Stepped Clevis . . . . . . . . . . 1
25 . B010302 . . . . . . . . . . 12867 . . . . . . . . . PAD. Rubber . . . . . . . . . . . . . . . . . . . 2
January 15. 1999 4-3

Revision 5 Page 9
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90T400SLN
GROUND POWER UNIT
VIEW FROM FRONT

4-3
Figure 5A. GPU End View January 15, 1999
Page 10 Revision 5
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90T400SLN
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January 15, 1999 4-3

Figure 5 8 . GPU Left Side View
Revision 5 Page 11
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9OT40OSLN
GROUND POWER UNIT
4-3 Figure 5C. GPU Right Side View January 15, 1999
Page 12 Revision 5
a 9OT4OOSLN
GROUND POWER UNIT
Figure 5. Canopy and Exterior Components
5- . . . REF . . . . . . . . . . . . 12867 . . . . . . . . . 90T400SLN Ground Power Generator . . . . REF
1 . . 807871 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY. Frontcanopy . . . . . . . . . . . . 1
2 . . 807868 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY. Rear Canopy . . . . . . . . . . . . 1
3 . . IL5022 . . 314A-12V . . . 01364 . . . . . . . . . BEACON. Amber Warning 12V (Optional) . . . . 1
3 . . lL5056 . . 314A-24V . . . 01364 . . . . . . . . . BEACON. Amber Warning 24V (Optional) . . . . 1
3 . . 115070 . . 314B-12V . . . 01364 . . . . . . . . . BEACON. Blue Warning 12V (Optional) . . . . . 1
3 . . IL5100 . . 314B-24V . . . 01364 . . . . . . . . . BEACON. Blue Warning 24V (Optional) . . . . . 1
-3A . . . . . . . 1196 . . . . . . 01364 . . . . . . . . . BULB. Replacement. 12V(Optional) . . . . . . . 1
-3A . . . . . . . 312 . . . . . . 01364 . . . . . . . . . BULB. Replacement. 24V(Optional) . . . . . . . 1
Alternate Part- Electronic Strobe
-3B . IL5172 . . 2004BHBA . . AUSTIN . . . . . . . . BEACON. BLUE. 12124V. Model 2004(0ptional) . 1
-3B . IL5173 . . 2004BHRA . . AUSTIN . . . . . . . . BEACON. RED. 12124V. Model 2004(0ptional) . 1
-38 . IL5174 . . 2004BHAA . . AUSTIN . . . . . . . . BEACON. AMBER. 12124V. Model 2004(0ptional) 1
-38 . IL5175 . . 2004BHCA . . AUSTIN . . . . . . . . BEACON. CLEAR. 12124V. Model 2004(0ptional) 1
-38 . IL5181 . . 01-0441 566-00 AUSTIN . . . . . . . . . FLASH TUBE ASSY. F T I OA. IOW . . . . . . . 1
4 . . lL5025 . . 330-01 36 . . . 80019 . . . . . . . .

. REFLECTOR. Amber (Optional) . . . . . . . . . 2
4A . lL5024 . . 330-0636 . . . 80019 . . . . . . REFLECTOR. Red (Optional) . . . . . . . . . .
. . . 2
5 . . B02908B . . . . . . . . . . 12867 . . . . . . . .
. PLACARD. Warning. High Voltage . . . . . . . . 1
6A . KH5096 . TL-200B . . . . 72794 . . . . . . . .
. LATCH. Toggle . . . . . . . . . . . . . . . . . . 4
6B . B4032A . . . . . . . . . . 12867 . . . . . . . .
. BRACKET. Latch Support . . . . . . . . . . . . 4
6C . KH5099 . 98320A383 . . OKVE6 . . . . . . .
. PIN. Quick Release . . . . . . . . . . . . . . . . 4
6D . KH5100 . 90312A21 . . . OKVE6 . . . . . . . . LANYARD. Type B . . . . . . . . . . . . . . . . 4
-0R-
6A . KH5231 . C7-20 . . . . . 2M626 . . . . . . . . . LATCH. Soft . . . . . . . . . . . . . . . . . . . 4
6B . BY1150A . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Latch Support . . . . . . . . . . . . 2
7 . . 803692 . . . . . . . . . . 12867 . . . . . . . . . DOOR. Inspection. Assembly . . . . . . . . . . . 1
-7A . KH5112 . E3-67-15 . . . 94222 . . . . . . . . . LATCH. Knob Style . . . . . . . . . . . . . . . . 2
-70 . B03690 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY. Trim. Inspection Door . . . . . . . . 1
8 . . B3149H . . . . . . . . . . 12867 . . . . . . . . . PLACARD. Caution: Rotating Parts. . . . . . . . . 1
9 . . KH5102 . T-1755-4 . . . . 04729 . . . . . . . . . HANDLE. Internal . . . . . . . . . . . . . . . . . 8
10 . 807875 . . . . . . . . . . 12867 . . . . . . . . . STATIONARY Mid-canopy Assembly . . . . . . 1
11 . B05431 . . . . . . . . . . 12867 . . . . . . . . . PLACARD. Low Fuel Warning (Optional) . . . . . 1
12 . B04574 . . . . . . . . . . 12867 . . . . . . . . . PLACARD. Caution: Maint. Service Schd . . . . . 1
13 . KH5040 . LJ93030RS-H . SIERR . . . . . . . . . HINGE. Slip Assembly . . . . . . . . . . . . . . 4
14 . B4490J . . . . . . . . . . 12867 . . . . . . . . . PLACARD. AC Cable . . . . . . . . . . . . . . . 1
15 . A02909 . . . . . . . . . . 12867 . . . . . . . . . PLACARD. Warning. High Voltage . . . . . . . . 1
16 . B3149H . . . . . . . . . . 12867 . . . . . . . . . PLACARD. Caution: Rotating Parts . . . . . . . . . 1
17 . B03692 . . . . . . . . . . 12867 . . . . . . . . . DOOR. Inspection. Assembly . . . . . . . . . . . 1
-17A KH5112 . E3-67-15 . . . 94222 . . . . . . . . . LATCH. Knob Style . . . . . . . . . . . . . . . . 2
-17 8 B03690 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY. Trim. Inspection Door . . . . . . . . 1
18 . C05088 . 401 074 . . . . 8K511 . . . . . . . . . PLUG. Engine Blk Htr. 11OVAC (Optional) . . . . 1
18A . EH0158 . 890-L 314" . . . 8K511 . . . . . . . . . BOX. Bell (Optional) . . . . . . . . . . . . . . . 1
20 . B04490S . . . . . . . . . . 12867 . . . . . . . . . PLACARD. Diesel Fuel . . . . . . . . . . . . . . 1
21 . B04574 . . . . . . . . . . 12867 . . . . . . . . . PLACARD. Caution: Maint. Service Schd . . . . . 1
22 . 806063 . . . . . . . . . . 12867 . . . . . . . . . CABLE ASSY. AC. Without Remote Sensing . . 1
January 15. 1999 4-3

Revision 5 Page I 3
FIG. TI
a
VENDOR
90T400SLN
GROUND POWER UNIT
Figure 5. Canopy and Exterior Components
UNITS
. . . . . . . . . 12867 . . . . . . . . CABLE ASSY, AC, Wlth Remote Sensing . . . . 1

. . . . . . . . . 12867 . . . . . . . . CABLE ASSY, DC Pwr, Complete (Optional) . . . 1
-0R-
22 . 15930 . . . . . . . . . 12867 . . .. . . . . CABLE ASSY, DC Pwr (European Type)
-22A C05359 M3lMK2 . . . LPA . . . .. . . . . AIRCRAFT GND SUPPLY CONNECTOR . . . . 1
23 . REF . . . . . . . . . . 12867 . . .. . . . . PLACARD, Engine Pre-Heater (Optional) . . . . . 1
Visability Package - Not Illustrated
l263AD . . . 6V625 . . . . . . . . CLEARANCE, LIGHT AMBER . . . . . . . . . . 4
1263RD . . . 6V625 . . . . . . . . CLEARANCE, LIGHT, RED . . . . . . . . . . . . 4
313-24V . . . 6V625 . . . . . . . . CLEARANCE LIGHT BULB, 24V (#464) . . . . . 4
16-4206 . . . INVICTA . . . . . . . REFLECTOR LENS CLEAR, 2" RND . . . . . . . 4
330-0136 . . . 8001 9 . . . . . . . . REFLECTOR LENS, AMBER, 2" RND . . . . . . 4
487.77 . . . . ABBERLY . . . . . . REFLECTOR, RED, 6" TRIANGLE . . . . . . . . 2
Austin Electronics, CEDA Industrial Park, Charlestown, NH 03603
-ITEM NOT ILLUSTRATED. ITEM 19 NOT USED.
4-3 January 15, 1999

Page 14 Revision 5
a 90T400SLN
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&
DETAIL C
Figure 6. Window Assembly, Control Panel

6- . . . 804312 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY, Dust CoverIGauge Wlndow . . 1
1 . . B04304-1 . . . . . . . . 12867 . . . . . . . . . PLATE, Side, Gauge Wlndow, Left Side . . . . . 1
1A . B04304-2 . . . . . . . . 12867 . . . . . . . . . PLATE, Side, Gauge Window, Right Side . . . . 1
2 . . B04306 . . . . . . . . . . 12867 . . . . . . . . . HINGE, Gauge Window Dust Cover . . . . . . . 1
3 . . BO43l9 . . . . . . . . . . 12867 . . . . . . . . . HINGE SUPPORT, Gauge Wlndow . . . . . . . 1
4 . . KH5049 . COMM . . . . . 12867 . . . . . . . . . POP RIVET, 3/16" Dia., 1/8"1/4" Grip . . . . . AR
5 . . IN5007 . . 722.12-3116" . . 7\1\1514 . . . . . . . . RUBBER, Close Cell, 3116" x 314" x 20" . . . . . 2
6 . . BO43l2 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY, Dust Cover, Gauge Window . . . . 1
7 . . HWF088 . COMM . . . . . 12867 . . . . . . . . . SCREW, Phillips Hd., # I 0-32 x 718" . . . . . . . 6
8 . . HRFCCI . COMM. . . . . 12867 . . . . . . . . . WASHER, FL,#10 . . . . . . . . . . . . . . . . 12
9 . . HRFCBI . COMM . . . . . 12867 . . . . . . . . . WASHER, LK, # I 0 . . . . . . . . . . . . . . . . 6
10 . HRFCAl . COMM . . . . . 12867 . . . . . . . . . NUT, Hex, #lo-32 . . . . . . . . . . . . . . . . . 6
11 . B04309 . . . . . . . . . . 12867 . . . . . . . . . COVER, Dust, Gauge Wlndow . . . . . . . . . . 1
12 . B04308 . . . . . . . . . . 12867 . . . . . . . . . FRAME, Support, Gauge Window . . . . . . . . 1
13 . BO43ll . . . . . . . . . . 12867 . . . . . . . . . SPACER, Hinge . . . . . . . . . . . . . . . . . 1
14 . B04320 . . . . . . . . . . 12867 . . . . . . . . . HINGE, Gauge Window . . . . . . . . . . . . . . 1
15 . IN5007 . . 722.12-3116" . . 7\1\1514 . . . . . . . . RUBBER, Close Cell, 3116"x3/4"x31.75"" . . . . 1
16 . IN5006 . . 722.12-1I8 . . . 7\1\1514 . . . . . . . . RUBBER, Close Cell, 1/8"x3/4"x10.56"" . . . . . 1
17 . AA0063 . A98-1 . . . . . 8W008 . . . . . . . . ADHESIVE, Armstrong . . . . . . . . . . . . . AR
18 . IN0015 . . COMM . . . . . I2867 . . . . . . . . . RUBBER, Neoprene, 1/8"x3/4"x31.75" . . . . . . 1
19 . K H 5 l l 2 . E3-10-621-50 . 94222 . . . . . . . . . LATCH, Vice Action . . . . . . . . . . . . . . . . 2
January 15, 1999 4-3
Revision 5 Page 15
a90T400SLN
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I I I
S l D E VlEW END VlEW
REAR C A N O P Y
END V l E W
FRONT CANOPY
4-3 January 15, 1999

Figure 7. Support, Canopy Pivot
Page 16 Revision 5
ia 90T400SLN
GROUND POWER UNIT
Figure 7. Support. Canopy Pivot
7- . . . REF . . . . . . . . . . . . 12867 . . . . . . . . . SUPPORT ASSEMBLY. Canopy Pivot . . . . REF
1 . . H B l E K l . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. LK. 318"-16 . . . . . . . . . . . . . . 12
2 . . B08103 . . . . . . . . . . 12867 . . . . . . . . . GUIDE. ROD. Canopy . . . . . . . . . . . . . . 4
3 . . 808104 . . . . . . . . . . 12867 . . . . . . . . . WELDMENT. Canopy Guide Rod . . . . . . . . 4
4 . . COMM . . . . . . . . . . . 12867 . . . . . . . . . NUT. Hex. 318"-24 . . . . . . . . . . . . . . . . 4
5 . . EB5289 . TR-6 . . . . . . 76474 . . . . . . . . . ROD END. 318"-24 Female . . . . . . . . . . . . 4
6 . . B08106B . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Canopy Pivot Mntg. RHS . . . . . . 2
7 . . B08106A . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Canopy Pivot Mntg. LHS . . . . . . . 2
8 . . HRGBAI . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. 114"-20 . . . . . . . . . . . . . . . . 8
9 . . HHG075 . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex. 114"-20 x .75" Grd. 8 . . . . . . . . . 8
10 . SA5036 . 1281-38-N . . . 55566 . . . . . . . . . WASHER. Nylon .380 1.D.x 5 0.D.x 318" . . . . . 12
11 . HGJ225 . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 318"-16x225". Grd 8 . . . . . . . 6
11A . HRlBCl . COMM . . . . . 12867 . . . . . . . . . WASHER. FL. 318" . . . . . . . . . . . . . . . . 4
January 15. 1999 4-3

Revision 5 Page 17
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90T400SLN
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4 -3 January 15,1999
Page 18 Revision 5
a
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OPTIONATRACOR
OPTIONAL CUMMINS
FUE FILTER
I RlEL FILTER
WATER SEPARATOR I
WATER ~ E P ~ T O RL -
January 15, 1999 4-3
Revision 5 Figure 8A. Engine Mounted Components, Cummins Engine
Page 19
a 90T400SLN
GROUND POWER UNIT
I LINE
OFTONAL
FlJEL MLTER
WATER SEPARATOR
4 -3 Figure 8B. Engine Mounted Components, John Deere Engine January 15, 1999
Page 20 Revision 5
FIG. TI
a VENDOR
9OT40OSLN
GROUND POWER UNIT
Figure 8 . Engine Mounted Components
UNITS
8- . . . REF . . . . . . . . . . . . 12867 . . . . . . . . . COMPONENTS. Engine Mounted . . . . . . REF
1 . . . . . . . . 6BT5.9.C200 . 4G366 . . . . . . . . . ENGINE. Cummins. 6.Cyl. Jet-A Compatible . . 1
2 . . GE0002 . 101-20396-00 . 32770 . . . . . . . . . GENERATOR ASSY.. Kato@.2400 RPM . . . REF
-0R-
. . . GE5042 . 430PSLl315A . 00705 . . . . . . . . . GENERATOR ASSY. Marathon@.2000 RPM . REF
3 . . REF . . . . . . . . . . . . 12867 . . . . . . . . . PICKUP. Magnetic. See Figure 12 . . . . . . . . 1
4 . . . . . . . . 3908615 . . . . 4G366 . . . . . . . . . CARTRIDGE. Oil Filter. Replacement . . . . . . 1
5 . . . . . . . . 3903410 . . . . 4G366 . . . . . . . . . CARTRIDGE. Fuel Filter. Replacement . . . . . 1
6 . . . . . . . . 3903640 . . . . 4G366 . . . . . . . . . CARTRIDGE. Fuel Filter. Replacement . . . . . 1
7 . . EC0044 . FS1212 . . . . 15434 . . . . . . . . . CARTRIDGE. Fuel Filter. Replacement. Optional 1
8 . . FM0001 . 2556-6 . . . . . 01276 . . . . . . . . . HOSE. #6 x 59" . . . . . . . . . . . . . . . . . . 1
9 . . FL0004 . 190516-6s . . 01276 . . . . . . . . . FITTING. 90'. 9116"-18. #6 Hose . . . . . . . . . 2
10 . EC0029 . 142784s . . . . 15434 . . . . . . . . . HEAD. Filter. Optional . . . . . . . . . . . . . . 1
I 1 . FM0002 . 2556-4 . . . . . 01276 . . . . . . . . . HOSE #4 x 73" . . . . . . . . . . . . . . . . . . 1
12 . FL0014 . 4797-4B . . . . 01276 . . . . . . . . . FITTING. Swivel. 7116"-20 #4 . . . . . . . . . . . 1
13 . FL0047 . 4797-6B . . . . 01276 . . . . . . . . . FITTING . . . . . . . . . . . . . . . . . . . . . . 2
14 . EB0330 . CP-30B . . . . 29771 . . . . . . . . . VALVE. Check . . . . . . . . . . . . . . . . . . 1
15 . F10027 . . 202702-1 0-6s . 01276 . . . . . . . . . ADAPTER. 0-Ring 718"-14x9116"-18 . . . . . . . 2
16 . EB0572 . 900FG . . . . . 4L990 . . . . . . . . . FILTER. Fuel (Optional) . . . . . . . . . . . . . 1
-16A B08413 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Filter Mounting . . . . . . . . . . . . 1
17 . FB0029 . 421 131 . . . . 15434 . . . . . . . . . FAN. Radiator. 6BT . . . . . . . . . . . . . . . . 1
18 . . . . . . . 391 1562 . . . . 15434 . . . . . . . . . BELT. Fan . . . . . . . . . . . . . . . . . . . . 1
19 . SR0069 . SA503-G . . . OBXW5 . . . . . . . . SWITCH. Overspeed. Woodward Gov. Only . . . 1
-19A 804477 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Switch. Overspeed . . . . . . . . . . 1
20 . REF . . . . . . . . . . . . 12867 . . . . . . . . . ACTUATOR. Governor. See Figure 12 . . . . . REF
21 . SR5020 . SP-2-BB-5R . . 85814 . . . . . . . . . SWITCH. Oil Pressure. 10 psi . . . . . . . . . . 1
-21A F10045 . . 2040-2-2s . . . 01276 . . . . . . . . . ADAPTER. 90'. ~ / ~ " M P T x ~ / ~ ".J.I C
. . . . . . 1
22 . ME5020 . F279B . . . . . 56289 . . . . . . . . . SENDER. Oil Pressure . . . . . . . . . . . . . . 1
-22A F10045 . . 2040-2-2s . . . 01276 . . . . . . . . . ADAPTER. 118"-27M x 118"-27F-NPT . . . . . . 2
23 . VM0013 . 22004-1 3 . . . 81860 . . . . . . . . . MOUNT. Engine. Isolation . . . . . . . . . . . . 1
24 . VM0014 . 9810145-04 . . 81860 . . . . . . . . . WASHER. Snubbing . . . . . . . . . . . . . . . 3
25 . HGV6OO . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 718"-9 x 5" Grd#8 . . . . . . . . 2
-25 . HRVBKI . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. LK. 718"-9 Grd#8 . . . . . . . . . . . 2
26 . HRVBCI . COMM . . . . . 12867 . . . . . . . . . WASHER. FL. 718" . . . . . . . . . . . . . . . . 2
27 . . . . . . . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. 718" . . . . . . . . . . . . . . . . 2
28 . VM0013 . 22004-13 . . . 81860 . . . . . . . . . SUPPORT. Engine. Rear. Isolation . . . . . . . . 2
29 . B10039 . . . . . . . . . . 12867 . . . . . . . . . BUSS BAR ASSEMBLY . . . . . . . . . . . . . 1
30 . VMOOIO . 22003-13 . . . 81860 . . . . . . . . . MOUNT. Engine. Front. Isolation . . . . . . . . . 1
31 . VMOOl I . 9810145-3 . . . 81860 . . . . . . . . . WASHER. Snubbing. Front . . . . . . . . . . . . 1
32 . . . . . . . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. M I 6-2.0 x 90mm. Grd#lO.9 . . . 1
33 . . . . . . . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. 16mm . . . . . . . . . . . . . . . 1
34 . . . . . . . COMM . . . . . 12867 . . . . . . . . . WASHER. FL. 16mm . . . . . . . . . . . . . . . 1
35 . . . . . . . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. LK. 518"-11 UNC-2B . . . . . . . . . 1
36 . ME0009 . 02025-00 . . . 16476 . . . . . . . . . SENDER. Water Temperature . . . . . . . . . . 1
37 . SR5040 . 363-G . . . . . 85814 . . . . . . . . . SWITCH. OverTemperature. 2 2 5 ' ~ . . . . . . . 1
January 15. 1999 4-3

Revision 5 Page 21
a 9OT4OOSLN
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Figure 8. Engine Mounted Components (Continued)
38 . . . . . . . COMM . . . . 12867 . . . . . . . . BOLT. Hex Hd.. M36x80mrn . . . . . . . . . . . 4
39 . HRHBBI COMM . . . . 12867 . . . . . . . . WASHER. LK. 5/16" . . . . . . . . . . . . . . . . 4
40 . . . . . . . 3916854 . . . 46366 . . . . . . . . STARTER. Engine. 12V . . . . . . . . . . . . . . 1
-OR -
40 . . . . . . . 1113277 . . . 9K537 . . . . . . . . STARTER. Engine. 24V . . . . . . . . . . . . . . 1
41 . . . . . . . 3016628 . . . 4G366 . . . . . . . . ALTERNATOR. 12V . . . . . . . . . . . . . . . . 1
-0R-
41 . . . . . . . . . . . . . . . . 4G366 . . . . . . . . ALTERNATOR. 24V . . . . . . . . . . . . . . . . .
42 . . . . . . . AR50041 . . . 9R569 . . . . . . . . ELEMENT. Fuel Filter. Replacement. Rectangle . 1
-0R-
-42A . . . . . RE53400 . . . 9R569 . . . . . . . . ELEMENT. Fuel Filter. Replacement. Round . . . 1
43 . . . . . . . T I 9044 . . . . 9R569 . . . . . . . . CARTRIDGE. Oil Filter. Replacement . . . . . . . 1
44 . . . . . . . RE31694 . . . 9R569 . . . . . . . . ALTERNATOR. 12V . . . . . . . . . . . . . . . . I
-OR -
44 . . . . . . . AT1 30930 . . 9R569 . . . . . . . . ALTERNATOR. 24V . . . . . . . . . . . . . . . . 1
45 . . . . . . . RE51551 . . . 9R569 . . . . . . . . BELT. Fan . . . . . . . . . . . . . . . . . . . . . 2
46 . . . . . . . RE44151 . . . 9R569 . . . . . . . . STARTER. 24V . . . . . . . . . . . . . . . . . . 1
-OR -
46 . . . . . . . RE41755 . . . 9R569 . . . . . . . . STARTER. 12V . . . . . . . . . . . . . . . . . . 1
47 . . . . . . . 6059T . . . . 75160 . . . . . . . . ENGINE. John Deere. 6-Cyl . Diesel . . . . . . . . 1
48 . FB5014 . AT24834 . . . 65453 . . . . . . . . FAN BLADE (John Deere Engine) . . . . . . . . 1
-48A FB5015 . R90563 . . . . 65453 . . . . . . . . SPACER. Fan (39mm) . . . . . . . . . . . . . . 1
49 . REF . . . . . . . . . . . OBXW5 . . . . . . . . BRACKET.w/Kit . . . . . . . . . . . . . . . . REF
50 . VM5000 . . . . . . . . 12867 . . . . . . . . ENGINE SUPPORT. Front . . . . . . . . . . . . 2
51 . . . . . . . NOT USED
52 . B07937 . . . . . . . . . 12867
. . . . . . . ENGINE SUPPORT. Rear . . . . . . . . . . . . . 2
. .
53 . JD5020 . JDI-101-IN . 65453
. . . . . . . HEATER Engine BLK John Deere (Opt) . . . . . 1
. .
54 . SR5040 363-G . . . . 85814 . . . . . . SWITCH. Water Temp. 2 2 5 ' ~ . . . . . . . . . . . 1
. .
55 . (See Chapter 5. Ether Start Kit) . . . . . . . . SWITCH. Temp.. Ether Start (Optional) . . . . . . 1
. .
56 . EC5032 391627 . . . . 15434 . . . . . . . . HEATER. BLK. Cummins Engine. 115VAC
Optional . . . . . . . . . . . . . . . . . . . . . . 1
-56A . . . . . 39051 13 . . . 15434 . . . . . . . . CORD. Heater. Optional . . . . . . . . . . . . . . 1
57 . IYF035 . COMM . . . . 12867 . . . . . . . . BOLT. Hex Hd.. M12x1.72x35MM. Grd#9 . . . . 11
58 . HRKB4B COMM . . . . 12867 . . . . . . . . WASHER. LK. 112" . . . . . . . . . . . . . . . 11
59 . C7478-1 . . . . . . . . 12867 . . . . . . . . BOARD ASSEMBLY. Cable Connect . . . . . . 1
4-3 January 15. 1999

Page 22 Revision 5
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Figure 9A . Radiator and Associated Hardware. Cummins Engine

NO. NO. NO . FVC PART NO. NOMENCLATURE ASSY
9A- . . REF . . . . . . . . . . . . 12867 . . . . . . . . . Radiator And Associated Hardware. Cummins REF
1 . . EB0552 . 94796312 . . . 76225 . . . . . . . . . RADIATOR. 6BT Engine . . . . . . . . . . . . . 1
2 . . AH5008 . FM44 . . . . . 6V625 . . . . . . . . . HOSE. Radiator. Upper. 1-3/4"I.D.x19"Lg . . . . 1
3 . . CY0036 . 705-1208 . . . 6V625 . . . . . . . . . CLAMP. Hose. #28. 1-114" to 1-314" . . . . . . . 2
4 . . AH0024 . FM57 . . . . . 241 61 . . . . . . . . . HOSE. Radiator. Lower. 2.25" I.D. . . . . . . . . 1
5 . . CY0037 . 705-1018 . . . 6V625 . . . . . . . . . CLAMP. Hose. #32 . . . . . . . . . . . . . . . . 2
6 . . REF . . . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Radiator Mounting . . . . . . . . . . 2
7 . . CY0025 . 900729-4 . . . 01276 . . . . . . . . . CLAMP. Hose. Hydraulic. 314" #4 . . . . . . . . 2
8 . . HFH063 . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 5116"-18x.625" Grd# 8 . . . . . . 7
9 . . HGHI 00 . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 5116"-18x1.0" Grd# 8 . . . . . . 8
10 . HRHBCI . COMM . . . . . 12867 . . . . . . . . . WASHER. FL. Plated. 5/16" . . . . . . . . . . . 15
11 . HRHBBI . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. Plated. 5/16" . . . . . . . . . . . 15
12 . HRHBAI . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. 5116"-18. Plated. Grd# 8 . . . . . . . 2
13 . VA5000 . 145 . . . . . . 0G852 . . . . . . . . . DRAIN. Petcoc. Radiator. 1N"NPT . . . . . . . . 1
14 . EB5071 . 94962224 . . . 76225 . . . . . . . . . SHROUD. Radiator . . . . . . . . . . . . . . . . 1
15 . EB5134 . 06-435 . . . . . 6V625 . . . . . . . . . HOSE. Radiator Over Flow. 5116"I.D. . . . . . . 1
16 . REF . . . . . . . . . . . . 12867 . . . . . . . . . SPACE. Fan Orifice Adjust . . . . . . . . . . . . 1
17 . EB0006 . SP-18 . . . . . 6V625 . . . . . . . . . CAP. Radiator . . . . . . . . . . . . . . . . . . . 1
-1 8 . EC5371 . 3922500 . . . . 15434 . . . . . . . . . CONTAINER. Overflow . . . . . . . . . . . . . . 1
January 15. 1999 4-3

