90T400 Cummins PDF

TRlLECTRON INDUSTRIES INC.
GROUND POWER GENERATOR

MODEL 90T400
INTRODUCTION
This manual provides operation, servicing and maintenance
instructions. It contains physical and functional descriptions,
operating instructions, maintenance overhaul, parts list, and
manufacturer's information for the Ground Power unit (GPU) Type
90T400. This ground power unit also referred to as Power Plant
is manufactured by Trilectron Industries Inc, Port Manatee,
Florida.
The operating Instructions are designed for new, or experienced

operators, and fully describe the Control Panel operations in a
step-by-step sequence. The operator is also made aware of normal
operating indications, and indications of a defective unit.
A set-up preparation section shows all necessary details on how

the unit is prepared for operation, and gives a basic
introduction to the control circuitry.
The functional description and theory of operation fully describe

the Engine, Generator and Controls, and can be used in
conjunction with maintenance and troubleshooting procedures.
Illustrations are provided to indicate various component
locations on the engine.
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
the engine and generator, plus schematic diagrams for the
controlling circuitry.
The overhaul section provides instructions based on the expected
life span of the entire unit. Consult the vendor's maintenance
manual in the event of the premature failure of a major
component.
The illustrated parts list is intended for use in provisioning

requisitioning, storing and issuing replaceable parts and in the
identification of new and reclaimed parts. It contains all parts
in formation for which maintenance is economically feasible.
...
'
Intra
Page 1
TRiLECTRON INDUSTRIES INC.
MODEL 9OT400
EOUIPMENT WARRANTY
TRILECTRON INDUSTRIES INC. (The company) guarantees to the original

purchaser of the Ground Power unit (GPU), that the Company will
replace, or at is option, repair at its factory the GPU unit,
within one (1) year from date of shipment, if it is proven to be
defective in material or workmanship under normal use and operating
conditions; provided the Company is notified immediately upon
discovery of any claimed defect, and the defective part returned,
freight prepaid.
If said part is supplied previous to the return of the suspected

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 c~pacity will
void this guarantee.
If this unit has malfunctioned during warranty period, and the

defect cannot be located by the user, In USA the user should
contact Customer Service department (813) 723-1841, FAX (813) 723-
3160 or TELEX (510) 823-0091. In Europe contact John Gear P.O Box
23 Shopston-On-stour Warwickshire CV364EP, England Tel: (0) 608-
61152 Fax: (0) 608-62766, Asia contact Richard Lim 81-A Frankel
Ave. singapore 1545, Singapore Tel: (65) 242-3400 Fax: 242-3400
Telex 20957. The user then may at his option, request one of the
following:
a. Request for return authorization. Unit to be returned to the

Company prepaid, and will be shipped from the Company collect.
b. Request field service for which travel and expenses, plus a

nominal differential charge between shop and field labor rates
are imposed.
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.
- NOTICE -
This unit is specifically designed for the special applications
described in this manual. It will provide years of service if it is
installed, operated and maintained in accordance with these
instructions. Damage to the unit caused by improper installation,
operation or maintenance is not covered by the warranty. STUDY the
instructions contained in this manual, they must be followed to
avoid difficulties. Spare parts are available from Trilectron, and
it is the responsibility of the user to have an ample supply of
parts available to ensure continuous operation.
- -t.; ; .....-.
TRILECTRON INDUSTRIES INC.

MODEL 9OT400
TABLE OF CONTENTS
Introduction
warranty
Safety summary Chapter/Section
General.In~ormation and operating Instructions 1

Descr1pt1on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operation . ..................................................... .. 1-2
SP7ci~ications and Capabilities •••••......••••..•............. 1-3
Sh1pp1ng ................................................................................ 1-4
storage ................................................................................ 1-5
Maintenance 2
servicing ........... . -...................................................................... .. 2-1
Troubleshooting ............................................................................... 2 - 2
Removal and Installation ......••.•.........•.••.•............. 2-3
Repairs ......................................................................................... 2-4
,
Overhaul/Major Repair 3
Overhaul Information .••.•••••...........•.• '•••................ 3-1
Illustrated Parts List ..•.•••••...........•.•••................. 4

Parts Procurement ..•.••.•............•••••.•.................. 4 - 2
Numer ic Index ................................................................................. 4 - 3
Detailed Parts List •.••...........•...••...................... 4-4
Manufacturers' Appendices 5
Introduction .............................................................................. 5-1
Woodward Governor Installation Manual .•..•.•.................. 5-2
KATO Engineering Instructional Manual, AC Generator .......•... 5-3
Cummins Shop Manual, B Series Engines •••••••.................. 5-4
cummins Troubleshooting and Repair Manual B Series Engines .... 5-5
cummins Operation and Maintenance Manual ..•••................. 5-6
Cummins Parts Catalog 4B, 4BT, 4BTA3.9 •.••.................... 5-7
CONTENTS
]UN 15190 Page I
: tin •

MODEL 9OT400
SAFETY SUMMARY
ALL SPECIFIC CAUTIONS AN WARNINGS IN THIS MANUAL SHALL BE

STRICTLY ADHERED TO. FAILURE TO ADHERE TO THE CAUTIONS MAY CAUSE
DAMAGE TO THE EQUIPMENT OR PREVENT IT FROM FUNCTIONING PROPERLY.
FAILURE TO ADHERE TO THE WARNINGS PRESCRIBED IN THIS MANUAL MAY
RESULT IN INJURY OR DEATH TO PERSONNEL.
WARNING: THIS GROUND POWER UNIT PRODUCES DANGEROUS HIGH VOLTAGE

DURING OPERATION. SEVERE PHYSICAL INJURY OR DEATH MAY
RESULT FROM FAILURE TO OBSERVE PROPER SAFETY
PRECAUTIONS. DISCONNECT THE BATTERY GROUND CABLE BEFORE
REMOVING AND INSTALLING COMPONENTS ON THE ENGINE OR IN
THE ELECTRICAL CONTROL PANEL.
WARNING: THIS UNIT FEATURES A CABLE INTERLOCK SAFETY CIRCUIT

THAT PREVENTS VOLTAGE OUTPUT THROUGH THE AC POWER
CABLE WHEN THE CABLE IS NOT CONNECTED TO EITHER AN
AIRCRAFT OR AN ELECTRICAL LOAD BANK. THIS FEATURE CAN
BE BYPASSED. IT IS RECOMMENDED THAT THE INTERLOCK
SAFETY CIRCUIT BE UTILIZED WHENEVER POSSIBLE TO PREVENT
AN EXPOSED LIVE POWER CABLE FROM CONTACTING PERSONNEL
OR SHORTING AGAINST THE UNIT FRAME, ENCLOSURE OR'OTHER
OBJECTS IN THE IMMEDIATE VICINTIY.
WARNING: DO NOT USE A FORK LIFT TO RAISE THE UNIT, AS THE CRANK
CASE WILL BE RUPTURED. UNIT MUST BE LIFTED BY USE OF
SPREADER BAR AND THE FORE AND AFT MEMBERS OF THE FRAME.
WARNING: DO NOT ATTEMPT TO SERVICE OR OTHERWISE MAKE ANY

ADJUSTMENTS, CONNECTIONS, OR RECONNECTIONS UNTIL THE
UNIT HAS BEEN SHUT DOWN AND COMPLETELY DEENERGIZED.
WARNING: PROLONGED EXPOSURE TO HAZARDOUS NOISE CAN CAUSE

PERMANENT HEARING LOSS. HEARING PROTECTION DEVICES MUST
BE WORN WHEN IN THE IMMEDIATE VICINITY OF THIS UNIT.
WARNING: DO NOT SMOKE OR ALLOW OPEN FLAME WITHIN THE IMMEDIATE

VICINITY OF THE UNIT DURING REFUELING.
SAFETY SUMMARY
JUN 15/90 Page 1
:".. ---- - -

MODEL 90T400
SAFETY SUMMARY
WARNING: TO PREVENT SPARKING BETWEEN FILLER NOZZLE AND FUEL

TANK, ALWAYS MAINTAIN METAL TO METAL CONTACT BETWEEN
FILLER AND FUEL TANK.
WARNING: REMOVE JEWELRY I.E., RINGS WATCHES WHEN WORKING ON THE
UNIT.
WARNING: THE UNIT HAS ROTATING PARTS. DO NOT WEAR LOOSE CLOTHING
AROUND THE UNIT WHEN CANOPY IS OPEN AND ENGINE IS
RUNNING.
WARNING: BATTERIES GENERATE EXPLOSIVE GASES. DO NOT SMOKE OR
EXPOSE BATTERIES TO OPEN FLAME WHEN SERVICING
BATTERIES.
WARNING: ETHER QUICK START SYSTEM IS HIGHLY EXPLOSIVE. DO NOT

SMOKE OR EXPOSE THE ETHER SYSTEM TO OPEN FLAME WHEN
PERFORMING MAINTENANCE.
'--
WARNING: EXHAUST DISCHARGE CONTAINS NOXIOUS AND DEADLY FUMES. DO
NOT OPERATE THE UNIT IN ENCLOSED AREAS UNLESS EXHAUST
DISCHARGE IS PROPERLY VENTED TO THE OUTSIDE
WARNING: ADEQUATE SUPPORT OF HEAVY ITEMS SUCH AS THE ENGINE

AND/OR GENERATOR MUST BE UTILIZED DURING REMOVAL OR
INSTALLATION. FAILURE TO UTILIZE LIFTING DEVICES OF
ADEQUATE CAPABILITY MAY RESULT IN EQUIPMENT DAMAGE
AND/OR INJURY TO PERSONNEL.
SAFETY SUMMARY
JUN 15190 Page 2
MODEL 9OT400
CHAPTER 1
TABLE OF CONTENTS
General InfOrmation & Operating Instructions

Description
1. General ..•••.••.... ••
2. Major Components ••.
3. System Description.
A. Engine............. ..
B. Engine Electrical circuit.
C. AC Generator System ••
D. AC Output Control •.•.
E. Protective Circuitry.
Operation
1. Controls and Indicators . . . . . . . . . . . . . .
A. Engine Control and Indicators •.••.
B. Generator controls and Indicators.
2. Operating Procedures
A. Pre-Operational Inspection.
B. Engine Start Procedures ••••
C. Generator Operating Procedures.
Specifications and Capabilities

1. General . . . . . . . . . . . . . . . .
2. Vehicle ....... '........ .
3. Engine and Accessories.
4. Generating System ..... .
5. AC Protective System .. .
Shipping
1. General.
2. Preparation.
storage
1. General .............•.•..
2. Preparations for Storage.
A. Short Term Storage.
B. Long Term Storage •...•
I-CONTENTS
JUN 15190 Page I
.~.

MODEL 9OT400
DESCRIPTION
1. GENERAL
The purpose of the generator set is to provide regulated, 400 Hz,
115/200 VAC, 172.5 amperes, three phase power to aircraft for
operation of the aircraft electrical equipment when the on-board
generators are not running. The unit is operable when provided
with fuel and a battery source.
2. MAJOR COMPONENTS (See Figure 2)
A. The power plant, designated as Model 90T400. has the overall

dimensions of 126 inches in length, 64 inches width, and 62.5
inches in height.
B. The main generator is directly coupled to the diesel engine.

An electrically controlled governor regulates the engine
speed. As protection against engine overspeed, an engine
speed sensing circuit automatically stops .the engine at 2550
RPM.
C. The power plant is trailer mounted, self contained, requiring

no external electrical or mechanical. sources of power. It
may be towed at speeds up to 15 MPH. Rated efficiency of the
power plant is not affected on an incline of 15 degrees
maximum, under an ambient temperature range of -30 to 125
degrees F, or under relative humidity up to 100%. The plant
will operate efficiently at altitudes ranging from sea level
to 6,000 feet. When operating the power plant observe the
safety precautions at the front of the manual.
D. All components of the power plant are protected by a weather

resistant enclosure. This Clam Shell enclosure consists of an
arrangement of covers and access doors over the welded frame.
The enclosure reduces the operational noise level in the
immediate area of the unit, and provides for a cooling air
passage. Additional see through doors are provided for the
access to controls and indicators. A slide control drawer
allows complete access to all electronic control components.
E. The unit is equipped with one hard-wired AC power cable.
1-1
JUN 15190 Page 1
MODEL 90T400 .
F. The chassis is equipped with a turntable steering front axle

(5th wheel), and leaf type suspension springs on the rear
axle to minimize vibration during transport. The rear axle
contains a pair of expanding shoe brakes that is operated by
a hand brake lever located on the front right side. The
running gear rides on four 6.SxS inch 6 ply pneumatic tires.
126.00
106.00
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L"oo~ All dimensions are in

inches.
Overall View
Figure 1.
JUN 15/90 1-1
REV 2 Page 2
MODEL 90T400
REAR CANOPY
FRONT CANOPY
CHASSIS
DRAW8AR ASSEM8LY
GENERATOR
CONTROL PANEL
AIR CLEANER
ENGINE
RADIATOR CONTACTOR PANEL
FUEL FILTER
Locations of Major Components

Figure 2
1-1
JUN 15/90 ,Pag'e 3
MODEL 90T400
3. SYSTEM DESCRIPTION
A. Engine.
The engine is a cummins six cylinder! four cycle,
turbocharged, aftercooled diesel eng~ne, Model No.5BT5.9.
Engine controls and indicators are located on the
instrument panel.
(1) As received from the manufacturer, the engine includes
the following equipment:
(a) Three fuel filter assemblies (spin on type).
(b) Full flow oil filter (spin on type).
(c) Fuel solenoid and pump.
(d) Turbocharger.
(2) A Trilectron modified electronic governor system is
utilized to control engine RPM from idle speed (800 RPM)
to run speed (2400 RPMl. The electronic governor system
consists of the follow~ng:
(a) Magnetic Pickup.
This is mounted on the flywheel housing, and
feeds a signal to the Speed Control unit for
comparison with a preset frequency.
(b) Speed Control unit.
This solid state unit receives a signal from
the Magnetic pickup, and provides voltage to
the Actuator. It also features engine overspeed
shutdown.
(c) Actuator.
The actuator receives voltage from the Speed
Control Unit, and moves the fuel control
lever.
(3) The engine fault system is designed to prevent increased
engine damage by shutting down the engine and turning ON
a specific trouble light. The engine fault system
consists of three safety devices, they are:
(a) Overspeed Shutdown switch:
An overspeed shutdown circuit built into the
electronic governor senses engine RPM. This
circuit will stop the engine should RPM exceed
2500.
(b) Low Fuel engine shut down.
Shuts off fuel to the engine during a low fuel
condition; preventing the fuel injector pump from
cavitating;
JUN 15190 1-1
REV 2 Page 4
MODEL 90T400
(c) Temperature Sensing switch: This switch is activated

when engine water temperature reaches 210 F. The
fuel solenoid is de-energized shutting off fuel to
the engine.
(d) Low oil Pressure Switch:

Shuts the engine down if the oil pressure drop
to 6 psig.
1
4 5
.~.
1. Water Temp. Sender 5. Fuel Solenoid

2. Water Temp. Switch 6. oil Pressure switch
3. Over Speed Switch 7. oil Pressure Sender
4. Actuator 8. Magnetic Pickup
Engine Sensing Components

Figure 3.
JUN 15/90 1-1

REV 2 Page 5
MODEL 9OT400
~--
DJSTRlBtlTOR TYPE
INJECTION PUMP ~r=~;;~·~==~;:~~~~::::~~~~~==============l
~~,..;;;;;;;;;;;!~:;.....J IIIGII PRESSURE
FUELUNES
t
INIECTORS
r;=="~==~ RETURN UN B l
PRIMARY/SECONDARY FUEL TANK

SPIN-ON FILTER CASH
SEPARATOR/FILTER WITH WATER DRAIN
Fuel Flow schemat1c

Figure 4
'-
1-1
JUN 15/90 ,Pagb 6
MODEL 9OT400
Engine Controls and Indicators

Figure 5
1-1
JUN 15/90 Page 7
.t.:.

MODEL 9OT400
ITEM CONTROL/INDICATOR FUNCTIONAL DESCRIPTION
1 OIL PRESSURE GAUGE Indicates engine oil pressure
2 FAULT INDICATORS Indicates to operator the
(red): protective system that caused

Low oil 6 psi min. engine shutdown.
Overspeed 2550 RPM
Temp. 2100 F.
3 IGN. ON Indicator Lights when the ENGINE CONTROL

(yellow) POWER switch is turned on.
4 WATER TEMP. GAUGE Indicates engine water temp.
2100 F max.
5 BATTERY VOLTMETER Indicates battery voltage

condition. Do not start unit if
voltage is less than 10 VDC.
6 FUEL LEVEL GAUGE Indicates amount of fuel

remaining in fuel tank.
7 START switch Starts engine, Pushbutton,

momentary contact switch.
8 IGNITION switch On position supplies starting

ON/OFF and controlling voltages to
engine circuits.
9 GOVERNOR CIRCUIT Protects the electronic governor

BREAKER (CB1) control (10 ampere).
10 INSTRUMENT CIRCUIT Protects the instrument elect.