Revision 5 Page 23
a 9OT4OOSLN
GROUND POWER UNIT
Figure 9B.Radiator and Associated Hardware, John Deere Engine

9B- . B07552 . . . . . . . . . . 12867 . . . . . . . . RADIATOR AND ASSOCIATED HARDWARE,
John Deere Engine . . . . . . . . . . . . . . REF
RADIATOR . . . . . . . . . . . . . . . . . . . . 1
CAP, Radiator . . . . . . . . . . . . . . . . . . . 1
BRACKET, Radiator Mounting . . . . . . . . . . 1
WELDMENT, Fan Shroud . . . . . . . . . . . . . 1
GUARD, Radiator Fan, 23.0", Modified . . . . . . 1
CLAMP,2.25" . . . . . . . . . . . . . . . . . . . 4
HOSE,2.25"I.D.. . . . . . . . . . . . . . . . . . 1
HOSE, 2.25" I.D. x 27" Lg. . . . . . . . . . . . . 1
DRAIN, Petcock, 114"NPT . . . . . . . . . . . . . 1
CONTAINER, Overflow . . . . . . . . . . . . . . 1
4-3 January 15, 1999

Page 24 Revision 5
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Figure 10. Engine Air Filter Assembly

NO. NO . NO. FVC PART NO . NOMENCLATURE ASSY
10- . . B07553 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY. Air System . . . . . . . . . . . REF
1 . . EB5195 . 77003N . . . . 76700 . . . . . . . . . CLEANER. Air . . . . . . . . . . . . . . . . . . 1
2 . . EB5196 . Q27183 . . . . 76700 . . . . . . . . . BAND. Mounting . . . . . . . . . . . . . . . . . 2
3 . . CY5035 . 89580-K . . . . 6V625 . . . . . . . . . CLAMP. 3.0" . . . . . . . . . . . . . . . . . . . 1
3A . CY5035 . 89582-K . . . . 6V625 . . . . . . . . . CLAMP. 4.0" . . . . . . . . . . . . . . . . . . . 1
4 . . EB5103 . 89844-K . . . . 76700 . . . . . . . . . HUMP HOSE. 3.0" to 4.0" . . . . . . . . . . . . 1
5 . . ME001I . 3781-325 . . . 59150 . . . . . . . . . FILTER MINDER . . . . . . . . . . . . . . . . . 1
5A . 808378 . . . . . . . . . . 12867 . . . . . . . . . MOUNTING BRACKET. Filter Minder . . . . . . 1
6 . . 8041 26 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Air Filter . . . . . . . . . . . . . . . 1
7 . . IYF035 . . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd. M12x1.75x35mm Grd. 10.9 . . . 2
8 . . IWFBCI . COMM . . . . . 12867 . . . . . . . . . WASHER. FL. M I 2 . . . . . . . . . . . . . . . . 3
9 . . IWFBB1 . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. M I 2 . . . . . . . . . . . . . . . . 3
10 . . . . . . . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 12Mx1.75x30mm Grd 8 . . . . . 1
11 . . . . . . . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 5116"-18 x 718" Lg. . . . . . . . . 4
12 . HRHBCI . COMM . . . . . 12867 . . . . . . . . . WASHER. FL. 5/16" . . . . . . . . . . . . . . . 4
13 . HRHBBI . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. 5/16" . . . . . . . . . . . . . . . 4
14 . HRHBAI . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. 5/16"-18 . . . . . . . . . . . . . . . . 4
January 15. 1999 4-3

Revision 5 Page 25
a 90T400SLN
GROUND POWER UNIT
Figure 11A. Engine Exhaust Assembly, John Deere and Standard Cummins Engine
11A- . B07554 . . . . . . . . . . 12867 . . . . . . . . EXHAUST SYSTEM, John Deere and
Standard Cummins Engine . . . . . . . . . . REF
MUFFLER, Silencer, 4" Outlet . . . . . . . . . . . I
BLANKET, Thermal . . . . . . . . . . . . . . . . 1
BRACKET, Exhaust, John Deere . . . . . . . . . 1
CLAMP, Guillotine 4.0" . . . . . . . . . . . . . . 4
WELDMENT, Tube & Elbow, 4.0" . . . . . . . . . 1
. . . . . . ELBOW, go0, 4.0", Modified . . . . . . . . . . . . 1
EB5160 . ELBOW, go0, 4.0", Modified . . . . . . . . . . . . 1
B08350 . SEAL, Exhaust, 4.0" . . . . . . . . . . . . . . . . 1
808351 . PLATE, Seal, Hold Down, 4.0" . . . . . . . . . . 1
807391-3 STRAP, Muffler Mounting . . . . . . . . . . . . . 1
COMM . STRAP, Tie Wrap . . . . . . . . . . . . . . . . . 3
COMM . WRAP, Insulating Exhaust, 2"x50' . . . . . . . . 3
4-3 January 15, 1999

Page 26 Revision 5
a 9OT4OOSLN
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Figure 11B. Engine Exhaust Assembly. 200HP Cummins Engine

11B- . B10873 . . . . . . . . . . 12867 . . . . . . . . . EXHAUST SYSTEM. 200HP Curnmins Enaine . REF
1 . . EB5285 . TS40TRRO . . 6S431 . . . . . . . . . MUFFLER. w/Outlet . . . . . . . . . . . . . . . 1
2 . . EB5287 . TS40TRRO . . 65453 . . . . . . . . . BLANKET. Thermal . . . . . . . . . . . . . . . . 1
3 . . B10875 . . . . . . . . . . 12867 . . . . . . . . . STRAP. MuMer . . . . . . . . . . . . . . . . . . 1
4 . . CY5018 . 89548K . . . . 76700 . . . . . . . . . CLAMP. Guillotine. 4" . . . . . . . . . . . . . . . 3
5 . . EB5312 . 89027A . . . . 76700 . . . . . . . . . PIPE. Stack. 4" . . . . . . . . . . . . . . . . . . 1
6 . . EB5074 . 891 85A . . . . 76700 . . . . . . . . . REDUCER. 4"OD x 3"ID . . . . . . . . . . . . . 1
7 . . CY5017 . 89545K . . . . 76700 . . . . . . . . . CLAMP. Guillotine. 3" . . . . . . . . . . . . . . . 2
8 . . B10810 . . . . . . . . . . 12867 . . . . . . . . . ELBOW. Weldrnent . . . . . . . . . . . . . . . . 1
9 . . EB5224 . 11002 . . . . . THERM . . . . . . . . WRAP. Exhaust Insulation. 2"x50 ft Roll . . . . . 1
10 . EB5226 . 12002 . . . . . THERM . . . . . . . . COATING. High Heat . . . . . . . . . . . . . . . 1
11 . EB5225 . . . . . . . . . . THERM . . . . . . . . STRAP. Tie Wrap . . . . . . . . . . . . . . . . . 1
12 . IN5016 . . 14001 . . . . . THERM . . . . . . . . BARRIER. Heat. 40"W x 5 Yards Long . . . . . . 1
13 . 808071 . . . . . . . . . . 12867 . . . . . . . . . EXHAUST MOUNTING. Weldrnent . . . . . . . . 1
January 15. 1999 4-3

Revision 5 Page 27
a 90T400SLN
GROUND POWER UNIT
Figure 116 . Engine Exhaust Assembly. 200HP Cummins Engine (Continued)
14 . IYFO35 . COMM . . . . 12867 . . . . . . . . BOLT. Hex Hd.. Grd#10.9 . . . . . . . . . . . . . 4
15 . IWFBCI COMM . . . . 12867 . . . . . . . . WASHER. FL. 12mm . . . . . . . . . . . . . . . 4
16 . IWFBBl COMM . . . . 12867 . . . . . . . . WASHER. LK. 12mm . . . . . . . . . . . . . . . 4
17 . HRlEKl COMM . . . . 12867 . . . . . . . . NUT. Hex. Elastic LK. 318"-16 . . . . . . . . . . . 1
18 . HRIBCI COMM . . . . 12867 . . . . . . . . WASHER. FL. 318" . . . . . . . . . . . . . . . . 1
19 . . . . . . . NOT USED
20 . B08351 . . . . . . . . . . 12867 . . . . . . . .
PLATE. Seal . . . . . . . . . . . . . . . . . . . . 1
21 . HWFOSO COMM . . . . 12867 . . . . . . . . .
SCREW. PHD. Pillips. #lo-32x112" SST . . . . . 4
22 .
23 .
HRFCCI COMM . . . .
HRFCBI COMM . . . .
12867
12867
.
.
.
.
.
.
.
.
.
.
.
.
. . ..
WASHER. FL. # l o . SST . . . . . . . . . . . . .
WASHER. LK.# l o . SST . . . . . . . . . . . . .
. .
4
4
24 . KH5050 AKS7-1032-130 OKKK7 . . . . . . INSERT. Threaded. # I 0-32 . . . . . . . . . . . .
. . 4
25 . B08350 . . . . . . . . . . 12867 . . . . . . . . SEAL. Exhaust. 4" . . . . . . . . . . . . . . . . . 1
26 . EB5160 . 8910514 . . . . 76700 . . . . . . . . ELBOW. 900.4"I.D. . . . . . . . . . . . . . . . . 1
27 . EC0090 3910993 . . . 15434 . . . . . . . . ELBOW. 900 . . . . . . . . . . . . . . . . . . . . 1
28 . HRHBAI COMM . . . . 12867 . . . . . . . . NUT. Hex. 5116"-18 . . . . . . . . . . . . . . . . 1
29 . HRHBBI COMM . . . . 12867 . . . . . . . . WASHER. LK. 5/16" . . . . . . . . . . . . . . . . 1
30 . HGH125 COMM . . . . 12867 . . . . . . . . BOLT. Hex Hd.. 5116"-18 . . . . . . . . . . . . . 1
31 . HRHBCI COMM . . . . 12867 . . . . . . . . WASHER. FL. 5/16" . . . . . . . . . . . . . . . . 2
4 .3 January 15. 1999

Page 28 Revision 5
a 9OT4OOSLN
GROUND POWER UNIT
Figure 12. Fuel Tank Assembly

12- . . 808912 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY, Fuel Tank . . . . . . . . . . . . REF
1 . . LF8844 . . . . . . . . . . 12867 . . . . . . . . . WELDMENT, Fuel Tank . . . . . . . . . . . . . 1
2 . . ME0008 . C4253-10 . . . 16476 . . . . . . . . . SENDER, Fuel Level . . . . . . . . . . . . . . . 1
3 . . EB5l83 . 5343-6 . . . . . 7R617 . . . . . . . . . CAP, Fuel Fill, Bail Handle . . . . . . . . . . . . 1
-0 R-
3 . . EB5092 . 398 . . . . . . 9H249 . . . . . . . . . CAP, Fuel Fill, Protectoseal . . . . . . . . . . . . 1
4 . . EB5217 . . . . . . . . . . 7R617 . . . . . . . . . SCREEN, Fuel Neck . . . . . . . . . . . . . . . 1
5 . . B07509B . . . . . . . . . . 12867 . . . . . . . . . PICK-UP Fuel 318"-16NPTx9116"-18 Tube . . . 1.
-5A . F10044 . . 2024-6-4s . . . 01276 . . . . . . . . . FITTING go0, 3/8"-l6NPTx7/l6"-2O Tube . . . 1.
6 . ,807395 . . . . . . . . . . 12867 . . . . . . . . . COVER, T a n k . . . . . . . . . . . . . . . . . . 1.
7 . . B06156 . . . . . . . . . . 12867 . . . . . . . . . GASKET . . . . . . . . . . . . . . . . . . . . 1.
8 . . HFG063 . COMM . . . . . I2867 . . . . . . . . . BOLT, Hex Hd., 114"-20x518" Grd.#8 . . . . . . 6.
9 . . HRGBCI COMM . . . . . 12867 . . . . . . . . . WASHER, FL, 114" . . . . . . . . . . . . . . . . 6
10 . HRGBBI . COMM . . . . . 12867 . . . . . . . . . WASHER, LK, 114" . . . . . . . . . . . . . . . . 6
11 . TS0007 . COMM . . . . . I2867 . . . . . . . . . PLUG, Sq. Hd., 112"-14 NPT, Sch.#40 . . . . . . 2
12 . SR5044 . LS-70014 NC SNGL 04034 . . . . . . . . . SWITCH, Fuel Level, NC Single
(lights warning light or shuts off engine) . . . . . 1
-0R-
12 . SR5042 . LS-70014NC DUAL 04034 . . . . . . . . . SWITCH, Fuel Level, NC Dual . . . . . . . . . . 1
(Low fuel lights warning light €4 shuts
down engine) . . . . . . . . . . . . . . . . . . . 1
January 15, 1999 4-3
Revision 5 Page 29
a 90T400SLN
GROUND POWER UNIT
\
\
\ \
STARTER
T O STARTER
TO
GROUND
//
Figure 13. Engine Battery Assembly
13- . B08367. . . . . . . . . . 12867 . . . . . . . . ASSEMBLY, Battery & Cable . . . . . . . . . REF
1 . BA0003. 24-60550CCA BATTERY, 12VDC . . . . . . . . . . . . . . . . 2
1A . B8008A. . . . . . . . . . HOLD DOWN, Battery, RH . . . . . . . . . . . . 1
1B . B8008B. . . . . . . . . . HOLD DOWN, Battery, LH . . . . . . . . . . . . 1
2 . COMM . . . . . . . . . . CONNECTOR, Battery, Negative . . . . . . . . . 2
3 . B044298Z . . . . . . . . CABLE ASSEMBLY, Battery to C/P . . . . . . . . 1
4 . B04498AA . . . . . . . . CABLE ASSEMBLY, Battery to Engine . . . . . . 1
5 . B04498AD . . . . . . . . CABLE ASSEMBLY, Starter to C/P . . . . . . . . 1
6 . B04498AC . . . . . . . . CABLE ASSEMBLY, Engine to Ground . . . . . . 1
7 . COMM . . . . . . . . . . CONNECTOR, Battery, Positive . . . . . . . . . 2
-8 . BA5003 . ACC-42-445 . SET, Battery Terminal Cover . . . . . . . . . . . 2
9 . BA5001 . 44D-900 . . . BATTERY, 12VDC, 900 CCA, Size 4 . . . . . . . 1
10 . 811842. . . . . . . . . . TRAY, Battery, 4D . . . . . . . . . . . . . . . . . 1
11 . 811843. . . . . . . . . . HOLD DOWN, Battery, 4D . . . . . . . . . . . . 1
4-3 January 15,1999
Page 30 Revision 5
Figure 14A. Engine Speed Governor Assembly. Woodward (Optional)
NO. NO. NO. FVC PART NO .
NOMENCLATURE ASSY
14A- . . . . . . . 1474 . . . . . . 31 361 . . . . . . . . . KIT. Woodward Governor Assy . . . . . . . . REF
1 . . EGO021 . 8256-021 . . . 31361 . . . . . . . . . ACTUATOR. Governor. 24V . . . . . . . . . . . 1
-0R-
1 . . EG5011 . 8256-022 . . . 31361 . . . . . . . . . ACTUATOR. Governor. 12V . . . . . . . . . . . 1
- l A . SR0069 . SA503-G . . . OBXW5 . . . . . . . . SWITCH. Overspeed. Woodward Gov. Only . . . 1
-1 B . B04477 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Switch. Overspeed . . . . . . . . . . 1
2 . . EGO035 . 8290-039 . . . 31361 . . . . . . . . . CONTROL. Governor. 24V . . . . . . . . . . . . 1
-0R-
2 . . EGO046 . 8290-040 . . . 31361 . . . . . . . . . CONTROL. Governor. 12V . . . . . . . . . . . . 1
3 . . EGO019 . 5430-929 . . . 31361 . . . . . . . . . PICKUP. Magnetic . . . . . . . . . . . . . . . . 1
4 . . . . . . . . COMM . . . . . 12867 . . . . . . . . . SCREW. Cap. Hex Hd.. 318"-16x1" . . . . . . . . 2
5 . . HRGCBI COMM . . . . . 12867 . . . . . . . . . WASHER. LK. .25" . . . . . . . . . . . . . . . . 5
6 . . . . . . . . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. 318"-24 . . . . . . . . . . . . . . . . 2
7 . . HRGBAI . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. .25"-20 . . . . . . . . . . . . . . . . 1
8 . . HRGBCI COMM . . . . . 12867 . . . . . . . . . WASHER. FL. .25" . . . . . . . . . . . . . . . . 6
9 . . . . . . . . COMM . . . . . 12867 . . . . . . . . . SCREW. Cap. Hex Hd.. .25"-20x1.25" . . . . . . 1
10 . EG5001 . 3979-007 . . . 31361 . . . . . . . . . LEVER. Actuator . . . . . . . . . . . . . . . . . 1
11 . . . . . . . COMM . . . . . 12867 . . . . . . . . . SCREW. Cap. Hex Hd.. .25"-20x.75" . . . . . . . 4
12 . . . . . . . COMM . . . . . 12867 . . . . . . . . . ROD. Threaded. .3/8"-24x4.38" . . . . . . . . . . 1
13 . EB5289 . AR-5N . . . . . 8E125 . . . . . . . . . ROD. End. female. 318"-24 . . . . . . . . . . . . 2
14 . HRIBCI . COMM . . . . . 12867 . . . . . . . . . WASHER. FL. 318" . . . . . . . . . . . . . . . . 2
15 . HBlBBl . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. 318" . . . . . . . . . . . . . . . . 2
16 . B03222 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Elect . Governor . . . . . . . . . . . 1
January 15. 1999 4-3
Revision 5 Page 31
a 90T400SLN
GROUND POWER UNIT
ENGINE TOP
Figure 14B. Engine Speed Governor Assembly, Governors of America (Cummins)
4-3 January 15, 1999

Page 32 Revision 5
FIG.
ITEM
NO.
TI
PART
NO.
a VENDOR
PART
NO.
90T400SLN
GROUND POWER UNIT
FVC
AIRLINE
PART NO. NOMENCLATURE
UNITS
PER
ASSY
148-
1 .
. REF . . . . . . . . . . . . 12867 .
. HGG200 . COMM . . . . . 12867 .
. . . . . . . .
. . . . . . . .
.
KIT. Installation. GOA Governor Cummins . 1
SCREW. Cap. 114"-20 x 2.00 . . . . . . . . . . . 2
2 . . HRGEK1 . COMM . . . . . 12867 . . . . . . . . . NUT. LKing. 114"-20 . . . . . . . . . . . . . . . 5
3 . . HHG108 . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 114"-20 x 1.00" . . . . . . . . . . 5
4 . . HRGEKI . COMM . . . . . 12867 . . . . . . . . . NUT. LKing. 114"-20 . . . . . . . . . . . . . . . 5
5 . . BIZ382 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Actuator. Governor. Top Mount . . . 1
6 . . EG5001 . ESD5221 . . . OBXW5 . . . . . . . . LEVER. Arm. Governor Actuator . . . . . . . . . 2
7 . . EG5018 . ADB225 . . . . OBXW5 . . . . . . . . ACTUATOR. Governor . . . . . . . . . . . . . . 1
8 . . SB0271 . RD100-4 . . . . OBXW5 . . . . . . . . ROD. Linkage. 114"-28 x 3.50" . . . . . . . . . . 1
9 . . HRTCAI . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. 114"-28 . . . . . . . . . . . . . . . . 2
10 . EB5014 . BR200 . . . . . OBXW5 . . . . . . . . ROD END. Ball Bearing . . . . . . . . . . . . . 2
11 . NV5076 . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. Split. 112" . . . . . . . . . . . . . 4
12 . SA5001 . . . . . . . . . . 12867 . . . . . . . . . SPACER. 112" Dia . x 1.00" . . . . . . . . . . . . 2
13 . . . . . . . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. M I 2x1.75x35rnrn . . . . . . . . 4
14 . NV5613 . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 114"-20 x 1.25" Long . . . . . . . 1
15 . B12384 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Linkage . . . . . . . . . . . . . . . . 1
16 . EGO053 . MSP-6718 . . . OBXW5 . . . . . . . . SENSOR. Magnetic Pickup . . . . . . . . . . . . 1
16A . CHI 202 . . . . . . . . . . 12867 . . . . . . . . . HARNESS. Magnetic Sensor . . . . . . . . . . . 1
17 . EGO051 . ESD5221 . . . OBXW5 . . . . . . . . CONTROL. Governor . . . . . . . . . . . . . . . 1
18 . BK1113 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Actuator. Governor. Side Mount . . . 1
January 15. 1999 4-3

Revision 5 Page 33
a 90T400SLN
GROUND POWER UNIT
Figure 14C. Engine Speed Governor Assembly. Governors of America (John Deere)
14C- . EG5028 KT140T . . . OBXW5 . . . . . . . . KIT. Installation. GOA Governor . . . . . . . 1
1 . EGO051 ESD5221 . . . CONTROL. Governor . . . . . . . . . . . . . . . 1
2 . EG5029 ADB120 . . . ACTUATOR. Governor . . . . . . . . . . . . . . 1
3 . HGGI 00 COMM . . . . BOLT. Hex Hd.. 114"-20 x 1.00" . . . . . . . . . . 5
4 . HRGEKI COMM . . . . NUT. LK. 114"-20 . . . . . . . . . . . . . . . . . 5
5 . EB5014 . BR200 . . . . ROD END. Ball Bearing . . . . . . . . . . . . . . 2
6 . HRTCAI COMM . . . . NUT. Hex. 114"-28 . . . . . . . . . . . . . . . . . 2
7 . SB0271 . RD100-4 . . . ROD. Linkage. 114"-28 x 3.50" . . . . . . . . . . 1
8 . HRGEKI COMM . . . . NUT. LK. 114"20 . . . . . . . . . . . . . . . . . . 5
9 . HGGI 00 COMM . . . . BOLT. Hex Hd.. 114"-20 x 1.00" . . . . . . . . . . 5
10 . REF . . . . . . . . . . . BRACKET. Actuator (with kit) . . . . . . . . . . . 1
11 . LEI 4002 . . . . . . . . LEVER. Actuator . . . . . . . . . . . . . . . . . 1
12 . SA5001 . . . . . . . . . . SPACER. 112" Dia . x 1.00" . . . . . . . . . . . . 2
13 . HGG200 COMM . . . . SCREW. Cap. 114"-20 x 2.00" . . . . . . . . . . . 2
14 . HRGEKI COMM . . . . NUT. LK. 114"-20 . . . . . . . . . . . . . . . . . 5
15 . EG5030 MSP-6721 . . SENSOR. Magnetic Pick-up . . . . . . . . . . . . 1
15A CHI202 . . . . . . . . HARNESS. Magnetic Sensor . . . . . . . . . . . 1
4-3 January 15. 1999

Page 34 Revision 5
\
ETHER
START
PUS11
@r-
6+
-
B 63 \ I \
\
MTE: LOCATION OF AC
CONTROLWHEN ONLVONE AC tern 19 Note: 2 Options. Low Fuel or Neutral Fault.
OUTPUT IS PROVIDED. c 060297Rb,pcx
a 9OT40OSLN
GROUND POWER UNIT
4-3 January 15, 1999

Figure 158. Control Panel Assembly, Dual AC Output, Single DC
Page 36 Revision 5
FIG. TI
a VENDOR
9OT4OOSLN
GROUND POWER UNIT
Figure 15. Control Panel Assembly
UNITS
15- . . B06044 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY. Control Panel. Engine & Dual AC
Service. Without DC Output . . . . . . . . . . REF
-0R-
15- . . B06042 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY. Control Panel. Engine & AC
Service. Wtth DC Output . . . . . . . . . . . REF
-0 R-
15- . . B06040 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY. Control Panel. Engine & Single AC
Service. Wtthout DC Output . . . . . . . . . . REF
1 . . 806739 . . . . . . . . . . 12867 . . . . . . . . . PANEL. Control. EngineIAC Service . . . . . . . 1
2 . . MV0041 . 016-Ol-WA-PZPZ . 39732 . . . . . . . . . VOLTMETER. 0-1 50 Volts (M2) . . . . . . . . . 1
-0R-
2 . . MV0006 . R3PB-AVD-JOOSNL 39732 . . . . . . . . . VOLTMETER. 0-300 Volts (M2) . . . . . . . . . 1
3 . . IL0016 . . F151-12R . . . 54388 . . . . . . . . . LAMP. Red 12 VDCt Fault (DS7-11) . . . . . . . 5
-0R-
3 . . IL0017 . . F151-24R . . . 54388 . . . . . . . . . LAMP. Red 24 VDCt Fault (057-11) . . . . . . . 5
4 . . MA0052 . 016-02-AA-LSSF . 39732 . . . . . . . . . AMMETER. 0-500 Amp. ( M I ) . . . . . . . . . . . 1
5 . . ME0012 . 06339-1 . . . . 16476 . . . . . . . . . GAUGE. Fuel (MB) . . . . . . . . . . . . . . . . 1
-5A . HRECA1 . COMM . . . . .
. 12867 . . . . . . . . . NUT. Hex. SST #8-32 . . . . . . . . . . . . . . 2
5B . ME0016 . 06215-00 . . . 16476 . . . . . . . . . LIGHT KIT. 12 Volt . . . . . . . . .. . . . . . . 1
6 . . ME0014 . 06341-1 . . . . 16476 . . . . . . . . . GAUGE. Oil Pressure (M9) . . . . . . . . . . . . 1
-6A . ME0016 . 0621 5-00 . . . 16476 . . . . . . . . . LIGHT KIT. 12 VDC . . . . . . . . . . . . . . . . 1
-0 R-
-6A . ME0028 . 06294 . . . . . 16476 . . . . . . . . . LIGHT KIT. 24 VDC . . . . . . . . . . . . . . . . 1
-6B . HRECAI . COMM . . . . . 12867 . . . . . . . . . NUT. Hex.. SST #8-32 . . . . . . . . . . . . . . 2
7 . . IL0016 . . F151-12R . . . 54388 . . . . . . . . . LAMP. Red 12 VDC Fault (DSl4-16) . . . . . . 3
-0R-
7 . . IL0016 . . F151-24R . . . 54388 . . . . . . . . . LAMP. Red 24 VDC Fault (DSl4-16) . . . . . . 3
8 . . IL0072 . . 5131-038 . . . 8P940 . . . . . . . . . HOLDER. Lamp LH 7311 (XDS21) . . . . . . . . 2
-8A . IL0004 . . 131A-304Y . . 8P940 . . . . . . . . . LENS. Amber. Ignition ON . . . . . . . . . . . . 1
-8B . IL5012 . . 394 . . . . . . 8P940 . . . . . . . . . BULB. 12 VDC . . . . . . . . . . . . . . . . . . 1
-0 R-
-8B . IL0051 . . 387 . . . . . . 8P940 . . . . . . . . . BULB. 24 VDC . . . . . . . . . . . . . . . . . . 1
9 . . ME001 3 . 06350-01 . . . 16476 . . . . . . . . . GAUGE. Water Temperature (M10) . . . . . . . 1
-9A . ME0016 . 0621 5-00 . . . 16476 . . . . . . . . . LIGHT KIT. 12 VDC . . . . . . . . . . . . . . . . 1
-0 R-
-9A . ME0028 . 06294 . . . . . 16476 . . . . . . . . . LIGHT KIT. 24 VDC . . . . . . . . . . . . . . . . 1
9C . HRECAI . COMM . . . . . 12867 .
. . . . . . . . . NUT. Hex. SST #8-32 . . . . . . . . . . . . . . 2
10 . ME0005 . 06351-1 . . . . 16476 . . . . . . . . . VOLTMETER. 16-32 VDC ( M I 1) . . . . . . . . . 1
-10A ME0016 . 0621 5-00 . . . 16476 . . . . . . . . . LIGHT KIT. 12 Volt . . . . . . . . . . . . . . . . 1
-0R-
-1 0A ME0028 . 06294 . . . . . 16476 . . . . . . . . . LIGHT KIT. 24 VDC . . . . . . . . . . . . . . . . 1
-1 0B HRECAI . COMM . . . . . 12867 . . . . . . . . . .
NUT. Hex. SST #8-32 . . . . . . . . . . . . . . 2
11 . ME0003 . 56458-10 . . . 16476 . . . . . . . . . HOURMETER (M12) . . . . . . . . . . . . . . . 1
12 . SP0019 . 4200 . . . . . . 73752 . . . . . . . . . SWITCH. Pushbutton. N.O. Start (S13) . . . . . 1
13 . ST0023 . 7561 K4 . . . . 15605 . . . . . . . . . SWITCH. Toggle. DPDT ( S l ) . . . . . . . . . . . 1
14 . CB5006 . W58XBlA4A-10 77342 . . . . . . . . . CIRCUIT BREAKER. 10 Amp ( C B I ) . . . . . . . 1