BREAKER (CB2) circuits (5 ampere).
11 IGNITION CIRCUIT Protects engine ignition system

BREAKER (CB3) (15 ampere).
12 RUN/IDLE switch Two position switch. Controls

engine speed. IDLE position for
starting. RUN position for
generator operation.
13 HOURMETER Indicates total engine run time.
Table 1.
Engine Controls and Indicators Panel
1-1
JUN 15190 Page 8
MODEL 9OT400
(4) The fuel tank is located at the rear of the power plant. The
fuel filler with a captive cap is located behind and access
door at the rear of the unit. A removable strainer located
inside the filler neck should be periodically removed and
cleaned.
Fuel flow begins as the lift pump pulls fuel from the supply
tank. The pump supplies low-pressure fuel (2l-34 kPa, [3-5
psi]) to the fuel filter head, through the filter and then
to the distributor injection pump. The distributor pump
builds the high injection pressures required for combustion,
and routes the fuel through the individual high-pressure
fuel lines to each injector. When the high pressure fuel
reaches the injector, the pressure lifts the needle valve
against the spring tension to the fuel enter the combustion
chamber. Any leakage past the needle valve enter the fuel
drain manifold. The fuel drain manifold routes the
controlled venting from the distributor injection pump and
leakage from the injectors back into the fuel tank.
(5) Exhaust System. The exhaust system consists of a noise

reducing muffler, connected by a pipe to the exhaust outlet
of the turbocharger. The muffler and tail pipe is located
beneath the frame near mid-section, and towards the left
side of the unit.
(6) Radiator. The radiator is of the cross-flow design, with the

filler at the front, center of the unit. The overflow tube
is mounted on the side of the f~ller tube. .
(7) Air Cleaner. The air cleaner is a dry cartridge type with a
Filter Minder indicator showing when the cartridge should be
replaced. The Filter Minder Indicator is connected to the -,_
air cleaner with a rubber hose.
B. Engine Electrical Circuit (Refer to Figure 6)
(l) All engine instruments, except the filter minder indicator,

are located on the engine control panel. The filter minder
indicator is located below the air filter. Engine instrument
sensors locations are shown in Figure 3 and the gauges are
shown in Figure 5. 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. Engine air filter change indicator.
1-1 "'.
JUN 15190 Page 9
MODEL 90T400
(2) Instrument Lights:

The engine instrument lights (054, 5, 30, and 31,) are
controlled by the Ignition switch. The panel illumination
light (0517) is controlled by the Panel Light switch located
on the instrument panel.
(3) Engine start:

Power for the starter motor instrumentation, and running
circuits is provided by the 12 VOC battery. The power is
applied through the ignition switch 51, (see Figure 6). When
switch 51 is ON the following occurs:
(a) Ignition ON indicator (0521) is illuminated.

(b) 12 VOC is applied to the instrumentation, fuel
solenoid, and the electronic governor system.
(c) K42 energizes and removes voltage from the hourmeter.
The engine is started by pressing the start Button S13.

This causes contacts on the starter solenoid to close
energizing the starter motor. In addition, S13 charges
capacitor CB and enerrgizes the low oil pressure lockout
relay (KB). The engine will then run up to idle speed.
The engine is brought to run speed by placing the IDLE
switch (S14) on the Engine Control Panel, in the RUN
position, (see Figure 6). This signals the Electronic.
Governor Control (EGC) to bring the engine up to an
operating speed of 2400 RPM. In the RUN mode, the rated
speed of the governor system is controlled by the FREQUENCY
ADJUST potentiometer (RB) on the generator control panel and
by the SPEED adjustment screw on the EGC. Also, when the
IDLE switch 514) is in the RUN position, battery voltage is
also applied to the generator control system.
(4) Engine Fault System:

There are four engine fault systems which when activated
shut down the engine (refer to Figure 6). 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) Oil Pressure (low): < 6 psi
(b) Overspeed: > 2550 RPM
(c) Water Temperature (High): > 210 degrees
(d) Low Fuel Engine Shut down
1-1
JUN 15190 Page 11
MODEL 90T400
(5) Low Oil Pressure Fault system (See figures 5 and 6).
The low oil pressure circuit is used to stop the engine
should oil pressure drop below 6 psi. The switch also
prevents the starter motor from being energized anytime the
engine is running. The Low oil Pressure circuit consists of
the following:
(a) Low Oil Pressure switch and Oil Pressure sensor are
mounted on the engine, near the oil filler neck.
(b) Low oil lock out relay (Ka), and CR40, R9 and ca.
(c) Fault relay (K7), on Control Chassis Relay Board.
(d) Diodes CR9, CR20, and CR34 are located on the Diode
Logic Board in the Control Chassis.
(e) Low Oil indicator (DS14), located on the Engine

Control and Indicators Panel (Figure 5).
NOTE: CR40, R9, and C8 are located on TB3, on the

contactor panel.
(6) Low Oil Pressure Fault Function.

During normal operation, engine oil pressure opens Low Oil
Pressure switch S16. If oil pressure drops below 6 psi, S16
closes completing a gound circuit to the Engine Fault Relay
K7. K7 deenergizes the fuel solenoid, stopping fuel flow and
shutting down the engine. .
(7) Low Oil Pressure Lockout.

During initial engine cranking, no oil pressure exists. The
low oil pressure switch is closed completing a ground
circuit to the engine fault relay K7. K7 receives 24 vdc
when the ignition switch is placed to the ON position. A
ground to the negative side of the relay by any of the fault
sensors, which includes the low oil pressure switch, causes
the relay to energize. When energized, it deenergizes the
fuel solenoid, stopping fuel flow to the engine. During
initial starting, the low oil pressure fault circuit must be
temporaily disabled. This is accomplished as follows:
When the start switch S13 is pressed, in addition to the
starter motor, a time delay relay TD1 is energized. TD1 then
ener9izes the Low Oil Lockout relay K8. TD1 contacts will
rema1n 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 6 psi within 14
seconds, TD1 contacts will open deenergizing K8 which will
complete the circuit from ground through the oil pressure
switch to the engine fault relay K7. K7 deenergizes the fuel
solenoid stopping fuel flow and shutting dow the engine.
NOV 01/90 1-1

Chg. 1 Page 12
MODEL 9OT400
(8) Overspeed Fault Components. (See figure 6).

The Overspeed circuit consists of the following:
(a) Overspeed switch (S19) mounted on the engine.
(b) Fault relay (K7).

(c) Diodes CR34. CR21 and CR10.
(d) Engine Overspeed Indicator (DS16).
(9) overspeed Fault Function (Refer to Figure 6).

In normal running conditions, the Overspeed switch (S19)
contacts are open, preventing a ground path to fault relay
K7. An overspeed causes the following:
(a) Overspeed switch (S19) N.O. contacts close, providing a

ground path through diode CR35 for fault relay (K7).
(b) Fault relay (K7) is actuated, opening N.C. contacts to

de-energize the fuel solenoid.
(c) Fuel solenoid shuts off fuel to engine.
(d) Current path through diode CR21 lights engine overspeed

indicator.
(10) High Water Temperature Fault components. (See figure 6). The
High Water Temperature circuit cpnsists of the following:
(a) High Water Temperature switch (S17) engine mounted.
(b) Diodes CR36, CR22.
(c) Fault relay (K7).
(d) HIGH TEMP indicator DS15.
(11) High Water Temperature Fault Function. (Refer to Fig. 6)

High water temperature (210° F.) causes the following to
occur:
(a) High Water Temperature switch (S17) contacts close,

providing a ground path through diode CR36 to fault
relay K7.
(b) Fault relay (K7) is actuated, opening normally closed

contacts in the fuel solenoid circuit.
(c) Fuel solenoid is deenergized, shutting off fuel to

engine.
(d) Current path through diode CR22 lights HIGH TEMP

indicator.
NOV 01190 1-1
Chg.l Page 13
::~ ..

MODEL 90T400
(12) Low Fuel Fault Function. (Refer to Fig. 6)

The circuit is designed to prevent engine shut-down due to
fuel starvation. The low fuel level switch closes with
approximately 2 inches of fuel remaining in the tank. The
circuit function is as follows:
(a) Low fuel level switch S39 closes completing a ground

circuit to the engine fault relay K7.
(b) K7 energizes, opening its contacts and removes voltage

from the fuel solenoid. The fuel solenoid de-energizes
stopping fuel flow to the injector pump.
(c) Low fuel level switch (S39) also completes the ground
circuit to the Low fuel engine fault indicator (DS??)
causing it to illuminate.
(13) Fault Lamp Test. (Refer to Figure 6)

The indicators for the fault circuits can be tested by
depressing the FAULT LAMP TEST pushbutton switch (S21),
located on the Control Panel. Battery voltage supplies the
power to operate the engine fault lamp test. The fault lamp
test switch applies a ground to each lamp when depressed. By
placing the ignition switch ON, the fault lamps may be
tested without the engine running.
C. AC Generator System (Refer to Figure 7).
(1) Generator
The 400 HZ generator is a brushless, revolving field,
three-phase, alternating current type. The rotor assembly is
mounted by a single ball bearing race located between the
exciter rotor and main generator rotor. The bearing race is
mounted in the stator housing which is bolted to the engine
housing. The front end of the rotor shaft extends forward
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.
NOV 01190 1-1

Chg. 1 Page 14
TRILECTRON INDUSTRIES INC,
MODEL 90T400
(2) Exciter
The brushless exciter is used to provide excitation
current to the rotating field assembly. The exciter
consists of two basic component assemblies: the exciter
stationary field assembly, and the exciter rotor
comprising 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 on the shaft
extension with a Woodruff Key, and is secured by washer
and cap screw.
(3) Generator Output

Generator output is controlled by the amount of DC current
supplied to the exciter field by the field voltage
regulator.
(4) Cooling Fan

A radial blade fan that is part of the hub coupling
assembly, draws cooling air over all internal windings. Air
enters the exciter end and is discharged through the drive
end.
D. AC Output Control Circuitry (Refer to Figures 7 and 8).
(1) Generator Control System

"--
controls, devices and modules for AC system are located in
the Control Drawer, and on the ~ontactor Panel. wiring'
diagrams are located in the Section 2-2.
(2) Frequency Regulation
Regulation of the 400 Hz output is controlled through the
Electronic Governor Control System and can be adjusted with
voltage adjust potentiometer R2 located on the Generator
Control Panel.
(3) AC Voltage Regulation

AC generator output voltage is fed back to supply
transformer T1 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.
(4) Automatic Voltage Regulator (AVR).
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 sufficent field voltage
to permit voltage buildup in the generator output. Generator
output voltage is fed to Transformer T1 primary for voltage
sensing.
1-1
JUN 15/90 Page 16
MODEL 90T400
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Figure 8.
1-1
JUN 15190 Page 17
,-~

MODEL 90T400 .
INDEX NO. CONTROL/INDICATOR FUNCTION
AC OUTPUT SECTION
1 voltmeter Shows generator (L-N)

output voltage (0-150
volts)
2 FAULT MODE Indicators
UNDER VOLTS When lit indicate

OVER VOLTS problem shown.
UNDER FREQUENCY OVERVOLTS & OVER-
OVER FREQUENCY LOAD also trip breaker.
OVERLOAD
3 LOAD ON Indicator Light Indicates AC load ON.
3 Ammeter Indicates generator (L-N)

output current.
4 AMMETER OFF 1 2 3 Measures current of

switch, rotary phases 1,2 or 3.
5 AC LOAD CABLE OFF Removes output power ,

Push Button from cable 1.
6 AC LOAD CABLE ON Supplies AC power to

Push Button Cable 1. Used in conjun-
ction with INTERLOCK/BY-
PASS switch. When ON
is pushed with
INTERLOCK setting GPU
provides momentary 28 V
DC to aircraft connector
pins E & F.
7 Frequency Meter Shows generator output

frequency (360-440Hz).
8 VOLTMETER switch, rotary Three positions: selects
L1-N Line to Neutral volt-
L2-N ages shown on voltmeter.
L3-N
Table 2
Generator Controls and Indicators (Cont'd)
JUN 15/90 1-1

Page 18
~,,----~-- ~ -.-~ -- - ----, - --- --------..-.".. -

MODEL 9OT400

AC OUTPUT SECTION
9 FAULT LAMP TEST. Pushbutton When pressed it lights

all faults lamps, with
power plant in RUN mode.
10 FAULT RESET Clears fault indications,

(pushbutton switch) returns unit to normal
after protective AC
limits of load, voltage
and frequency have been
reached.
11 PANEL LIGHTS, Switch Turns panel lights On for

night time operation.
Table 2
JUN 15190 1-1

Page 19
MODEL 9OT400
Transformer T1 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.
(5) AVR Voltage Adjustment

Voltage adjustment for the Automatic Voltage Regulator (AVR)
is determined by the following:
(a) The setting of Voltage Adjustment potentiometers R5 and

R32 on the AVR.
(b) Sensing transformer T1 which senses the output voltage
at the output contact or K1.
(6) Power supply

The Power Supply is directly fed from the generator, through
Circuit Breaker (CB5), and provides voltage and current
sensing input to the Fault Modules, Test Push buttons, and
other low voltage devices. Load sensing transformers CTl-3,
and Voltage Sensing transformer (T1) also feed into the
Power Supply. These sensing transformers work in conjunction
with the fault modules to shut off power on overload,
over/under voltage and over/under frequency conditions. The
Fault Lamps and Fault Relays receive power from the 12 VDC
battery circuit.
(7) DC Control Power

with the engine running at rated speed, The batteries
provide 12 VDC to the AC system through the IGNITION and
IDLE/RUN switches (located on the engine control panel). The
following components are DC powered:
a. AC voltage regulator
b. Protective circuits
c. Fault Lamps
E. PROTECTIVE CIRCUITRY
(1) Protective Circuits

There are three AC modular protective circuits, on the
contactor panel, all disconnect AC output power. The Over-
voltage and Overload circuits also shut off the voltage
regulator, and light the appropriate fault lamp(s). The
circuits and ground returns (GR) are:
(a) Over/Under Voltage. GR pin #5

(b) Over/Under Frequency. GR pin #5
(c) Overload. GR pin #7
JUN 15/90 1-1

Page 20
•.1lII:

MODEL 9OT400
(2) Protective Circuit Conditions. Conditions activating

the protective circuits are as follows:
(a) Overvoltage: 135 volts adjustable.
(b) Undervoltage: 100 volts (5-7 second delay).
(c) Overfrequency: 420 Hz
(d) Underfrequency: 380 Hz (5-7 second delay).
(e) Overload: Trips 125% rated load within 5 minutes.
Trips 150% rated load within 30 seconds.
(3) Protective Circuit Functional Description
The protective circuitry is comprised of the Over/Under
(O/U) Voltage Over/Under (O/U) Frequency, 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 CT 1-3 sense output current. When activated
each of these module complete a ground circuit to the AC
fault relay K4. The protective circuits operate as follows:
(a) Circuit closure is provided to energize relay K4.

(Closure is on pins 2 and 4 of these modules).
(b) When.K4 is energized, it's contacts open. 28 VDC taken

from bridge rectifier CR50 is removed from the output
contactor (K1) causing it to de-energized. AC output
VOltage is now removed from the load.
On Over-voltage or Overload conditions only, the Automatic

Voltage Regulator (AVR) is shut off; this is accomplished as
follows:
1 K6 receives voltage from the battery through

circuit breaker CB4, and switch Sll. The
overload and overvoltage modules provides a
ground circuit to the coil of K6 causing it to
energize. K6 when energized removes the 12 VDC
from the automatic voltage regulator.
2 When the AVR shuts off, current through the
generator exciter is stopped and generator
output is halted.
(4) Fault Signal Events.

When a fault signal occurs, a circuit in a protective module
latches 'ON'; after the fault has been corrected, the
protective circuit must be reset. The module latching
function serves two purposes:
JUN 15/90 1-1

Page 21
MODEL 9OT400
(a) To maintain fault indication.

(b) To prevent the unit from operating until the fault
has been cleared.
(5) Protective Circuit Reset
Resetting of the circuit is accomplished by pressing
the FAULT RESET switch 511 to the RESET position.
Resetting the circuit does the following:
(a) Resets the protective circuit.
(b) Energizes relay K5 (closes normally open
contacts). Relay K5 grounds a capacitor in the
overload module. This capacitor must discharge to
allow the overload module to reset.
(6) Fault Lam~s 057-11. These lamps are supplied voltage
through c~rcuit breaker CB4 and Fault Reset switch Sll.
A ground path is supplied through steering diodes on
the protective modules. The steering diodes allow the
fault lamps to be tested independently from circuit
operation.
(7) Generator Fault Lamp Test
The fault lamp test circuit includes diodes CR4 through
CRS and pushbutton switch S21. The purpose of the
diodes is to maintain separation of all fault circuits.
Generator fault lamps are battery powered, and function
when the engine is at operating (RUN) speed. A
generator fault lamp test should only be performed when
the engine is runni~g at normal speed. The fa1;llt lamps,
are tested by press~ng the FAUL~ LAMP TEST sw~tch S21.
(S) Current Transformers

(a) Ammeter Current Transformers (CT4 through CR6) These
transformers are used for metering purposes, and are
connected to the AMMETER switch S2 for appropriate line
selection.
(b) Overload Current Transformers (CT1 through CT3) 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 input
Pin S.
(12) AC Output contactor K1
K1 is supplied voltage by bridge rectifier CR50. The K1
relay functions only when the engine RUN\IDLE switch is
placed in the RUN position, generator output voltage is
established and relays K2 and K10 have been energized.
Circuit description is as follows:
JUN 15190 1-1

Page 22
MODEL 9OT400
(a) Generator output voltage is supplied transformer Tl

primary. T1 ouput terminals 4, 5 and 6 are fed to the
power supply module where it is recitified. 28 VDC
output from the Power Supply (pin J8-4) energizes K10
and is made available at LOAD ON switch (S4A). K10
contacts latches the coil of K2 to ground.
(b) When S4A is pressed K2 is energized closing its

contacts.
(c) 28 VDC taken from CR50 energizes the output contactor

K1. K1 closes it's contacts and the generator output
voltage is now applied to the load.
WARNING: THE USE OF THE CABLE INTERLOCK SWITCH S6 IS

RESTRICTED TO AIRCRAFT CAPABLE OF PROVIDING 28
VDC. SERIOUS DAMAGE TO THE AIRCRAFT OR THE UNIT
MAY RESULT IF THE SWITCH IS IMPROPERLY USED.
CONSULT THE AIRCRAFT TECHNICAL MANUAL FOR PROPER
USAGE OF THIS SWITCH.
(13) Cable Interlock Switch S6

This switch gives aircraft ground support personnel the
ability to control the GPU output contactor K1 with 28
VDC supplied by the aircraft. The Cable Interlock
switch S6has two purposes:
,
(a) Interlock - This safety feature is selected by placing
S6 to the INTERLOCK position. The generator output
contactor (K1) will not energize close unless the AC
power cable is securely connected to the aircraft/load
bank. Should the power cable disconnect during
servicing, the generator output contactor will
immediately deenergize and remove power from the AC
cable.
NOTE: The interlock feature will work only with

aircraft/load banks that provides 28 VDC on E pin
(b) Bypass - This feature is selected by placing S6 to the

BYPASS position. It bypasses the cable interlock safety
circuit and allows the operator to power the cable with
or without the cable being connected to the aircraft or
load bank.
(14) Voltmeter Switch S3

This switch is connected to all 3 output phases and neutral,
with common leads to the Voltmeter. switch positions are:
Line to Neutral (L-N), disconnected from output (OFF).
(15) Test Pushbuttons
~15~ 1-1
Page 23
MODEL 90T400
These individual pushbutton switches connect the fault

module points to a common ground. with the module points
connected to ground, a fault simulation condition exists to
test the circuit operation. The fault lamps will operate
indicating the particular fault being simulated, e.g.,
Overload.
(16) Time Delay Test
Where time delays are incorporated in the protective circuit
test, the test will also simulate a delay feature.
(17) Test Completion
When a time delay test has been completed, the system must
be reset as if an actual fault had occurred.
JUN 15190 1-1

Page 24
"' •.