January 15. 1999 4-3
Revision 5 Page 37
FIG. TI
a
VENDOR
9OT4OOSLN
GROUND POWER UNIT
Figure 15. Control Panel Assembly (Confinued)
UNITS
NO. FVC PART NO . NOMENCLATURE ASSY
W58XBlA4A-5 77342 . . . . . . . . CIRCUIT BREAKER. 5 Amp (CB2) . . . . . . . . 1
W58XBlA4A-15 77342 . . . . . . . . CIRCUIT BREAKER. 15 A& (cB~). . . . . . . 1
7592K6 . . . . 15605 . . . . . . . . SWITCH. Toggle. DPDT (S14) . . . . . . . . . . 1
5131-038 . . . 8P940 . . . . . . . . HOLDER. Lamp LH 7311 (XDS21) . . . . . . . . 1
LC12RT2 . . . 83330 . . . . . . . . LENS. Red. Low Fuel (XDS23) (Optional) . . . . 1
394 . . . . . . 8P940 . . . . . . . . BULB. 12Volt . . . . . . . . . . . . . . . . . . . 1
-0 R-
387 . . . . . . 8P940 . . . . . . . . BULB. 24 VDC . . . . . . . . . . . . . . . . . . . 1
. . . . . . . 12867 . . . . . . . . DECAL. Low Fuel . . . . . . . . . . . . . . . . . 1
-0 R-
12867
. . . . . . . . . . . . . . . . . DECAL. Neutral Fault . . . . . . . . . . . . . . . 1
C10A048-623E 10983 . . . . . . . . SWITCH. Ammeter WIG001 Handle (S2) . . . . . 1
016-41-SA-PNBI 39732 . . . . . . . . METER. Frequency. 380-420 Hz (M7) . . . . . . 1
3SB02-PFR01D 9L773 . . . . . . . . SWITCH. PB. NC Red Cap (S4B) . . . . . . . . . 1
3SB02-TFCGP 9L773 . . . . . . . . SWITCH. PB. Mom NO. Grn Lens (S4A) . . . . . 1
CM1815 . . . 71744 . . . . . . . . BULB. 12 VDC . . . . . . . . . . . . . . . . . . . 1
-0 R-
CM1829 . . . 71744 . . . . . . . . BULB.24VDC . . . . . . . . . . . . . . . . . . . 1
ClOA005-621 10983 . . . . . . . . SWITCH. Voltmeter WIG001 Handle
0-15OV . . . . . . . . . . . . . . . . . . . . . . 1
-0 R-
C10A007-621 10983 . . . . . . . . SWITCH. VoltmeterWIG001 Handle
0-3OOV . . . . . . . . . . . . . . . . . . . . . . 1
10-9 . . . . . 81073 . . . . . . . . SWITCH. PB. SPNO (S21) . . . . . . . . . . . . 1
7307K38 . . . 15605 . . . . . . . . SWITCH. Toggle SPDT OFFIMOM ( S l I) . . . . . 1
2FA53-63 . . 15605 . . . . . . . . SWITCH. Toggle SPST (S18) . . . . . . . . . . . 1
10-9 . . . . . OBE70 . . . . . . . . SWITCH. PB. Ether Start (Optional) . . . . . . . . 1
. . . . . . . . 12867 . . . . . . . . PLACARD. Ether Start Push (Optional) . . . . . . 1
3SBO2-TFCGP 9L773 . . . . . . . . SWITCH. PB. Mom NO. Grn Lens . . . . . . . . 1
CM1815 . . . 71744 . . . . . . . . BULB. 12 VDC . . . . . . . . . . . . . . . . . . . 1
-0R-
CM1829 . . . 71744 . . . . . . . . BULB. 24 VDC . . . . . . . . . . . . . . . . . . . 1
3SB02-PFROI D 9L773 . . . . . . . . SWITCH PB NC Red Cap . . . . . . . . . . . . . 1
F151-12R . . 54388 . . . . . . . . LIGHT. Red. Fault Modes 12VDC . . . . . . . . . 2
-0 R-
F151-24R . . 54388 . . . . . . . . LIGHT. Red. FaultModes24VDC . . . . . . . . . 2
RSPB-Dw-OSOSNL 39732 . . . . . . . . VOLTMETER. DC. 0-50 Volts . . . . . . . . . . . 1
RE3PB-DAA-IOOSNL 39732 . . . . . . . AMMETER. DC. 0-2.5K. 0-100 MVT . . . . . . . 1
RA20NAsD103~ 12697 . . . . . . . . POTENTIOMETER. 1OK Ohmn . . . . . . . . . . 1
7592K6 . . . . 15605 . . . . . . . . SWITCH. Toggle. DPDT . . . . . . . . . . . . . . 1
3SB02-PFROID 9L773 . . . . . . . . SWITCH Pushbutton NC Red Cap (S4B) . . . . . 1
CM1815 . . . 71744 . . . . . . . . BULB. 12 VDC . . . . . . . . . . . . . . . . . . . 1
-0 R-
CM1829 . . . 71744 . . . . . . . . BULB. 24 VDC . . . . . . . . . . . . . . . . . . . 1
3SB02-TFCGP 9L773 . . . . . . . . SWITCH P.B. Mom NO. Gm Lens (S4A) . . . . . 1
4 .3 January 15. 1999

Page 38 Revision 5
a 9OT4OOSLN
GROUND POWER UNIT
January 15, 1999 Figure 16A. Electrical Drawer Assembly, AClDC Output 4-3
Revision 5 Page 39
a 9OT40OSLN
GROUND POWER UNIT
4-3 Figure 16B. Electrical Drawer Assembly, AC Output With DC Output Option JanuW' 15, 1999
Page 40 Revision 5
a 9OT40OSLN
GROUND POWER UNIT
Figure 16. Electrical Drawer Assembly
16- . . REF . . . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY. Electronic Control Drawer . . . REF
1 . . TB1118 . 600-1 8 . . . . . 75382 . . . . . . . . . BLK. Terminal. 18 Pos. . . . . . . . . . . . . . . 1
-lA . MS1118 . MS600-18 . . . 75382 . . . . . . . . . STRIP. Marker. 18 Pos. . . . . . . . . . . . . . . 1
2 . . FH5007 . 35481GY . . . 75915 . . . . . . . . . BLK. Fuse . . . . . . . . . . . . . . . . . . . . AR
3 . . LF6550 . . . . . . . . . . 12867 . . . . . . . . . TRANSFORMER ASSY . . . . . . . . . . . . . 1
4 . . FU0005 . AGC5 . . . . . 71400 . . . . . . . . . FUSE. 5 Amp . . . . . . . . . . . . . . . . . . AR
5 . . RA2152 . RA20NASD152A . 12697 . . . . . . . . . POTENTIOMETER. 1.5K. 2 W (R5) . . . . . . . . 1
-5A . B05126 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Switch Mounting . . . . . . . . . . . 1
6 . . ST0020 . 7582K8 . . . . 15605 . . . . . . . . . SWITCH. Toggle SPDT (S6) . . . . . . . . . . . 1
7 . . ST0049 . 2FA53-63 . . . 73559 . . . . . . . . . SWITCH. Toggle. SPDT (S40) . . . . . . . . . . 1
8 . . C05006 . CA3102E28-9P-F80 91577 . . . . . . . . . RECEPTACLE. Connector (J13) . . . . . . . . . 1
9 . . C05032 . CA3102E28-12PW-F80 91577 . . . . . . . RECEPTACLE. Connector (J12) . . . . . . . . . 1
10 . C05005 . C A ~ I O ~ E - 2~ ~~ --I F 91
~ O577 . . . . . . . . RECEPTACLE. Connector ( J l ) . . . . . . . . . . 1
11 . LO1429C . . . . . . . . . . 12867 . . . . . . . . . BOARD. PC Power Supply . . . . . . . . . . . . 1
12 . L01492C . . . . . . . . . . 12867 . . . . . . . . . . BOARD. PC Diode Logic . . . . . . . . . . . . . 1
13 . LO1979 . . . . . . . . . . 12867 . . . . . . . . . BOARD. PC AC Volt Regulator . . . . . . . . . 1
14 . EGO051 . ESD5221 . . . OBXW5 . . . . . . . . CONTROL. Speed. Governor
(12 or 24 VDC) (Governors of America) . . . . . 1
-0 R-
14 . EGO040 . 8290-052 . . . 31361 . . . . . . . . . CONTROL. Speed. Governor. Woodward.
24VDC . . . . . . . . . . . . . . . . . . . . . . 1
-0R-
14 . EG5035 . 8290-051 . . . 31361 . . . . . . . . . CONTROL. Speed. Governor. Woodward.
12VDC . . . . . . . . . . . . . . . . . . . . . . 1
15 . LO1901 . . . . . . . . . . 12867 . . . . . . . . . BOARD. PC. Remote Sensing . . . . . . . . . . 1
16 . LO1939 . . . . . . . . . . 12867 . . . . . . . . . BOARD. PC. Relay Module (24VDC) . . . . . . . 1
-0R-
16 . LO1921 . . . . . . . . . . 12867 . . . . . . . . . BOARD. PC. Relay Module (I2VDC) . . . . . . . 1
-0R-
16 . LF16324 . . . . . . . . . . 12867 . . . . . . . . . BOARD. PC. Relay Module wINeutral Fault (72VDC) 1
17 . LO1054 . . . . . . . . . . 12867 . . . . . . . . . BOARD. PC. OverIUnder Frequency . . . . . . . 1
18 . LO1055 . . . . . . . . . . 12867 . . . . . . . . . BOARD. PC. OverIUnder Voltage . . . . . . . . 1
19 . LO1053B . . . . . . . . . . 12867 . . . . . . . . . BOARD. PC. AC Overload . . . . . . . . . . . . 1
20 . 807534 . . . . . . . . . . 12867 . . . . . . . . . WELDMENT. Drawer Control Panel . . . . . . . 1
21 . KH5058 . 6107-B-2520 . 1FJ15 . . . . . . . . . SCREW. Captive. .25"-20x.812" . . . . . . . . . 2
21A . KH0150 . 12-11-014-26 . 94222 . . . . . . . . . RETAINER . . . . . . . . . . . . . . . . . . . . 2
21 B . KH5076 . 85-46-103-39 . 94222 . . . . . . . . . WASHER. Wear . . . . . . . . . . . . . . . . . 2
22 . KH5102 . T1755-4 . . . . 04729 . . . . . . . . . HANDLE. Drawer . . . . . . . . . . . . . . . . . 2
23 . SP0021 . 10-9 . . . . . . 81073 . . . . . . . . . SWITCH. Pushbutton (S32-36) . . . . . . . . . . 5
24 . EB5110 . 9563K43 . . . . OKVE6 . . . . . . . . PLUG. Button. SO" Dia . . . . . . . . . . . . . . . 1
25 . B04991 . . . . . . . . . . 12867 . . . . . . . . . PLATE. Etch. Test buttons . . . . . . . . . . . . 1
26 . KH5135 . C-300-S-214 . 06666 . . . . . . . . . . SLIDES. Drawer . . . . . . . . . . . . . . . . . 2
January 15. 1999 4-3

Revision 5 Page 41
FIG. TI
a
VENDOR
90T400SLN
GROUND POWER UNIT
Figure 16. Electrical Drawer Assembly (Continued)
UNITS
27 . LO1051 . . . . . . . . . . 12867 . . . . . . . . BOARD, P.C. DC Over Voltage,
Dual ACIDC Service, ~ ~ V D . C. . . . . . . . . 1
-0 R-
LO1051 B . . . . . . . . 12867 . . . . . . . . BOARD, P.C. DC Over Voltage,
Dual ACIDC Service, 12VDC . . . . . . . . . . 1
LO1534 . . . . . . . . . . 12867 . . . . . . . . BOARD, P.C. DC Component . . . . . . . . . . . 1
LO1 1508B . . . . . . . . 12867 . . . . . . . . BOARD, P.C. Line Drop Comp./Soft
Start Dual AC/DC Service, 12VDC . . . . . . . . 1
-0 R-
LO1661 B . . . . . . . . 12867 . . . . . . . . BOARD, P.C. Line Drop comp./Soft
Start Dual ACIDC Service, 24VDC . . . . . . . . 1
CA0013 124-902 . . . OFREO . . . . . . . . RELAY, Engine Shutdown Solenoid, 12VDC . . . 1
-0 R-
CA0045 124-903 . . . OFREO . . . . . . . . RELAY, Engine Shutdown Solenoid, 24VDC . . . I
RE0007 20C249 . . . . 77342 . . . . . . . . CLIP, Relay, DC Sensing . . . . . . . . . . . . . 1
RE0043 27E125 . . . . 77342 . . . . . . . . SOCKET, Relay, DC Sensing . . . . . . . . . . . I
- items 31 and 32 used only with Woodward Governor -
B16045 . . . . . . . . . . 12867 . . . . . . . . BOARD, Overspeedswitch 12Vl24V (A3) . . . . . 1
RE0012 R l O E X l - ~ 2 ~ 1 8 5 77342 . . . . . . . . RELAY, Overspeed (K55) 12V . . . . . . . . . . 1
-0 R-
RE0003 RIOEI -X2V700 77342 . . . . . . . . RELAY, Overspeed (K55) 24V . . . . . . . . . . 1
B14782 . . . . . . . . . . 12867 . . . . . . . . BRACKET, Mounting, AVR Board . . . . . . . . . 1
814782 . . . . . . . . . . 12867 . . . . . . . . BRACKET, Mounting, PCB Board . . . . . . . . . 1
RE0012 R10E1-X2V185 77342 . . . . . . . . RELAY, DC Sensing, 12VDC (K46) . . . . . . . . 1
-0R-
RE0003 RIOEI-X2V700 77342 . . . . . . . . RELAY, DC Sensing, 24VDC (K46) . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL,Control . . . . . . . . . . . . . . . . REF
4-3 January I S , 1999

Page 42 Revision 5
a 90T400SLN
GROUND POWER UNIT
5. 999 Figure 17A. Electrical Contactor Assembly, Without DC Output Option 4-3
Revision 5 Page 43
a 90T400SLN
GROUND POWER UNIT
-
7i-+--4
. a
1
, .
.
-
I I -
2
E I
t I I
4-3 January 15, 1999

Page 44 Figure 17B. Electrical Contactor Assembly, With DC Output Option Revision 5
a 9OT4OOSLN
GROUND POWER UNIT
Figure 17. Electrical Contactor Assembly
17- . . B08916 . . . . . . . . . . 12867 . . . . . . . . . ASSEMBLY. Contactor Panel . . . . . . . . REF
1 . . TB31 03 . 602-3 . . . . . 75382 . . . . . . . . . TERMINAL STRIP. 3-Point
(John Deere engine units only) . . . . . . . . . 1
2 . . TB1122 . 600-22 . . . . . 75382 . . . . . . . . . TERMINAL STRIP. 22-Point . . . . . . . . . . . 1
3 . . B03147 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Neutral Grounding . . . . . . . . . . 1
4 . . TT0018 . 5SFT501 . . . 9A611 . . . . . . . . . TRANS . Current Meter 5005 (CT4.5. 6) . . . . . 3
5 . . TO0951 . . . . . . . . . . 12867 . . . . . . . . . TRANS.. Current Overload (CT1.2.3) . . . . . . . 3
6 . . CA0007 . CT350E-24E1 . 2P016 . . . . . . . . . CONTACTOR. AC 24V . . . . . . . . . . . . . . 1
-0R-
6 . . CA5028 . CT350E-12E1 . 2P016 . . . . . . . . . CONTACTOR. AC 12V . . . . . . . . . . . . . . 1
7 . . FH5007 . 354812GY . . . 75915 . . . . . . . . . BLK. Fuse . . . . . . . . . . . . . . . . . . . . . 1
-7A . FU007 . . AGC 20 . . . . 71400 . . . . . . . . . FUSE. 20 Amp (F2) . . . . . . . . . . . . . . . . 1
8 . . FH5007 . 354812GY . . . 75915 . . . . . . . . . BLK. Fuse . . . . . . . . . . . . . . . . . . . . . 1
-8A . FU0005 . AGC 5 . . . . . 71400 . . . . . . . . . FUSE. 5 Amp ( F I I ) . . . . . . . . . . . . . . . . 1
9 . . CA0013 . 124-902 . . . . OFREO . . . . . . . . CONTACTOR. 12VDC (K48) . . . . . . . . . . . 1
-0R-
9 . . CA0045 . 124-903 . . . . OFREO . . . . . . . . CONTACTOR. 24VDC (K48) . . . . . . . . . . . 1
10 . RE5032 . 471 0A-3-A-1 . . OAGK2 . . . . . . . . RELAY. Time Delay (TDI) (24VDC) . . . . . . . 1
-0R-
10A . RE5031 . 4710A-2-A-1 . . OAGK2 . . . . . . . . RELAY. Time Delay (TDI) (12VDC) . . . . . . . 1
11 . R54994 . RLR07C4994FS . . 04061 . . . . . . . . . RESISTOR. Carbon 4.99 Meg. .25W . . . . . . . 1
12 . RE0003 . R10E1-X2V700 77342 . . . . . . . . . RELAY. 24VDC . . . . . . . . . . . . . . . . . 3
-OR-
12 . RE0012 . RIOEI-X2V185 77342 . . . . . . . . . RELAY. 12VDC . . . . . . . . . . . . . . . . . . 3
13 . TB1118 . 600-18 . . . . . 75382 . . . . . . . . . BLK. Terminal. 18 Pos. . . . . . . . . . . . . . . 1
-13A MS11 18 . MS600-18 . . . 75382 . . . . . . . . . STRIP. Marker. 18 Post . . . . . . . . . . . . . . 1
14 . B08257 . . . . . . . . . . 12867 . . . . . . . . . PANEL. Contactor. AC Output Only . . . . . . . 1
15 . CA0007 . CT350E-24E1 . 2P016 . . . . . . . . . CONTACTOR. AC 24V (Dual AC Units Only) . . 1
-0R-
15 . CA5028 . CT350E-12E1 . 2P016 . . . . . . . . . CONTACTOR. AC 12V (Dual AC Units Only) . . 1
16 . FH5007 . 354812GY . . . 75915 . . . . . . . . . BLK. Fuse . . . . . . . . . . . . . . . . . . . . 1
-16A FU0005 . AGC 5 . . . . . 71400 . . . . . . . . . FUSE. 5 Amp (F12) . . . . . . . . . . . . . . . . 1
17 . RE0003 . RIOEI-X2V700 77342 . . . . . . . . . RELAY. 24VDC . . . . . . . . . . . . . . . . . . 1
-0R-
17A . RE0012 . RIOEI-X2V185 77342 . . . . . .RELAY. 12VDC . . . . . . . . . . . . .
. . . . . . . . 1
18 . B08689 . . . . . . . . . . 12867 . . . . . . . . .
PANEL. Contactor. AC With DC Output . . . . . 1
19 . FH5007 . 354812GY . . . 75915 . . . . . . . . .
BLK. Fuse . . . . . . . . . . . . . . . . . . . . 1
-1 9A FU0005 . AGC 5 . . . . . 71400 . . . . . . . . .
FUSE. 5 Amp (F13) . . . . . . . . . . . . . . . . 1
20 . B04743 . . . . . . . . . . 12867 . . . . . . . BRACKET. DC Terminal . . . . . . . .
. . . . . . . 3
21 . DT0007 . V47ZA7 . . . . 09214 . . . . . .
. . . TRANSIENT. M.O.V. . . . . . . . . . . . . . . . 3
22 . CA0007 . CT350E-24E1 . 2P016 . . . . . . . . . CONTACTOR. AC 24V . . . . . . . . . . . . . 1
-0R-
22 . CA5028 . CT350E-12E1 . 2P016 . . . . . . . . . CONTACTOR. AC 12V . . . . . . . . . . . . . . 1
23 . REF . . . . . . . . . . . . 12867 . . . . . . . . . TRANSFORMERIRECTIFIER. See Figure 18 . REF
January 15. 1999 4-3

Revision 5 Page 45
a
90T400SLN
GROUND POWER UNIT
4-3 Figure 18A. TransformerlRectifier Assembly, T R I & 1.5 January 1 5 , 1999

Page 46 Revision 5
a 9OT40OSLN
GROUND POWER UNIT
Figure 18A. TR1 & TRI .5 Transformerlrectifier Assembly
18A- . 601 926 . . . . . . . . . . 12867 . . . . . . . . . TransformerIRectifer Assy. TRI & TR1.5 . . . REF
1 . . 6026061-3797-1 . . . . . . 12867 . . . . . . . . . BRACKET. Transformer Mounting. Upper . . . . 2
2 . . 6026061-3797-1 . . . . . . 12867 . . . . . . . . . BRACKET. Transformer Mounting. Lower . . . . 2
3 . . LO1865 . . . . . . . . . . 12867 . . . . . . . . . TRANSFORMER Assy. T-1043 . . . . . . . . . 1
4 . . W10010 . . . . . . . . . . 12867 . . . . . . . . . WIRE. 210 x 10" . . . . . . . . . . . . . . . . . . 3
5 . . HS0013 . . . . . . . . . . 12867 . . . . . . . . . HEATSINK . . . . . . . . . . . . . . . . . . . . 2
6 . . COMM . . . . . . . . . . . 12867 . . . . . . . . . LUG. Ring. 318"ID-210 . . . . . . . . . . . . . . . 3
6A . COMM . . . . . . . . . . . 12867 . . . . . . . . . LUG. Ring. 5116"lD-210 . . . . . . . . . . . . . . 3
7 . . FB0036 . MC24A3 . . . . 4\1\1042 . . . . . . . . FAN. Tube Axial. 115V 400 Hz . . . . . . . . . . 1
8 . . AF0017 . . . . . . . . . . 12867 . . . . . . . . . BUS BAR. Diode . . . . . . . . . . . . . . . . . 3
-9 . DD0014 . IN4047R . . . . 7L243 . . . . . . . . . DIODE. Reverse. CR7-12 . . . . . . . . . . . . 6
10 . DD0013 . IN4047 . . . . 71-243 . . . . . . . . . DIODE. Forward. CRI-6 . . . . . . . . . . . . . 6
11 . COMM . . . . . . . . . . . 12867 . . . . . . . . . SCREW. .31"-18x1". SST . . . . . . . . . . . . 6
12 . COMM . . . . . . . . . . . 12867 . . . . . . . . . WASHER. FL. .31". SST . . . . . . . . . . . . . 18
13 . COMM . . . . . . . . . . . 12867 . . . . . . .
. . . WASHER. LK. .31" SST . . . . . . . . . . . . 6
14 . COMM . . . . . . . . . . . 12867 . . . . . . .
. . . NUT. Hex. .31"-18. SST . . . . . . . . . . . . . 6
15 . COMM . . . . . . . . . . . 12867 . . . . . . .
. . . SCREW. .25"-20x.75" SST . . . . . . . . . . . 6
17 . . . . . . . 847448 . . . . 98749 . . . . . . . . . BRACE. HS . . . . . . . . . . . . . . . . . . . . 2
18 . TB1 108 . 600C-8 . . . . 75382 . . . . . . . . . BLK. Terminal . . . . . . . . . . . . . . . . . . . 1
-18A MS1 108 . 600-8M . . . . 75382 . . . . . . . . . STRIP. Marker . . . . . . . . . . . . . . . . . . 1
19 . AF0011 . . . . . . . . . . 12867 . . . . . . . . . MOUNTING. Bracket. Fan . . . . . . . . . . . . 1
20 . B0376-2747 . . . . . . . . 12867 . . . . . . . . . LINK. HS. U H . . . . . . . . . . . . . . . . . . . 1
20A . AF0029 . 847426 . . . . 98749 . . . . . . . . . LINK. HS. RIH . . . . . . . . . . . . . . . . . . 1
21 . COMM . . . . . . . . . . . 12867 . . . . . . .
. . . SCREW. .37"-16x.75" SST . . . . . . . . . . . 4
23 . COMM . . . . . . . . . . . 12867 . . . . . . . . . WASHER. LK. .37". SST . . . . . . . . . . . . . 6
24 . SR0027 . SC-240 . . . . 59270 . . . . . . . . . SWITCH. Over Temperature . . . . . . . . . . . 1
25 . CSFOR5 . C P S ~ B IEFSO~KI . 12867 . . . . . . . . . CAPACITOR. 5MFD. 600V . . . . . . . . . . . . 1
-26 . SU0022 . 873-9200-3CXX 39732 . . . . . . . . . SHUNT. Current. 1250A. 50MV . . . . . . . . . 1
January 15. 1999 4-3

Revision 5 Page 47
a 90T400SLN
GROUND POWER UNIT
4-3 Figure 188. TransformerlRectifier Assembly, TR213 January 15, 1999

Page 48 Revision 5
a 9OT4OOSLN
GROUND POWER UNIT
Figure 18B. TR213 TransformerIRectifier Assembly 150012500 Amperes
NO. NO . NO. FVC PART NO. NOMENCLATURE ASSY
18B- . 801 924 . . . . . . . . . . 12867 . . . . . . . . . TRANSFORMERIRECTIFER ASSY. TR2 . . REF
. . . LO2082 . . . . . . . . . . 12867 . . . . . . . . . TRANSFORMERIRECTIFER ASSY. TR3 . . . REF
NOTE: Illustration is for component reference only . Expect variation between models. i.e., TRI utilizes 12
di odes. TR2 utilizes 24 diodes. and the TR3 utilizes 24 diodes and two 1.5 kW resistors .
1 . . B026061B . . . . . . . . 12867 . . . . . . . . . BRACKET. Transformer Mounting. Upper . . . . 2