MODEL 9OT400
OPERATION
1. CONTROLS AND INPICATORS
Prior to operating the GPU, personnel must become thoroughly

familiar with the operating controls, indicators and procedures
described in this section.
A. Engine Controls and Indicators (See Figure 1 and Table 1) Controls

and indicators necessary for starting and operating the GPU are
located on the Engine Control Panel.
1 3
~~
8~
~
-
8
Engine Controls and Indicators

Figure 1
1-2
JUN 15/90 Page 1
MODEL 9OT400
ITEM CONTROL/INDICATOR FUNCTIONAL DESCRIPTION
1 OIL PRESSURE GAUGE Indicates engine oil pressure
2 FAULT INDICATORS Indicates to operator the
(red): protective system that caused

Low oil 6 psi min. engine shutdown.
Overspeed 2550 RPM
Temp. 2100 F.
3 IGN. ON Indicator Lights when the ENGINE CONTROL

(yellow) POWER switch is turned on.
4 WATER TEMP. GAUGE Indicates engine water temp.
2100 F max.
5 BATTERY VOLTMETER Indicates battery voltage

condition. Do not start unit if
voltage is less than 10 VDC.
6 FUEL LEVEL GAUGE Indicates amount of fuel

remaining in fuel tank.
7 START switch Starts engine, Pushbutton,

momentar¥ contact switch.
8 IGNITION switch On position supplies starting

ON/OFF and controlling voltages to
engine circuits.
9 GOVERNOR CIRCUIT Protects the electronic governor

BREAKER (CB1) control (10 ampere).
10 INSTRUMENT CIRCUIT Protects the instrument elect.

BREAKER (CB2) circuits (5 ampere).
11 IGNITION CIRCUIT Protects engine ignition system

BREAKER (CB3) (15 ampere).
12 RUN/IDLE switch Two position switch. Controls

engine speed. IDLE position for
starting. RUN position for
13 HOURMETER Indicates total engine run time.
Table 1.
Engine Control Panel Index
1-2
JUN 15/90 Page 2
MODEL 9OT400
B. Generator Controls and Indicators
Controls and Indicators for AC Power Output are located on the AC

section of the control panel, (see Figure 2 and Table 2).
i'
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Generator Controls and Indicators

Figure 2.
1-2
JUN 15/90 Page 3
:.2. . '.:--.JIo...

MODEL 9OT400

AC OUTPUT SECTION
1 voltmeter Shows generator (L-N)

output voltage (0-150
volts)
2 FAULT MODE Indicators
UNDER VOLTS When lit indicate

OVER VOLTS problem shown.
UNDER FREQUENCY OVERVOLTS & OVER-
OVER FREQUENCY LOAD also trip breaker.
OVERLOAD
3 LOAD ON Indicator Light Indicates AC load ON.
3 Ammeter Indicates generator (L-N)

output current.
4 AMMETER OFF 1 2 3 Measures current of
Switch, rotary phases 1,2 or 3.
5 AC LOAD CABLE OFF Removes output power

Push Button from cable 1.
6 AC LOAD CABLE ON Supplies AC power to

Push Button Cable 1. Used in conjun-
ction with INTERLOCK/BY-
PASS switch. When ON
is pushed with
INTERLOCK setting GPU
provides momentary 28 V
DC to aircraft connector
pins E & F.
7 Frequency Meter Shows generator output
frequency (360-440Hz).
8 VOLTMETER Switch, rotary Three positions: selects
L1-N Line to Neutral volt-
L2-N ages shown on voltmeter.
L3-N
Table 2
1-2
JUN 15/90 Page 4
MODEL 90T400

AC OUTPUT SECTION
9 FAULT LAMP TEST. Pushbutton When pressed it lights

all faults lamps, with
power plant in RUN mode.
10 FAULT RESET Clears fault indications,

(pushbutton switch) returns unit to normal
after protective AC
limits of load, voltage
and frequency have been
reached.
11 PANEL LIGHTS, switch Turns panel lights On for

night time operation.
Table 2
1-2
JUN 15/90 PageS
MODEL 90T400
2. OPERATING PROCEDURES
A. Pre-Operational Inspection
CAUTION: 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 IN SEVERE DAMAGE TO THE EQUIPMENT.
(1) Enclosure Visually inspect for

obvious defects, i.e.,
security of common
hardware.
(2) Towbar Excessive movement.
(3) Brakes Check brakes for

proper operation.
(4) Tires Inspect tread wear,

and check tire in-
flation. 75 psig
(5) Engine hoses and clamps Inspect for leaks and

security.
(6) Radiator Coolant Open radiator access

door, remove radiator
cap. Observe that
coolant is visible at
top of radiator.
Service as required,
(Refer to section 2-2,
Servicing).
(7) oil level Open left front access
door. Check that oil
level is at the full
mark on the dip stick,
(Refer to section 2-2,
Servicing) .
(8) Fuel level Set IGNITION switch to
ON position, observe
reading on fuel gauge.
Service with diesel
fuel as necessary.
1-2
JUN 15/90 Page 6
MODEL 90T400
(9) Engine Assembly Visually inspect fuel

lines and fittings for
evidence of fuel leak-
age. Inspect valve
covers, oil pan, and
cylinder block for
evidence of oil leak-
age.
(10) Fan Belt Visually inspect for

wear and cracking.
Check belt for proper
tension.
(11) Air Filter (Minder) Check filter Minder

Indicator located to
the left of the right
front access door,
under the air filter
assembly. Replace air
filter if a reading of
25 is noted. Recheck
when unit is running
under load.
WARNING: DO NOT CONNECT LIVE POWER CABLES TO AIRCRAFT. SEVERE

ELECTRICAL SHOCK CAUSING SERIOUS INJURY, DEATH AND OR
DAMAGE TO THE EQUIPMENT MAY RESULT.
B. ENGINE START PROCEDURES
The following steps must be performed in the sequence in

which they are presented: (See Figure 1 and Table 1)
NOTE: Gauge lights automatically come ON when Ignition

is ON. Turn Panel Lights on using the Panel Light
switch.
WARNING: PROLONGED EXPOSURE TO HAZARDOUS NOISE MAY RESULT IN

PERMANENT HEARING LOSS. EAR PROTECTION DEVICES MUST BE
WORN WHEN WORKING CLOSE PROXIMITY OF THIS EQUIPMENT.
(1) Set ENGINE IGNITION SWITCH (8) to ON position. IGNITION ON

indicator (2) will be illuminated.
(2) Set IDLE/RUN switch (12) to IDLE.
1-2
JUN 15190 Page 7
MODEL 90T400
CAUTION: BATTERY MUST BE FULLY CHARGED TO SUPPLY VOLTAGE FOR

ENGINE STARTING AND CONTROL.
(3) Observe the VOLTMETER gauge (5) on the Engine Control

Panel, charge battery a low voltage is indicated.
CAUTION: DO NOT HOLD START BUTTON FOR LONG PERIODS OF TIME AS

THIS DEPLETES THE BATTERY CAPACITY AND COULD DESTROY
THE STARTER.
(4) Press START pushbutton (7) for 1 - 2 seconds to start

engine. Engine will come up to idle speed.
CAUTION: IF LOW OR NO OIL PRESSURE IS INDICATED AFTER 10-15

SECONDS OF OPERATION, IMMEDIATELY STOP ENGINE BY
PLACING ENGINE IGNITION SWITCH (10) IN OFF POSITION.
FAILURE TO COMPLY CAN RESULT IN SEVERE ENGINE DAMAGE.
(5) OIL PRESSURE gauge (1): oil should read pressure 10 psi
minimum at idle speed, 30 psi minimum at run speed.
(6) WATER TEMPERATURE gauge (4): When engine has warmed,
water temperature should be 170-195 F.
(7) VOLTMETER gauge (6): 8-16 VDC ~n a 12 volt system.
CAUTION: DO NOT ALLOW THE ENGINE TO IDLE FOR LONG PERIODS OF

TIME. FAILURE TO COMPLY COULD RESULT IN ENGINE DAMAGE.
(8) Let the engine idle for 2-3 minutes to warm engine.
(9) Bring the engine to operating speed by placing the
engine RUN/IDLE switch (12) to the RUN position.
(10) Turn VOLTMETER knob (3, Figure 2) to L1-N (Line 1 to-
Neutral).
CAUTION: DO NOT ATTEMPT TO PLACE UNIT INTO SERVICE IF VOLTAGE

AND/OR FREQUENCY CANNOT BE ADJUSTED TO REQUIRED
OUTPUT. SHUT UNIT DOWN AND SERVICE AS REQUIRED.
(11) Observe VOLTMETER (1, Figure 2) reading for 115 VAC.

(12) Observe FREQUENCY (7, Figure 2) reading for 400 Hz.
1-2
JUN 15190 Page 8
·TRILECTRON INDUSTRIES INC.
MODEL 9OT400
CAUTION: BATTERY MUST BE KEPT FULLY CHARGED FOR PROVIDING

STARTING AND CONTROL VOLTAGES. SHUT ENGINE DOWN IF LESS
THAN 10 VOLTS.
(13) Observe VOLTMETER gauge (5) on the Engine Control Panel. If

less than 12 volts is indicated, unit is not charging. Use
the normal engine shut down procedure.
(14) After engine has warmed to operating temperature, place the

engine RUij/IDLE switch to the IDLE position before
connecting power cable to the aircraft.
C. GENERATOR OPERATING PROCEDURES
Controls and Indicators for AC Power Output are located on

the AC section of the control panel, see Figure 2 and Table
2. Additional controls needed for AC operation are located
on the Engine control panel, refer to figure 1 and Table 1.
Procedure for operating the AC Power Output is as follows:
(1) GENERATOR OPERATION
WARNING: DO NOT CONNECT AN ENERGIZED POWER CABLE TO AIRCRAFT.

SEVERE ELECTRICAL SHOCK CAUSING SERIOUS INJURY, 'DEATH
AND OR DAMAGE TO THE EQUIPMENT MAY RESULT.
(a) Connect AC Cable to the aircraft.
(b) Set the RUN/IDLE (12, Figure 1,) switch on the Engine
Control panel to RUN position. This will bring the
engine up to operating speed of 2400 RPM.
(c) Measure AC voltage on all lines on the as follows:
CAUTION: IF A READING OF LESS THAN 100 VOLTS OR MORE THAN 130

VOLTS IS SHOWN, THE UNIT MUST BE SHUT DOWN AND
SERVICED.
(d) Turn VOLTMETER knob (8, Figure 2) to L1-N to read Line

to (L-N) Neutral on Line 1.
(e) Observe and note VOLTMETER (1, Figure 1) reading, 115

VAC should be shown.
1-2
JUN 15/90 Page 9
MODEL 90T400
(f) Observe and note the FREQUENCY METER (7, Figure 2)

reading. 400 Hz should be shown.
CAUTION: THE CABLE INTERLOCK SWITCH IS USED ACCORDING TO

AIRCRAFT SYSTEM REQUIREMENTS. CONSULT THE AIRCRAFT
TECHNICAL MANUAL FOR PROPER USAGE OF THIS SWITCH. THE
SWITCH IS LOCATED IN THE GENERATOR CONTROL BOX DRAWER.
ONLY AUTHORIZED GROUND SUPPORT PERSONNEL SHOULD CHANGE
THE POSITION OF THIS SWITCH.
(i) Set the CABLE INTERLOCK/BY-PASS switch according to

aircraft requirements.
INTERLOCK
In this position the AC power wll not be available
unless the power cable is securely connected to an
aircraft or to a load bank that returns 28 VDC on
cable pin E. In this position aircrew personnel
from within the aircraft may terminate GPU output.
BY-PASS
Use this position to directly energize the GPU
output contactor and energize the AC cable. Output
power to the aircraft may only be terminated from
the GPU control panel.
WARNING: DO NOT PLACE THE AC LOAD SWITCH ON, OR MAKE ANY

FURTHER SWITCH ADJUSTMENTS UNTIL THE UNIT IS PROPERLY
CONNECTED TO THE AIRCRAFT OR LOADBANK. FAILURE TO
COMPLY COULD RESULT IN SEVERE EQUIPMENT DAMAGE, AND/OR
INJURY TO PERSONNEL.
(j) Press AC LOAD ON (6, Figure 2) to provide AC power to

the aircraft.
(k) To monitor load conditions at the unit perform the
following:
(~) Turn AMMETER knob (4, Figure 2) to position 1

for A phase, 2 for B phase and 3 for C phase
cable current readings.
(~) Observe reading shown on AMMETER (3, Figure

2) •
(2) Turn AMMETER knob to positions 2 and 3 and

observe load measurements of Lines 2 and 3.
1-2
JUN 15/90 Page 10
-~

MODEL 90T400
(m) Set the PANEL LIGHT switch (11, Figure 2) to the ON

position for operation at night.
(2) AC FAULT INDICATORS.

If the AC output reaches the protective limits, the
appropriate AC FAULT indicators (2, Figure 2) will light,
and the output contactor will open to remove the load from
the generator set. Press the FAULT RESET (10, Figure 2)
switch to reset the electrical system when the fault has
been cleared.
(3) SHUT-DOWN PROCEDURES
WARNING: NEVER DISCONNECT OUTPUT CABLES WHILE AC POWER IS

BEING DELIVERED
(a) Press AC LOAD OFF (5, Figure 2) pushbutton.
(b) Set engine RUN/IDLE switch (12, Figure 1) to IDLE.
(c) Disconnect cables from aircraft.
(d) Allow engine to run at Idle speed for 2-3 minutes to

cool off.
(e) Set the IGNITION switch (8, Figure 1) to OFF.
(4) FAULT LAMP TEST.
The AC, and Engine fault lamps are tested as follows:
(a) Set the IGNITION (8, Figure 1) switch to ON.
(b) Set the RUN/IDLE switch (12, Figure 1) on the Engine

Control Panel to RUN. The engine need not be running.
(c) Press the FAULT LAMP TEST pushbutton (9, Figure 2).
Fault lamps will be illuminated.
(d) Restore switches to normal IDLE and OFF positions when

test is completed.
(5) SYSTEM TEST.

A Test Panel ,located on the right side panel of the
generator control box drawer, with 6 test pushbuttons is
provided to check the AC protective circuits. The AC Test
1-2
JUN 15/90 Page 11
MODEL 90T400
pushbuttons switches are: UNDER & OVER VOLTS, UNDER & OVER
FREQUENCY, and OVERLOAD. A test of the protective system is
performed as follows:
(a) Press the pushbutton for the AC protective circuit to

be tested (Figure 3).
(b) Hold the pushbutton in until the protective circuit

operates (approx. up to 30 seconds). Observe the
control panel Fault Lights. The light on the circuit
being tested should be lit.
NOTE: If the circuit under test does not operate within
60 seconds, it is defective and must be replaced.
Retest the new circuit after replacement.
(c) After performing a test of the protective circuit

operation, press the FAULT RESET switch (10, Figure 2)
on the AC Panel to reset the circuit(s).
PUSH BIJITON SWITCHES
r
I
I
I
L
Fault Test Pushbutton Switches

Figure 3
1-2
JUN 15/90 Page 12
...
{

MODEL 90T400
SPECIFICATIONS AND CAPABILITIES
1. GENERAL (See figure 1)

Length (approx) .•••••.•••••••••.....•••• 126" (320 cm).
width (approx) .•••.•..••.••••....••.•••• 64" (162.5 cm).
Height (approx) •...•••••.••.••••••••.... 62.5" (159 cm).
Weight (approx) .••.••..•.•••••••.••.•••• 3900lbs w/cables (1773 kg.).
Operating Temp ••...••.••..•..••••••••••• -30 o F. to +125 0 F.
storage Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . -40 0 F. to +150 0 F.
Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 85 DBA on 20 foot
radius.
2. VEHICLE
Frame and Running Gear .•..•.•••......••• Welded steel; leaf spring
suspens10n on rear wheels:
four steel wheels equipped
with 6.9x9 pneumatic tires.
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 psi (414 (kPa).
Brakes .••.••.•......••••.......••.••.••. Rear wheel mechanical drum
parking brakes.
Enclosure (Engine & Gen) ....•.•••••..•.. Aluminumi hinged canopy for
service access.
-- 3. ENGINE AND ACCESSORIES

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cummins Engine Co. 6 cylinder
diesel, series 6BT5.9
(Modified, Turbocharged).
Horsepower ••.......••..••••.•.....•••••• 152 at 2500 RPM.
Governor .....••.•••.......•••••••..•.•.. Speed: 2400 RPM, maintained
within 1/2% from no load to
full load.
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fir ing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 • 5 . 3 . 6 . 2 . 4
Displacement .••.••..••....•.•••••••••••• 359 cubic inch (5.88 liters)
Useable Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Fuel Tank Capacity .••.••.••.•••.•.••..•. 45 gals. (42.75 liters).
oil capacity (w/filter) •........•••••••. 15 quarts (14.2 liters).
Fuel Gauge •..••.••••••.•........•..••.•• Electric, direct reading
Air Cleaner ..•..••.••••...•.......•.•.•• Dry cartridge type with
service indicator.
oil Filter •.•••....•.•.••••.•••.•.....•• Full flow replaceable
cartridge type.
Cooling system •.••.•••.•.......••••••••• 5.5 gals (5.23 liters)
Thermostat (Fully Opn) ••.•.....•.••••••• 190 degrees (88 C).
Charging system . . . . . . . . . . . . . . . . . . . . . . . . . 12 VOC.
Table 1.
JUN 15190 1-3

REV I Page 1
, .cL .. '.

MODEL 9OT400
126.00
106.00
iii
D- ~
I I
I Ih
~ ~) ~ !()J I
f-$W
,
9.50 \; $ 10.00
----,
79.00
64.00
- 34.00-
B0 . 'If
.
I
62.5o
11'11' 1'I'I'fI
-j I-
LI',I Lid"! L,LI U.U
NOTE:
All dimensions are in
inches.
Overall Dimensions
Figure 1.
1-3
JUN 15/90 l~age'2
MODEL 90T400 .
Specifications and Capabilities (Cont'dl
3. ENGINE AND ACCESSORIES (Cont'd)

Protective system; Engine Cut-out
High water Temperature .••.•.....••••• 210 degrees F (98.8° C)
engine shuts down.
Low Oil Pressure ••••.•••.••..••••••• 6 psig; engine shuts down.
Overspeed Cut-out •••.••••••...•.••••• 2550 RPM.
4. GENERATING SYSTEM
AC Output •..•••••••••••.••..•.••••..•••• 115/220 VAC 3-phase 4-wire.
100% duty cycle at 2400 RPM.
single AC output.
output Power Rating •••••••.••.•..••..•.• 90 kva at .8 PF.
output Kilowatts . . . . . . . . . . . . . . . . . . . . . . . . 72 kw.
AC Rated Load capacity •..•.••••.....••.• 260. amps. Overload capacity
325 amps. (125% rated load).
Frequency . . . . . . . • • . . . . . . . • . . . . • • . . . . . . . . 400 Hz.
Field Excitation •••••.•..•.••••••.••••.• Static type. automatic field
flashing.
Frequency Adjustment •.••...••••••...•••• 390-410 Hz.
5. AC PROTECTIVE SYSTEM
overvoltage ••••.••.•••••.••.•••••.••.•• Tril?s 135 volts (adjustable)
with 5-7 sec. delay.
Undervoltage •••.••..••••..•....•••••... Trips 100 volts. with 5-7 sec.
delay.
Overfrequency •.....•••••....••••••••... Trips 420 Hz
Underfrequency •••••••....••.•••••.....• Trips 380 Hz (adjustable) 5-7
sec delay.
Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . Trips within 5 minutes at
125% rated load. Trips within
30 seconds at 150% rated load.
6. OPTIONS
Engine Block Preheater ...•••••.•......•• Cummins. 120 VAC 750 watts
(Refer to Cummins Engine Oper-
ations and Maintenance Manual
located in the appendices)
Ether Assist (Engine) •••..•..•.••••••.•• Includes electric thermostat.
Ground interupt opens at 95 +-
10 0 F. Recloses at 70 0 F.
Table 1.
JUN 15190 1-3

REV 1 Page 3
...;::J:._ ---~

MODEL 9OT400
SHIPPING
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

A. 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(es).
(4) Inspect fuel tank cap for proper seal and security.
CAUTION: UNDER NO CIRCUMSTANCES SHOULD THE POWER PLANT BE

ANCHORED BY PASSING BANDS OR CABLES OVER' THE
SUPERSTRUCTURE.
(5) Use 1-1/4 inch steel banding (minimum) or 3/8 inch minimum
cables and secure the unit the skid base. Attach
cables/banding to the front and rear axles or the FORE and
AFT members of the frame may be used to secure the unit. On
units that have them, tie down rings may also be used to
secure the unit to the skid base.
CAUTION: DO NOT USE FORK LIFT TO RAISE THE UNIT, AS THE CRANK
CASE WILL BE RUPTURED. UNIT MUST BE LIFTED BY USE OF
SPREADER BAR AND THE FORE AND AFT MEMBERS OF THE FRAME.
B. When deemed advisable by the shipping activity, the GPU

should be covered with waterproof canvas or polyethylene
material in such a manner as to prevent the entry of natural
elements into the electrical and instrument areas.
JUN 15190 1-4

Page I
MODEL 90T400
SHIPPING
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.
,"
JUN 15/90 1-4

Page 2
_ Mil -
TRILECTRON INDUSTRIFB INC.

MODEL 9OT400
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 parts 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 a thoroughly mixed coolant is adequate for the

lowest anticipated temperatures during time of storage.
(2) Add oil to the FULL mark level on dip stick
(3) Drain a small portion of fuel from fuel tank by removing

drain plug at bottom of tank. This will remove any water
that may have accumulated on 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.
(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.
1-5
JUN 15/90 Page 1
MODEL 9OT400
Parts of the diesel requiring special attention are given

below. The unit should be prepared for storage as soon as
possible after being removed from service.
(1) Drain the cooling system. (See Figure 1) Flush with clean
water. Refill with 50/50 mix of water and anti-freeze and
add a rust inhibitor, or mix according to ratio for
temperature as shown in Chapter 2, section 1, Table 1.
(2) Circulate the coolant by operating the engine until the

normal operating temperature is reached.
(3) stop the engine.
(4) Drain the engine crankcase. Reinstall the drain plug.
Install new lubricating oil filter elements and gaskets.
Refill with high quality lubricating oil: Shell code 66202,
or Texaco Preservative oil 30 (MIL-L-21260C Grade 2).
(5) Drain the fuel tank of contaminants, fuel/water. Add

additives, fill with fuel, and operate the engine for about
ten minutes.
1. Fan
2. Radiator hose (Upper)
~ . 3. Bolt, Radiator support
f'1 I~·I. 4. Drain Petcock
i« I I "i
... ~ ..J:i.
5. Radiator hose (Lower)
Engine Cooling System Drains

Figure 1
1-5
JUN 15190 Page 2
MODEL 90T400
NOTE: If the unit is stored where water or condensation may

be a problem, add pure waterless isopropyl alcohol
(isopropanol) to the fuel, at the rate of 1 pint to 125
gallons of fuel(.OlO% 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.
(6) Remove the spin-on fuel filters, discard, fill new filters
with No. 1 diesel fuel and reinstall on the engine.
(7) 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 batter~. '
store the battery in a cool dry place (never below 32 F or
0 0 C). Keep the battery fully charged and check the specific
gravity of the electrolyte regularly.
(8) Seal all engine openings, including the exhaust outlet, with
moisture resistant tape. Use cardboard, plywood, or metal
covers where practical.
(9) Tag engine Control Panel "NOT TO RUN, STORAGE READY".
1-5
JUN 15/90 Page 3
MODEL 9OT400
CHAPTER 2
MAINTENANCE
TABLE OF CONTENTS
Chapter/section
servicing 2-1
1. General
Consumable Materials .......................................................................................... 1
2 .. Lubricating Instructions .................................................................................. 2

A.. Eng ine .............. -. ................................................................................................ 2
B. Chassis and running gear ••....•............................... 3
3.. Inspection .............................................................................................................. 5

A. Preventive Maintenance •.................................•..... 5
B. Initial Inspection ...............•..••••...................... 9
C. Returning to service ....•..•..•..•............................ 9
D. Engine Fuels .........•.....•......•••••••.................... 10
Troubleshooting 2-2
1. General ................................................................................................................... 1
2. Troubleshooting Chart ..••.•••.•.••.....•......................... 1
A. Engine hard to start or will not start .•...................... 3
B. Engine starts but will not keep running . . . . . . . . . . . . . . . . . . . . . . .'3
C. Engine will not reach rated speed when ·loaded ................. 6
D. High water Temperature Indicator ON ••••••.•..••............... 9
E. Overspeed Indicator ON •.•.................................... 10
F. Low oil Pressure Indicator ON ....•....•................••.... 10
G. Eng. will not go to Govern speed .....••..................•... 10
H. Engine Shuts OFF ......................................................................................... 11
I. Low AC Voltage .•.......••.......••.••.•••.................... 13
J.. AC Output Voltage High .............................................................................. 14
K. No AC Voltage to Power Cable ....•...•........................ 14
L. Overload Indicator ON ..•..............••....•................ 14
M. Over/Under Frequency Indicator ON •.••.••..................... 14
N. Over Voltage Indicator ON ....•..•.....•...................... 15
P. Under Voltage Indicator ON •...•..•....•...................... 16
Q. Panel Lights and Instruments lights do not Light ............. 16
R. Electrical Component & Functional Description ................ 18
T. Wiring Diagrams ..•.••..•......•.••....•...................... 27
Removal and Installation 2-3

1. General ................................................................ 1
2. Torque Values For General Assembly ......••....................... 1
3. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Engine /Generator Removal ............•..........•................ 3
5. Engine/Generator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Generator Removal/Installation .••.••.••.••....•.................. 8
2-CONTENTS
JUN 15190 Page 1
NNILECTRON INDUSTRIES INC.
MODEL 90T400
CHAPTER 2
MAINTENANCE
TABLE OF CONTENTS
Chapter/Section Page
Repair 2-4
1. General ............................................................................................................. 1
A. Tires .............................................................................................................. 1
B.. Eng ine ................................................................................................................ 1
C. Electrical Components .................•••...•.•....•..•....... 1
2-CONTENTS
JUN 15190 Page 2
MODEL 90T400
SERVICING
1. GENERAL
Service Intervals.- 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 (depending upon
local conditions). At this time the GPU should be sent to a
qualified depot. All work must be performed by qualified
mechanical, and electrical technicians, and should include
replacement of accessories as necessary (See Table 1 for
Consumables Materials Applications).
Component Description Quantity

Application
Fuel Tank Fuel oil, Diesel 54.2 gal.
Crankcase Lubricating oil 10 qts. (US)

CC-CD 15W-40 (NOTE 1)
Lub points Grease, General as required

Running gear Purpose
Door Hinges oil can, OE30 as required
Radiator Antifreeze Ethylene 5.5 gal. (US)

Gylcol (NOTE 2)
Filters, Fuel Filter element, fuel tank 1 ea.

Filter element, primary 1 ea.
Filter element, secondary 1 ea.
Filter, Oil cartridge 1 ea.
Air Cleaner Element 1 ea.
NOTES
1. While 15-40W oil is recommended for most climates, refer

to Figure 1 for oil viscosity recommendations for extreme
climates
2 antifreeze concentration level should not exceed recom-

mended levels. To do so can cause cooling system failure.
Table 1
Consumable Operating and Maintenance Supplies
2-1
JUN 15190 Page 1
MODEL 9OT400
a. A mixture of 50 percent antifreeze and 50 percent

water is required for temperatures above -34 0 F.
[_37 0 C.].
b. A mixture of 60 percent antifreeze and 40 percent

water is required for environments below -34 0 F.[-37 0
C] This provides protection to -65 0 F.[-54 0 C]. NEVER
exceed a 60 percent antifreeze and 40 percent water
mix.
c. NEVER use 100 percent antifreeze for makeup coolant.
Table 1 (Cont'd)
Consumable Operating and Maintenance Supplies
1 1 1 1 1 1 1 1 1
o C -50 -40 -30 -20 -10 o 10 20 30 40
of -58 -40 ·22 .·4 14 32 50 68 86 104
Anllclpaled Ambient Temperalure
PSA oil viscosity Recommendations

Figure 1
2. LUBRICATION INSTRUCTIONS
To ensure that the unit is kept in correct operating condition,

it must be inspected and maintained on a regular basis. Proper
replacement of filters, lubricating oil, etc. at recommended
intervals will prevent damage or failure of the unit, and
provide optimum performance.
2-1
JUN 15/90 Page 2
MODEL 9OT400
A. Engine oil Change Schedule. (Refer to Sect. 2-1, Table 2.)
Time schedules indicated in Table 2 are based on average

operating conditions. It may be necessary to change oil and
air filters 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.
Check the oil level after every 8-10 hours of operation

during the break-in period (first 50 hours). Add oil as
necessary.
(1) Always clean around oil filler openings (Figure 2.) before
removing caps or plugs.
(2) Do not over lubricate or overfill the engine crankcase. Use

engine oil level dipstick (Figure 2.) to check oil level.
(3) Prevent dust, dirt or water from contaminating lubricants
or lubricating equipment.
(4) Do not mix brands, weights or types of oil when servicing

unit.
(5) Check engine daily, adding oil as required to bring level

to FULL mark on oil level dip-stick.
B. Chassis and Running Gear
(1) Lubricate chassis and running gear grease points at

designated intervals
(2) Running gear bearings and joints should be greased with

lithium based grease, refer to Table 2 for maintenance
schedule. The following grease fittings are installed on
the GPU
(a) Tie rod ends, 2-fittings (under side) .
(b) Emergency hand-brake shaft ends, 2 fittings.
(c) Front and Rear wheels are lubricated by grease packing

the wheel bearing. For grease packing it is
recommended that a number 2 lithium base hydroxy
stearate grease containing an E.P. additive be used.
This grease should pass a load bearing test of 40
pounds minimum, with a base pour point at -10 0 F.
2-1
JUN 15190 Page 3
,~. .-.~-~.-

MODEL 9OT400
Cold Slarting Aid

011 Fill ---------------_O..,L Elher Injection
Intake Air Tap. ~=:::~~=7~~~§~~~~

Accessory Pulley --------1 Integral Intake Manllold
High Pressure --------~~~_h~~bfll Heater Waler Supply

Fuel Lines 41ltit-:----;-j-----__
-----------llt~~~Ltl~ 1 Air Compressor Waler Supply
Fuel Pump ~~z>~~~~~~~~;:tt~
Engine Data Plate
Oil Pressure Taps-
-======::::::::::~F~~~~fP~~ Water Separator
Fuel Filler
Fuel Lilt Pump
Secondary au Fill
Dlpsllck
Water Temperalure and

Pressure Tap.
Tumocha~er ~----------------~j
tf=t-----:::::---,L------- Tumocharger all
Supply
Fuel Injection Nozzle _ _ _ _ _ _ _ _ _ _-:~~~~=~~
Inlegrat Thermostat Water
HHi..------ Outlet Housing with Inlernal
Cootant Bypass Circuit
Alternator
Coolant Heater Location
Starter
Spln·on 011 Filler r@)~..:1.=====-- Waler Heater Relurns
Turbocharger 011 Return Water tnlet
:
R.,."lbl. 011 Pan
all Healer
:::~=======~~~~~:::~:
=:::::::.,,1------------ 011 PreSlure Regulator
011 Drain
Engine Assembly
Figure 20
JUN 15/90
MODEL 9OT400
3. INSPECTION (See Table 2)

A. Preventive Maintenance Inspection Schedule
A periodic inspection schedule should be established and
maintained. A suggested inspection/check schedule is
provided below. The criteria listed below meets the minimum
requirements necessary to ensure safe reliable service
under normal operating conditions. However, it may be
modified as required to meet varying operating and
environmental conditions.
NOTE: Change oil and filter after first 50 hours then
every 125 hours.
PREVENTIVE MAINTENANCE INSPECTION SCHEDULE
LUBRICATION SYSTEM Daily 125 HR 250 HR 375 HR 500 HR 625 HR 750 HR
1. Inspect for leaks. X X X X X X X

2. Check oil level. X
3. Change oil filter. X X X X X X
COOLING SYSTEM

2. Inspect Radiator. X X X X X X X
3. Check Coolant level X XX X X X )(
4. Condition of belts. X XX X X X X
5. Change antifreeze
solution yearly or every 750 hours which ever comes first. X
AIR INTAKE

2. Ins~ect for air
res rictions. X X X X X X X
3. Inspec~ for
corrOSl.on. X X X X X X
4. Change air filter
element. X X X
FUEL SYSTEM
1. Inspect fuel lines
for leaks, chaffing X X X X X X X
and excessive bends
2. Change fuel filters X X X X X X
3. Drain sediment from
fuel tank. X X X X X X
TABLE 2
2-1
JUN 15190 Page 5
MODEL 90T400
EXHAUST SYSTEM Daily 125 HR 250 HR 375 HR 500 HR 625 HR 750 HR