2 . . B026061C . . . . . . . . 12867 . . . . . . . . . BRACKET. Transformer Mounting. Lower . . . . 2
3 . . LO1867 . . . . . . . . . . 12867 . . . . . . . . . TRANSFORMER Assembly . . . . . . . . . . . 1
4 . . W10010 . . . . . . . . . . 12867 . . . . . . . . . WIRE. 210 x 10" . . . . . . . . . . . . . . . . . . 6
5 . . LO1925 . . . . . . . . . . 12867 . . . . . . . . . HEATSINK . . . . . . . . . . . . . . . . . . . . 2
6 . . COMM . . . . . . . . . . . 12867 . . . . . . . . . LUG. Ring. 3I8"ID-210 . . . . . . . . . . . . . . . 6
6A . COMM . . . . . . . . . . . 12867 . . . . . . . . . LUG. Ring. 5I16"lD-210 . . . . . . . . . . . . . . 6
7 . . FB0036 . MC24A3 . . . . 4\1\1042 . . . . . . . . FAN. Tube Axial . . . . . . . . . . . . . . . . . 1
8 . . AF0017 . . . . . . . . . . 12867 . . . . . . . . . BUS BAR. Diode . . . . . . . . . . . . . . . . . 6
-9 . DD0014 . IN4047R . . . . 7L243 . . . . . . . . . DIODE. Reverse. CR13-24 . . . . . . . . . . . . 12
-9A . . . . . . . 120-8 . . . . . 05820 . . . . . . . . . COMPOUND. Thermal . . . . . . . . . . . . . AR
10 . DD0013 . IN4047 . . . . 7L243 . . . . . . . . . DIODE. Forward. CRI-12 . . . . . . . . . . . . . 12
-10A . . . . . 120-8 . . . . . 05820 . . . . . . . . . COMPOUND. Thermal . . . . . . . . . . . . . AR
11 . COMM . . . . . . . . . . . 12867 . . . . . . . . . SCREW. .31"-18x1". SST . . . . . . . . . . . . . 12
12 . COMM . . . . . . . . . . . 12867 . .
. . . . . . . . WASHER. FL. .31" SST . . . . . . . . . . . . . 36
14 . COMM . . . . . . . . . . . 12867 . .
. . . . . . . . NUT. Hex. .31"-18. SST . . . . . . . . . . . . . 12
15 . COMM . . . . . . . . . . . 12867 . .
. . . . . . . . SCREW. .25"-20x.75" SST . . . . . . . . . . . 6
17 . . . . . . . 847448 . . . . 98749 . . . . . . . . . BRACE. HS . . . . . . . . . . . . . . . . . . . . 2
18 . TBI 108 . 600C-8 . . . . 75382 . . . . . . . . . BLK. Terminal . . . . . . . . . . . . . . . . . . . 1
-18A MS1 108 . 600-8M . . . . 75382 . . . . . . . . . STRIP. Marker . . . . . . . . . . . . . . . . . . 1
19 . AF0011 . . . . . . . . . . 12867 . . . . . . . . . MOUNTING. Bracket. Fan . . . . . . . . . . . . 1
20 . 80376-2747 . . . . . . . . 12867 . . . . . . . . . LINK. HS. U H . . . . . . . . . . . . . . . . . . . 1
20A . . . . . . . 847426 . . . . 98749 . . . . . . . . . LINK. HS. RIH . . . . . . . . . . . . . . . . . . 1
21 . COMM . . . . . . . . . . . 12867 . . . . . . . . . SCREW. .37"-16x.75". SST . . . . . . . . . . . 4
22 . COMM . . . . . . . . . . . 12867 . . . . . . . . . WASH.ER. FL. .37". SST . . . . . . . . . . . . . 6
24 . SR0027 . SC-240 . . . . 59270 . . . . . . . . . SWITCH. Over Temperature . . . . . . . . . . . 1
25 . . . . . . . NOT USED
26 . SU0022 . 873-9200-3CXX 39732 . . . . . . . . . SHUNT. Current. 1250A. 50 mV . . . . . . . . . 1
27 . A02751 . . . . . . . . . . 12867 . . . . . . . . . PLATE. Bottom. Insulating . . . . . . . . . . . . 1
28 . A02752 . . . . . . . . . . 12867 . . . . . . . . . PLATE. Top. Insulating . . . . . . . . . . . . . . 1
- ITEM 29 ONLY ON TR3 RECTIFIER ASSEMBLY -
-29 . R14R44 . 40-320-0.44 . . MlLWA . . . . . . . . RESISTOR. 0.44 Ohm. 1.5 kW . . . . . . . . . . 2
January 15. 1999 4-3

Revision 5 Page 49
a
90T400SLN
GROUND POWER UNIT
4-3 Figure 19. Bridge Assembly January 15, 1999

Page 50 Revision 5
a 90T400SLN
GROUND POWER UNIT
Figure 19. Bridge Assembly
19-1 . B03604 . . . . . . . . . . 12867 . . . . . . . . . BRIDGE ASSEMBLY . . . . . . . . . . . . . REF
2 . . 804242 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Racom Fuel Filter Mtg . . . . . . . . 1
3 . . 803643 . . . . . . . . . . 12867 . . . . . . . . . ENCLOSURE. Electrical Drawer Assy . . . . . . I
4 . . HGH088 . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 5116"-18 x .88" . . . . . . . . . . 8
5 . . HRHBCI . COMM . . . . . 12867 . . . . . . . . . WASHER. FL. 5/16" . . . . . . . . . . . . . . . 8
6 . . HRHBBI . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. 5/16" . . . . . . . . . . . . . . . 8
7 . . HWF050 . COMM . . . . . 12867 . . . . . . . . . SCREW. PHD. # I 0-32 x .50" . . . . . . . . . . . 7
8 . . HRFCCI . COMM . . . . . 12867 . . . . . . . . . WASHER. FL. # I 0 . . . . . . . . . . . . . . . . 13
9 . . HRFCBI . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. # I 0 . . . . . . . . . . . . . . . . 13
10 . HRFCAI . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. #lo-32 . . . . . . . . . . . . . . . . . 6
11 . VM0002 . VMB5013 . . . 76385 . . . . . . . . . BUMPER . . . . . . . . . . . . . . . . . . . . . 6
12 . B04363 . . . . . . . . . . 12867 . . . . . . . . . BRACKET. Cable Connecting & Shield . . . . . 2
13 . B04370 . . . . . . . . . . 12867 . . . . . . . . . BOARD. Cable Connecting . . . . . . . . . . . . 1
14 . TB1106 . 600C-8 . . . . 75382 . . . . . . . . . BLK. Terminal. 6-Point . . . . . . . . . . . . . . 1
-14A M S I 106 . MS600-6 . . . 75382 . . . . . . . . . STRIP. Marker. &Point . . . . . . . . . . . . . . 1
15 . HD1175 . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 318"-16 x 1.75" Slotted. Brs . . . 4
16 . HRlACl . COMM . . . . . 12867 . . . . . . . . . WASHER. FL. 318" Brs . . . . . . . . . . . . . . I 2
17 . HRlABl . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. 318" Brass . . . . . . . . . . . . . 8
18 . HRlAAl . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. 318"-16. Brass . . . . . . . . . . . . . 8
19 . HWFI 00 . COMM . . . . . 12867 . . . . . . . . . SCREW. PHD. # I 0 -32 x 1.0" . . . . . . . . . . 4
20 . HRFCCI . COMM . . . . . 12867 . . . . . . . . . WASHER. FL. # I 0 . . . . . . . . . . . . . . . . 8
21 . HRFCBI . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. # I 0 . . . . . . . . . . . . . . . . 4
22 . HRFCAI . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. #lo-32 . . . . . . . . . . . . . . . . . 4
23 . HFG088 . COMM . . . . . 12867 . . . . . . . . . BOLT. Hex Hd.. 114"-20 x . . . . . . . . . . . . 4
24 . HRGBCI COMM . . . . . 12867 . . . . . . . . . WASHER. FL. 114" . . . . . . . . . . . . . . . . 8
25 . HRGBB1 . COMM . . . . . 12867 . . . . . . . . . WASHER. LK. 114" . . . . . . . . . . . . . . . . 4
26 . HRGBAI . COMM . . . . . 12867 . . . . . . . . . NUT. Hex. 114"-20 . . . . . . . . . . . . . . . . 4
27 . B10118 . . . . . . . . . . 12867 . . . . . . . . . COVER. Protective. Terminal Board . . . . . . . 1
28 . KH5135 . C-300-S-214 . 06666 . . . . . . . . . SLIDE. Drawer . . . . . . . . . . . . . . . . . . 2
January 15. 1999 4-3

Revision 5 Page 51
a 90T400SLN
GROUND POWER UNIT
HOT SUPPLY LINE

TO ENGINE
Figure 20. Kim Hotstart Start System (Optional)

20- . 805366. . . . . . . . . . 12867 . . . . . . . . Hot Start Engine Heater System (Optional) . . REF
FITTING, Reducer, 1-114" x 314" . . . . . . . . . 2
FITTING, 114"-14 . . . . . . . . . . . . . . . . . 4
HOSE, Heater, 314" x 24" . . . . . . . . . . . . . 1
FITTING, 112" x 314"-14 . . . . . . . . . . . . . . 2
HEATER, Engine, Thermostat Controlled,
120VAC, 2250W, ON 1OO~F/OFF 1 2 0 ' ~. . . . . 1
FITTING, go0, 314"-14 . . . . . . . . . . . . . . . 1
HOSE, Heater, 314" x 18" . . . . . . . . . . . . . 1
CLAMP, Hose, #12, 11/16" to 1-114" . . . . . . . 4
CLAMP, Hose, #20, 314" - 1-118" . . . . . . . . . 1
4-3 January 15, 1999

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a 90T400SLN
GROUND POWER UNIT
L,,.L
ETHER START ASSEMBLY
Figure 21. Ether Start System-Quick Start@ (Optional)

21- . . 805351 . . . . . . . . . . 12867 . . . . . . . . . ETHER START -QUICK START@ (O~tional)
. . . REF
1 . . EB5171 . QK2001-F05 . 78280 . . . . . . . . . SYSTEM, Ether Start, 12VDC . . . . . . . . . AR
-0R-
1 . . EB5385 . QK2107-C48 . 78280 . . . . . . . . . SYSTEM, Ether Start, 24VDC . . . . . . . . . AR
2 . . . . . . . . LP-535 . . . . 78280 . . . . . . . . . CYLINDER, Ether. . . . . . . . . . . . . . . . . 1
3 . . . . . . . . QS-1107-10 . . 78280 . . . . . . . . . BRACKET, Valve Mounting . . . . . . . . . . . . 1
4 . . . . . . . . QS4-3TC . . . 78280 . . . . . . . . . VALVE, Electric, 12VDC, 6cc . . . . . . . . . . . 1
-0R-
4 . . . . . . . . QS4-4TC . . . 78280 . . . . . . . . . VALVE, Electric, 24VDC, 6 c c . . . . . . . . . . . 1
-4A . . . . . . . QS-1181 . . . . 78280 . . . . . . . . . GASKET, Valve . . . . . . . . . . . . . . . . . . 1
5 . . . . . . . . QS-1194-1 . . 78280 . . . . . . . . . SOLENOID, 12VDC . . . . . . . . . . . . . . . 1
-0R-
5 . . . . . . . . QS-1146-1 . . 78280 . . . . . . . . . SOLENOID, 24VDC . . . . . . . . . . . . . . . 1
6 . . . . . . . . LP-1698-1 . . . 78280 . . . . . . . . . FITTING, Valve, Angle . . . . . . . . . . . . . . 1
-6A . . . . . . . LP-3239-48 . . 78280 . . . . . . . . . TUBE, Nylon, 48" . . . . . . . . . . . . . . . . . 1
-0R-
-6A . . . .
. . . LP-2978-48 . . 78280 . . . . . . . . . TUBE, Copper, 48 . . . . . . . . . . . . . . . . 1
7 . . . . . . . . QS-1192-1 . . 78280 . . . . . . . . . CAP & CHAIN ASSEMBLY . . . . . . . . . . . . 1
8 . . . . . . . . LP-2299 . . . . 78280 . . . . . . . . . CLAMP, Cylinder, 25G (Optional) . . . . . . . AR
9 . . . . . . . . QS-1I 8 9 . . . . 78280 . . . . . . . . . CLAMP, Cylinder, w1W1ng Nuts . . . . . . . . . . 1
-10 . EB5185 . QS-1190-2 . . 78280 . . . . . . . . . THERMOSTAT, Cut-Off . . . . . . . . . . . . . 1
-1 1 . . . . . . . QR4-12 . . . . 78280 . . . . . . . . . KIT, Repair, Electrical, 12VDC . . . . . . . . . AR
-0R-
-1 1 . . . . . . . QR4-24 . . . . 78280 . . . . . . . . . KIT, Repair, Electrical, 24VDC . . . . . . . . . AR
-12 . SP0021 . 10-9 . . . . . . 81073 . . . . . . . . . SWITCH, Pushbutton, SPNO, Black . . . . . . . 1
-13 . BO449OK . . . . . . . . . . 12867 . . . . . . . . . PLACARD, "ETHER START" . . . . . . . . . . . 1
January 15, 1999 4-3

Revision 5 Page 53
a
90T400SLN
GROUND POWER UNIT
Figure 22. Ether Start System-KBIB (Optional)

4-3 January 15, 1999
Page 54 Revision 5
FIG. TI
a 9OT4OOSLN
GROUND POWER UNIT
VENDOR UNITS
22- . . EB5593 . 22045 . . . . . 4K048 . . . . . . . . . KB18 ETHER START SYSTEM (Optional) . REF
(12 VDC)
. . . EB5594 . 22045 . . . . . 4K048 . . . . . . . . . KB18 ETHER START SYSTEM (Optional) . . REF
(24 VDC)
1 . . . . . . . . 21201 5 . . . . 78280 . . . . . . . . . 12VDC-VALVE, ELECTRIC . . . . . . . . . . AR
. . . . . . . . . 224005 . . . . 78280 . . . . . . . . . 24VDC-VALVE, ELECTRIC . . . . . . . . . . AR
. . . . 4K048 . . . . . . . . .FUSE HARNESS . . . . . . . . . . . . . . . . . 1

. . . . 4K048 . . . . . . . . .WIRING HARNESS. . . . . . . . . . . . . . . . 1
. . . . 4K048 . . . . . . . . .NOZZLE . . . . . . . . . . . . . . . . . . . . . 1
. . . . 4K048 . . . . . . . . .ENGINE TEMP. SENSOR SW, . . . . . . . . . . 1
C L O S E @ ~ O ~( 4F' ~ )
. . . . 4K048 . . . . . . . . . CLAMP . . . . . . . . . . . . . . . . . . . . . . 1
. . . . 4K048 . . . . . . . . . TUBING, NYLON, 10' . . . . . . . . . . . . . . . 1
. . . . 4K048 . . . . . . . . . LOOM, 10' . . . . . . . . . . . . . . . . . . . . 1
. . . . 4K048 . . . . . . . . . KOMPAC8 CYLINDER, ETHER, 8 0 2 . . . . . . 1
4K048 - KBIB Kold Ban Internaltional, 900 Pingree Rd., Lake in the Hills, 11 60102-9637 U.S.A.
January 15, 1999 4-3

Revision 5 Page 55
a 90T400SLN
GROUND POWER UNIT
Figure 23. Tow Bar Slide Brake Assembly (Optional)
4-3 January 15, 1999

Page 56 Revision 5
FIG.
ITEM
NO.
TI
PART
NO.
a
VENDOR
PART
NO.
9OT4OOSLN
GROUND POWER UNIT
FVC
AIRLINE
PART NO . NOMENCLATURE
UNITS
PER
ASSY
23- LF17751 . . . . . . . . . . 12867 . . . . . . . . . TOW BAR SLIDE BRAKE ASSEMBLY . . . . REF

. .
See Figure 1.)
10-1 B01 1385 . . . . . . . . . . 12867 . . . . . . . . . TOW BAR STOP . . . . . . . . . . . . . . . . . 1
10-2 801 1704 . . . . . . . . . . 12867 . . . . . . . . . BRAKE SLIDE RETAINING ANGLE . . . . . . . 1
10-3 KH5337 . 9416K15-3 . . OKVE6 . . . . . . . . GAS SPRING. 6.77" TO 10.71" @6OLBS . . . . 2
10-4 KH5278 . H-9400 . . . . 2K900 . . . . . . . . . BALL STUD. 10MM . . . . . . . . . . . . . . . . 4
10-5 B017703 . . . . . . . . . . 12867 . . . . . . . . . BRAKE. SLIDE WELDMENT . . . . . . . . . . . 1
10-6 KH5256 . 9416K71 . . . . OKVE6 . . . . . . . . BALL SOCKET. END FITTING. . . . . . . . . . 4
10-7 HGGI 00 . . . . . . . . . . 12867 . . . . . . . . . BOLT. HEX HD . . . . . . . . . . . . . . . . . . 2
10-8 HRGBBI . . . . . . . . . . 12867 . . . . . . . . . WASHER. LK 114" . . . . . . . . . . . . . . . . 2
10-9 HRGBCI . . . . . . . . 12867 . . . . . . . . . WASHER. FL. 114 . . . . . . . . . . . . . . . . . 2
10-10 KH5257 . 9416K77 . . . . OKVE6 . . . . . . . . SAFETY CLIPS. 10MM . . . . . . . . . . . . . . 4
January 15. 1999 4-3

Revision 5 Page 57
a
90T400SLN
GROUND POWER UNIT
4-3 January 15,1999

Page 58 Revision 5
GROUND POWER UNIT
CHAPTER
5
MANUFACTURER'S APPENDICES
TABLE OF CONTENTS
1. Kat o@ or M arat hon@Generator lnst allat ion & Maintenance Manual
2. Engine Speed Control Governor (Model used and manual provided determined by unit
options).
Governors America Gorp.@ Engine Mounted Governor lnformat ion Sheet
(If applicable).
Woodw ard@ Engine Mounted Governor lnformat ion Sheet (If applicable).
Engine Operat ion and Maintenance Manual and Parts Manual.
RacorB Fuel Filter information sheet (if applicable).
Quick Start@ Ether Start Assembly informat ion sheet (if applicable).
KBI@Ether Start Assembly information sheet (if applicable)
January 15, 1999 5 - TABLE OF CONTENTS

Original Page 1
UNIFIED INCH BOLT A N D CAP SCREW TORQUE VALUES
1 or 2b 5 5.1 5.2 8 8.2

SAE
Grade
and NO MARK
Head
Marklngs
SAE
Grade
and NO MARK
Nut
Marklngs
Grade 1 Grade Zb Grade 5, 5.1, o r 5.2 Grade 8 o r 8.2
Lubrlcatedn I Drya Lubrlcatedn Dry. Lubricated. I

iq-iz-';.T-z
9.5 7 12 9
20 15 25 18
35 26 44 33
55 41 70 52
05 63 110 80
125 00 155 115
170 125 215 160

300 225 375 280
490 360 625 150
725 510 925 675

900 675 1150 850
1300 950 1650 1200
1700 1250 2150 1550

2250 1650 2850 2100
DO NOT use these values if a different torque value Fasteners should be replaced with the same or
or tightening procedure is given for a specific higher grade. If higher grade fasteners are used,
application. Torque values listed are lor general use these should only be tightened to the strength of the
only. Check tightness of fasteners periodically. original.
Shear bolts are designed to fail under predetermined Make sure fasteners threads are clean and that you
loads. Always replace shear bolts with identical properly start thread engagement. This will prevent
grade. them from failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts

to approximately 50 percent of the dry torque shown
in the chart, applied to the nut, not to the bolt head.
a "Lubricated" means coated with a lubricant such as engine oil, or Tighten toothed or serrated-type lock nuts to the full
lasleners with phosphate and oil coatings. "Dry" means plain or zinc torque value.
plated without any lubrication.
b Grade 2 applies for hex cap screws (nor hex bolts) up to 152 mm
(6-in.) long. Grade I applies lor hex cap screws over 152 mm (6-in.)
long, and lor all other types of bolts and screws of any length.
METRIC BOLT AND CAP SCREW TORQUE VALUES
,
4.8 8.8 9.8 10.9 12.9
0
Property
Clarr
and
Head
@QQQ Q
--
nz] El
Merklngo
5
[ nzn 10 10
[El
12
Properly
and
Nut
Marklngr
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Drya Lubrlcateda I Dry. Lubrlcateda Lubricated'
Kpz- X-pZ-
6 4.5 13 9.5 15 11.5
15 11 32 21 37 28
29 21 63 47 75 55
50 37 110 80 130 95
80 60 175 130 205 150
125 92 275 200 320 240
175 125 375 275 440 325

240 180 530 400 625 460
330 250 725 540 850 625
425 310 925 675 1075 800

625 150 1350 1000 1600 1150
850 625 1850 1350 2150 1600
1150 850 2500 1850 2900 2150

1450 1075 3200 2350 3750 2750
DO NOT use these values if a different torque value Make sure fasteners threads are clean and that you
or tightening procedure is given for a specific properly start thread engagement. This will prevent
application. Torque values listed are for general use them from failing when tightening.
only. Check tightness of fasteners periodically.
Tighten plastic insert or crimped steel-type lock nuts
Shear bolts are designed to fail under predetermined to approximately 50 percent of the dry torque shown
loads. Always replace shear bolts with identical in the chart, applied to the nut, not to the bolt head.
property class. Tighten toothed or serrated-type lock nuts to the full
torque value.
Fasteners should be replaced with the same or
higher property class. If higher properly class
fasteners are used, these should only be tightened to
the strength of the original.
"LubricaIed means coated with 8 Iubricanl such BS engine oil, or
fasleners with phosphate arld oil coatings. "Dry means plain or zinc
plaled wilhou! any lubricalion.
GENERATOR
280 - 430 Frame
Service Manual
CONTENTS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Information . . . . . . . . . . . . . . . . . . . . . . 2, 3
PLEASE READ ALL OF THE INFORMATION
CONTAINED IN THIS MANUAL BEFORE
ATTEMPTING TO INSTALL, OPERATE, OR
L
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 4 SERVICE THE GENERATOR. I
Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . 5 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7, 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . 8-10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 10-12 GENERAL
Parts List 8 Recommended Spare Parts . . . . . 13-14
INFORMATION
RECEIVING INSPECTION
SAFETY All product is shipped FOB the factory. Upon receipt of
your generator, it is recommended that it be carefully
A FEW WORDS ABOUT SAFETY examined for possible shipping damage. The generator
PLEASE REMEMBER SAFETY FIRST. If you are not was given to the freight carrier in good condition, and
sure of the instructions or procedures, seek qualified they are responsible for the product from our dock to
help before continuing. yours. Any damage should be noted on the freight bill
before accepting the shipment. Claims for damage
This service manual emphasizes the safety precautions must be promptly filed with the delivering carrier.
necessary during the installation, operation, and
maintenance of your Magna PLUS generator. Each
section has caution and warning messages. These UNPACKING AND HANDLING
messages are for your safety, and the safety of the
equipment involved. If any of the cautions or warnings Read and understand any instruction tags shipped with
are not readily understood, seek clarification from the unit. When lifting, attach an overhead crane to the
qualified personnel before proceeding. lifting eyes. If the generator is equipped with a lifting eye
Before any service work is done, disconnect all power
bolt, insure that it is firmly screwed into place prior to
lifting. Apply lifting forces in a vertical direction only.
-
sources and, lock out all controls to prevent an
unexpected start-up of the generator set. Proper WARNING
grounding in compliance with local and national e!ectrical
codes must be provided. These safety precautions are THE LIFTING EYES ON THE GENERATOR
necessary to prevent potential serious personal injury, ARE DESIGNED TO SUPPORT THE
or even death. GENERATOR ONLY. DO NOT LIFT A
COMPLETE GENERATOR SET (ENGINE) BY
The hazards associated with lifting or moving your MEANS OF LIFTING EYES O N THE
generator are pointed out in the installation and service GENERATOR. PERSONAL INJURY OR
sections. Incorrect lifting or moving can result in personal DAMAGE TO THE EQUIPMENT MAY RESULT.
injury or damage to the unit.
Whenever the generator is running, always assume and STORAGE
proceed as if voltage is present. Residual voltage is
In the event that the generator is not to be installed on
present at the generator terminals, and at the regulator
its prime mover immediately, it is recommended that the
panel connections, even with the regulatorfuse removed.
unit be stored in a clean, dry area which is not subject
Caution must be exercised, or serious personal injury or
to rapid changes in temperature and humidity.
death can result.
In the event of long term storage, the generator should
Whenever solvents, cleaners, or flammable liquids are
be tested, cleaned and dried as required, before being
present, adequateventilation must be available to avoid
put into service. See the Maintenance Section of this
fire, explosion, and health hazards. Always avoid
manual for further information. If the unit has been
breathing vapors and use suitable personal protective
stored in an area where it has been subjected to
equipment to prevent personal injuries (head, eyes,
vibration, it is recommended the bearing(s) be inspected
face, feet, hand, respirator, etc.).
and replaced as necessary.
This manual is not intended to be a substitute for
properly trained personnel. Installation and repairs should
only be attempted by qualified people. The cautions and
warnings point out known conditions and situations that
are potentially hazardous. Each installation may well
ENVIRONMENTAL CONSIDERATIONS
Dirt, moisture, heat and vibration are enemies of electric
-
create its own set of hazards. No manual can cover equipment. Excessive exposure to the elements WII,
every possible situation. shorten the life of the generator. The temperature of the
cooling air entering the intake openings of the generator Remove all shipping tapes, bags, blocks and skids
should not exceed the ambient temperature rating which are used to prevent vibration and rotor movement
shown on the nameplate. during shipment. In the case of two bearing machines,
rotate the shaft by hand to insure that it rotates smoothly
The MagnaPLUSgenerator is built in a NEMAopen type without binding.
enclosure. Although the standard insulation system is
moisture resistant, the addition of special tropical The connections and insulation on all lead wires should
insulation and space heaters may be advisable under be inspected and all hardware should be checked to be
extrerne conditions. In extremely dirty or dusty sure everything is tight and correct.
environments, a means of providing filtered cooling air
to the generator is recommended.
GENERATOR MOUNTING
Generators intended for outdoor application should be
protected from the elements with a suitable enclosure. WARNING
The enclosure should be designed to allow proper
ventilation and to prevent the direct contact of wind DISABLE ANY ENGINE CRANKING DEVICES
driven dirt, rain, snow, etc. BEFORE ATTEMPTING TO INSTALL OR
SERVICE THIS UNIT. FAILURE TO COMPLY
WlTH THESE SAFETY PROCEDURES COULD
PARALLELING OPERATIONS RESULT IN SEVERE INJURY TO PERSONNEL
OR DAMAGE TO THE EQUIPMENT.
All MagnaPlus generators are built with 213 pitch main
stator windings and full amortisseur (damper) windings.
These features in design and construction make DO NOT APPLY ANY FORCE TO THE
MagnaPLUS generators suitable for parallel operation GENERATOR FAN. NEVER "BAR OVER" THE
when equipped with the proper voltage regulators and ENGINE-GENERATORSETBY USING THE FAN.
voltage regulator accessories. Consult with the factory FAILURE TO COMPLY WlTH THESE SAFETY
for further information relative to parallel operations. PROCEDURES COULD RESULT IN SEVERE
INJURY TO PERSONNEL OR DAMAGETO THE
EQUIPMENT.
TORSIONAL VIBRATION
SINGLE BEARING GENERATORS
Torsional vibration will be generated in all rotating shaft
systems to some degree. In some cases, these vibrations Single bearing units are provided with an SAE flywheel
can be strong enough to cause damage to the generator, housing adapter and flexible drive discs to match the
the prime mover, or both. Torsional analysis to assure engine. Close tolerances are maintained in the
torsional compatibility of the system is the responsibility manufacture of the generator to promote ease of
of the generator set assembler. alignment.
Special steel drive discs are bolted to the shaft. In some
cases spacers are used to achieve the proper 'XG"
THYRISTORORSCR LOADING dimension. Holes are provided in the periphery of the
Solid state electronic control devices which utilize coupling discs which correspond to tapped holes in the
engine flywheel. The outside diameter of the drive discs
thyristors or SCR firing circuits (such as variable
frequency induction motor controls, precision motor fit in a rabbet in the flywheel so that concentricity is
speed controls, no-break powered battery chargers, assured.
etc.) may introduce high frequency harmonics which CAUTION: Grade 8 place bolts and hardened washers
adversely affect, or totally distort the normal wave form are recommended to mount the drive discs to the
of the generator. This creates additional heat in the flywheel. DO NOT USE SPLITTYPE LOCK WASHERS
generator windings and may cause the generator to they will cause stress risers, and may result in disc
overheat. Problems which can occur are not limited to failure.
the generator. Poor wave shape may adversely effect
the thyristor devices, the equipment they power, and The SAE flywheel housing adapter and the engine
any other connected load. Please contact Marathon flywheel housing are designed to match each other, with
Electric for application assistance. no further alignment necessary.
Shims may be necessary under the generator feet to
insure a solid mounting. Do not force the feet to an
INSTALLATION uneven mounting surface, serious problems could result.
PREPARATION FORUSE
Although the generator was carefully inspected and
tested in operation before it left the factory, it is
recommended the unit be thoroughly inspected.
3
MARblWON0
ELECTRIC
ENDPLAY TEST PROCEDURES ELECTRICAL CONNECTIONS
After the generator has been assembled to the engine, WARNING
check for endplay of the assembled set. Using a suitable -- - -
lever, force the engine flywheel forward so that the To avoid an electrical hazard to personnel and
crankshaft is pressed against its thrust bearing. When possible equipment damage, all wiring and
force is removed, the engine crankshaft should remain grounding should be done by qualified personnelin
in position. Apply force in the opposite direction forcing accordance with all applicable codes and standards.
the crankshaft towards the generator, and observe if the All connections must be made and insulated
crankshaft remains in this position after force has been properly.
removed. Refer to the engine manual for proper or
recommended endplay. If the crankshaft springs away A hole saw or other appropriate tool may be used to
in either direction after force has been removed, it is an provide for conduit entrance. Protect the interior of the
indication that the generator shaft is not moving freely, generator from shavings when drilling or sawing. An
and normal life of the thrust bearing could be impaired. approved connector must be used in conjunction with
Probable causes of this problem are: the conduit.
1. Improper "XG" dimension of either the generator or To minimize the transmission of vibration, it is essential
the engine flywheel, or both. Generator bearing may that flexible conduit be used for all electrical entrance to
be bottoming out in its bearing bracket. the generator.
2. Misalignment: Refer to the connection diagram supplied with the
a. lmproper seating of generator drive discs in the generator andlor the proper diagrams shown in this
engine flywheel. manual for the voltage and configuration desired. Use
b. Improper mating of the generator frame to the high quality terminalsand make sure all connections are
engine flywheel housing. clean and tight. Properly insulate ALL connections.
c. Set sub-base is not true. Generator andlor engine Support and tie all wiring to prevent movement and
feet require shims. See mounting instructions. chafing of the insulation.
Be sure the generator frame is grounded in accordance
TWO BEARING GENERATORS with national and local codes.
-
Two bearing units are provided with a shaft extension
and keyway.
For direct drive units, the assembler furnishes a flexible
coupling which is installed between the driver and the
generator shaft.
CAUTION: Aligning the generator and its driver as
accurately as possible will reduce vibration, increase
bearing life, and minimize coupling wear. It may be
necessary to shim the generator feet for proper support
and alignment. Consult the coupling manufacturer's
instructions for alignment specificationsand procedures.
Two bearing generators can be belt driven. We
recommend sizing and alignment per NEMAguidelines.
Please refer to your supplier of belts and sheaves for
correct sizing and belt and tensioning specifications.
Cog type belts are not recommended. They may cause
vibration which could lead to premature failure of the
bearings.
CONNECTION DIAGRAMS
12 LEAD HI WYE
I
12 LEAD LOW WYE