2. Ins~ect system for
res rictions. X X X X X X X
3. Inspect clamps for
tightness. X X X X X X X
4. Ins~ect for cor-
ros~on. X X X X X X X
5. Inspect muffler for
security. X X X X X X
TURBOCHARGER
1. Inspect oil lines
to turbocharger for
leaks, & chaffing. X X X X X X X
2. Inspec~ for
excess~ve noise. X X X X X X X
ELECTRICAL SYSTEM
1- Inspect batter
electrolyte level
covers plates. X X X X X X X
2. Inspect battery
hold-down. X X X X X X X
3. Inspect battery
terminal for
security and
corrosion. X X X X X X X
CHASSIS & RUNNING GEAR
1. Inspect doors and
hinges for defects.
Lubricate hinges X X X X X X
(See Table 1).
2. Inspect unit for
loose nuts, bolts X X X X X X X
and missing hard-
ware.
3. Inspect drawbar
for cracks, cor-
rosion and exces- X X X X X X X
sive wear.
TABLE 2. (Cont'd)
2-1
JUN 15/90 Page 6
MODEL 90T400
CHASSIS & RUNNING GEAR Daily 125 HR 250 HR 375 HR 500 HR 625 HR 750 HR
4. Inspect drawbar X X X X X X X
latch for proper
operation.
5. Inspect center arm X X X X X X
for excessive play.
6. Inspect tie-rods X X X X X X
for wear. Grease
(See Table 1)
7. Inspect axles for X X X X X X
security.
8. Inspect tires for X X X X X X X
wear and inflation.
9. Inspect wheel
bearings for loose- X X X X X X
ness.
10. Repack wheel bearings yearly or 750 hours which ever comes first.
GENERATOR
1. Inspect air inlet, X X X X X X X

outlet screens for
,
obstructions.
2. Inspect wiring for X X X X X X X
cuts, excessive
bends and chaffing.
3 . Inspect generator X X X X X X X
mount bolts for
tightness.
AC ELECTRICAL SYSTEM
1. Inspect AC cable X X X X X X X
for cuts and
abrasions.
2. Inspect AC cable X X X X X X X
head for abrasions
exposing pin con-
nections. Remove
cable from service
if any electrical
pins are exposed.
3 . Inspect terminal X X X X X X X
boards for loose
connections and
evidence of over
heating.
TABLE 2. (Cont'd)
2-1
JUN 15190 Page 7
MODEL 9OT400
AC ELECTRICAL SYSTEM Daily 125 HR 250 HR 375 HR 500 HR 625 HR 750 HR
4. Contactor Panel
Inspect for:
a. Loose wires and X X X X X X X
evidence of over
heating.
b. Transformer for X X X X X X X
deterioration of
insulation and
evidence of over
heating.
c. Contactor for X X X X X X X
loose wires.
5. Instrument Panel
Inspect:
a. Gauges for pro- X X X X X X X
per operation,
cracked glass.
b. Switches for X X X X X X X
proper operation
c. Fault lamp test X X X X X X X
,
switch and indi-
cators for
obvious defects.
d. Fault Circuit X X X X X X X
test.
e. Panel illumina- X X X X X X X
tion lights.
TABLE 2. (Cont'd)
2-1
JUN 15190 Page 8
.~. ....::~,

MODEL 9OT400
B. Initial inspection and preparation
(1) Remove all packaging material from unit.

(2) Inspect exterior of unit for damage that may have occurred
during shipment.
(3) Open the canopy by unlatching and lifting each half until
each comes to rest at a full vertical position. Each canopy
half is held open by its own weight. Inspect interior of
unit for foreign material such as rags or shipping
material.
(4) Inspect all wiring connections for security.
(5) Lower and latch both halves of the canopy.
(6) Lift open the rear 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 fluid level. Ensure electrolyte is above

the plates. Service batteries as necessary, using distilled
water •
(8) Connect battery.
CAUTION: BEFORE ATTEMPTING TO START UNIT, PERFORM A PRE-

OPERATIONAL INSPECTION (SEE CHAPTER 1.) PERFORM ONLY
THOSE TASKS NOT ACCOMPLISHED IN THIS PROCEDURE.
(9) Check-fuel level by turning on the ignition switch (Refer

to Section 1-2 pages 1 and 2). Observe fuel gauge. service
as necessary with diesel fuel.
C. Returning unit to service after extended storage.
(1) Remove covers and tape from all engine and fuel tank
openings.
NOTE: Do not over-look the exhaust outlet.
(2) Remove covers and tape from electrical system components.
(3) Drain and refill radiator with 50/50 mixed solution of

water and antifreeze (ethyl glycol) or according to a ratio
for temperature as described in Table 1, note 2. Coolant
capacity is 5.5 gallons.
2-1
JUN 15190 Page 9
MODEL 9OT400
(4) Drain engine crankcase, (Figure 2). Install oil drain plug
and change oil filter. Add oil to engine.
(5) If isopropyl alcohol (isopropanol) was added to fuel for
storage, drain and refill fuel tank with diesel fuel.
CAUTION: BEFORE ATTEMPTING TO START UNIT, PERFORM A PRE-

OPERATIONAL INSPECTION (SEE CHAPTER 1.) PERFORM ONLY
THOSE TASKS NOT ACCOMPLISHED IN THIS PROCEDURE.
D. Engine Fuel (See Table 3)

The Cummins diesel engine uses 12 diesel, or fuels meeting
ASTM 0975 Standard Specification of Diesel Fuels, or the
following lighter fuels: No. 1 Diesel, kerosene, or blends
of these fuels.
CAUTION: JP-4 FUEL IS NOT RECOMMENDED AS IT ACCELERATES WEAR OF

THE FUEL INJECTION SYSTEM, DUE TO ITS LOWER VISCOSITY
OF LESS THAN 2.0 CENTISTROKES. THE FUEL CAN BE BROUGHT
TO AN ACCEPTABLE VISCOSITY BY ADDING LUBE OIL, OR
VISCOSITY IMPROVERS, HOWEVER, A PERFORMANCE LOSS OF
20-25% SHOULD BE EXPECTED.
Viscosity 1.3 to 5.8 centistroke.

(ASTM 0-445) (1.3 to 5.8 mm 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 1% by weight.
(ASTM D-129 or
1552)
Carbon Residue Not to exceed 0.25% by weight on 10% residue.
(Ransbottom ASTM
0-524 0189)
Table 3.
RECOMMENDED FUEL OIL PROPERTIES
2-1
JUN 15190 Page 10
·h..:

MODEL 9OT400
Flash Point 125 F (52 C) min. certain marine registries

(ASTM 0-93) require higher flash points.
Density 30 to 42 F (-1 to 6 C) A.P.I. at 60 F (16 C)
(ASTM 0-287) (0.816 to 0.876 Sp. Gr.).
Cloud Point 10 F (-12 C) below lowest temperature expected
(ASTM 0-97) to operate.
Active Sulfur- Not to exceed No. 2 rating after 3 hours at
Copper strip- 122 0 F., (50 C).
Corrosion
(ASTM 0-130)
Ash (ASTM 0-482) Not to exceed 0.02% by weight.
Distillation Curve should be smooth and continuous.
(ASTM 0-86) Minimum 90% of fuel should evaporate at less
than Ash (ASTM 0-482) Not to exceed 0.02% by
weight.
Table 3. (cont'd)
RECOMMENDED FUEL OIL PROPERTIES
2-1
]UN 15/90 Page 11
MODEL 9OT400
TROUBLESHOOTING
1. GENERAL
This section contains troubleshooting information for 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 you to determine probable causes and corrective
action to take. You should perform the tests/inspections and
corrective action in the order listed.
Troubleshooting is a logical and systematic process in
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 you
have verified the trouble, you need to identify all components
in the circuit whose failure may cause the symptoms observed
du during the operational checkout. You should start by checking
those items which are the easiest to get to. Inspect and test
each component, until the exact cause of the problem is found.
WARNING: EXERCISE EXTREME CARE TO AVOID CONTACT WITH HIGH

VOLTAGE LEADS. REMOVE ALL JEWELRY, SUCH AS RINGS,
WATCHES, CHAINS. ETC., THAT COULD COME INTO CONTACT
WITH EXPOSED POINTS. FAILURE TO COMPLY MAY RESUL~ IN
SERIOUS INJURY OR DEATH TO· PERSONNEL AND OR DAMAGE TO
THE EQUIPMENT.
WARNING: EAR PROTECTION DEVICES MUST BE WORN WHEN IN THE

IMMEDIATE VICINITY OF THIS UNIT DURING OPERATION.
REPEATED EXPOSURE TO HAZARDOUS NOISE CAN CAUSE
PERMANENT HEARING LOSS.
WARNING: FUEL, OILS AND OTHER PETROLEUM PRODUCTS CAN READILY BE

ABSORBED THROUGH THE SKIN AND INTO THE BLOOD STREAM.
WASH IMMEDIATELY AFTER COMING IN CONTACT WITH THESE
PRODUCTS.
2. TROUBLESHOOTING CHART.
This troubleshooting chart (See Table 1) lists information

under three headings as follows:
Problem
Cause.
Remedy.
2-2
JUN 15/90 Page 1
MODEL 90T400· .
A. Use of the Troubleshooting Chart.

If the cause of a trouble is uncommon and cannot be located
using the chart, a good place to start your checks is at
the last known source of power. Then proceed by checking
each component in the circuit/system thoroughly. Use the
schematics and diagrams.
Electrical components in the troubleshooting chart (such as
Sl, Tl, etc), are identified by a noun name an a
corresponding symbol to identify the item on schematic
diagrams. It is assumed that wiring and connections in
defective circuits have been thoroughly checked before
condemning any components.
B. support Test Equipment Required.
(1) Multimeter (Simpson 260 VOM or equivalent)
(2) Tachometer
(3) See Cummins Shop Manual B Series Engine located in the
appendices for tool requirements.
C. Parts Failure.
stop the engine immediately should any parts fail.
Practically all engine failures give some warning to the
ope~ator before t~e parts fail and ruin the engine. Many
englnes have been saved because alert operators heed
~ warning si9ns such as a sudden drop in oil pressure,
unusual nOlses,etc., and immediately shut down the engine.
3. SCHEMATICS AND WIRING DIAGRAMS
This troubleshooting section incorporates schematics and

associated wiring diagrams for use by the technician. They
should be use in conjunction with the Troubleshooting Chart
(Table 1 ). When troubleshooting the Diesel Engine, the
troubleshooting chart (Table 1) should be used in conjunction
with the Cummins Troubleshooting and Repair Manual located in
the appendices. The Cummins manual supplies an in-depth and
comprehensive trouble-shooting guide with repair instructions.
The schematic and wiring diagrams include:
(a) Engine Controls and Protective

Circuits Schemtaics ........•......••.....••... Figure 1
(b) AC Generator Schematic •.....••.•...•.•....•... Figure 2
(c) Generator Control Drawer
Wiring Diagram .•..•.....••..•..••• :~; .•....... Figure 3
(d) Power Panel Wiring Diagram •.•••••••••.••.....• Figure 4
(e) Instrument Panel Wiring Diagram •••.•...•.•••.. Figure 5
(f) Engine Mounted Components Wiring Diagram ..•... Figure 6
(g) Engine Instrument Panel Wiring Diagram .......• Figure 7
(h) Connector Wiring Diagram ..••••.•...••..•...... Figure 8
(i) Fuel System Schematic .•...•.••.....•...•...... Figure 9
2-2
JUN 15/90 Page 2
MODEL 90T400
ENGINE TROUBLESHOOTING CHART
Fault & Condition Probable Cause Test, Check, Remedy
Excessive Fuel Con- 1. Fuel Leak. Check/correct the

sumption. source of the leak.
2. Additional Loading from Check/Repair acces-

malfunctioning accessories and vehicle
sories. Components.
3. Poor Quality Fuel. Make sure DIESEL fuel

oil is being used.
4. Inadequate Intake Air or Check/change Air

Exhaust restriction. intake Filter, and
remove any restric-
tions found in the
exhaust.
5. fuel Pump Timing. Check/time the pump.
6. Worn or Malfunctioning Check and/or replace

injectors. injectors. '
7. Valves Not Seating. Check/adjust Valves.
Engine Hard to Start 1. Engine cranking speed Check engine cranking

or will not Start too slow. RPM. Refer to engine
(Exhaust smoke Pre- will Not Crank or
sent). cranks Slowly.
2. starting Aid Needed for Check and repair or
Cold Weather or Not replace cold starting
Working properly. aid, if necessary.
3. Air in the fuel System. Bleed the fuel system
4. Fuel Supply Restricted Clean or replace pre-

filters and screens
check fuel lines for
restrictions.
5. Intake Air System Check intake system.
restricted.
Table 1.
2-2
JUN 15190 Page 3
MODEL 9OT400

Engine cranks, but 1. No fuel in tank Add fuel.

will not start (no
smoke from exhaust). 2. Fuel solenoid not ener- Check for loose wires
gized open. verify that the
solenoid is function-
ing.
3. Fuel Filter clogged with Drain Fuel - Water

water or other contamin- separator or Replace
ants Fuel Filter
4. Worn or Malfunctioning Loosen high pressure

Injector Pump line at two injectors
and visual check
fuel delivery while
cranking the engine.
Replace the pump if
fuel is not being
delivered.
5. injection Pump Timing Verify timing; time

incorrect. injection pump if
required.
Engine starts But 1. Idle speed too low. Adjust governor link-
will Not keep age.
running.
2. Air in the Fuel System. Bleed the fuel system

and check for suction
leaks.
3. Fuel Filter clogged or Drain fuel-water sep-
Fuel Waxing Due to cold arator or replace
Weather. filter.
4. Fuel Supply Restricted. Clean or replace pre-

filters and screens
and check for fuel
line restrictions.
Table 1. (Cont'd)
2-2
JUN 15190 Page 4
MODEL 90T400
(cont.) Engine 5. Fuel contaminated. Verify by operating

Starts But will engine from a tempor-
Not keep running. 'i"ry supply tank.
6. Injection Pump out of Check/correct pump

Time. timing.
Rough Idle, Warm 1. Idle speed set too low Adjust governor link-
Engine. age.
2. Air Fuel System. Bleed fuel system and

check for suction
leaks.
3. Injection Timing Check/correct injec-

incorrect. tion timing.
4. Injector Nozzles clogged Replace Injectors.

or inoperative.
5. Broken Engine Mounts Replace inj ectors'.
6. Malfunctioning Injector Replace Pump.

Pump.
Engine surges at 1. Low fuel level in tank. Fill supply Tank.

idle.
2. Idle Speed Set too Low. Check and Adjust
governor linkage.
3. Air in the Fuel System. Bleed fuel system and

check for suction
leaks.
4. Restricted Fuel Supply. Clean or replace pre-
filters and screens
and check fuel lines
for restrictions.
5. Malfunctioning or worn Remove pump. Have
Injector pump. pump re~calibrated or
replace "pump.
Table 1. (Cont'd)
2-2
JUN 15/90 PageS
TRILEcrRON INDUSTRIES INC.
MODEL 9OT400
Fuel or Oil Leaking 1. Intake Air Restriction. Check/Replace Filter

from Exhaust Mani- Element.
fold.
Review operation for
Excessive idling.
2. Injector Needle Valve Locate and replace
Stuck Open. Malfunctioning Injec-
tor.
3. Obstructed Turbocharger Check/Clean Line.

Drain Line.
4. Turbocharger Seals Check/Replace Turbo-
Leaking Oil. charger.
Engine will Not 1. Throttle Linkage incor- Check Throttle link-
Reach Rated Speed rectly adjusted. age adjustment for
When Loaded. full travel to the
high idle stop screw.
2. Fuel Supply Restricted. Change the fuel filter

and check fuel line,
pre-filter and screens
for restrictions.
3. Incorrectly adjusted or Check with a hand
defective R8 held or digital tac-
ometer, adjust R8.
4. Electronic governor Adjust governor speed

incorrectly Adjusted. screw.
5. Malfunctioning injection Replace Injection
pump.
Low Power 1. Lubricating oil too high Drain oil to proper

. level.
2. Throttle Linkage adjust- Check and adjust

ment Wrong.' throttle for full
travel of the fuel
control ,lever.
Table 1. (Cont'd)
2-2
JUN 15190 Page 6
MODEL 90T400
Low Power (cont.) 3. Low intake air temp. Allow engine to warm
(Below (OoC. [32 o F]) up to proper tempera-
ture before attempting
to bring it up to Run
speed.
Engine Misfiring 1. contaminated Fuel. Verify by operating

from a temporary
supply tank.
2. Air in the Fuel System. Bleed Fuel System and

Check for suction
leaks.
3. Fuel Injection lines Inspect and Replace

leaking. broken lines.
4. I~correct Valve adjust- Inspect push rods,

ment. springs and adjust
valves.
5. Injector Nozzles Clogged Replace injectors.

or Inoperative.
6. Injector Pump Timing Check/time injection

incorrect. pump.
Fuel Knock 1. Poor quality fuel. Drain tank; fill with

correct diesel fuel.
2. Air in Fuel System. Bleed fuel system and

check for suction
leaks.
3. Incorrect injection Pump Check pump timing.

Timing.
4. Injection Nozzles Mal- Remove nozzles. Test
functioning. and Repair.
Engine will not 1. Battery voltage low. Remove and load test
crank or cranks too battery. Recharge bat-
slowly tery.
Table 1. (Cont'd)
2-2
JUN 15190 Page 7 .
MODEL 90T400
Fault & condition Probable Cause Test, Check, Remedy
Engine will not

crank or cranks too 2. Defective Fuse (F2) or Check fuse (F2) and
slowly. (Con't) circuit breaker CB2 circuit breaker CB2
for open; replace if
defective.
3. Starting Circuit connec- Check and tighten
tions loose or corroded. connections.
4. No voltage to solenoid. Check wiring, perform
voltage check at
solenoid.
4. Solenoid or Starting Replace starting

Motor Malfunctioning. motor.
6. Starting Motor Operating Remove the starting

But Not cranking the motor and check for
engine. broken teeth on the
• flywheel or starting
motor spring.
Alternator NOT 1.. Loose or Corroded Clean/tighten battery

charging or battery connections. connections.
charging is NOT
sufficient. 2. Alternator Belt Slipping Check/Replace belt
tensioner.
3. Alternator Pulley Loose Tighten pulley.
on Shaft.
4. Malfunctioning Alter- Replace alternator.
nator
ENGINE WILL NOT 1. Low battery voltage. Check battery
START. NO fault connections. Tighten
indicators ON. if necessary. Perform
load test on battery;
recharge if necessary.
2. Defective IGNITION With switch at ON

switch (Sl). position, check
voltages-at switch
(12 VDC) Replace if
defective.
Table 1. (Cont'd)
2-2
JUN 15/90 Page 8
.~,

MODEL 90T400
ENGINE WILL NOT

START. NO fault 3. Defective RUN/IDLE Check switch, replace
indicator ON. switch S14. if; defective.
(Cont'd)
4. Defective starter Check starter solenoid
solenoid. Replace solenoid if
defective.
5. Defective starter. Check starter. Replace

starter if determined
it is defective.
6. Defective fuel solenoid Check fuel solenoid.
7. Defective K7 relay. Check N.C. contacts to

open when energized.
S. Defective time delay Check relay K3 for

relay KS. fused N.O. contacts.
Replace if defective.
Engine WILL NOT 1. IGNITION circuit breaker Reset circuit breaker

START. CONTROL (CB3) tripped. CB3
POWER ON indicator
not illuminated
2. Defective Fuse (F2). Check Fuse F2, replace
if defective.
Engine will Not
Start.
No reading on fuel 1. Low Fuel Check fuel gauge.
gauge. Fill fuel tank if
required.
2. Defective Fuel level Check sending unit.
sending unit. 35 +- 10 ohms full,
250 +- 10 ohms empty.
High Water Temp- 1. ,High water Temperatu1='e Check Water tempera-
ature indicator - ture level gauge &
ON. fluid level in radi-
ator.
2. Hi~h Water Temperature Check high water
sW1tch defective. temperature switch
S3 for short replace
if defective.
Table 1. (Cont'd)
2-2
JUN 15190 Page 9
MODEL 90T400
Overspeed 1. Overspeed condition Reset overspeed.

indicator ON. Adjust governor to
2400 RPM.
,
2. Defective Overspeed Perform continuity
switch. check terminals NQ1
and COM. Circuit
should be open below
2550 RPM.
Low oil Pressure 1. Low Oil pressure. Check oil dip stick.
indicator ON. Add oil as required.
Low oil Pressure 2. Low oil pressure Check low oil level
switch defective. pressure switch
for binding or short.
ENGINE WILL NOT GO 1. Defective RUN/IDLE with S14 in the RUN
TO RUN SPEED. switch (S14). position, check for
continuity. If switch
• contacts are open in
. the RUN position,
~- replace switch.
2 . Incorrectly adjusted· or Check R8 for open.
defective fre9uency Replace if defective .
adjust potent10meter R8
3. Defective K47 relay Check relay coil for
control box. open and contacts for
operation.
4. Defective actuator. Check actuator for
freedom of movement.
Check coil for open or
short.
5. Maladjusted or defective Turn MPU clockwise
Magnetic Pickup (MPU) until contact with 1
flywheel is made then
turn counter-clockwise
one (1) full rotation.
Check MPU for 50 - 350
ohms, or open/shorted
coil. Replace MPU if
found to be defectiwe.
5. Maladjusted or defec- . Check/ad~ust clearance
tive magnetic pickup. Check c01l for open;
replace if defective.
Table 1. (Cont'd)
2-2
JUN 15/90 Page 10
MODEL 90T400

ENGINE SHUTS OFF.
Fault condition
exists, but fault
indicator does not
light. Indicators
checks OK with test
push-buttons.
Overspeed indicator 1. O~en diode CR21 on Replace diode logic
indicator does not d10de logic board. board.
light.
2. Defective overspeed Replace indicator if
indicator (DS16). defective.
High temperature 1. Open diode CR22 located Replace diode logic
indicator does not on diode logic board. board.
light.
2. Defective high temper- Replace indicator if
ature indicator (DS15). defective.
Low oil pressure 1. Open CR20 on diode Replace diode logic
indicator does not logic board. board.
> light.
2. Defective low oil pres- Replace indicator if
sure indicator (DS14). - defective.
Fuel level gauge 1. Defective fuel level Check for 12 VDC at
inoperative. gauge. gauge. Check fuel
level sender. Re~lace
gau~e if 12 VDC 1S
ava1lable and sender
checks OK.
2. Defective fuel level Check wiring to the
sender. sender.
ENGINE WILL NOT 1. Defective fault relay Check K7 coil for
SHUT OFF, fault K7. open. Replace if
indicator ON. defective.
2. Defective Fuel solenoid Check fuel solenoid
coil for open. Check
contacts for proper
operation.
ENGINE WILL NOT '.
SHUT OFF. No fault
indicator lights!
but fault condit10n
observed.
Overspeed condi- Defective contacts on Check contacts on
tion. overspeed switch (55) overspeed switch.
Table 1 (Cont'd)
2-2
JUN 15190 Page'11
MODEL 901'400 -

Over temperature. Defective high temperature Check hiih temper-
switch. ature sw tch.
Rt;!place if defective.
;
Low oil pressure Defective low oil Check low oil

condition. pressure switch. pressure switch.
AC GENERATOR TROUBLESHOOTING CHART
Problem Cause Remedy

NO AC VOLTAGE. 1- Voltmeter selector Place switch in L1, L2
Engine at RUN speed switch in OFF position. or L3 position.
No fault indicator
ON, frequency at 2. Defective voltmeter. Check voltage at meter
400 Hz. if 115 VAC ~s obtained
replace meter.
NO AC VOLTAGE. 1- Defective RUN/IDLE Ignition ON, Place S14
Engine at RUN speed , to RUN position. Check
. No fault indicators S14 wire 163 for 12VDC
ON. Check wire #170 for 12
VDC. Replace S14 if,
voltage is on wire 163
and NOT on wire 170.
2. AVR fuse blown or AVR Check fuse on AVR.
defective. Check 12 VDC to AVR.
Check generator field
windings. Replace AVR
if fuse, generator
field checks OK and 12
VDC is obtained at AVR
3. Defective generator Perform continuity
exciter field. test between Fl - F2.
4. Defective Power supply. Check condition of
transformer T1, ter-
minals 1 through 9. If
transformer checks OK
-. change power supply.
-
5. Defective supply Inspect T1 for loose,
transformer T1. burned or shorted
wiring. Terminals 1
through 9.
6. Defective Diodes in Check diodes for open.
generator field exciter Replace if defective.
Table 1. (Cont'd)
2-2
JUN 15/90 Page 12
MODEL 90T400

LOW/HIGH AC VOLTAGE 1. Defective fusees). Check fuses F3 - F5
NO CONTROL. and F6 - Fa.
Engine at RUN speed
Undervoltage indi- 2. Defective or mal- Adjust R32. Counter
cator ON. adjusted R32 on the clockwise increases
Automatic Voltage output. If no change
Regulator (AVR) board in output change AVR.
3. Defective supply 1. Inspect T1 for o~en
transformer T1. loose or burned wirlng
Check fuses F3, F4, F5
F6, F7, and Fa.
4. Defective volts adj. Measure R5 for 0 to
potentiometer. 1.5K ohms.
5. Defective generator Check diodes for open.
exciter field diodes.
6. Defective sensing 1. with unit running,
relay K1 on remote S40 in REMOTE position
sensing assembly. and K1 OFF, measure
voltage on terminals 3
6, & 9 on the remote'
sense board. Record
readings.
2. Connect AC output to
30 KVA load Bank.
3. Apply load (K10N),

observe voltmeters on
load bank for voltages
all three phases.
4. verify voltages on
terminals 3, 6, & 9 on
the remote sense board
(use voltmeter) .
a. If remote sense is
working meter readings
will equal voltmeter
readings on load bank.
Terminals:
3 will equal A phase.
6 will equal B phase.
9 will equal C phase.
Table 1 (Cont"d)
2-2
JUN 15/90 Page 13
MODEL 90T400

b. If remote sense is
not working '/01 tage
measured at terminals
3, 6, & 9 will equal
measurements taken in
step 1 and voltage
observed on load bank
meters will be low.
AC OUTPUT VOLTAGE 1. R32 on the AVR board Adjust R32. Clockwise
HIGH. NO CONTROL. defective or adjusted decreases output.
Shuts down on over- incorrectly.
voltage.
2. Defective R5 potentio- Check R5 0 to 1.5K
meter. ohms.
3. Defective supply/sen- Check T1 output for
sing transformer T1. 8 to 9 VAC, terminals
7, 8, & 9. If output
is low replace Tl.
NO AC OUTPUT VOLT- 1. Defective K1 relay, Check 12 VDC at coil.
AGE AT CABLE CONNEC Output contactor. Volts good, change coil
TOR. AC voltage at
panel meter. 2. Defective K2 relay. Check 12 VDC at coil,.
and closing of contacts
3. Defective K4 relay. Check N.C. contacts of
relay K4.
NO AC OUTPUT VOLT-
AGE AT CABLE CON-
NECTOR.
Overload indicator 1. Overload condition. Check for overload on

ON. GPU. Remove overload and
reset.
2. Defective AC overload If indicator stays ON
module. with overload removed,
replace overload
module.
'.
3. Defective relay K5. Check relay K5. Replace

if defective.
Over or Under (O/U) 1. O/U frequency condi- Adjust frequency adjust

frequency indicator tion exits. R8 not potentiometer R8 to
ON. proper adjusted. obtain 400 Hz. on meter.
Table 1. (Cont'd)
2-2
JUN 15/90 Page 14
~~-----. -- --

MODEL 90T400 .

Over or Under 2. Defective or binding Check actuator for

frequency indicator actuator. binds. Replace if
ON. (Cont'd) def~ctive.
3. Defective over freq. If indicator stays ON,

module. but freq. is correct
replace over/under
frequency module.
Over voltage 1. Overvoltage condition. Adjust R5 to obtain

indicator ON. Voltage adjust poten- proper voltage.
tiometer (R5) not
properly adjusted.
2 Potentiometer R32 on Adjust R32. If no
AVR not adjusted pro- change in output
perly or defective. change AVR.
3. Over/Under voltage Reset AC. If voltage

module defective. stabilizes at 115 VAC
and after 5 to 7
seconds the Overvolt-
age indicator turns on
change module.
4. Defective Power supply Check condition of
transformer T1, ter-
minals 1, 2, 3, 4, 5,
& 6. If transformer
checks good change
Power Supply.
5. Defective voltage Replace voltage regu-
regulator. lator.
6. Defective supply/ Replace supply/sensing
sensing tranformer transformer T1.
Tl.
7. Defective volt adjust Replace voltage adjust

potentiometer R5. potentiometer R5.
8. Defective generator Check diodes
exciter field diodes.
Table 1. (Cont'd)
2-2
JUN 15190 Page 15
- .~

MODEL 90T400
Under voltage indi- 1. Undervoltage condition Adjust R5 to correct

cator ON. Voltage adjust pot. R5 voltage.
incorrectly adjusted.
2. over/Under voltage Reset AC. If AC voltage

(O/U) module defective stabilizes at 115 VAC
and after 5 - 7 seconds
indicator illuminates
change O/U voltage
module.
AC OUTPUT VOLTAGE 1. Defective volts adjust Check R5 for opens or

ADJUSTMENT RANGE potentiometer R5. intermittent readings.
LIMITED. Voltage Replace if defective.
cannot be adjusted
to 115 VAC line to
neutral, 200 line 2. Voltage regulator pot. Set voltage adjust
to line. incorrectly adjusted. potentiometer R5 on
control panel at mid
point. Adjust pot. R32
on voltage regulator
board for a reading' of
200 VAC line to line
on the AC output volt
meter
PANEL LIGHTS AND
INSTRUMENTS LIGHTS
DO NOT LIGHT.
Instrument circuit open circuit breaker. Reset circuit breaker.
Individual panel Blown lamp. Reset circuit.

lights do not light
Individual fault 1. Blown lamp. Replace lamp.
lamp does not light
when FAULT LAMP 2. Defective diode Check diode for
TEST pushbutton is open:
pressed. CR6-U/V
CRB-O/V
CR5-0/F
CR4-U/F
CR7-0/L
CR11-Hi Temp
Table 1. (Cont'd)
2-2
JUN 15190 Page 16
MODEL 90T400
Individual fault
lamps does not
light when FAULT
LAMP TEST push
button is pressed.
(Cont'd) CRIO-Overspeed
CR9-Low Oil pressure
Replace diode logic
board
Individual failure Defective diode. Check diode for open.
lamp does not light CR17-U/V
CR19-0/V
CR16-0/F
CRI5-U/F
CRIB-O/L
CR22-Hi Temp
CR21-0verspeed
• CR20-Low Oil Pressure
Table 1. (Cont'd)
2-2
JUN 15/90 Page 17
MODEL 90T400
LEGEND
Item No. Nomenclature Location and Functional

description
A2 Over/Under Voltage control Box Drawer: Protects

Module aircraft and generator from
over/undervoltage
conditions.
A3 Over/Under Frequency Control Box Drawer: Protects

Module Aircraft and Generator from
an over/under frequency
condition.
A4 Overload Module Control Box Drawer: Protects

generator from overload
condition.
AS Power Supply Module Control Box Drawer: Provides

Control voltage for
protective circuit card
operation and rectifies
voltage for field operation.
A6 Module, Diode Logic Control Box Drawer:

eering diodes for circuit
operation.
A7 Remote Sense Module Control Box Drawer: Allows

voltage regUlator to sense
load conditions at the end
of the cable. Precise
voltage regulation is main-
tained at the cable end
under all load conditions.
AS Electronic Governor Control Box drawer: Governor
Control Box System - Provides Engine
speed control, gain and
stability.
Act. Actuator Engine: Governor System -
Electronic fuel control
actuator. Receives signal
from AS and moves throttle
linkage to control engine
speed.
ALT Alternator, Engine Engine: Battery Charging.
Schematic Drawings and Wiring Diagrams 2-2

JUN 15190 Table 2 Page 18
MODEL 90T400
LEGEND
description
AVR Voltage Regulator control Box Drawer:

maintains voltage at preset
level under all load
conditions.
B1 Battery Battery Box:- 12 VDC source

for engine starting.
C8 capacitor contactor Panel: Low oil

pressure Fault delay.
Provides voltage to K8 after
513 is released. C8
discharges through K8 coil
and sustains K8 in energized
state (approx 4 seconds) to
allow engine oil pressure to
pressurize above 6 psi
before K8 returns to its
N.C. position.
CB1 Circuit Breaker Engine Panel: Protects

Governor Control Box and
harness.
CB2 Circuit Breaker, 5a Engine Panel: Instruments

and harness protection
CB3 Circuit Breaker, 15a Engine Panel: Ignition and
harness protection.
CB4 Circuit Breaker 5a Generator Control Panel:

Provides protection to
generator circuits and
harness.
CB5 Circuit Breaker 5a Control Box Drawer: Power

supply protection.
CR9,10,11 Diode Diode Logic PC Board: Lamp

Test Circuit - provides for
1 point ground to lamps test
D814, D815 and D816.
CR20 Diode Diode Logic PC Board: Engine
fault circuit - Isolates K7
to during lamp test of D814.

JUN 15/90 Table 2 Page 19
MODEL 9OT400
LEGEND
description
CR2l Diode Diode Logic PC Board: Engine

during lamp test of DS16.

during lamp test of DS15.

fault circuit. Isolates
oil pressure switch from
other fault indicators.

fault circuit. Isolates
overspeed switch from other
fault indicators.

fault circuit. Isolates high
temperature circuit from
other fault indicators.
CR40 Diode Contactor Panel: Low oil

pressure fault delay.
Prevents C8 from discharging
through starter solenoid.
CR50 Rectifier, Bridge T4 Transformer, Rectifies
control voltage for load
contactor.
CTl Current Transformer contact or Panel: Provides

current signal (A phase) to
power supply module then to
overload module.
CT2 Current Transformer contactor Panel: Provides

current signal (B phase) to
overload module.

MODEL 9OT400
LEGEND

description
CT3 Current Transformer Contactor Panel: Provides
current signal (C phase) to
overload module.
CT4 Meter Transformer Contactor Panel: Provides
current signal for A phase
ammeter readings.
CTS Meter Transformer Contactor Panel: Provides
current signal for B phase
ammeter readings.
CT6 Meter Transformer Contactor Panel: Provides
current signal for C phase
ammeter readings.
DSS Lamp Engine Panel: Illuminates
MlO.
DS2 Indicator, Load ON Generator Control Panel:
Illuminates when load ,
contact or is energized and
generator voltage is applied
to load.
DS7 Indicator, Overload Generator Control Panel:
Illuminates when overload
fault has occurred.
Dsa Indicator, Overvoltage Generator Control Panel:
Illuminates when an
overvoltage condition has
occurred.
DS9 Indicator, Undervoltage Generator Control Panel:
Illuminates when an
undervoltage condition has
occurred.
DSI0 Indicator Underfreq. Generator Control Panel:
Illuminates when an
under frequency condition has
occurred.
schematic Drawings and Wiring Diagrams 2-2

lUN 15/90 Table 2 Page 21
---.--, -·---------i .. ---- ~~-

MODEL 9OT400
LEGEND
description
DSll Indicator, Overfreq. Generator Control Panel:

Illuminates when an
overfrequency condition has
occurred.
DS14 Fault Indicator, L/oil Engine Panel: Illuminates

when a low oil fault
condition has occurred.
DS15 Fault Indicator W/Temp. Engine Panel: Illuminates

when high water temperature
fault condition exists.
DS16 Fault Indicator, Engine Panel: Illuminates

O/Speed when an overspeed fault
condition occurs.
DS17 Lamp Canopy: Illuminates GPU

control panels.
DS21 lamp Indicator Engine Panel: illuminates

when ignition switch Sl is
place to ON.
DS31 Lamp Engine Panel: Illuminates

MS.
F1 Fuse, 35a contactor Panel: Harness
protect.
F2 Fuse, 20a contactor Panel:- Main

power/Harness protect.
F3 Fuse 5a Control Box Drawer: Harness
Instrumentation protection
(A phase).