r 1
Tweave k.0 gen.ralo,s sr. dual r011aQe pmmralofa w l n 31,

coals me! don I ha* ~ h . c m r ~ c l ~ o01n I h Ihr.0 m M l C a l l
1h.t. ar. 12 D. I I C.QI.I c m w out of IM gwne-tol
1
12 LEAD LOW DELTA
2 LEAD HI DELTA
12 LEAD SINGLE PHASEZIGZAG CONNECTION
I 1
12 LEAD SINGLE PHASE DOUBLE DELTA
12 LEAD SINGLE PHASE PARALLEL DELTA

I
WARNING
OPERATION
DO NOT APPLY ANY FORCE TO THE
PRE-START INSPECTION GENERATOR FAN. NEVER 'BAR OVER" THE
Before starting the unit for the first time, the following ENGINE-GENERATORSET BY USING THE FAN.
FAILURE TO COMPLY WITH THESE SAFETY
inspection checks are recommended:
PROCEDURES COULD RESULT IN SEVERE
1. A visual inspection should be made for foreign INJURY TO PERSONNEL OR DAMAGETO THE
materials. Inspectfor any remainingpacking materials EQUIPMENT.
and remove any loose debris, building materials,
rags, etc., that could be drawn into the generator. 2. Check for clearance in the generator and exciter air
Removeany maskingmaterialsaffixed during painting. gap. Be sure the set turns freely. Bar the set over by
Be sure that nameplates, and all safety warning1 hand for at least 2 revolutions to be sure that there is
caution signs and decals are in place and clearly no interference.
visible.
3. Check all wiring against the proper connection
diagrams, and make sure all connections tight a-
properiy insulated.
4. Be sure the equipment is properly grounded.
Check all fasteners for tightness. low voltage and/or frequency conditions during
generator 'coast down".
Check to be sure no tools or other hardware have
been left inside or near the machine. 2. Shut down prime mover - follow the manufacturer's
instructions.
Install and check to be sure all covers and guards are
in place and secure. 3. Eliminate any condition that could allow the generator
to see a voltage input to its terminals while at rest.
Verify that end play test was made. (See endplay test Failure to do so could result in ~ersonneliniury
page 3). or e a u i ~ m e n damaae.
t
START UP PROCEDURE
WARNING MAINTENANCE
Wheneverthe generator is running,always assume The following maintenanceproceduresshould be followed
and proceed as if voltage is present. Residual to insure long equipment life and satisfactory
voltage is present at the generator terminals, and performance. Maintenance intervals will depend upon
at the regulator panel connections, even with the operating conditions.
regulator fuse removed. Caution must be
exercised, or serious personal injury or death can All MagnaPLUS generators are equipped with double
shielded or double sealed ball bearings lubricated for
result.
-
-
the life of the bearing. Periodicallycheckthe bearing(s)
for smooth, quiet operation. For continuous duty
The following procedure should be followed for starting- generators, recommended practice is to replace the
up the generator set for the first time. bearing during major overhauls of the engine.
The generator output must be disconnectedfrom the
lnspect all electrical connections to be sure they are
load. Be sure that the main circuit breaker or is in the
clean, tight, and properly insulated. Check ground
open position. straps too.
Disable the regulator by removing the fuse. Check and clean intake and exhaust air screens.
Follow the manufacturer's instructions and start the Clogged screens will increaseoperatingtemperatures,
prime mover. Check the speed and adjust to the RPM and reduce the generator's life.
shown on the generator nameplate. lnspect the unit for buildup of contamination on the
Check all line to line and line to neutral residual windings. Internal cleaning should be accomplished
voltages to be sure they are balanced. If voltages are by an authorized service facility.Recommended
unbalanced, shut down and correct wiring. Record practice is to have the generator internally cleaned in
residual voltage as a bench mark for future conjunction with major overhaul of the engine, or
troubleshooting. more frequently if service is in a dirty environment.
Buildup of dirt and contaminants on the windings
Replace the regulator fuse and adjust the voltage inhibits heat transfer, and can lead to shortened
regulator for the desired voltage. Check all line to line insulation life.
and line to neutral voltages to be sure they are correct
and balanced. If the voltages are not correct, shut Monitor and record insulation resistance with a 500
down immediately and recheck all connections. (See volt megohm meter.The minimum acceptable reading
instructions for the voltage regulator for more is 2 Megohms. If the reading drops below the minimum
information about its features and adjustments). the generator should be cleaned and dried at an
Record Line to Line voltage, engine speed, and no- authorized service shop. Consult Marathon Electric
load excitation. (DC voltage across F+ and F- terminals for more information.
on the voltage regulator.) This data is useful as bench
mark data for future troubleshooting.
Close the main circuit breaker to the load.
Monitor the generator output current to verify that it is
at, or below nameplate value.
REPAIR
Checkgenset speed under load. Adjust as necessary.
(Refer to prime mover/governor manuals).
PROCEDURES
CONSTANT EXCITATION (12V BATTERY) TEST
THEORY: The generator output voltage is dependent
SHUT DOWN PROCEDURES
on generator speed, generator design, load, and exciter
1. Remove load and open the main circuit breaker. This input current. If the generator speed and exciter input
is especially important if loads can be damaged by are known,the output voltage at no load can be measured
and compared to the design value. Problems can be FIGURE 1
isolated to either the generator or regulator system by
using this test. Forward (Normal) Reverse (R)
Terminal 'End
TEST PROCEDURE: / \
Shut the generator set down.

Connect a voltmeter to the generator output.
Disconnect the F1 and F2 leads at the regulator.
Connect a 12 volt battery capable of supplying 1 amp
to the F1 and F2 leads. I
Anode
;4
Cathode-
-
Stud End
I
CAUTION: Beware of arcing when connecting leads. A. Stud type diodes may be tested in the field without
Stay clear of battery vents. Escaping hydrogen gas unsoldering and removing the load from the diode
-
can explode. If hazardous conditions exist use a terminal. Remove the diode load lead terminal lug
suitable switch to connect or disconnect the battery. from its terminal post, and insure that it is not making
With no load on the generator, (main breakers open) contact with any adjacent metallic part. An ohmmeter
run generator at rated speed (1800 rpm - 60 Hz or or a battery-light continuity tester may be used to find
-
1500 rpm 50 Hz). a short or open condition in the diode. Connect the
positive test lead to the anode, and the negative lead
Measure the generator output voltage. to the cathode, take a reading, reverse the test leads
and take a reading. These checks should indicate
Shut generator down. one of three conditions:
Disconnect battery (see Caution - Step 3). 1. Good diode: Will have a much greater reverse
Conclusion: If voltage output is near nominal, the main resistance (positive lead on cathode) than
generator and exciter are operating properly. If voltage forward resistance (negative lead on cathode).
output is less than 50% of nominal, the problem is in the Typical reverse resistance will be 30,000 -
generator. Continue testing diodes, surge suppressor, 300,000 ohms or greater, while typical forward
windings. resistance will be less than 10 ohms. The
continuity tester will have the light "on" in one
BEARING REPLACEMENT direction, and "off" in the other.
Remove the four bearing bracket bolts and the bearing 2. Shorted condition: Ohmmeter reading will be
bracket to expose the bearing. Use a bearing puller to zero, or very low in both directions. Continuity
remove the old bearing. Do not reuse an old bearing, tester light will be on in both directions.
always replace it with a new one. Prior to removal from 3. Open condition: Ohmmeter will have a maximum
the shaft, visually inspect the bearing for obvious wear (infinity) reading in both directions. Continuity
and damage. Inspect the bearing bracket bore, and '0" tester light will be dark (off) in both directions.
ring for wear or damage.
Always install the same type bearing that was supplied
as original equipment. Order by part number from the REPLACEMENT OF DIODES
parts k t . and include the generator model and serial a diode tests bad, replace all the diodes, or the
numbers the Install the bearing with a complete rectifier assembly. Remove the diode leads to
conventional bearing tool. When damage the main rotor terminal posts, along with the plastic lead
to the bearing outer race, and bearing shields. Apply wire clamps. The individual diodes are .stud typen,
pressing force to the inner race only. retained by 114-20 hex head nuts and a lock washer.
Prior to installing a replacement diode on the heat sink,
RECT'FIERASSEMBLY run a bead of a thermal-electrical contact compound
AND TEST PROCEDURE around the base of the diode. The threads should not be
Individual rectifiers, or the complete rectifier assembly coated. Toque the diodes to 27-30 inch-pounds. Do not
can be accessed by removing the end bracket opposite over tighten.
the drive end of the unit. Remove the end bracket to
expose the bearing and rotating rectifier assembly for REPLACEMENT OF THE RECTIFIER ASSEMBLY
test, assembly or service. Refer to Figure 1.
Remove the bearinqfrom the main shaft. Disconnect the
exciter rotor and main rotor leads. Remove the hold-
down screws which secure the rectifier assembly to its
mounting. The rectifier assembly is then free for removal.
To replace, reverse the procedure. Check all connections.'
1
Always install a new bearing.
ELECTRIC 8
RESTORING RESIDUAL MAGNETISM The first and perhaps most important step of trouble
(FLASHING THE EXCITER FIELD) shooting should to be to gather as much first hand
information as is possiblefrom personnel who may have
To restore the small amount of residual magnetism been present when the failure occurred. Information as
necessary to begin voltage buildup, connect a 12 volt to how long the unit had been operating, what loads were
battery to the exciter field while the generator set is at on line, weather conditions, if any protective equipment
rest as follows: or devices functioned, etc., can help isolate the problem.
1. Remove exciter field leads F+ and F-from the voltage
WARNING
regulator. CAUTION: Failure to remove the field
leads from the regulator during flashing procedures
may destroy the regulator. HIGH VOLTAGES MAY BE PRESENT AT THE
GENERATOR TERMINALS WHEN THE UNlT IS
2. Measure the exciter field resistance from the F+ to the RUNNING. SOME ACCESSORY EQUIPMENT
F- lead. It should be about40 ohms. Also, check to be SUCH AS SPACE HEATERS MAY BE
sure there is no path to ground. ENERGIZED FROM AN OUTSIDE POWER
SOURCE WHEN THE UNlT IS AT REST. TOOLS,
3. Connect F+ to the positive pole of the battery.
EQUIPMENT CLOTHING AND YOUR BODY
4. Hold the F- lead by the insulated portion of the lead MUST BE KEPT CLEAR OF ROTATING PARTS
wire, touch F- to the negative pole of the battery for AND ELECTRICAL CONNECTIONS.
about 5 to 10 seconds, then remove.
SPECIAL CAUTION MUST BE TAKEN DURING
5. Reconnect F+ and F- to the regulator. Repeat the TROUBLESHOOTING SINCE PROTECTIVE
procedure if the generator fails to build voltage.
COVERS AND SAFETY DEVICES MAY BE
REMOVED OR DISABLED TO GAIN ACCESS
AND MAKE TESTS.
TROUBLESHOOTING BE CAREFUL. SERIOUS PERSONAL INJURY
This section is intendedtosuggest a systematic approach OR DEATH CAN RESULT FROM THESE
to locating and correcting generator malfunctions. The HAZARDS. CONSULT QUALIFIED PERSONNEL
section is arranged according to the symptoms of the WITH ANY QUESTIONS.
problem. The steps have been arranged in an attempt
to, 1, do the easy checks first, and 2, prevent further
damage when trouble shooting a disabled machine.
TROUBLESHOOTING SYMPTOMS
SYMPTOM: GENERATOR PRODUCES NOVOLTAGE OR RESIDUALVOLTAGE
Regulator Fuse Blown Check fuse with an ohmmeter. Replace bad fuse, refer to regulator
manual.
Voltmeter Off Check to be sure meter phase selector switch is not in the off position.
Incorrect Connections Verify generatorconnections. Refer to drawings supplied with generator

set and/or this manual.
Defective ConnectionsNViring Inspect all wiring for grounds, open circuits, short circuits.
Defective Voltmeter Verify proper operation of panel meter with another meter that is
known to be accurate.
No Regulator Input Check connections and measure voltage at regulator input.
Defective Diodes, Surge Suppressor, Test generator with constant excitation (12 volt battery test).
or Generator Windings
I
Voltage Regulator Protective Correct problem and adjust regulator. Refer to regulator manual.
Shutdown Circuits are Operating
Voltage Regulator Inoperative Adjust or replace regulator. Refer to regulator manual.

SYMPTOM: GENERATOR PRODUCES LOW VOLTAGE - NO LOAD
Underspeed Operation Check speed using tachometers and/or frequency meters
Defective Voltmeter Verify operation of panel meter with another meter that is known to be
accurate.
Residual Voltage Disconnect F1 and F2 leads at the voltage regulator. If voltage goes
down continue on to next step, if voltage does not change refer tc
troubleshooting for symptoms of 'No Voltage - Residual Voltage".
Incorrect Generator Connections Verify generator connections, refer to drawings supplied with generator
Defective ConnectionsNViring Inspect all wiring for grounds, open circuits, short circuits, loose
connections, dirty connections.
Regulator Adjustments Adjust regulator. Refer to regulator manual. Check exciter field volts
Defective Diodes, Surge Suppressor, Test generator with constant excitation (12 volt battery test).
or Generator Windings Check no load DC excitation across regulator terminals F+ & F-. ( s e
Start-up Procedures Paragraph 5, page 8). If greater than v a l u
recorded, proceed with diode and winding checks. If data no
available, conduct 12 V battery test detailed on page 9.
Voltage Regulator not Operating Properly Adjust or replace regulator. Refer to regulator manual
SYMPTOM: GENERATOR PRODUCES LOWVOLTAGE WHEN LOAD IS APPLIED

Overload Measure amps and verify that the load does not exceed the nameplatc
rating of the generator.
Overload - Defective Ammeter Verify operation of ammeter by using a separate meter that is knowr
to be accurate.
Droop Circuit If the generator set is equipped for paralleling, some voltage droop is
normal as load increases. Refer to the regulator instruction manual.
Faulty Main Rotor Check DC excitation voltage across regulator terrninals F+ and F-
Compare to full load excitation on nameplate. If regulator is producin
DC voltage considerably above the full load level, have service s h o
check main rotor for defective pole windings.
Continue troubleshooting for symptoms 'Generator Produces Low Voltage - No Load".

SYMPTOM: GENERATOR PRODUCES HIGH VOLTAGE- NO LOAD
Defective Voltmeter Verify operation of panel meter with another meter that is known to b~
accurate.
Incorrect Operating Speed Verify speed with tachometer or frequency meter.
lncorrect Connections Verify generator connections. Refer todrawings supplied with generato1
Defective Connections/Wiring Inspect all wiring for grounds, open circuits, short circuits.
Regulator Adjustments Adjust regulator. Refer to regulator manual.

A
Diode Polarity lncorrect Checkdiodes, verify proper diodes are installed and polarity is correc
Voltage Regulator not Operating Properly Adjust or replace regulator. Refer to regulator instruction manual.
SYMPTOM: GENERATOR PRODUCES HIGH VOLTAGE WHEN LOAD IS APPLIED
Leading Power Factor Load Correct load power factor.
SYMPTOM: GENERATORVOLTAGE IS FLUCTUATING

Incorrect Speed Verify speed with tachometer or frequency meter
Unstable Speed Verify governor stability.
Voltage Regulator Stability Adjust regulator stability. Refer to regulator manual.
DefectiveILoose Connections Inspect all wiring for loose or dirty connections.
Defective Diodes, Surge Suppressor, Test generator with constant excitation (12 volt pattery test)
or Generator Windings
Remote Voltage Adjust Rheostat Check operation of rheostat. Refer to regulator manual.
(if used)
Defective Regulator Replace regulator. Refer to regulator manual.
Defective Bearing or Worn Bearing Replace worn bearing. Check bearing carrier for wear. Replace as
Carrier Causing An Uneven Air Gap necessary.
SYMPTOM: GENERATOR BUILDSVOLTAGE FROM START-UP,

THEN GOES TO LOW (RESIDUAL) VOLTAGE
Regulator Protective Circuit is Operating Check indicators on regulator. Correct problems and adjust regulator
as required. Refer to regulator manual.
SYMPTOM: EQUIPMENT RUNS NORMALLY ON UTILITY POWER,

BUT WILL NOT RUN ON GENERATOR SET
Voltage Waveform is Distorted Analyze load. Excessive SCR (Thyristor) loading will cause distortion.
Some equipment may be sensitive to distorted waveforms. Refer to
Marathon Electric.
Improper Generator Voltage Check generator output voltage and frequency. Compare to utility.
And/or Frequency. If generator does not match utility, adjust as necessary
Phase Sequence is Wrong. Compare generator phase sequence with utility. If generator phase
sequence is improper, reverse two generator leads at circuit
breaker.
11
-ONe
ELECTRIC
PARTS LIST - SINGLE BEARING
TYPICAL GENERATOR CROSS SECTION
Part No. Part Name
1 End Bracket
2 Bearing
3 0-Ring
4 Rectifier Assembly
5 Screen. Intake
6 Exciter Rotor
7 Exciter Stator
8 Terminal Block
9 Conduit Box
10 Generator Frame
11 Generator Stator
12 Generator Rotor
13 Key. Rotor
14 Fan
15 Adapter
Shaft
Hub
Drive Discs
Screen. Exhaust.
Base
PARTS LIST - TWO BEARING

TYPICALGENERATOR CROSS SECTION
Part No. Part Name
End Bracket (ODE)

Bearing
0-Ring
Rectifier Assembly
Screen. Intake
Exciter Rotor
Exciter Stator
Terminal Block
Conduit Box
Generator Frame
Generator Stator
Generator Rotor
Key. Rotor
Fan
End Bracket (DE)
Bearing
Shaft
Key. Output
Screen. Exhaust
Base
Marathon Electric
100 East Randolph Street
P.O.Box 8003 w
Wausau, WI 54402-8003 This manual Is printed on
Phone: (715) 675-331 1 recycled paper because
TWX: 910-281-1521
Telex: 2601 75 ME WAS
Fax: (71 5) 675-6361
Marathon Electric shares in
the concern for our
environment. i
Lltho ~nU S.A SB 504 2/94 (Revised 6195)
Marathon Electric Manufacturing Corporation
400 HERTZ SUPPLEMENT TO:
MagnaPLUS Service Manual S B ~ O ~ / G P N O O -~430
280 : FIL4MES
SER SERVICE MANUAL SB505 (360 AND LARGER FRAMES)
General Information. Marathon Electric Manufacturing Corporation's 400 Hertz line of AC
gene&itors are synchronous, brushless, AC generators employing a 24 pole main revolving field to
prod~lce400 Hertz at 2000 RPM. The main stator (armature windings) are two circuit 10 lead
designs, internally connected in a Wye connection Design output voltages are 208Yl120 volts (Low
Wye connection), and 416Y/240 volts (High Wye connection).
Applicable Service Manuals.
1. 400 Hertz generators manufactured in our 360 Frame such as catalog models
360SSL1311A, 360SSL13 12A, and 360SSL13 l3A are essentially Marathon's type SER generators,
and Service Manual SB505 (Old 3600s) applies to these generators with the few exceptions covered
in this Supplement.
I
2. 400 Hertz generators manufactured in our 430 frame such as catalog models
430PSL1314A, 3430PSLl312A, and 43OPSL1313A are essentially Marathon's type MagnaPLUS
generators, and Service Manuals SB504 and GPNOO5 apply to these generators with the few
exceptions covered in this Supplement.
Operating Speed. Synchronous speed for 400 Hertz operation is 2000 RPM. All startup, operating
and running trouble shooting procedures contained in the above referenced service manuals should
be conducted at 2000 RPM. Substitute 400 Hem, 2000 RPM for 60 Hertz, 1800 RPM, or 50 H e m ,
1500 RPM wherever these two frequencies and speeds are indicated
Connection Diagrams. The external generator connections applicable to these generators,

regardless of frame size, are on Page 2 of this Supplement
Automatic Voltage Regulator. The standard automatic voltage regulator furnished by Marathon Y.>
for use with our 400 Hertz generators is Basler Electric Company Mode1 VR485-100-L. For parallel
operation, Model VR485-100-P and a paralleling current transformer will be required Pgwer
transformer (part number 76 1554-0 1) is required to provide the proper input voltage to the voltage
regulator. The connection diagrams on Page 3 of this Supplement are typical for hook-up of the
generators with the standard Model VR485-100-L. Should your specific unit be equipped with
additional regulator accessories, or with an automatic voltage regulator other than the VR485-100-
L, please contact the factory, or your supplier for the appropriate diagrams.
Technical Data. Typical technical data such as winding resistances, excitation requirements and
limited general data are contained on Page 4 of this Supplement. For rewind data, or more in depth
technical data, please consult the factory.
. .- . . - - - -- .
Far 7158757290 T d e r XiOlE UE W W
CONNECTION DIAGRAMS
3 LEAD LOW WYE
Ten lead generators are dual voltage generators having a two

circuit stator with two major coil groups per phase with the finish
I L1 leasd o f the inner coils (T10, 111, 112) tied together internally to
t form a neutral, and a single lead TD brought out to the connection

box along w i t h leads T I through T9.
VOLTAGE CONNECT L1 L2 L3 NEUTRAL

L-L L-N LO
T I -T7
T2 T8 -
''I LEAD HIGH WYE
Ten lead generators are dual voltage generators having a two

circuit stator w i t h t w o major coil groups per phase w i t h the finish
leasd o f the inner coils (T10, T11, T12) tied together internally to
f o r m a neutral, and a single lead TO brought out to the connection
box along w i t h leads T I through T9.
Hz VOLTAGE CONNECT L1 L3 NEUTRAL

L - L L-N LO
416 T3
- TO
400 240
CONNECTION DIAGRAMS
10 LEAD LOW W E
10 LEAD HI W E
EXCITER
FIELD
F+ F-
SPECIFICATIONS
General Data Applicable to all Models Listed in Table 1
Phase Sequence: ABC with CCW rotation when viewed from opposite drive end.
Cooling Air Volume @ at Rated 2000 RPM

360 Frame - 400 CFM
430 Frame - 1200 CFM
Insulation Resistance: > 1.5 Megohms
High Potential Tests

Main Stator: 2000 Volts
- Main Rotor: 1500 Volts
Exciter Stator: 1500 Volts
, Exciter Rotor: 1500 Volts
Overspeed: 2500 RPM
Table 1
Excitation & Resistance Data - 208Y1120 / 416Y240 VOLTS, 400 Hertz - 2000 RPM (Note 1)
Generator
Model
Number
oNI= Exciter Field
(Note 2)
Resistance Values in Ohms
Main
@tator (Note 3)
Main
Rotor
I
I
- Nominal Cold (25'
Exciter
Stator
/
C)
Exciter
Rotor
360SSL1311A 20 Volts 0.063 1.500 28.5 0.240
23 Volts 0.027 0.235 28.5 0.240
23 Volts 0.027 0.240 28.5 0.240
.28.5 Volts 0.01 5 1.250 28.5 0.1 10

28.5 Volts 0.01 5 1.255 28.5 0.110
0.01 5 1.260 28.5 0.1 10
Notes:
1. Values shown are typical and may vary slightly from unit to unit.
2. For rated load exciter volts - see generator nameplate.
3. Main stator resistance values shown are for Low (208Y) voltage connection.
For High (416Y) voltage connection multiply value shown by 4.
P 0 . Box 8003 Wsusau. WI 54402-80aJ

Ph: 715-675-331 1 m: 910-281-1521
Fnc. 715-675-7290 T d e 260175
~ ME WAU
AND
AUTOMATIC TURN-KEY
STARTING F L U I D SYSTEMS
INSTALLATION OPERATION
MANUAL
U.S.A.
9280
ATA VMRS - T 4 4 KLDBN
Do not smoke when installing, maintaining, testing or troubleshooting a DIE-
SELMATIC System. Make sure you are in a well-ventilated area away from heat,
open flames or sparks. Wear goggles when testing to avoid eye injury. Make sure
that openings in the valve, tube, or nozzle ( n o u l e opening indicated by red dot),
are pointed away from yourself while testing.
.
I The engine starting fluid used in DIESELMATIC Systems contains ethyl ether and
is extremely flammable and toxic. It can be harmful or fatal if swallowed. Avoid
;ontact with skin or eyes or breathing fumes. If swallowed, DO NOT INDUCE
I
--
VOMITING. Call a physician immediately.
If fluid enters the eyes or if fumes irritate the eyes, they should be washed with large
quantities of clean water for 15 minutes. A physician, preferably an eye specialist,
should be contacted.
I Contents of cylinder are under pressure. Store in a cool dry area. Do not incinerate,
puncture or attempt to remove cores from cylinder.
SAFETY AWARENESS SYMBOLS are inserted in this manual to alert you to possible
SAFETY HAZARDS. Whenever you see these symbols:
SAFETY AWARENESS SYMBOLS AND MEANINGS:
THlS WARNING SYMBOL' IDENTIFIES SPECIAL INSTRUCTIONS

OR PROCEDURES WHICH, IF NOT CORRECTLY FOLLOWED,
COULD RESULT IN PERSONAL INJURY.
THlS CAUTION SYMBOL IDENTIFIES SPECIAL INSTRUCTIONS OR

PROCEDURES WHICH, IF NOT STRICTLY OBSERVED, COULD
RESULT IN DAMAGE TO, OR DESTRUCTION OF EQUIPMENT.
TABLE OF CONTENTS:
Introduction ....................................................................... 3
Nozzle Installation ............................................................. 5
Valve and Cylinder Assembly Installation ......................... 8
Engine Temperature Switch .............................................. 10
Mounting Template(s) ....................................................... 11
Wiring ................................................................................ 13
Installing Tubing and BLOCKOR@Fitting .......................... 16
Operation ................................ ;......................................... 17
Servicing and Troubles hooting ........................................1 8 : ,: ,
"-
.
Maintenance Schedule ...................................................... 22 ......
NOTES:
KBI, DIESELMATIC, KOMPAC, and BLOCKOR are Registered Trademarks of Kold Ban
International, Ltd. KBI was established in the late 1960's and its only business is the
manufacture, research, and development of starting aids for cold diesel engines. KBI products
are O.E.M. approved and installed by most engine and equipment manufacturers.
INTRODUCTION
Before installing, familiarize yourself with the parts contained in your kit. Note that you have
the following items in DlESELMATlC Systems:
DlESELMATlC I. Mounting Hardware

Valve Assembly J. External Reservoir (Engines
Starting Fluid Cylinder 12 liters and over)
ETS Switch K. Fuse Assembly
Wiring Kit L. Valve Cap
Nylon Tubing M. Cylinder Clamp
Injector N o u l e N. Noule
BLOCKOR Fitting 0. Nylon Tubing Protective
Reducer Bushing Sheathing
Disconnect glow plugs. Glow plug systems and manifold preheat

systems should be disconnected when your KBI DlESELMATlC
System is used, as they can ignite starting fluid prematurely and cause
engine damage.
Parts in DlESELMATlC kit

Note that you have the following items in DlESELMATlC KOMPAC Systems:
DlESELMATlC KOMPAC I. Mounting Hardware

Valve Assembly J. External Reservoir (Engines
Starting Fluid Cylinder 12 liters and over)
ETS Switch K. Fuse Assembly
Wiring Kit L. Valve Cap
Nylon Tubing M. Cylinder Clamp
Injector Nozzle N. Nozzle
BLOCKOR Fitting 0. Nylon Tubing Protective
Reducer Bushing Sheathing
I FIGURE 2 I
1 Parts in DlESELMATlC KOMPAC kit I
NOZZLE INSTALLATION
Installing the injector nozzle in a proper location is essential if the DIESELMATIC System is
to work properly on your engine. It is preferred to choose an installation point for the nozzle
that will assure even distribution of starting fluid to all cylinders. On turbocharged engines the
nozzle should be on the pressure side of the turbocharger.
The straight brass fitting "nozzle injector" supplied with your system should be used. The
nozzle itself fits most engines; but, for some engines it may be necessary, or desirable, to also
use the 114" NPT Reducer Bushing with the nozzle. An elbow fitting substituted in place of the
straight fitting will interfere with proper vaporization of starting fluid. If an elbow fitting
installation is necessary, use KBI Special lnjector Nozzle; for engines 12 liters and over PIN
22C1424 (end orifice), or PIN 220475 (side orifice). For engines under 12 liters, use KBI PIN
2, ,,I (end orifice), or PIN 220375 (side orifice).
--
DRAWING NOTES
The following drawing notes should be used in conjunction with the engine diagrams on the
following two (2) pages, that indicates your air intake system.
NOTE: Some engine manufacturers' pre-tapped nozzle locations are not desirable to use
because they will result in the uneven distribution of starting fluid to all of the
cylinders of the engine. Uneven distribution, or favoring only one or two cylinders
of an engine, can cause engine lock-up during cranking. The solution for this type
of problem is to change the location of the injector nozzle or use a Special lnjector
Nozzle, which will direct the starting fluid into the main air flow when orientated
correctly. To correctly orientate the nozzle, unless instructed otherwise upon
installation, orientate the nozzle to spray against oncoming air stream. The punch
mark on the fitting supplied with KBl's Special lnjector Nozzles indicates spray
direction.
1. The usual engine manufacturers' tapped nozzle location is indicated by

than one nozzle location is shown on your engine drawing and one is a preferred
A
. If more
location, it is indicated by A : a non-preferred location is indicated by A.

2. On enaines that do not have a re-tamed hole, or the tapped hole(s) are not in the
recommended location, the crossover tube between the intake manifold and turbo-
charger (or between the intake manifold and air cleaner), should be removed. An "R" size,
or 21/64" diameter hole, can be drilled near where the tube connects to the intake
ani if old and tapped with a 118"-27 NPT tap. If the walls of the tubing are too thin to be
rpped, a 17/32" hole may be drilled and the 114" to 118" reducer bushing can be inserted
+-andbrazed to provide a mounting place for the nozzle.
NOTE: Be sure all chips are cleaned out of the inside of the tube before it is reinstalled
on the engine.
3. If the engine is equipped with a plug in the intake manifold, the plug can be removed and
drilled with an "R" size or 21/64" bit, and tapped with a 118"-27 NPT tap to provide an
installation place for the nozzle.
ENGINE DIAGRAMS
FIGURE 3
Typical six (6)cylinder
FIGURE 4
Typical two (2) cylinder
I Typical four (4) Cylinder
FIGURE 6 FIGURE 7
Typical three (3) cylinder Locomotive type engine
rlCURE 8
Typical "V" Engine
NOTE. Some Dual Manifold Engines require a two-nozzle Adapter Kit. The kit contains
one Tubing-Tee Fitting, three Nut and Sleeve sets, two 24" Lengths of Nylon
Nozzle Tubing, and two Nozzles.
VALVE AND CYLINDER ASSEMBLY INSTALLATION
Cylinder Assembly should be mounted in an accessible location away

from extreme heat - the exhaust system - and protected from road dirt,
ice, and snow. If protected, it can be mounted in the engine compart-
ment on the firewall, radiator frame, or any other convenient location.
DO NOT mount the unit on the engine or drive train because excessive
vibration can cause premature failure. The assembly does not have to
be mounted in a direct upright position, but some usable fluid will not
be dispensed if the assembly is tipped too far from vertical. See r' -'?
, .
below. . .
UPRIGHT
96% (795rnl) 27 FL. OZ.
92%
(761ml) 26 FL. OZ.
USABLE QUANTITIES SHOWN

FIGURE 9
Loss of usable fluid in cylinder when not mounted vertically
1. When selecting a location, hold the Assembly in place to determine if it will clear the hood
and other movable parts, and that the distance from the assembly's bottom to the nozzle
location does not exceed the length of tubing provided. Be sure there is adequaLe
'.>,
clearance to change the fluid cylinder after installation.
.,...
2. The mounting plate may be used as a template, but a paper template is provided in the
middle section of this manual. If the mounting plate is used and the cylinder is removed
from the valve, the top of the valve should be protected from debris by installing the yellow
valve cap.
NOTE: On the mounting template located in this manual, @ represents the cen-
ter of mass assembly. Four (4) point mounting is recommended for maximum
resistance to vibration. Mounting point locations should be spaced symmetri-
cally about the center of mass, above and below the "X" axis.
Four bolts, lock washers (or jam nuts), and nuts are provided for mounting the valve and
cylinder assembly. Preferably four bolt assemblies must be used; otherwise, warranty
conditions may not apply. Space the mounting bolts as widely apart as possible to
eliminate any unnecessary vibration of the unit during the equipment's operation.
Center punch and drill the holes for mounting. Bolt the assembly into place.
If the mounting plate was used as a template, the starting fluid cylinder should be properly
installed back onto the valve by turning the cylinder in direction of the arrow
(clockwise) until the cylinder dirt and moisture seal ("0" Ring) contacts valve. Tighten the
cylinder an additional 1 1/1 turns (540°). DO NOT OVERTIGHTEN OR REMOVE CAP
ON TOP OF CYLINDER!
REMEMBER: When handling cylinder, OBSERVE WARNING NOTE ON PAGE 1 of

this manual.
Make sure that the cylinder clamp is tightened.
NOTE: 1. Do not neglect to occasionally check tightness of the cylinder clamp to make
sure it has not loosened.
2. KBI offers an optional Low Cylinder Indicator (LCI), which is used to determine
when the contents of the cylinder are nearing an empty level. Contact KBl's
sales office (800-527-8278), for more information.
3. KBI offers a Cylinder Return Program for used Starting Fluid Cylinders. This
program applies only to DOT39NRC Starting Fluid Cylinders. No other high
pressure cylinders, other than Starting Fluid (ether), Cylinders will be accepted
by KBI for recycling. Call KBl's sales office (800-527-8278), for a Return
Authorization Number and more infromation.
ENGINE TEMPERATURE SENSOR (ETS),
SWITCH LOCATION
1. THE SURFACE rYPE should be mounted where it can most easily sense the engine
temperature, such as against the engine block.
It should never be mounted against the exhaust manifold since
that there is no air aaD between the metal face of the unit and the
engine.
2. THE SCREW-IN TYPE should be located in the engine water jacket. Usually the best
-
location is found by removing a water drain plug. The plug size is 112" 14 NPT wh&q
is a standard. . :
3. Special care should be taken when installing the ETS on an engine that is equipped with
an engine block heater. The ETS's location should be in an area where heat from the
engine's block heater will not affect the ETS. On such installations, an area such as the
engine's oil pan flange, etc., would be a preferred location.
4. Make sure good electrical continuity exists between the engine block and the ground lead
of the ETS. It may be necessary to remove any paint from the engine block at the
grounding point to insure continuity. Wire one lead to the ground lead of the valve. The
second lead of the ETS should be grounded. The surface t v ~ can
e be grounded by putting
the lead under the mounting bolt; the screw-in t v ~ can
e be grounded to any convenient
place on the engine.
5. The NORMAL ETS Switch included in DIESELMATIC units allows the system to function
at an operating threshold temperature of 40°F (~OC);i.e. 40O~(~OC)and lower. If your
particular equipment requires a different temperature device, please contact your dealer.
NOTE: All ETS's are identified by either a stamp on the bottom of the ETS or by a sleeve
on the lead wire. The numbers in these locations refer to the operating threshold
temperatures.
MOUNTING PLATE
TEMPLATE
TEAR OUT TEMPLATE

AND SELECT HOLES
/1 (SEE VALVE AND CYLINDER 11

f7\
IN~TALLATIONINSTRUCTIONS)
II
AXIS
ONLY INDICATE THE SIZE OF THE

KOMPAC
MOUNTING PLATE
TEMPLATE
AND SELECT HOLES

DESIRED
(SEE VALVE AND CYLINDER
INSTALLATION INSTRUCTIONS)
Y
AXIS
/ NOTE: THE DIMENSIONS SHOWN I

/ / ONLY INDICATE THE SIZE OF THE 1
I I HOLES IN THE MOUNTING PLATE. /
WIRING
For Electric Starter Systems
The standard KBI DIESELMATIC Solenoid Valve Assembly is not a

continuous-duty type solenoid design. Any deviation from the stan-
dard wiring circuit which would allow prolonged activation of the
solenoid valve, may result in premature valve failure. Contact KBI
directly for any unique applications you may have.
1. The valve assembly should be checked for proper operation before the ETS Switch is
wired into the circuit. To do this, disconnect the battery and complete the wiring circuit
as shown in Figure 10 (if series parallel wiring is required, see Figure 11). However,
a
\.
,
'
: connect the black valve lead directly to a uood around. Reconnect the battery.
-'
REMEMBER: DANGER, GOOD VENTILATION, GOGGLES.
2. With the fluid cvlinder installed on the valve, activate the cranking motor for a brief
period of time. Starting fluid should spray from the valve only for the time the cranking
motor is activated. WHEN PERFORMING THIS OPERATION BE SURE TO SPRAY
STARTING FLUID INTO AN APPROPRIATE CONTAINER.
To prevent damage to internal seals in the DIESELMATIC valve,

do not repeat this procedure more than twice.
3. After this check is made and propervalve operation is verified, disconnect the battery and
complete the wiring circuit for the ETS Switch as shown in Figure 10 (if series parallel was
required Figure 11). Be sure all wires are routed away from heat, moving parts, sharp
edges, etc. If possible, route wiring with existing harnesses. Reconnect the battery.
4. Fasten the wires and tubing down with wire ties.
5. Check all connections for proper crimping and insulation.
NOTE: MRE FUSE TO START V T C H PRESSURIZED

INTO URClllT AS FLUID CYUNDER
a o s E TO u (MOTOR)
TERMINAL AS POSSIBLE DIESELMATIC V A L E
LEAD
...
c$Jp'-)
I . .
. . SW TCH
L.,
& E m NOZZLE
J
CRANKING MOTOR
/ R&OR flmNt
N n O N 'TUBING
FIGURE 70
Wiring diagram for electric starter systems
For Air Starter Systems
The standard KBI DIESELMATIC Solenoid Valve Assembly is not a
continuous-duty type solenoid design. Any deviation from the stan-
,dard wiring circuit which would allow prolonged activation of the
solenoid valve, may result in premature valve failure. Contact KBI
directly for any unique applications you may have.
The air switch (KBI Part Number 301 125), should be installed before wiring.
Ensure that the air reservoir tank is empty (0 Ibs. pressure).
Find the relay valve located at the opposite end of the large air line and on one of the
smaller air lines from the starter.
.---. .
Remove the smaller starter air line from the relay valve and install a tee fitting in its' pl . .
Re-install the air line and fitting into the tee.
Install the air switch into the tee.
The valve assembly should be checked for proper operation before the ETS Switch is
wired into the circuit. To do this, disconnect the battery and complete the wiring circuit
as shown in Figure 12. However. connect the black lead directlv to a sood around.
Reconnect the battery.
REMEMBER: DANGER, GOOD VENTILATION, GOGGLES
With the fluid cvlinder installed on the valve, activate the cranking motor for a brief
period of time. Starting fluid should spray from the valve only for the time the crankinq
motor is activated. WHEN PERFORMING THIS OPERATION BE SURE TO SPRAY
STARTING FLUID INTO AN APPROPRIATE CONTAINER.
damage to internal seals in the DIESELMATIC valve,

repeat this procedure more than twice.
After this check is made and proper valve operation is verified, disconnect the battery and
complete the wiring circuit for the ETS Switch as shown in Figure 12. Be sure all wires
are routed away from heat, moving parts, sharp edges, etc. If possible, route wiring with
existing harnesses. Reconnect the battery.
Fasten the wires and tubing down with wire ties.
Check all connections for proper crimping and insulation.

NOTES:
I . WIRE THE WHITE/BLUE DIESELMATIC PRESSURIZED
VALVE LEAD TO THE START SWITCH.
TERMINAL ON W E SERIES PARALLEL
SWITCH.
DIESELMATIC VALVE
2. WIRE THE FUSE INTO THE CIRCUIT
AS CLOSE TO THE SERIES PARALLEL
SWITCH AS POSSIBLE.
TO START
+ SWlTCH
SERIES PARALLEL BLOCKOR FITTING
SWITCH
NYLON TUBING
FIGURE 7 7
Wiring diagram for series parallel installation
DIESELMATIC VALVE
STARTER CONTROL
NORMALLY OPEN AIR SWITCH
60 PSI (KBI PART NO. 301125)
TEE
FROM COMPRESSOR
'. - ,-'/CURE 12
/ Wiring diagram for air starter systems
INSTALLING TUBING AND BLOCKOR FITTING
Nylon tubing length must not be shorter than two feet to assure the
proper vaporization of the starting fluid as it is propelled from the
BLOCKOR fitting to the injector nozzle.
The DIESELMATIC System's "metered flow" feature is controlled by the special (BLOCKOR),
fitting which has to be installed into the bottom of the valve.
The BLOCKOR fittina end that is to be inserted into the bottom of the valve has left-hand
drv seal threads. Install this end into valve, finaer tiaht. Tiahten fittina with a wrench
ao~roximatelvone (1) to two f2) turns. de~endinaon desired orientation. ./-
A length of protective sheathing for the nylon tubing, to protect the nylon tubing from
chaf ng, has beensupplied in your kit. Be sure to insert the nylon tubing into the sheathing
prior to connecting the tubing to the BLOCKOR fitting and to the nozzle.
Route nylon tubing from the BLOCKORfitting installed in the valve, to the nozzle installed
in the intake manifold in such a way that it does not come in contact with the exhaust
system. Be careful the tubingwill not be damaged by vibration or by the engine enclosure,
throttle linkage, etc. Avoid contact with all objects that may cut or wear the tubing. If
tubing is cut to a shorter length, be sure to cut it squarely. A bias cut may cause leaks
or it may become disconnected since the nut sleeve will not seal properly.
When connecting the tubing to the BLOCKOR fitting and to the nozzle, keep the tubing
fully seated while tightening the nut. Avoid over tightening since the sleeve can become
distorted or collapsed, restricting fluid flow through the tubing. The nut should
l v (1) turn after it is f i n ~ e tiaht.
tightened a ~ ~ r o x i m a t eone r
Check all fittings and tubing connections for leaks and make sure they are secure.
SYSTEM INSTALLATION IS NOW COMPLETED.

ERATION
KBl's DIESELMATIC System is a fully-automatic Engine Starting Fluid System designed to
spray a controlled amount of starting fluid into the air intake system of an engine during and
immediately after cranking.
The System's EngineTemperature Sensor(ETS), Switch determines when the DIESELMATIC

System should function. When needed, the solenoid valve is activated automatically during
engine cranking; then starting fluid is released from the pressurized cylinder, flows through the
valve, through a flow metering orifice fitting at the bottom of the valve, through the nylon tubing,
and out of an injector nozzle located in the engine's air intake system. A reservoir in the valve
maintains a flow of starting fluid through the BLOCKOR after cranking to prevent the just-
started engine from faltering or dying.
! .
' 1
&&e diesel engine injection systems are equipped with mechanisms to advance timing or
inject extra fuel for cold-weather starting. Check your engine manual to determine the proper
procedure and throttle setting for cold starting of your engine.
At very cold temperatures, additional cranking cycles may be necessary because the engine
will start and then die after running a short period of time. To eliminate the need for this type
of additional cranking cycle, an accessory - KBI ArcticTMKit assembly - may be purchased or
installed.
NOTE: WHENEVERTHE ENGINE DOES NOT START WITHIN A NORMAL PERIOD OF

CRANKING,THE DIESELMATIC FLUID CYLINDERMAY BE EMPTY-REFERTO
"SERVICING AND TROUBLESHOOTING".
Tips on Cold-Weather Starting

1. Batterv and Cables -To start in cold weather, a diesel engine must crank at a fairly high
speed. Worn out batteries, partially discharged batteries, and poor or loose cable
connections will reduce the cranking speed. Batteries, cables and connections should
be cleaned and tightened regularly.
2. m-For an engine to start and keep running, fuel must flow through the injection system.
Unblended #2 diesel fuel "clouds", forrning.fi1ter-cloggingwax at temperatures around
15OF (-1o°C), making starting and running impossible. Most engine manufacturers
recommend that fuel have a cloud point at least 1 0 O ~(-12O~),below the coldest
anticipated temperature. If straight #2 fuel is to be used at temperatures lower than 2 5 O ~
(-4OC), a fuel additive or a fuel heater may be necessary. A blend of 9 parts #2 fuel to
1 part kerosene, (in Europe - paraffin), would lower the "cloud" temperature to approxi-
. mately A OF (-lsOc).A blend of 3:l would lower the "cloud" temperature to approximately
.L OF (-20°C); 1:1 for -22O~(-30°c).
3. Lube Oil - Engine lubricating oil gets thicker at lower temperatures. Many oils that flow
freely at ~ O O F(21%) are extremely thick at oOF (-18OC). Follow your engine manufacturer's
recommendations regarding oil viscosity for the coldest temperatures you expect your
engine to encounter.
17
SERVICING AND TROUBLESHOOTING
If a diesel engine is not injecting its primary fuel into its cylinders, the KBI DIESELMATIC will
not start the engine even though it is functioning. The many possible primary fuel system
failures are waxed fuel filter, water in fuel filter, injector pump has lost prime, fuel solenoid valve
has failed, fuel tank is empty, fuel line is frozen, or injector pump not supplying sufficient fuel
at cranking RPM.
Many other equipment components or lubricants can affect cold starting. Review prior section,
"Tips on Cold-Weather Starting".
F
.'
The following guide is limited to troubleshooting of the DIESELMATIC System. Its' rr
'
common problems are an empty fluid cylinder (step I ) , or a clogged metering orifice inside II
BLOCKOR fitting (step 3).
1. Check the fluid cylinder contents and valve gasket.
~ e ~ l a gasket
ce
IMPORTANT
inside valve each time cylinder is replaced. Read entire cylinder
label for additional information on cylinderivalve gasket installation.
REMEMBER:
I
When handling cylinder, QBSERVE WARNING NOTE ON PAGE 1 of
this manual.
Clean all dirt from neck of cylinder and top of valve before removing the fluid cylinder.
Protect the top of valve from dirt when cylinder is removed by installing the yellow
valve cap. ,
An empty net weight 21 oz. fluid cylinder weighs 16 oz. (454 gr.); a full fluid cylinder
weighs 37 oz. (1049 gr.).
weighs 33 or. (935 gr.).
weighs 18 oz. (510 gr.).
To determine the amount of fluid remaining in the cylinder, it should be weighed: .
subtract the empty net weight, convert the difference into liquid volume of fluid
remaining using 39 ml. per oz. weight (1.4 ml. per g.).
Check that fluid cylinder has pressure. Minimum of 120 PSI at 68OF (20°C).
Install a new KBI valve gasket, #300012, each time cylinder is replaced. All,~ni~
replacement cylinders will have a New KBI valve gasket inside the thread protec
white cap on the cylinder. Remove old gasket from the valve and discard, BE SURE
ONLY ONE GASKET IS USED Spread a light film of clean oil on new gasket when
~nstalling.
Coat the new cylinder's threads with clean oil and install your engine starting fluid
cylinder by turning cylinder in direction of arrow (clockwise) until the cyl-
inder dirt and moisture seal ("0" Ring) contacts valve. Tighten an additional 1 '/1
turns (540"). DO NOTOVERTIGHTEN CYLINDER OR REMOVE CAP ON TOP OF
CYLINDER! Be sure to retighten cylinder clamp.
NOTE: KBI offers a Cylinder Return Program for used Starting Fluid Cylinders.
This program applies only to DOT39NRC Starting Fluid Cylinders. No
other high pressure cylinders, other than Starting Fluid (ether), Cylinders
will be accepted by KBI for recycling. Call KBl's sales office (800-527-
8278), for a Return Authorization Number and more information.
Most times the fluid cylinder is shelf stored in a position

opposite of its use when installed on a valve; therefore, when
\ , . d l it is first installed onto a valve, its contents are agitated due
to the turning over. Because of flux residue remaining from
the manufacturing and brazing of the raw cylinder, the
contents of the cylinder should be allowed to settle back
down before a System is functioned. This takes approxi-
mately 15 to 20 minutes. Failure to allow this settling often
causes premature clogging of the System and necessitates
cleaning or replacement of the valve's BLOCKOR metering
orifice filter. When installing our System, we recommend
allowing time for this settling to take place before testing the
System to see if it is functioning correctly. The design of the
cylinder is such that the 1" 20 screw fitting also functions as
a small standpipe; therefore, once the flux residue settles it
will not enter the valve and cause clogging.
2. Check of electrical system.

a. Check to see if the fuse is blown.
b. Check all wiring for loose connections, shorts, and broken wires.
c. Check that the DIESELMATIC System is wired in accordance with Figure 10, 11,
or 12 depending upon the wiring diagram that was required for your particular
installation.
NOTE: To check system for proper operation, the NORMA1 Engine Tempera-
ture Sensor (ETS) must be below 40°F (~OC),or be bypassed by
connecting the valve's black lead directly to a good ground. After
checking, be sure to reconnect the black lead in accordance with Figure
10, 11, or 12.
d. Test valve by removing fluid cylinder and momentarily engaging cranking motor.
The valve plunger should move up and remain up while the cranking motor is
\ -'
engaged. If valve operates, proceed to (2)f.
e. If valve plunger did not function, check valve by disconnecting leads from cranking
motor and ground. Momentarily touch leads directly across battery terminals. The
valve plunger should move up and remain up until the leads are disconnected. If
the valve does not activate when connected across the battery, it is faulty and should
be replaced.
f. Check ETS Switch performance by thoroughly chilling to sub-freezing ternpera-
tures for 10 minutes or more, the NORMAL ETS Switch should be closed (i.e., show
continuity when checked with a DC powertest light or ohmmeter). When thoroughly
warmed to temperatures above 6 5 O ~(1~OC),the NORMAL ETS Switch should be
open (i.e., not show continuity). If your ETS Switch is not a NORMAL ETS (see page
l o ) , adjust the above stated temperatures accordingly for the proper closing and .
opening temperatures.
If either continuity test fails, the ETS Switch should be replaced.
NOTE: The ETS Switch may require 10 to 15 minutes to react to temperature -
change. At room temperatures, a properly functioning switch ma1' .
either open or closed, depending upon which ETS is used in your sysl. .
DO not attempt to check ETS Switch by shorting it across

battery terminals. EXCESS CURRENT WlLL BURN OUT
THE SWITCH AND IT WlLL HAVE TO BE REPLACED.
3. Check for clogging of flow metering orifice inside the BLOCKOR fitting.
he DIESELMATIC'Sfluid flow rate is controlled by a serviceable filtered metering orifice

inside the BLOCKOR fitting (see Figure 13), at the bottom of the valve assembly;
therefore, the following procedure is recommended:
a. Remove the System's injector nozzle from engine. '
During the following procedures, some pressurized fluid

1- may be trapped in the system. Loosen all connections
slowly.
b. Activate the system, if starting fluid does not spray from the injector nozzle when the
system is activated, disconnect tubing from the valve's fitting. Activate the system,
If startina fluid sDravs from the BLOCKOR fitting when the System is activated,
reconnect tubing to the valve's BLOCKOR fitting, remove injector noule, and
activate system. If fluid sprays from the tubing end, replace injector nozzle. If fluid
does not sorav from the tubing end, check tubing for kinks, burns, cuts, or clogs.
WHEN PERFORMINGTHESEOPERATIONS, BE SURETOSPRAY FLUID I N T .