(B phase).
(C phase).
F6 Fuse 5a Control Box Drawer: Remote
Sensing, A phase protection.

MODEL 90T400
LEGEND
description

Sensing, B phase protection.

Sensing, C phase protection.
Kl Relay, Output contactor Panel: Applies or

contactor disconnects generator output
voltage from load.
K2 Relay, Hold-in Relay Module Board: Hold-in
relay for Kl contactor.
K4 Relay, Relay Module Board: Discon-
nects output contactor from
load during any detected
generator fault condition.
K5 Relay Relay Module Board: Provide
discharge path for capacitor
on overload module during
Fault Reset function.
K6 Relay Relay Module Board: Discon-
nects voltage regulator
(AVR) during overvoltage and
overload conditions.
K7 Relay, Engine Fault Relay PC Board assembly in
control box drawer. Provides
voltage to fuel solenoid
through N.C. contacts.
Interrupts power to fuel
solenoid when energized by
any engine fault detection
circuit.
K8 Relay contactor Panel: Low oil
pressure fault Delay.
Interrupts low oil pressure
fault circuit when
energized, enables fault
circuit in N.C. position.

MODEL 90T400
LEGEND
description
KIO Relay, Interlock Relay Module Board: Provides

ground for K2 relay when
Generator Interlock/Bypass
switch is placed in the
Interlock position.
K42 Relay Contactor Panel: Removes

power to hourmeter MI2 when
energized. K42 is
energized whenever engine
oil pressure is less than 6
psi.
MI Meter, Amperage Generator Control Panel:

Indicates amount of current
being drawn by load.
M2 Meter, Voltage Generator Control Panel:

Indicates generator voltage.
M7 Meter, Frequency Generator Control Panel:

Indicates Frequency of
generator.
M8 Meter, Fuel Level Engine Panel: Displays fuel
level.
MIO Meter, water Engine Panel: Displays
Temperature engine water temperature.
MI2 Hourmeter Engine Panel: Records engine

operating time.
Mag PU Magnetic Pickup Engine: Governor System -
Provides engine speed signal
to governor control from
engine flywheel.
R8 Potentiometer Control Panel: Governor
System - Provides operator
control for engine/frequency
trim.

MODEL 90T400
LEGEND
description
R9 Resistor contactor Panel: Low oil

pressure fault delay.
Current limiting to prevent
CB3 from tripping or F2 from
blowing when C8 is charging.
Sl switch, Ignition Engine Panel: Main Power

ON/OFF
S2 switch, Ammeter Phase Generator Control Panel:

Selects desired phase for
amperage monitoring.
S3 switch, volt Phase Generator Control Panel:

Selector Indicates line to neutral
voltage.
Sll switch, Fault Reset Generator Control Panel:
Resets generator fault
circuits.
S13 switch , start Engine Panel: Push Button

switch engages starter
mot;or.
S14 switch IDLE/RUN Engine Panel:

Governor/Generating System -
Two position switch, IDLE
position = 800 RPM, RUN
position = 2400 RPM for
S16 switch, Oil Pressure Engine: Low oil pressure
fault circuit. N.C. switch
opens on rise of oil
pressure to above 6 psi.
Closes below 6 psi and
activates low oil fault
circuit.
S17 switch, Temperature Engine: Engine fault circuit
- N.O. switch closes of rise
when engine water temper-
ature rises above 210 0 F.
activating the engine high
water fault temperature
circuit.

- ---cr.,.,-- - -
TRILECfRON INDUSTRIES INC.

MODEL 9OT400
LEGEND
518 switch, Panel lights Engine Panel: Operates panel

lamp 0517.
519 switch, Overspeed Engine: Engine fault circuit

- N.O., tach drive driven
switch, closes of engine
rise above 2550 RPM.
521 switch, Pushbutton N.O. Generator Control Panel:

Press-to-test fault lights.
532 switch, Pushbutton N.O. Generator control Panel:
simulates overload
condition.
simulates Underfrequency
condition.
simulates Overfrequency
Sender, oil Pressure Engine: Provides oil
pressure signal for M9.
Sender, water Temp. Engine: Provides water
temperature signal for MIO.
Sender, Fuel level Fuel Tank: Provides fuel
level signal for M8.
schematic Drawings and Wiring Diagrams 2-2

MODEL 9OT400 .
DlSTRIDUTOR TYPE
INmcnON rUMP
~--
t
INlfiE~CT;;;:o;:R=S===~ RETURN LIN B l
nIT'
PRIMARY/SECONDARY
SEPARATOR/FILTER SPIN-ON FILTER CASE
WITn WATER DRAIN
FUEL TANK
Fuel System Schematic

Figure 9
.'-
:.t;;:, -.
2-2
JUN 15/90 Page 35
MODEL 9OT400
REMOYALIINSTALLATIQN
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. Component boards can be
unplugged, and mounting hardware removed.
Removal/Installation instructions for engine subassemblies
i.e., water pump, fuel pump injectors etc., can be found in
the: Cummins TROUBLESHOOTING and Repair Manual B Series
En~ines, Shop Manual B Series Engine or the operation and
Ma1ntenance Manual B Series Engines. These manuals are located
in the appendices.
2. TORQUE VALUES FOR GENERAL ASSEMBLY.
The torque chart value (see Table 1) are provided for 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 to
Chapter 5, Manufacturers' 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:
A. Joints are assumed to be metal and rigid. Do not use these

values where gaskets or compressed material may be damaged
by over-torquing.
B. During disassembly, note bolt head marking and always

reassemble the same hardware or equivalent new hardware in
the correct locations.
C. As a general, when reusing previously removed hardware,

apply the minimum values form table 1.
D. Reduce the Table 1 values by 20 % when assembling plated

hardware or phosphate coated hardware.
E. Reduce Table 1 values by 30% when molykote, white lead, or
similar mixtures are used to lubricate threads.
F. Reduce the Table 1 values by 35% when torquing jam nuts

(thin nuts).
G. Special use column values in Table 1 are for capscrews in

gray iron castings when threads length engagement is at
least 1.5 times the capscrew diameter.
2-3
JUN 15190 Page 1
MODEL 9OT400
TABLE 1
Torque Values For General Assembly
0 TYPE 2
0TYPE 5
0 TYPE B
BOll
LENG Til BOLT
BOLT on OVER 6 LENGTlI
SfUD INCilfS AND 6 III(IIES SPE(IAL NOnl1AI
01 MIE TER HELD BOLTS AND LESS 5 IUDS USE USE
MI N. MAX. MIN. MAX. "IN. flAX. HIll. MAX. filII. ~IAX . MIN. HAX.
114 3 3 5 6 5 6 9 10 II 13 12 14
5/16 6 7 12 13 12 13 19 21 24 27 27 30
3/8 11 13 21 24 21 24 23 37 43 47 45 50
7116 19 21 35 38 35 38 53 60 69 76 75 85
1/2 29 32 52 58 52 58 80 90 104 117 115 130
9116 41 46 70 80 70 80 115 130 150 170 165 185
5/8 57 63 98 110 98 110 160 180 210 2 )0 220 250
3/4 100 112 174 195 174 195 290 320 350 390 400 45')
718 162 181 162 1B I 300 3)0 420 470 570 6)0 650 ))"
I 250 270 250 2 70 420 4 70 6)0 710 850 950 970 1090
1 1/8 350 380 )50 380 600 660 850 950 1200 1350 1380 1550
1 1/4 490 540 490 540 840 940 1200 1350 1700 1900 1940 21RO
1 3/B 640 710 640 710 1100 12)0 1570 1760 2)00 2500 2600 ?ROO
1 1/2 850 940 850 940 1470 1640 2000 2)00 3000 ))00 )]00 ) 70u
I )/4 1330 1490 1330 1490 2350 2450 )]00 )700 4700 5200 5300 6000
2 2000 2200 2000 2200 )500 3900 5000 5500 7000 HOO 8000 9001)
2-3
]UN 15/90 I Page 2
MODEL 90T400
3. PREPARATION
WARNING: BEFORE STARTING ANY INSTALLATION OR REMOVAL PROCEDURES
PERFORM THE FOLLOWING:
A. TURN THE ENGINE OFF BY PLACING THE IGNITION SWITCH TO THE

OFF POSITION.
B. DISCONNECT THE NEGATIVE GROUND LEAD OF THE BATTERY BEFORE

DISCONNECTING THE POSITIVE LEAD.
4. ENGINE/GENERATOR REMOVAL
A. Canopy Removal (Refer to Chapter 4-4, Figure 7)
(1) Open front canopy half (2) and support canopy by placing a
suitable brace of at least 36 inches in height under
canopy. This will prevent the canopy from falling once the
canopy retaining rods are removed.
(2) Remove bolt (23) and nut (25) and remove retaining
rods.
(3) Tem~orarily place brake handle in vertical (up)
pos1tion to facilitate removal of canopy roof.
(4) Lift canopy roof off of brace and slide entire
assembly until hinge assemble separates.
(6) Set hand brake.
(7) Repeat steps a, b, and d to remove rear canopy roof.
B. Engine
(1) Loosen radiator shroud.
(2 ) Disconnect and cap fuel pressure and return lines.
(3) Drain engine coolant (5.5 gals.). Refer to cooling
system maintenance section 2-3.
(4) Disconnect upper and lower radiator hoses from the
engine. (See Figure 4)
(5) Disconnect engine coolant heater hoses. One on each
side of the engine.
(6) Disconnect engine ground wire.
(7) Disconnect electrical wires leading to fuel tank
sending unit.
C. Electrical (Refer to wiring diagrams in Chapter 2).
2-3
JUN 15190 Page 3
TRILECTRON INDUSTRIES' INC.
MODEL 90T400
Mount Bolts
Bridge Assembly
Figure 1.
2-3
JUN 15/90 , Page 4
· TRILECTRON INDUSTRIES INC.
MODEL 9OT400
mp
eO
)~
u o
Engine and Generator Assembly

Figure 2.
2-3
,
JUN \5/90 , Page 5
MODEL 90T400
NOTE: Tag/identify all leads required for disassembly.

Disassemble only to the extent necessary to
accomplish the repair.
(1) Disconnect AC output cable from Kl contactor and Terminal
Board 2 (TB2).
(2) Disconnect generator output wires from TBI on the Power
Panel Assembly Bridge.
(3) Disconnect and cap the fuel pressure and return lines.
(4) Remove six (6) bolts attaching bridge to frame. (Refer to
Figure 1).
(5) using a suitable lifting device and lift chain, lift bridge
assembly up and away from the generator.
(6) Install generator lifting eye bolt (Figure 2.) into stator
housing.
D. Exhaust System Removal
(1) Loosen and remove the V-band clamp connecting the exhaust
piping to the turbocharger.
(2) Remove muffler and exhaust pipes by removing the 4 bolts
attaching 2 universal hangers ori the side of the engine.
E. Engine/Generator Removal (Refer to Figure 2)
CAUTION: WHEN LIFTING THE ENGINE AND GENERATOR, USE A HOIST

WITH LIFTING CAPABILITY OF AT LEAST 3000 LBS.
CAUTION: MAKE SURE THE LIFTING CHAINS ARE POSITIONED TO ALLOW
THE ENGINE/GENERATOR TO BE LIFTED HORIZONTALLY FROM
THE UNIT.
(1) Using a lifting hoist and chains, attach chains to the

front engine lifting eyelet and the generator lifting eye
bolt.
WARNING: BEFORE REMOVING THE ENGINE/GENERATOR MOUNT 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 MOUNT BOLTS ARE
LOOSENED.
2-3
JUN 15190 Page 6
MODEL 90T400
(2) Remove front and rear mount bolts securing

engine/generator to frame Refer to Figure 3.
(3) Lift engine and generator from unit.
1. Front Engine Mount 2. Rear Engine Mounts
Engine Generator Assembly (3 'Point Mount) .

Figure 3.
CAUTION: DO NOT PLACE ENGINE/GENERATOR DIRECTLY ON GROUND.

DAMAGE TO ENGINE OIL PAN WILL RESULT. PLACE AN 8 1/2
INCH WOODEN BLOCK UNDER THE FRONT ENGINE MOUNT
BRACKET AND AT LEAST A 3 INCH BLOCK ON EACH SIDE OF
THE GENERATOR, BENEATH THE WELDED GENERATOR SUPPORT
BRACES.
5. ENGINE/GENERATOR INSTALLATION
WARNING: UTILIZE TORQUE VALUES FOR GENERAL ASSEMBLY (TABLE 1

CHAPTER 2-3) WHEN INSTALLING ENGINE/GENERATOR MOUNT
BOLTS AND OTHER ATTACHING HARDWARE.
A. Preparation.
(1) Install front engine mount to engine.
2-3
JUN 15/90 , Page 7
MODEL 90T400
(2) Attach the two rear engine mounts to fly wheel housing (4
bolts per assembly).
(3) Install generator lifting eye bolt to stator housing.
CAUTION: WHEN LIFTING THE ENGINE AND GENERATOR, USE A HOIST

WITH LIFTING CAPACITY OF AT LEAST 3000 LBS.
(4) Attach a suitable hoist to front engine lifting eyelet and

to generator lifting eye bolt.
B. Installation
CAUTION: BEFORE INSTALLING ENGINE/GENERATOR, INSPECT EACH

SNUBBER WASHER FOR SERVICEABILITY. REPLACE IF CRACKED
OR FOUND TO BE OTHERWISE DEFECTIVE.
(1) Align engine mounts with snubber washers installed in

frame.
(2) Install three engine mount bolts and torque.
,
C. Engine attachments
(1) Attach fuel pressure and return lines.
CAUTION: V-BAND CLAMP ATTACHING EXHAUST PIPE TO TURBOCHARGER

MUST BE SECURELY FASTENED AND TORQUED.
(2) Install exhaust system

(3) Install radiator shroud.
(4) Attach upper and lower radiator hoses.
(5) Attach heater hoses, one on each side of engine block.
(6) Add engine coolant (Refer to Servicing, Chapter 2).
(7) Attach wires leading to fuel tank sending unit.
(7) Install engine ground wire.
(8) Install Assembly Bridge, secure with 6 bolts.

(10) Attach all electrical wiring (Refer to wiring diagrams,
Chapter 2).
2-3
JUN 15190 Page 8
J.

MODEL 9OT400
6. GENERATOR REMOVAL/INSTALLATION
To Remove only the generator proceed as follows:
A. Electrical Disassembly
NOTE: Tag/identify all electrical leads required for

disassembly. Disassemble only to the extent
necessary to accomplish the repair.
(1) Electrical wiring.

(Refer to wiring diagrams in Chapter 2).
(a) Disconnect AC output cable from K1 contactor and

Terminal Board 2 (TB2).
(b) Disconnect generator output wires from TB1 on the

Power Panel Assembly Bridge.
(c) Disconnect engine ground wire from frame.

(d) Disconnect the three (3) electrical connectors and
slide the control panel component drawer assembly
completely out of the enclosure.
(e) Disconnect and cap the fuei pressure and return lines.
(f) Remove Assembly Bridge (Refer Figure 1).
~. Remove six (6) bolts attaching bridge to

frame.
~. using a suitable lifting device and lifting

chain, lift bridge assembly up and away from
the generator.
B. Generator Removal
(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.
2-3
JUN 15190 Page 9
,:~ ,

MODEL 90T400
(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
WARNING: UTILIZE TORQUE VALUES FOR GENERAL ASSEMBLY (TABLE 1

CHAPTER 2-3) WHEN ATTACHING THE ENGINE TO GENERATOR,
OR ATTACHING FLEX COUPLING TO FLYWHEEL, TIGHTENING TilE
FAN ASSEMBLY AND WHEN INSTALLING ENGINE/GENERATOR
MOUNT BOLTS
(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.

(9) Remove generator lifting eye bolt and secure to stator
housing using 3 x 3/4 inch bolt provided.
(10) Install Assembly Bridge and attach all wiring.
2-3
JUN 15/90 Page 10
MODEL 90T400
7. COOLING SYSTEM
A. Radiator removal (Refer to Figure 4.)
(1) obtain a container large enough to hold 13 quarts.
(2) Open Radiator access door, remove radiator cap.
(3) Open radiator petcock and drain coolant into

container.
(4) After coolant has been completely drained from the

engine, close petcock.
(5) Remove canopy shell to gain access to radiator and

engine.
(6) Loosen hose clamps and separate both hoses (Top and
Bottom) from radiator.
~;, I
I
I
I
,',' I
~J
1. Fan
• • 2. Radiator hose (Upper)
3. Bolts, Radiator support
4. Drain Pet cock
5. Radiator hose (Lower)
Radiator Assembly
Figure 4.
2-3
JUN 15190 ,Page 11
MODEL 9OT400
CAUTION: THE RADIATOR IS HELD IN PLACE BY SIX MOUNT BOLTS

(THREE ON EACH SIDE). SELECT A SUITABLE HOIST TO
SUPPORT RADIATOR WHEN REMOVING THE MOUNT BOLTS. BE
CAREFUL NOT TO DAMAGE FAN BLADES OR SHROUD WHEN
REMOVING RADIATOR.
(7) Remove six bolts, (Figure 4 item 3) 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 Figure 4.)