AN APPROPRIATE CONTAINER.
c. If startina fluid does not sDrav from the valve's BLOCKOR fitting, remove the
BLOCKOR fitting from the valve. REMEMBER: LEFT-HAND THREADS!
After removal of the BLOCKOR fitting from the valve, look at the stamping on the
side of BLOCKOR to determine which BLOCKOR series you have; the third number
will determine which BLOCKOR series you have.
For the BLOCKOR XX4XX serieg, remove its' filter and check to make sure that the
" 0 " Ring that belongs in the tip of the filter, is not left inside of the valve fitting. If the
" 0 " Ring remains in the valve fitting, remove it with a blunt item such as a broken
toothpick. If filter is to be cleaned, the " 0 " Ring must be removed from the tip of the
filter. Fitting and filter can be washed in clean solvent and blown with compressed
air; but do not allow any solvents to come in contact with the " 0 " Ring, because they
can destroy it. Reinstall the " 0 " Ring over the tip of the filter after cleaning and before
attempting to insert the filter back into the fitting. Reassemble filter with "0" Ring
into fitting. For best results, replace filterwith a new one, KBI Part Number 300813.
For the BLOCKOR XX5XX series, remove its filter by unscrewing filter counter
.. clockwise, being careful not to damage the sintered bronze material at the top of the
. -.-
filter. Fitting and filter can be washed in clean solvent and blown with compressed
air. For best results, replace filter with a new one, KBI Part Number 301876.
Reinstall filter into BLOCKOR fitting by turning clockwise, making sure that no
foreign objects fall into the well of fitting. Tighten filter, again being careful not to
damage the sintered bronze material at the top of the filter, finger tight; with pliers,
tighten 118 turn to make sure filter seats firmly.
d. It is suggested before the cleaned or new BLOCKOR fitting assembly is reinserted
into valve, that the system be flushed by activating the valve. WHEN PERFORM-
ING THIS OPERATION, BE SURE TO SPRAY FLUID INTO AN APPROPRIATE
CONTAINER.
valve, do not repeat this valve flushing more than twice.
e. Reinsert clean (or new), filtered BLOCKOR fitting assembly into valve. REMEM-.
BER: LEFT-HAND THREADS. Reinstall System's nozzle into engine. Reconnect
tubing to the valve's BLOCKOR fitting and engine's injector nozzle.
f. Check all fitting and tubing connections for leaks.
REMOVABLE
FILTER
BLOCKOR
FITTING
ORIFICE ----J ORIFICE
FlCURE 73 FIGURE 74
BLOCKOR fitting, XX4XX series B LOCK0 R fitting, XXXSX series
MAINTENANCE SCHEDULE
NOTE: 1. See "SERVICING AND TROUBLESHOOTING" for detailed procedures.
2. Whenever the fluid cylinder is removed, ALWAYS replace the valve
gasket, KBI #300012.
3. KB! offers a Cylinder Return Program for used Starting Fluid Cylinders.
Call KBl's sales office (800-527-8278), for a Return Authorization
Number and more information.
R = Replace
C = Clean
I = Inspect (After inspection, clean, adjust,
repair, or replace if necessary.)
Every Month or
Prior to the 15,000 Miles
Winter Season During the
Winter Season
Fluid Cylinder
I R
I
Fluid Cylinder
Contents I
BLOCKOR Fitting
and Filter C*
Valve Assembly I I
Tubing and Nozzle .. I I
System Wiring I I
Test ETS I
Bypass ETS and

Check System
Operation I I
-
* After cleaning the BLOCKOR fitting, reolace filter inside of t h e
BLOCKOR fitting.
LIMITED WARRANTY
All products are guaranteed against defects in material and workmanship for one
year from date of purchase. The Valve and Engine Temperature Sensor (ETS),
Switch are sealed units. If these components do not operate properly, they must
be returned to the factory, prepaid, for replacement. If factory inspection
determines the product to be defective under the terms of this warranty, it will be
replaced without charge.
Failure due to accident, abuse, neglect, improper installation or maintenance,

mishandling, and repairs or attempted repairs which have been made others,
are not covered under the terms of this warranty.
- Kold Ban International Ltd., shall not be liable for loss of use of the System or other
incidental or consequential costs, expenses or damages incurred by the &r-
chaser or user.
This warranty does not include labor for repair or replacement, nor does it apply
to used fluid cylinders or BLOCKOR Fittings, injector nozzles, and atomizers
clogged by dirt.
Kold B a n International, Ltd.

900 Pingree Road
Lake In The Hills, Illinois 601 02-9637
(847)658-8561
(800)527-8278
KBI'S DIESELMATIC PRODUCTS ARE PROTECTED BY ONE OR MORE OF

THE FOLLOWING U.S. PATENT NUMBERS: 4202309, 4326485, 4346683,
5474678. CANADIAN PATENT NUMBER 1,120,352, U.K. PATENT NUMBER
2026096 AND OTHER U.S. AND FOREIGN PATENTS PENDING.
KB I@
DIESELMATIC@
KOMPAC@
BLOCKOR@
01997
KBI Form #I30533 Rev. 01/97
d 900FG - 1OOOFG series Parker Hannifin Corporation
Racor Division
w
Fuel Filter / Water Separators

- P.O. Box 3208,3400 Finch Road
II
II for Diesel and Gasoline Engines I
Modesto, C A 95353 USA
209152 1-7860 8001344-3286
Filtration
The Racor 9OOllOOO Series Fuel Filter~WaterSeparators

protect the precision components of your engine from dirt,
rust, algae, asphaltines, varnishes and especially water
which is prevalent in engine fuels. Racor removes
contaminants using a patented three stage process:
1. Separation: The turbine separates large solids and

'free' water through centrifugal action.
2. Coalescing: Smaller water droplets and solids
coalesce on the surfaces of the conical baffle and fall
to the bottom of the collection bowl.
3. Filtration: Engines will benefit from near 100%
water separation and fuel filtration with Racor's
proprietary AquablocTM water repelling media.
The replaceable filter elements are available in 2, 1 0
and 3 0 micron (nominal) ratings.
These units are designed for installation on the suction

(vacuum) side of the fuel transfer pump for best efficiency.
The standard fuel ports are 718"-14 SAE J1926 O-ring

seal type. 22mm metric ports are optional. Fittings are not
supplied with this unit but are available from your Racor
dealer. Please refer to the fittings chart on the back page.
The bracket is an adjustable one-piece clamp-type with

grade 5 fasteners for ensured durability. The 900 series
use one clamp bracket and the 1000 series use two.
The see-thru contaminant collection bowl provides for a

quick visual check of water and solid accumulation.
OPTIONAL FEATURES: For diesel fuel applications

only. See Accessories.
contaminant drain #
u An in-filter 300 watt heater quickly warms the fuel
providing easier starting in colder climates.
SPECIFICATIONS 900 Series 1000 Series A watersensorprobe alerts the operator when it's time to
Fuel Ports, SAE J1926 718"-14 or 22mm 718"-14 or 22mm drain the bowl ( especially useful for models with a metal
Maximum Flow Rate 90 G P H I 341 LPH 180 G P H 1681 LPH bowl). Must be used with a Racor water detection kit.
Replacement Element 2040 (see parts list) 2020 (see parts list)
Overhead space required 5"/ 127mm, rnin. 10" / 254mm, rnin. A vacuum gauge kit (not shown) is also available to inform
Clean Pressure Drop' .34 PSI / 2.4 kPa .49 PSI / 3.3 kPa
,
the operator when it's time to change the element.
Height 16"/406 rnm 21" / 533 rnm
didth 6 " / 152 mm 6" / 152mm PART NUMBER lDENTlFlCATlON
,pth 7" / 178 mm 7" / l78mm The example below illustrates how the paFf numbers are constructed.
.eight, Dry 6 Ibs. / 3 kgs 10 Ibs. / 5 kgs
.dmperature Rating -
40' / +250° F - 40' / +250° F
-40°/+1210 C -40°/+121 OC
IOOOFG (1 80GPH) -P -324 -10
Basic Model Water Heater Element
I Specifications result from tests conducted at the maximum flow rate.
Ratins
1 d Rate Formula for Medium & Heavy Duty Engines
~ i m ~ l i f i eFlow Add 'M'for metal bowl Se"SO' 2 micron
I HorsepowerX .006=Approximate (GPM) fuel pump flow rate. (example: 9OOFGM) A 22 ,m,
312 = I 2 vdc
om* - A .,A-
10 micron
INSTALLATION INSTRUCTIONS
WHEN POSITIONING THE UNIT:
1. The Racor 90011000 Series should be installed on the suction (vacuum) side of the fuel transfer pump for opt~murnwatt
,/ -
separating efficiency. See the illustration below.
2. To keep fuel line restriction to a minimum, locate the unit between the horizontal planes of the bottom of the fuel tank and
the inlet of the fuel pump, if at all possible.
If the Racor filter is in an application where the fuel tank is higher, a shut-off valve must be installed between the tank and
the Racor INLET for use when servicing the replacement filter.
3. Maintain clearance above the unit for element servicing: 5 1127mm for the 900 and 10" 1254mm for the 1000.
BEFORE INSTALLING THE UNIT:

1. Ensure fuel port fittings are in hand along with fuel line and all needed installation tools and materials.
2. Maintain a safe working environment. Obtain good ventilation, lighting and Do not smoke or allow open flame near the
installation. The engine must be off and should be at ambient temperature.
MOUNTING HOLE PATTERNS: Use the dimensions below when drillinq holes or positioninq the unit.
900 Series (Not to scale)
i 1000 Series ( ~ otot scale)
L- 4.5" 1-
318" (1Omm) diameter

clearance for fasteners.
Bracket height is adjust-
able from 2" (5 1mm) to
5.5" (140rnm) above
port center line. 318" (1Omm) diameter
clearance for fasteners.
A NOTE: maintain proper clearance above the unii

-Suction (Vacuum) Side Installation I for element removal. See specifications.
Downstream
*Valve
Engine
-
1
Fuel Tank
Fuel transfer pump
(if applicable) 'A shut-off valve is recommended when the
fuel tank is mounted higher than the Racor.
INSTALLING THE UNIT:

1. Completely remove any vacuum side filter(s) in the fuel line between the fuel tank and fuel pump. This is where your
Racor filter will mount. Leaving these filters in place will only add to fuel line restriction. Filter heads cast into the engine
or that are non-removable or hard piped should be serviced with a new element and left in place.
2. To keep fuel flow restriction values to a minimum: Use maximum size fuel line where possible; Do not make sharp bends
with flexible fuel line as kinks may occur and avoid the use of two 4 S 0 elbow fittings where one 90° elbow will work.
3. If routing new fuel hose, avoid surfaces that will move, have sharp edges or will get hot, such as exhaust piping.
FUEL SYSTEM PRIMING:

Remove the lid using a 1 1/16" hex socket orwrench. Fill the unit with clean fuel and coat the lid seal with fuel as well. Replace
the lid and tighten by hand or 1 1/16" hex socket to 10 ft.lSs., maximum. If applicable, refer to the equipment operator's service
manual to complete the fuel priming 1 bleeding procedure. Start the engine and check the installation for potential leaks.
a
TROUBLESHOOTING PROCEDURES:
A major cause of poor starting or power loss is the result of an air leak or high restriction. If your unit will not prime, fails t c -
hold a prime or if air bubbles are visible in the see-thru bowl, first check that the lid and drain valve are properly tightened.
Next, check all fitting connections and ensure none of the fuel lines are pinched or clogged with contaminants. If your fuel
tank is equipped with an in-tank strainer, check it for potential clogging. If problems persist (and the filter element is new)
call your Racor dealer or Racor Customer Service for assistance at 8001344-3286, PST.
900/1000 REPLACEMENT PARTS LIST
Item Part No. Description (quantity is one each)
Lid Assembly
T-handle / Lid Assy. (not shown)
900 Rpl. Element, 2 micron
Rpl. Element, 10 micron
1000 Rpl. Element, 2 micron
900 Return Tube
1000 Return Tube
Body Clamp Bracket
Heater 12V/300W (base feed-thru type)
Heater 24V/300W (base feed-thru type)
Heater Feed-thru (electricalconnector)
Bowl Ring, 5" dia. (see-thru bowls)
Check Ball and Seal
Turbine & Centrifuge
See-thru Bowl wANater Sensor Port
Front Metal Bowl
Metal Bowl w/ water bullet probes'
Cutaway Metal Bowl w/ heater bullet probes
View of Water Sensor Probe (see-thru bowls)'
9OOFGP3 Self-venting Drain Valve
Seal Service Kit (all models)
'Must be used with Detection Module. See Accessories below.
ACCESSORIES FITTINGS CHART

Water Detection Kit # RK20725
-rdc underdash module which illuminates FUEL FILTER PLATED STEEL FllTlNGS FOR 718"-14 SAE J1926 PORTS '
LED when water is detected. Measures
J4" X 1" X 1 112". Hardware and instructions Description T2 1 Part Number
included. Wire and terminals are customer SAE
supplied. 314"-16 9010-1 0-8
37O
Elbow T2 718"-14 9010-1 0-1 0
Water Detection Kit # RK20726
12 or 24 vdc gauge type module which
illuminates an LED and sounds a momentary SAE 3 7 O 314"-16 9020-1 0-8
buzzer when water is detected. Fits 2 1/16" Straight 7-2 718"-14 9020-1 0-1 0
diameter panel openings. Hardware and
instructions included. Wire and terminals are 318" NPT 9040-1 0-6
customer supplied. 9040-1 0-8
Female T2 9040-1 0-1 2
Element Restriction Gauge Kit #I6068
Plumbed on the outlet side of the filter, the Hose Inside Diameter
Description Typical SAE100RS Pa' Number
gauge monitors element restriction. Helps in
determining when it's time for a filter change. 3/8"(#6) 13/32"(#8) 901OHF-10-8
Most hardware and instructions included.
Barbed 1/2"(#8) 1/2"(#10) 901o~F-10-1(
Frame Rail Mounting Kit #RK11-1518.
Elbow 5/8"(#10) 5/8"(#12) 9010HF-10-1:
T2
Adjustable to fit frame rails up to 10" in height
by 4" in depth and 314" in thickness. No drilling 3/8'(#6) 13/32'(#8) 9020HF-10-8
~ ~ ~ b ~
1/2"(#8)
d1/2"(#10) 9020HF-1&1(
or welding of the frame rail is necessary.
Hardware shown and instructions included.
Straight T2 - 5/8"(#10) 5/8"(#10) 9020HF-10-1:
Frame Rail
der metnc fitt~ngslrom your PARKER dealer Call 1-BM)-CPARKER for the dealer nearest you
WARNING 'Ihc following slatcmcnl IS rcqulrcd punuant lo R o p o c ~ t ~ o65 n appllcnblc In the Statc of Cahfomta 'Thm product may conwn a chcmscal known to thc Stalc of Caltfornia to cruse canccr
WARNING Fallurc w lmpmpcr selcttlon or Improper use of the products andlor systcmr dcwnbcd hcrcm or related ucms can cauw death p c ~ n a mjury l and propmy damage Thts documcnt and other 1nf0nn3110nfrom Pxkcr
~ f i nCorpauon. s u b s ~ d ~ v l u a nauthonzcd
d dtstnbutors prowdc product andlor sysicm optlons for funher mvcsugatlon by uwrs h b m g tcthn~calcxpcnlu It IS nnporont that you analyzc all i ~ ~ p e coft syour appllCPllon
WICWh e m f o m u o n conccmlng the Product or syslcm In the current product catalog Due to the vvlcty of o p c n t ~ o n cond~uonsand appl~canonsfor these products or systems. the uwr, through IIS own m a l ~ n and
s tcsung.
,cly rcspons~blcformaklngthe final xlcctlonof the productsand systemsand assunng thal all pcrformancc. ufcry and wmlngrcqurcmcnoof h c applxat~onsan met Thcproductsdcwnbcd h m m . lncludlng wlth Ilmtwuon.
duct f w N m . spcclficattons. dcs~gns.avvlablllry and pnclng. m subjecl to change by Parker H y l n ~ f i nCorpont~onand LL%s u b s ~ d ~ a nat c sany t m c wlthour nonce
A C O R LIMITED WARRANTIES STATEMENT
All pmduco m u f x t u r e d or dtsvlbuled by Racor arc subjctl to thc following, and only thc followng. LIMITED EXPRESS WARRrLLTiES and no olhcn For a penod of one ( I ) y e u from and aflcr thc date of p u ~ ofh ~
I a new Racor product. &or warrants and g u m n I u s only to thc onglnai purchaser-uwr that w c h a product shall be frcc from defects of matrnals and worlvnansh~pIn Ihc manufacrunng process Thc w m t y pcnod for pumps
and moton 1s succ~ficall~ r o ( ' W h y s f m m d a a o f w r c h i ~ ~Ac ~ r o d u c t c l a ~ m elodbe defcct~vcmust bc returned to the olaccofourchax Racor, at lo sole omon. shall rcrrlacc thcdcfcct~vcproduct wlIh acompanble
I ~ m ~ e dnlnc1Y
I new product 0; w a n Ihc dcfcctivc pmduct. This express warranty shall bc inapplicable to any product not properly installed and properly used by Ihc purchaser-uscrbr to any pmduct damaged or imporcd by cxremal forces.
M I S IS THE E X X i O F WARRANTIES AVAILABLE O N A l S PROdUCT RACOR SHALL HAVE NO LlABlLlTY WHATSOLER FOR CONSEOUENlTAL DAMAGES FLOWING FROM THE USE OF ANY1
DEFECTIVE PRODUCT OR BY REASON OFTHE FAILURE O F ANY PRODUCT RACOR SPECIFICALLY DISAVOWS ALL OTHER W A R R A N T ~ E EXPRESS ~ OR IMPLIED INCLUDING. WITHOUT LIMITA-
TION ALL WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE (EXCEPT FOR THOSE WHICH APPLY TO PRODbCT OR PART THEREOF THAT IS USED OR BOUGHT FOR USE PRIMARILY FOR
PERSONAL FAMILY OR HOUSEHOLD PURPOSES) WARRANTIES O F DESCRIPTION WARRANTIES OF MERCHANTABILKY TRADE USAGE OR WARRANTIES OR TRADE USAGE
R z r n r ' c n n l l r v I + n n e n f r n n t ~ n ~ l~r nn ni r n v e r n e n t In d e s m n 2 n d r n n n ~ l f n r t ~ l r l nt n I n s l l r e ~ t ~f il nl o r n r n d ~ ~ r t tsh.e r e f n r e snerlfrat~onseaumnent and ~roduct
INSTALLING OPTIONAL FEATURES
NOTE: RACOR ELECTRICAL OPTIONS ARE FOR USE WITH DIESEL FUEL ONLY.
WATER SENSOR. Most Racor units can be specified with a water sensor probe. The probe senses continuity values and
must be used with a special electronic detector to function properly. Due to the various models available, these electronic
detectors are sold separately and installation instructions are supplied with each kit. See Accessories for part numbers.
Kits may be ordered from your Racor Dealer.
IN-FILTER HEATER. The in-filter disc heater is a cold weather starting aid with an internal automatic thermostat that turns
the heater on if the fuel temperature drops below +45 OF (+7.2 OC).Heat is supplied in the unit just below the replacement
element to melt the wax crystals and allow fuel to pass through the element for quick, easy starts.
The 300 watt heater is available in 12 or 24 vdc (volts, direct current). The heater is operated by turning the ignition switch
ON for a minimum of five minutes prior to starting the engine.
CUSTOMER SUPPLIED ITEMS.
1. Because of the heater power demand: 25 amps for 12 vdc and 13
amps for 24 vdc, an additional relay is recommended for the safest Manual on-off
method of installation. switch (optional)
Racor offers two relay kits available from your dealer:
RK11861 (for 12 vdc) and RK11862 (for 24 vdc). \ Fuse
F=/Lt
These kits include an in-line fuse holder (and fuse) and the Relay
RKll862 kit also includes a resistor. Use the 25 amp fuse with
12 vdc and the 15 amp fuse (and resistor) with 24 vdc systems.
2. An on-off toggle switch may be used to control power to the heater
relay. This allows the operator to cut power tothe heater relay
during summer use.
3. All wires should be 14 AWG (American Wire Gauge) minimum.
9 $, 2
* J
INSTALLATION Ignition
1 . Either heater wire may be used for Hot (+) or Ground (-). Battery switch
2. Wire 1 terminal connections should be soldered and crimped.
3. Run wires in protected locations. Avoid hot surfaces and places
that could pinch or rub on the wires. *use resistor and 15 amp fuse with 24 vdc systems.
SERVICE
Frequency of water draining or element replacement is determined by the contamination level of the fuel. The collection bowl
must be drained before contaminants reach the bottom of the turbine or when the water detector (optional) indicates it's time
to 'drain waterJ. Inspect or drain the collection bowl of water daily and replace the element every 10,000 miles, every 500
hours, every other oil change or if a power loss is noticed, whichever comes first.
If a vacuum gauge has been installed on the outlet side of the filter, change the element between 6 to 10 inches of mercury
(restriction). The actual measurement varies in different fuel systems.
Note: Always carry an extra Racor element as one tankful of excessively contaminated fuel can plug a filter.
TO DRAIN WATER:
Open the self-venting drain to evacuate contaminants. If necessary, remove the lid and prime the unit by filling with clean
fuel. Replace the Lid and tighten by hand or with a 1 1/16" hex head wrench to 10 ftlbs., maximum.
TO REPLACE ELEMENT: Only genuine Racor replacementfilter elements feature specially treated AquablocTMmediaand
an exclusive seal design to resist element fuel by-pass. A convenient molded handle on the top of the element simplifies
removal. Remove the lid and then remove the element by slowly pulling upward on the molded handle with a turning motion.
Replace the lid gasket with the one supplied with the new element. Apply a coating of clean fuel to the seal priorto reassembly.
Fill the unit with clean fuel, then replace the lid and tighten by hand or with a 1 1116" hex head wrench to 10 ft.lbs., maximum.
Start the engine and check for leaks. Correct any leaks with the engine off.
PERFORMANCE GRAPHS These results are from controlled laboratory tests. your results may vary.
100 J 1- 7
75 0.75 6
\1OOO1 5
50 0.50
PSI 1 900 I
PSI 3
Percent 25 0.25 . 2
Effrcrency 1
0 OH 0
0 50 100 150 0 0.5 1 1.5 2 2.5 3
Time (Minutes) Flow (gpm) Grams
SAE J905 Solids Capacity (using
SAE J 1839 90011000 Water Separation SAE J905 Fuel Flow Restriction SOFTC-2A) @ 10 microns
SEPTEMBER 1997
ESD5200 SERIES
SPEED CONTROL UNIT
APPLICATION INFORMATlON The speed switch is factory set at its maximum speed setting.
The ESD 5200 Series speed control unit is rugged enough to be (10,000 HZ. speed sensor signal)
placed in a control cabinet or engine mounted enclosure with
other dedicated control equipment. If water, mist, or condensa- Startinq Enqine
tion may come in contact with the controller, it should be mounted
vertically. This will allow the fluid to drain away from the speed Crank the engine with D.C. battery power applied to the governor
control unit. system. The actuator will energize fully to the maximum fuel
position until the engine starts. The governor system should
Extreme heat should be avoided. control the engine at low idle speed. If the engine is unstable after
starting, turn the GAIN and STABILITY adjustments counter-
WARNING clockwise until the engine is stable.
An overspeed shutdown device, independent of the gover-
nor system, should be provided to prevent loss of engine
control which may cause personal injury or equipment dam- Governor Speed Settinq
age. Do not rely exclusively on the governor system electric The governed speed set point is increased by clockwise rotation
, actuator to prevent overspeed. A secondary shut off device, of the SPEED adjustment control. Remote speed adjustment can
such as a fuel solenoid, should be used. be obtained with an optional Speed Trim Control. See Diagram 1.
C
WIRING
Governor Performance
Basic electrical connections are illustrated in Diagram 1. Actuator
and battery connections to Terminals A, 8,E, and F should be Once the engine is at the operating speed and at no load, the
#16 AWG (1.3 mm sq.) or larger. L~~~ require an foilowing governor performance adjustments can be made.
increased wire size to minimize voltage drops. A. Rotate the GAIN adjustment clockwise until instability
develops. Gradually move the adjustment counterclockwise until
The battery positive ( + ) input, Terminal F,Should be fused for 15 stability returns. Move the adjustment one division further coun-
amps as illustrated. terclockwise to insure stable 'performance.
Magnetic speed sensor connections to Terminals C and D MUST B. Rotate the STABILITY adjustment clockwise until instability
BE TWISTED AND/OR SHIELDED for their entire length. The develops. Gradually move the adjustment counterclockwise until
speed sensor cable shield should only be connected to Terminal stability returns. Move the adjustment one division further coun-
D. The shield should be insulated to insure no other part of the terclockwise to insure stable performance.
shield comes in contact with engine ground, otherwise stray C. Gain and stability adjustments may require minor changes
speed signals may be introduced into the speed control unit. With after engine load is applied. Normally, adjustments made at no
the engine stopped, adjust the gap between the magnetic speed load achieve satisfactory performance. A strip chart recorder can
sensor and the ring gear teeth. The gap should not be any smaller be used to further optimize the adjustments.
than 0.020 in. (0.45 mm). Usually, backing out the speed sensor If instability cannot be corrected or further performance improve-
3/1 turn after touching a ring gear tooth will achieve a satisfactory ments are required, refer to section on SYSTEM TROUBLE-
air gap. The magnetic speed sensor voltage should be at least 1 SHOOTlNG to adjust the DIP switch positions and for other
VAC RMS during cranking. troubleshooting procedures.
position. adjustment control. When the engine is at idle speed, the speed
The speed control unit governed speed setting is factory set at control unit applies droop to the governor system to insure stable
approximately engine idle speed. (1000 HZ. speed sensor signal) Operation.
Speed Droop Operation When operating in the upper end of the control unit frequency
range, a jumper wire or frequency trim control may be required-
Droop is typically used for the parelleling of engine driven between Terminals G and J. This increases the frequency rangt
generators. of the speed control to over 7000 Hz.
Place the optional external selector switch in the DROOP posi-
tion. Droop is increased by clockwise rotation of the DROOP
adjustment control. When in droop operation, the engine speed Accessory Supply
will decrease as engine load increases. The percentage of droop
is based on the actuator current change from engine no load to The + 10 volt regulated supply, Terminal P, can be utilized to
full load. A wide range of droop is available with the internal provide power to GAC governor system accessories. Up to 20 ma
control. If more droop is required, a jumper between Terminals G of current can be drawn from this supply. Ground reference is
and H can be added to double the droop available. Droop level Terminal G. Caution - a short circuit on this terminal can
requirements above 1O0/0 are unusual. damage the speed control unit.
If droop levels experienced are higher or lower than those

required, contact the factory for assistance.
Internal Speed Switch
After the droop level has been adjusted, the rated engine speed
setting may need to be reset. Check the engine speed and adjust When the engine is running at the desired speed, push and hold
the speed setting accordingly. the TEST button. Rotate the OVERSPEED adjustment counter-
clockwise until the LED lights and the relay energizes. Current to
the actuator will be removed and the engine will shut off.
Accessory Input Release the TEST button. After the engine stops, press the
RESET button or remove battery power. Restart the engine and it
Tine Auxiliary Terminal N accepts input signals from load sharing will return to the original speed setting.
units, auto synchronizers, and other governor system accesso-
ries. GAC accessories are directly connected to this terminal. It is The overspeed function is now set to approximately 10% above
recommended that this connection from accessories be shielded the requested speed. If a different value for overspeed setting is
as it is a sensitive input terminal. required, standard procedures for overspeed setting a d j u s t m e n k
should be used.
If the auto synchronizer is used alone, not in conjunction with a
load sharing module, a 3 M ohm resistor should be connected Always use the relay contacts provided to shut down the system
between Terminals N and P. This is required to match the voltage by a means other than the governor or actuator.
levels between the speed control unit and the synchronizer.
It is recommended that the overspeed protection system be
When an accessory is connected to Terminal N, the speed will routinely tested and verified during scheduled service of the
decrease and the speed adiustment must be reset. equipment.
,DIAGRAM 1 WIRING DIAGRAM AND OUTLINE
.27 dia.
(7) 7
-
A
N.O. COM. N.C.
SWITCHES
SHOWN IN
0 @ 0 FACTORY SET
POSITIONS
OVERSPEED RESET TEST
@I @ /
'
1 2 3 OVERSPEED
SPEED
-
WI Y l l D C D r m
mY ~ C mns
~ C ro
DEAD TIME
COMPENSATION
1 LEAD CIRCUIT
ESD5200
DTC POSTS
DROOP
I
-
PICK-UP -
ACTUATOR
POWER
SUPPLY ( + lOV)
/ I ACCESSORY INPUT
ELECTRIC - , JUMPER TO
INCREASE
MAGNETIC 6711 DROOP RANGE
PICK-UP
I GROUND
REFERENCE
I
1 rI-
-
BATTERY
FUSE
15A
SPEED
TRIM
I T1 DROOP
I - - - J
EXTERNAL
SELECTOR
SWITCH
(NOT REOUlRED FOR SINGLE SPEED ISOCHRONOUS OPERATION)

SYSTEM TROUBLESHOOTING
System Inoperative 4
If the engine governing system does not function, the fault m a y be determined by performing the voltage tests described in Steps 1,2,3,
a n d 4, ( + ) a n d ( - ) refer to meter polarity. Should normal values b e indicated as a result of following the troubleshooting steps, the fault
m a y b e with the actuator or the wiring to the actuator. S e e actuator publication for testing details.
Probable Cause of
Step Terminals Normal Reading Abnormal Reading
1 F(+) 8 E(-) Battery Supply Voltage (12 or 24 VDC) 1. DC battery power not connected. Check for blown fuse.
2. Low battery voltage.
3. Wiring error.
2 C8D 1.0 VAC RMS min., while cranking 1. Gap between speed sensor and gear teeth too great.
Check gap.
2. Improper or defective wiring to the speed sensor. Resistance
between Terminals C and D should be 30 to 1200 ohms.
3. Defective speed sensor.
3 P( + ) 8 G( - ) 10 VDC, Internal Supply 1. Short on Terminal P. (This will cause a defective unit.)
2. Defective speed control.
4 ( +) & A -) 1.O-2.0 VDC while cranking 1. SPEED adjustment set too low.
2. Shortlopen in actuator w~ring.
3. Defective speed control.
4. Defective actuator. See Actuator Troubleshooting.
Unsatisfactory P e r f o r m a n c e
If the governin2 system functions poorly, perform the following tests.
Symptom Test Probable Fault

Engine Overspeeds 1. Do Not Crank. Apply DC power to 1. Actuator goes to full fuel. Then, Disconnect speed sensor
the governor system. at Terminals C 8 D. e
-
If actuator still at full fuel s e e d control unit defective.
If actuator at minimum fuel positicr. - erroneous speed
signal. Check speed sensor cable
2. Manually hold the engine at the desired 1. If the voitage reading is 1.0 to 2.0 VDC,
running speed. Measure the DC voltage a) SPEED adjustment set above desired speed.
between Terminals A (-) 8 F( .+ ) on the b) Detective speed control unit.
speed control unit 2. If the voltage reading is above 2.0 VDC,
a) Actuator or linkage binding.
3. If the voltage reading is below 1.0 VDC,
a) Defective speed control unit.
4. Overspeed set point too low.
Overspeed shuts down engine after 1. SPEED adjust set too high. Tum CCW to lower.
running speed is reached. 2. OVERSPEED set too close to running speed.
See OVERSPEED adjustment section.
3. Actuator or linkage binding.
4. Gain set too low.
5. Speed control unit defective.
Overspeed shuts down engine Check impedance between Terminals 1. OVERSPEED set too low. Adjust 5-6 turns CW.
before running speed is reached. C 8 D. Should be 30 to 1200 ohms. 2. Erroneous speed sensor signal. Check wiring.
. ...
Actuator does not energize fully 1. Measure the voltage at the banery 1. If the voltage is less than 7 V for a 12 V system, or
while cranking. 14 V for a 24 V system, replace the battery
if it is weak or undersized.
2. Momentarily connect Terminals 1. Actuator or battery wiring in error.
A and F. The actuator Should 2. Actuator or linkage binding.
move to the full fuel position. 3. Detective actuator. See actuator troubleshooting.
4. Fuse opens. Check for short in actuator or actuator wiring
harness.
4
Eng~neremalns below desired 1. Measure the actuator output, 1. If voltage measurement IS wlthln approximately 2 volts of
governed speed. Terminals A 8 B, while running the battery supply voltage, then tuel control restricted trom
under governor control. reaching full fuel posit~on.Possibly due to interference
from the mechanical governor. carburetor sprlng or
linkage alignment.
2. Speed setting too low.
SYSTEM TROUBLESHOOTING
Insufficient Magnetic Speed Instability
Sensor Signal Instability in a closed loop speed control system can be cate-
gorized into two general types. PERIODIC appears to be sinusoi-
A strong magnetic speed sensor signal will eliminate the possibility dal and at a regular rate. NON-PERIODIC is a random wandering
of missed or extra pulses. The speed control unit will govern well or an occasional deviation from a steady state band for no
with 0.5 volts RMS speed sensor signal. A speed sensor signal of 3
apparent reason.
v o b RMS or greater at governed speed is recommended. Mea-
surement of the signal is made at Terminals C and D. The PERIODIC type can be further classified as a fast or slow
instability. Fast instability is a 3 Hz. or faster irregularity of the
The amplitude of the speed sensor signal can be raised by speed and is usually a jitter. Slow periodic instability is below 3
reducing the gap between the speed sensor tip and the engine Hz., can be very slow, and is sometimes violent.
ring gear. The gap should not be any smaller than 0.020 in. (0.45
mm). When the engine is stopped, back the speed sensor out by If fast instability occurs, this is typically the governor responding
to engine firings. Raising the engine speed increases the fre-
turn after touching the ring gear tooth to achieve a satisfac-
quency of instability and vice versa. If this is the case, setting the
tory air gap.
LEAD switch (SW1) nearest the SPEED adjustment to "OFF" will
reduce this tendency. In extreme cases, this may not take all the
jitter out of the system. In this case, turn DTC switch (SW2) to
Electromagnetic lnterference (EMC) "OFF", to further stabilize the system. Switch locations are
EM1 SUSCEPTIBILITY - The governor system can be adver- illustrated in Diagram 1.
sely affected by large interfering signals that are conducted lnterference from powerful electrical signals can also be the
through the cabling or through direct radiation into the control cause. Turn off the battery chargers or other electrical equipment
circuits. to see if the symptom disappears.
All GAC speed control units contain filters and shielding designed Slow instability can have several causes. First DIP switches 1
to protect the units sensitive circuits from moderate external and 2 should be turned "ON" in the following order:
interfering sources. FIRST - SW1
Although it is difficult to predict levels of interference, applications SECOND - SW2
that include magnetos, solid state ignition systems, radio trans- THIRD - SW1 & SW2
mitters, voltage regulators or battery chargers; should be consid- Readjust the GAIN and STABILITY, after each change of the DIP
ered suspect as possible interfering sources. switch position. If this is unsuccessful, the dead time compensa-
If it is suspected that external fields either those that are radiated tion can be modified. Add a capacitor from posts E2 to E3
or conducted, are or will affect the governor systems operation; it (negative on E2). Post locations are illustrated in Diagram 1. Start
is recommended to use shielded cable for all external connec- with 10 mfds and increase until instability is eliminated. The
tions. Be sure that only one end of the shields including the speed control system can also be optimized for best performance by
sensor shield, is connected to a single point on the case of the following this procedure.
speed control unit. Mount the speed control unit to a grounded If slow instability is unaffected by this procedure, evaluate the fuel
metal back plate or place it in a sealed metal box. system and engine performance. Check the fuel system linkage
Radiation is when the interfering signal is radiated directly for binding, high friction, or poor linkage. Be sure to check linkage
through space to the governing system. To isolate the governor during engine operation. Also look at the engine fuel system.
system electronics from this type of interference source, a metal Irregularities with carbuereted or fuel injection systems can
shield or a solid metal container is usually effective. change engine power even with a constant throttle setting. This
Conduction is when the interfering signal is conducted through can result in speed deviations beyond the control of the governor
the interconnecting wiring to the governor system electronics. system. Adding a small amount of droop can help stabilize the
Shielded cables and installing filters are common remedies. system for troubleshooting.
As an aid to help reduce the levels of EM1of a conductive nature, NON-PERIODIC instability should respond to the GAIN control. If
a battery line filter and shielded cables is conveniently supplied increasing the gain reduces the instability, then the problem is
by GAC in KT310. To reduce the levels of EM1 of a radiated probably with the engine. Higher gain allows the governor to
nature, a shielded container P A CAI 14 can be sourced from respond faster and mrrect for the disturbance. Look for engine
GAC and its distributors. misfirings, an erratic fuel system, or load changes on the engine
In severe high energy interference locations such as when the generator set voltage regulator. If the throttle is slightly erratic, but
governor system is directly in the field of a powerful transmitting performance is fast, setting the left side switch (SW1) to OFF will
source, the shielding may require to be a special EM1 class tend to steady the system.
shielding. For these conditions, contact GAC application engi- If unsuccessful in solving instability, contact the factory for
neering for specific recommendations. assistance.
v:""\ L o w .
ENGINE
GOVERNING
SYSTEMS
INFORMATION
APRIL 1990
120 SERIES
ELECTRIC ACTUATOR
INTRODUCTION
The 120 Serles Actuator IS a rotary output, h e a r torque
servo deslgned for mechanlcal actuation of fuel system
control levers. It IS energ~zedby Ppproprlate speed control
un~tslgnals The actuator !s capable of 20 degrees
pJg$&k$fi$
rotatlon
INSTALLATION
- '4
The actuator must be rlqldlv mounted as close as DOSSI-
ble to the engine throttlejevkr. When selecting the mount- W
ing location, consideration must be given-to possible
i d
+-
-
Ill d
linkage obstructions.
The linkage should be direct, short, and as light as possi-
DIAGRAM 1
ble. Low friction rod end bearings should be used through-
Diesel System Linkage
out the linkage system.
For carburated systems, the linkage is typically non-linear.
The linkage should be adjusted that the fuel control The ideal linkage configuration is for the carburator but-
minimum and maximum
fuel stops are used rather than the terfly valve lever to be parallel with, and the linkage rod to
internal actuator stops.
be perpendicular
. . to the actuator lever at the maximum fuel
A. Drill the actuator mounting holes in a prefabricated position. See Diagram 2.
bracket. Hole configuration is illustrated in Diagram 4. The
position of the actuator on the mounting bracket should
insure minimum misalignment between each end of the
linkage. The rod end bearings can tolerate a maximum
misalignment of 10 degrees. c!
B. Attach the bracket to the engine.
C. Attach the actuator to the bracket.
D. Adjust and secure the linkage rod and rod end bearings.
. .C
i 4
L- -+
- 7-1, -:\.
k. ::,
..-.
,4,
Y$
---i h
1
For proportional actuators to operate with linear control
systems, it is important to obtain a linear relationship
between actuator stroke and fuel delivery.
- For diesel fuel systems, the linkage configuration is typ-

ically linear. The actuator lever should be nearly parallel to DIAGRAM 2
the fuel control lever and perpendicular to the linkage rod Carburated System Linkage
at the mid fuel position. See Diagram 1.
E. Fabricate a cable harness to connect the speed control F. Connect pins A and D of the ACBl20 connector or the
to the actuator. The recommended wire size forthe cable is ACC120 harness to the speed control unit output termi-
at least #16 AWG (1.3mm) for 12V systems, and #18 nals. Refer to the applicable speed control unit literature. A
AWG (1 .Omm) for 24V systems. The wiring must be capa- G. Before starting the engine, push the actuator lever to
ble of handling typical currents of 6A for 12V systems and the maximum fuel position. When released, the linkage
3A for 24V systems without experiencing a significant should return to the minumum fuel position smoothly.
voltage drop. Larger guage wire is necessary for cable Recheck the linkage installation to insure that both the
lengths greater than 10 ft (3 m). linkage and the levers are securely fastened and no bind-
The ACC120 is prewired for 12 or 24V. Use the included ing is present.
harness to connect the actuator to the speed control.
LINKAGE ADJUSTMENT
If an ACB120 is used, the cable harness electrical con-
nector must be wired in a configuration dependent on the The linkage may be optimized by adjusting it for an actua-
system voltage supply. See Diagram 3. tor current difference from engine no load to full load of
12 Volt Operat~on approximately 2A for 12V systems and 1A for 24V
AtoC systems.
B to D
A & D to output terminals The no load current is altered by varying the length of the
linkage, and the range is adjusted by changing the hole
used by the rod end bearing on the actuator lever.
Small angles of actuator travel may improve transient

To performance, but will reduce the force available at the fuel
Control Unit control lever. Adjusting the actuator to operate through at
least one half (10 degrees) of its stroke will provide near
optimum response.
24 Volt Operat~on
B to C
-- -
A 8; D to output term~nals
of speed control unit
/---
To
Control Unit
DIAGRAM 3 I
I - I
Gi-- g!K
- 1 lll 388
-
CONNECTOR WIRING
r-p I
i-- (98 6 )
I
ia a,
t
32 Volt Operation
Wire the electrical connector as illustrated for 24V opera- DIAGRAM 4
tion. Add a 2.0 ohm, 25W resistor in series with pin A of the ACTUATOR OUTLINE DIMENSIONS
actuator and the terminal of the speed control unit. Drmensrons rn inches (mm).
P.O.Box 2782 Springfield, Mass. 01101 (413) 733-4900

FAX (413) 739-1352
GOVERNING INFORMATION
BULLETIN JANUARY 1991
SYSTEMS
ESD 5221
SPEED CONTROL UNIT
APPLICATION INFORMATION governor syslern. The actuator will energize fully to tlie maximum
fuel position until the engine has started. The governor should
The ESD 5221 speed control unit is rugged enough to be control tho engine at !%.idle speed.
placed in a control cabinet or engine mounted enclosure with If the engine is unstable after starting, turn the GAlN and
other dedicated control equipment. If water or condensation may STABILITY adjustments counterclockwise until the engine is
come in contact with the controller, it should be mounted stable.
vertically.
Extreme heat should be avoided. Governor Speed Selling

The governed speed set point is increased by ,clockwise rola-
tion of the SPEED adjustment control. Precise speed adjust-
WARNING ments can be obtained with an optional Speed Trim control.
C
An overspeed shutdown device, independent of the gover-
nor system, should be provided to prevent loss of engine
Governor Performance
control which may cause personal injury or equipment
damage. Do not rely on the governor system electric actua- Once the engine is at the operating speed and at no load, the
tor to prevent overspeed. A secondary shut off device, such following governor performance adjustments can be made.
as a fuel solinoid, should be used.
A. Rotate the G A l N adjustment clockwise until instability
develops. Gradually move the adjustment counterclockwise until
stability returns. Move the adjustment one division further
WIRING counterclockwise to insure stable performance.
Electrical conneclions are illustrated in Diagram 1. Actuator
8. Rotate the STABILITY adjustment clockwise until insta-
and battery connections to Terminals A, B, E and F should be #16
bility develops. Gradually move the adjustment counterclockwise
AWG (1.3mm) or larger. The battery positive ( + ) input terminal
until stability returns. Move the adjustment one division further
should be fused. Magnetic speed sensor connections to Termi-
counterclockwise to insure stable performance.
nals C and D must be twisted and/or shielded for their entire
length. The speed sensor cable shield should only be connected C. Gain and stability adjustments may require minor changes
to Terminal D. The cable shield should be insulated to insure no after engine load is applied. Normally, adjustments made at no
part of the shield comes in contact with engine ground, otherwise ioad achieve satisfactory performance.
stray speed signals may be introduced in!o the speed control unit. If instability cannot be corrected, refer to controller technical
Speed switch relay contacts are rated at 5 amps. 'Nire size publication PTI 1030 for system troubleshooting.
should be sufficient to carry this current.
ldle Speed Setting
Place the optional external selector switch in the "IDLE" posi-
ADJUSTMENTS tion. ldle speed set point is increased by clockwise rotation of the
IDLE adjustment control.
Before Starting Engine
Check to insure the GAlN and STABILITY adjustments, and if
,.applied the external SPEED TRIM CONTROL, are set to niid- 3 e e d Droop Operation
oosition. Place the optional external selector switch in the "DROOP"
position. Droop is increased by clockwise rotation of Ihe DROOP
adjustment control. To increase the droop range, a jumper be-
Engine Start:
tween Terminals G and H can be added. Refer to ESD 5221
The controller is factory set at approximately engine idle speed. control unit technical publication PTI 1030 for further details.
(1000 HZ. Speed Sensor Signal)
Crank the engine with D.C. battery power applied to the
The nUXiliav
Accessory Input
Terminal N accepts input
signals from load
sharing units, a u t o - s y n c h o r n i ~ ~ r sand
, other governor sycJem
accessories. See specific product literature for dotails.
Accessory Supply
overspeed Switch
With the engine running at rated speed, press the TEST button.
Rotate the OVERSPEED adjustment cOunterciOckwiseuntilthe
relay energizes and the LED lights.
Tho ovorsoood swltch sol-point wlll bo 10% abovo tho o n ~ l n o
-
governor spked set-point.
The + l o volt supply, Terminal ' 8 can b e utilized to provide ~~~~t of the overspeed relay can b e achieved by pressing the
power to G A C load sharing units and other governor system reset button or by removing battery power,
accessories. Ground reference is Terminal G.
DIAGRAM 1 6.00
(152)
5.25
(133)
NO COM. NC
ESD 5221 __ __ -. ---.--
SYSTEM WIRING
-I
@- Ill
.,.-. .,
-44
0 0
OVERSPEED
1 2 3
. , CIRCUIT
SWITCH
I
DEAD TIME
- COMPENSATION
SWITCH
PI
ACTUJOR
r
SSORY POWER
LY ( + 10V)
t ACCESSORY INPUT
c3
l------
See specific :JUMPER TO INCREASE
actuator ,_I-
DROOP RANGE
publication for -t
Proper wiring ACTUATOR CW ,GROUND REFERENCE
of actuator FOR ACCESSORIES
connector in I---\
relabon lo TRIM I I
battery voltage I I IDLE
MAGNETIC I /(* ISOCHRONOUS
SPEEDSENSOR I
I
I
/
I
DROOP
'For wire connections longer I_ - -I

than 1011. (3 meters). (SWITCH NOT REQUIRED
Shielded cable should be FOR ISOCHRONOUS OPERATION)
used. Ground shield
at one end only. 44
P.O. Box 2782 0 Springfield, Mass. 01101 (413) 733-4900

FAX (413) 739-1352
Installation Guide for
Models 2004 & 2012 Strobe Beacons
(With Polycarbonate Base)
99 CEDA Road. Charlestown. New Hampshire 03603
MODEL 2004 1 5 WATT / 4 JOULE / 70 SFPM / SAE CLASS Ill MODEL 2012 1 15 WATT / 8 JOULE / 120 SFPM / SAE CLASS II
WARNING ... The strobe power supply is

a high voltage device. Do not remove flash
tubes or dismantle strobe light head assembl)
while in operation. Wait 10 minutes after
turning off power before starting work or
trouble shooting.
WARNING ... All customer supplied wires,

that connect to the positive (+) terminal
of the battery, must be sized to supply at
/>I I
WIRES TO BE CRIMPED TO CUSTOMER I
least 125% of the maximum operating
SUPPLIED TWO CONDUCTOR CABLE.
BLACK WIRE, NEGATIVE (-) GROUND, current, and fused at the battery to carry
RED WIRE POSITIVE i+). the load. (See Wiring Diagram)
SEE WIR~IG INSTRUCT~ONSON PAGE 2 I /
I
Whelen Englneerlng Company Inc.
0 1 998
Form No.13337 (060298)
MOUNTING INSTRUCTIONS:
ITEM DESCRIPTION OTY. PART NUMBER 2004 2012
This strobe light beacon features a combination
1 OPTIC DOME. HIGH PROFILE. AMBER 1 66-21 80483-1 0 base which may be used for either 1 INCH (NPTL
PlPE MOUNT, or PERMANENT MOUNT.
1 OPTIC DOME, HIGH PROFILE. BLUE 1 68-21 80483-20
1 INCH (NPT) PlPE MOUNT.
1 OPTIC DOME. HIGH PROFILE. CLEAR 1 68-21 80483-30 a The threading for a 1 inch (NPT) pipe mounting is
precast in the base.
1 OPTIC DOME, HIGH PROFILE. GREEN 1 68-21 80483-40
1. Feed power cable through the 1 inch pipe and
1 OPTIC DOME, HIGH PROFILE. RED 1 68-21 80483-50 a connect the cable to the wires of the beacon.
-- -
1 OPTIC DOME, LOW PROFILE. AMBER 1 68-21 80452-1 o a 2. Screw the strobe beacon to the threads on the
1" pipe, taking precaution not to damage the con-
1 OPTIC DOME. LOW PROFILE. BLUE 1 6 8 4 1 80452-20 a nected oower wires. NOTE: Do not trqhten base
I I
too hard on threads of pipe so as not-to damage
1 OPTIC DOME. LOW PROFILE. CLEAR 1 68-2180452-30
threads on base.
I 1 I OPTlC DOME, LOW PROFILE, GREEN I 1 / 68-2180452-40 1 I / PERMANENT MOUNT
/ 1 I OPTIC DOME, LOW PROFILE, RED / 1 1 68-2180452-50 1 1. Use the base (item 8) as a template and mark
the three mounting holes on the mounting surface.
#$x 112 INCH PHILLIPS PAN HEAD SHEET
METAL SCREW. STAINLESS STEEL 1 2 1 *
l a After removing the base, mark in the center
between the three mountmg holes the location of
the wire access hole.
1 I FTlOA STROBE LIGHT FLASH TUBE
ASSEMBLY KIT
364341566-00
*
2. Drill mounting holes in the mounting surface to
flt the m ~ u n t i n ~ s c r e wsupplied
s w ~ t hthe strobe
5 #6 x 5/16 INCH HEX WASHER HEAD 3
THREAD FORMING SCREW
light beacon. Drill wire access hole using a 318"
.. drill (.375 inch). Remove burrs from wire access
6 STROBE POWER SUPPLY ASSY.. 1 0 2 0 1 681 17-00 a hole so as not to damage wires. It is also
recomended that you install a rubber grommet in
6 STROBE POWER SUPPLY ASSY.. I 02-01 67278-00 each wire hole to further protect the wires.
7 NUT #4-FASTEX SCREW GROMMET, NYLON 2 21 -17020602-3 a 3. Gasket (item 11) will be used between the
strobe beacon base and the mountlng surface.
8 PIPEIFLAT MOUNT POLYCARBONATE BASE 1 06-181468401
4. After connecting the strobe light beacon to t h m
9 # l o x 518 INCH PHILLIPS PAN HEAD SHEET 3 * a 0 power cable, feed the wires through the cable
METAL SCREW (PERMANENT MOUNTING) access hole and place the base with the gasket o,.
* the mounting surface, lining up the mounting holes
10 #6 x 518 INCH PAN HEAD THREAD FORMING 2 I
SCREW (TO SECURE DOME TO BASE)

in the base with the lines in the mounting surface.
. Secure strobe light beacon firmly to the mounting
1 11 ISEAL BASE GASKET 1 1 1 384241596-00 1 a I a /
surface with the screws (item 9).
L I I I I I I
Available at your local hardware store. MAGNETIC MOUNT
With the magnetic mount kit you will be able to
WIRING INSTRUCTIONS: mount your strobe so that you can remove it if nec-
NOTE: DC voltage models are polarity sensitive. If the positive and negative wires are reversed the essary and avoid drilling.
unit will not function. The fuse is mstalled between the power source and the strobe light beacon, MAGNETIC MOUNT KIT MODEL MMK
IN THE POSITIVE (+) LINE (red wire) and must be fused at the battery. PART NUMBER 101-0461585-00
A 5 AMP FUSE IS RECOMMENDED FOR THIS UNIT
1. Connect RED wire on strobe light beacon to positive DC voltage (+).
2. A customer supplied single pole single throw (SPST) switch may be used to control the ON-OFF
function of the strobe light beacon.
WlRlNG
3. Connect the BLACK wire on strobe light beacon to negative (-) ground. DIAGRAM
SPECIFICATIONS:
MODEL 2004 MODEL 2012
INPUT VOLTAGE ....12.8 l(25.6) VDC INPUT VOLTAGE ....12.8 J(25.6) VDC
INPUT CURRENT ....0.5 / (0.25) AMPS INPUT CURRENT... 1.7 1 (.85) AMPS
INPUT POWER .......6.4 WATTS INPUT POWER .......21.7 WATTS
FLASHRATE ...........70 (+I- 20%) SFPM FLASHRATE ...........120 (+I- 20%) SFPM
ENERGY OUT ........7.6 JOULES
12 VDC
ENERGY OUT .........4.2 JOULES
BATTERY
OUTPUT POWER ...5 WATTS OUTPUT POWER ... 15 WATTS

Trielectron Mn1080 90t400sln TR Rev F

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TECHNICAL MANUAL

OPERATION AND MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS

CumminsB Engine 6BT WoodwardB Governor

a 11001 Hwy. 41 North Palmetto, FL 34221

July 15, 2000 Record Of Changes

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Record Of Changes July 15, 2000

LIST OF EFFECTIVE PAGES

July 15. 2000 List of Effective Pages

List of Effective Pages July 15. 2000

July 15, 2000 List of Effective Pages

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List of Effective Pages July 15, 2000

July 15, 2000 Introduction

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Introduction July 15, 2000

a. For equipment shipped to destinations in the Continental United States, WARRANTY IS

July 15, 2000 Introduction

Introduction July 15, 2000

SUBJECT CHAPTERISECTION PAGE

SECTION 2. OPERATION ..................................... 1.2 ......... 1

SECTION 3. SPECIFICATIONS & CAPABILITIES ................. . I . 3 . . . . . . . . . 1

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CHAPTER 2. MAINTENANCE ..................................... 2 . . . . . . . . . . . 1

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SECTION 2 . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 ......... 1

SECTION 3. REMOVALIINSTALLATION ........................ . 2 . 3 . ........ 1

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SECTION 5. CLEANING AND PAINTING ......................... 2-5 ......... 1

CHAPTER 3. OVERHAUUMAJOR REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . 3-0 . . . . . . . . . I

CHAPTER 4 . ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

CHAPTER 5. MANUFACTURERS' APPENDICES . . . . . . . . . . . . . . . . . . . . . 5-0 ......... I

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Figure 1A. 90T400SLN Side View

Figure 1B. 90T400SLN End View

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Figure 2. 90T400SLN Major Component Location

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unlts wth roof mounted

Figure 3. Engine Controls and lndicators

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: YE1 RUN/IULE SWlrCH TO IULE POSITION.

Figure 4A. Generator Controls and lndicators (Without DC Option)

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Fiqure 4B. Generator Controls and lndicators (With DC O ~ t i o n )

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