(1) position shroud on radiator and secure with eight (8)
screws, lock washers and flat washers.
CAUTION: BE CAREFUL NOT 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 was'hers
and flat washers.
(5) Attach hoses to radiator (Top and Bottom), position and
tighten both hose clamps.
(6) Close drain petcock before servicing cooling system (Refer
to Figure 4.).
8. ENGINE OIL CHANGE
A. Change the full-flow (spin-on) filter each time the oil is

changed:
NOTE: If lubricating oil is drained immediately after
the unit has been run for some time, most of the
sediment will be in suspension and will drain
readily.
2-3
JUN 15190 Page 12
MODEL 90T400
CAUTION: DO NOT USE SOLVENTS AS FLUSHING OIL IN RUNNING

ENGINES. ALWAYS USE CLEAN CONTAINERS. FUNNELS ETC.
(1) Provide a container for catching used oil. Capacity should

be greater than 5 gallons.
(2) Remove the drain plug and allow oil to drain completely.
(3) Change the oil filter cartridge.

(a) Unscrew the spin-on filter from the filter head;
discard the filter.
(b) Apply a light even coat of lubricating oil to the

gasket sealing surface of the new filter prior to
installing.
(c) position the filter to the filter head. Tighten by
hand until the seal touches the filter head; tighten
an additional one turn.
(4) Clean the drain plug and install securely after engine oil
has drained completely.
(5) Remove oil filler cap, or valve cover cap (See Chapter 2-1
Figure 2) and refill the system with new clean oil, which
meets engine manufacturer's recommendations. (See Chapter
2-1, Table 1)
CAUTION: 1. DO NOT FORGET TO REINSTALL THE DRAIN PLUG.

2. INSTALL A NEW OIL FILTER.
(6) Install filler cap and check oil level on dipstick. It

should indicate over full until the engine is started and
oil is circulated to fill the oil filters.
9. AIR CLEANER
A. The air cleaner is a dry type with a replaceable filter

cartridge. A definite time schedule for changing the filter
cartridge cannot be determined because of varying operating
and environmental conditions. To change the cartridge
perform the following: ( see Figure 5).
2-3
JUN 15190 Page 13
MOnEL 90T400
Air Cleaner cartridge Replacement

. Figure 5
(1) Unscrew the wingnut.
(2) Remove cover and second wingnut.

(3) Remove and discard cartridge.
(4) Install new cartridge.
(5) Replace wingnut and cover.
10. Maintenance/Repair Generator Control Box.

A. Disassembly
(1) Open generator control box.
(2) Remove the generator control box by disconnecting the

three electrical connectors located at the rear of the
control box.
(3) Press the tabs inward on the control box slides (each
side of the drawer and pull the control box away from
the enclosure. Place the control box assembly on work
a bench.
2-3
JUN 15/90 ,Page 14
...:.- •.. ~Ii

MODEL 90T400
(4) Disconnect the electrical connector or wiring attached

to the component that is to be replaced.
(5) Remove screws securing component assembly, then remove

component.
B. Reassembly
Reassemble generator control box drawer and components in
the reverse order of disassembly.
C. Circuit Card Adjustments

All circuit cards are preset at the factory. In most in-
stances adjustments will not be necessary after
installation of the circuit card. If after installation
fine tuning of the circuit card is necessary to obtain
optimum performance, follow procedures listed for each
circuit card.
~, .
'~"
ADJUST R32
Automatic Voltage Regulator (AVR) module

Figure 6
2-3
,
JUN 15/90 Page 15
MODEL 90T400
(1) Automatic Voltage Regulator (AVR) module (See Figure

6) •
(a) Start unit in accordance with normal start proce-

dures.
(b) Place RUN/IDLE switch to the RUN position.
(c) Adjust the voltage adjustment potentiometer (R5)
on the GPU instrument panel at mid range between
minimum and maximum settings.
(d) Adjust R32 on the AVR board obtain 115 VDC line
to neutral.
NOTE: Counter-clockwise rotation (R32) increases volt-

age.
"B" "ott
o o
.a-~IIC"
CI
WI
PI
o
AC Overload Module
Figure 7
2-3
JUN IS/90 ,Page 16
.. .;,:..,,:-,.- ................. .... ',...-:;.
. . • .-....&,
--,'

MODEL 90T400
(2) AC Overload Module (See Figure 7)

(a) Start unit in accordance with normal start procedures.
(b) Place RUN/IDLE switch to the RUN position and verify
115 VAC on the voltmeter. ."
(c) Place voltmeter at Test Point "B" and measure for 15 "
VDC +- 2 volts.
NOTE: If 15 VDC +- 2 volts is not present, replace cir-

cuit card.
(d) Place voltmeter at Test Point "C" and adjust R13 to

obtain 8 VDC.
(e) Turn R9 an R7 fully clockwise.
(f) Place voltmeter at Test Point "D" and adjust R4 to
obtain .85 VDC.
(g) Apply a 125% load to unit. Overload fault protection
shoulq activate between 3 to 5 minutes.
(3) Over/under Voltage Module (See Figure 8)

( a) Start unit in accordance with normal start proce-
dures.
(b) Place RUN/IDLE switch to the RUN position and
verify 115 VAC on the voltmeter.
(c) Place voltmeter at Test Point "A" and measure for
24 VDC +- 2 VDC •
. NOTE: If 24 VDC +- 2 VDC is not present, Check the power supply
module.
(d) Place voltmeter at Test Point "B" and measure for
15 VDC +- 2 volts.
NOTE: If 15 VDC +- 2 volts is not present, Replace circuit

card.
(e) Adjust R32 on voltage Regulator circuit card to

obtain 90 VAC indication on instrument panel
voltmeter.
2-3
JUN 15190 Page 17
" ',-, ---'-- .. "-!IF. '~"'-----'-'- ,""'''' .. i . _ , . . -.~- -;!'l+"

MODEL 90T400
o
to
o
t<>
I
'¢
'¢
PI
o ,0
' ' -_ _ _ IIAu
24 VDC ±2v (Pl-61
Over/Under Voltage Module

Figure 8
(f) Measure voltage at Test point 2 (TP2) on the cir-

cuit card.
(g) Place voltmeter at Test Point 3 (TP31. Adjust R10

to obtain the same voltage as TP2.
(hI Adjust R32 on the Voltage Regulator Circuit card
to obtain 115 VDC indication on the GPU
voltmeter.
(i) Clear faults by depressing fault reset switch
(Sl1) .
(j) Adjust R32 on the voltage regulator circuit card

to obtain 130 VAC indication on the GPU volt-
meter.
2-3
JUN 15190 Page 18
MODEL 9OT400
orpz
orPI
_--4- "B"
o
III
o
III
I
co
o
<OJ-
o o
"-----IIA"
24VDCt2v
(P1-9)
Over/Under Frequency Module

Figure 9
(k) Measure voltage at Test Point 2 (TP1).
(1) Place voltmeter at Test Point 1 (TP1). Adjust R9

to obtain the same voltage as TP2.
NOTE: Because the over-voltage condition will cause the

voltage regulator to shut off, it may be
necessary to depress the fault switch Sll during
the adjustment procedure.
(m) . Adjust R32 on the voltage regulator circuit card

to obtain 115 VAC on the GPU voltmeter.
2-3
JUN 15/90 ,Page 19
MODEL 9OT400
(4) over/Under Frequency Module (See Figure 9).

(a) Start unit in accordance with normal start procedures.
(b) Place RUN/IDLE switch to the RUN position and verify

115 VAC on the GPU voltmeter and 400 Hz on the GPU
frequency meter. Adjust if necessary.
(c) Place voltmeter at Test Point "A" and measure for 24

VDC +-2 volts.
NOTE: If 24 VDC +- 2 volts is not present , check power

supply module.
(d) Place voltmeter at Test Point 1 (TP1) and adjust R12

to obtain 1 VDC.
(e) Adjust governor control speed adjustment to obtain 380

Hz indication on the GPU frequency meter.
(f) Place voltmeter at Test Point 3 (TP3) and measure for

.954 VDC. Adjust R6 if necessary to obtain correct
measurement.
(g) Adjust governor control speed adjustment to obtain 400

Hz indication on GPU frequency meter.
(h) Clear fault by depressing Fault reset switch Sll on

the GPU instrument panel.
(i) Adjust governor control speed adjustment to obtain 420

(j) Place voltmeter at Test Point 2 (TP2) and measure for

1.045 VDC. Adjust R7 if necessary.
(k) Adjust governor control speed adjustment to obtain 400
Hz.
(1) Clear faults by depressing Fault Reset switch (Sll)on
2-3
JUN 15/90 Page 20
MODEL 9OT400
~-
REPAIR
GENERAL
This section contains general instructions for repair of
components in the Ground Power unit, Model 90T400. The need for
repair is usually identified during normal and periodic
servicing operation of the GPU, annotation of service records,
bulletins, etc.
A. Tires
Replace if tread shows signs of wear. Allowable tread wear
is generally a matter of common sense. However, the major
factors determining the condition of the tires may be such
things as sun damage/rot to the rubber, worn-out bearings
causing uneven wear, misaligned steering mechanism, etc. In
any case, the tread should not be less than 1/8 inch deep.
B. Engine
Refer to Chapter 5 Manufacturers' Appendices, for detailed

repair information.
C. Electrical Components
Control switches, circuits breakers, engine gauges, and

control valve solenoids are normally not considered to be
repairable. The normal procedure is to remove and replace
these components when defective.
Wire terminals should be cleaned, inspected for signs of

corrosion, and repaired as necessary.
2-4
JUN 15/90 Page 1
::::;,,;-

MODEL 90T400
CHAPTER 3
OYERHAULIMNOR REPAIR
TABLE OF CONTENTS
Chapter/Section Page
Overhaul Information 3-1
1. General ......................................................................................................... 1
3-CONTENTS
JUN 01190 Page 1
0--- - --'--.'.~''-'

MODEL 90T400
OVERHAUL INFORMATION
GENERAL
Under normal operating conditions and proper preventive
maintenance, the GPU should provide excellent service for a
period of 20,000 to 30,000 hours (depending on local
conditions). At this time the GPU should be sent to a qualified
depot. All work must be performed by qualified mechanical, and
electrical technicians, and should include replacement of
accessories as necessary.
3-1
JUN 15/90 Page I
MODEL 90T400
CHAPTER 4
ILLUSTRATED PARTS LISTS
TABLE OF CONTENTS
Figure Chapteri
Number section
Introduction 4-1
1. General .................................................................................................................. 1
2. How to Use The Illustrated Parts List .••••.•.••.....••..••......• l
Parts Procurement 4-2
Numeric Index 4-3

1. Introduction .......................................................................................................... 1
2.. Explanation of Columns ...................................................................................... 1
3. Alphanumeric Arrangement Sequence ••••.••.•...•......•••••••••.•.. l
4.. Sample Application .............................................................................................. 1
5.. Alphanumer ic .......................................................................................................... 2
Detailed Parts List 4-4

1. General ................................................................................................................... 1
A. Figure and Item Nomenclature •••••••..••.•...••...•..••.•••••.. 1
~ B. Part Number ...................................................................................................... 1
C. Nomenclature .......................................................................................... 1
D. uni ts Per Assembly ............................................................... 1
E. Index to Vendor Codes ............................................................... 2
F. Parts Lists ............................................................................. 4
1. Major Components ................................... 1 ..................... 4
2. Chassis Assembly............................. 2 . . . . . . . . . . . . . . . . . . . 6
3. Front Canopy Assembly .................. 3 . • . . . • . . . • . . . . . . 10
4. Rear Canopy Assembly... . .. . . . . . .. . .. . . . . .. 4 ................... 13
5. Window Frame .................................. 5 ..................... 16
6. Engine Instrument Panel .•.........•••.. 6 ••...•..••..•... 18
7. AC Control Panel.......................... 7 ....................... 20
8. Four Wheel Running Gear, 5TH Wheel .••.• 8 •..•.•.••••••... 23
9. 5th Wheel Assembly...................... 9 .................... 28
10. Engine and Chassis Assembly ••.••...... 10 •.•••.•••...•.•• 30
11. Chassis and Electrical Assembly ••.•••• 11 •..•......•••... 34
12. Battery and Cable Assembly •••••••••••• 12 •..••.•••••••... 36
13. Engine and Generator Assembly ••••.••.. 13 •..•...••••••... 38
14. Component Drawer Assembly •••••.••.•... 14 •••••.•••....... 41
15.. Fuel Tank Assembly.......................... 15 .................. 45
16. Fuel Filters and Hoses ................ 16 . . . . . . . . . . . . . . . . 47
17. Air Cleaner Assem.bly...................... 17 .................... 49
18. Exhaust System..................................... 18 .................... 50
19.. Radiator Assembly........................... 19 ....................... 52
20. Electronic Governor Installation ...... 20 •••.••.•.•...... 55
JUN 15/90 4-CONTENTS

REV 2 Page 1
MODEL 9OT400
INTRODUCTION
1. GENERAL
A. The illustrated Parts list is intended for use in
provisioning, requisitioning, storing and issuing
replaceable parts and in the identification of new and
reclaimed parts. It contains all parts in formation for
which maintenance is economically feasible.
2. HOW TO USE THE ILLUSTRATED PARTS LISTS

A. Figure Number - The figure identifies the illustration in
which the parts or the next higher assembly is shown. For
example, Figure 3 may show the brake assembly as a part of
the axle and Figure 4 shows the Brake assembly in an
exploded view.
B. Item Number - The item number on each illustration is

correlated to information provided in the detailed parts
list. For example, item 11 on Figure 3 may be Cone Roller
Bearings. Referring to the parts list for Figure 3, it is
possible to find additional information about the Bearing
for maintenance and supply purposes.
C. Detailed Parts List - The parts list provides the following

detailed information in the illustration to the listing.
(1) Figure and Item Number are given in the left hand column to
correlate the illustration to the listing.
(2) Part Numbers are shown in the second and third columns. In
the second column is the primary manufacturers part number.
If it is an item which has been reworked by the primary
equipment manufacturer, a notation in parenthesis following
the nomenclature will state "Modified from part number
made by (manufacturer's code)". In the third
~c~o'l~um==n is the sub vendor's part number, A component may
have one or both of the above.
(3) Nomenclature is shown in the forth column. The
identifying number or ke¥ word is given first, followed
by the balance of modifY1ng words of the part
description, For vendor items, the vendor's code, as
listed in Cataloging Handbook H4-1, federal Supply Codes
for Manufacturers. Vendor's codes are not listed for
common hardware items or for items or for items
manufactured by Trilectron. Those vendor codes preceded
by the letter "V" followed by five alphabetic characters
are abbreviation of vendors which are listed in detail
in Chapter 4-5, "Index to Vendor Codes".
4-1
JUN 15190 Page 1
f'

MODELT400
(i) Adjust governor control speed adjustment to obtain 420

(j) Place voltmeter at'Test Point 2 (TP2) and measure for
1.045 VDC. Adjust R7 if necessary.
(k) Turn governor control speed potentiometer to obtain 400
Hz.
(1) Clear faults by pressing Fault Reset switch (S11) on

(5) Electronic Governor Adjustments.
(a) Magnetic Pickup:

with engine stopped, adjust magnetic pick-up to
between .020 inches (0.45 mm) from flywheel ring
teeth. Usually, backing out the speed sensor 3/4 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 c~anking.
,>
'-->,
o o
o 0
OVERSPEED RESETITRT
@ ®
OVERSPEED
.. I
SP.EED-&~ >
GA'N-~
STABILITY I
El~E3
o DROOP-~
• PICK-UP _ + ~
ACTuATonnBATTERY
- II , - , -•
I'OLE1
r"-r AUX lOV
I
•
ABCDEFGHJ KLMNP
o o
o I·
o
Electronic Governor Control
Figure 28
• 4-1
Page 7
TRAINING USE ONLY
MODELT400
(b) Electronic Governor (EG) , See Figure 28.
II WARNING II
AN OVERSPEED SHUTDOWN DEVICE, INDEPENDENT OF THE GOVERNOR SYSTEM
SHOULD BE PROVIDED TO PREVENT LOSS OF ENGINE CONTROL WHICH MAY
CAUSE PERSONAL INJURY OR EQUIPMENT DAMAGE. DO NOT RELY ON THE
INTERNAL ELECTRONIC SHUT DOWN TO PREVENT OVERSPEED. A SECONDARY
SHUT OFF DEVICE, SUCH AS A FUEL SOLENOID, SHOULD BE USE.
PERSONNEL SHOULD BE IN POSITION (STANDBY) TO TURN THE· IGNITION
SWITCH TO OFF IMMEDIATELY UPON DETECTING ENGINE OVERSPEED.
~ Before starting the engine GAIN and STABILITY

adjustments are set to the mid position.
~ Turn theCignitiQn switch to ON and observe the

actuator: It should momentarily move, but must
return to minimum fuel position.
1. Start engine. As engine cranks, the actuator

should move to the maximum fuel position until
the engine fires. The governor should control /
the engine at low idle s p e e d . " " ,-,,!
± If the engine is unstable after starting, turn

the GAIN and STABILITY adjustment
potentiometers counterclockwise until the
engine is stable.
~ Place IDLE/RUN switch on engine panel to RUN

position. Adjust governor speed to 2400 RPM by
turning the SPEED adjustment CLOCKWISE to
INCREASE engine RPM, or COUNTER-CLOCKWISE to
DECREASE engine RPM.
2 With engine at 2400 RPM and NO LOAD, rotate the \

GAIN adjustment until instability develops. ,
Gradually move the adjustment counterclockwise
until stability returns. Move the adjustment
one division further counterclockwise to insure
stable performance.
Z with engine at 2400 RPM and NO LOAD, rotate the

STABILITY adjustment clockwise until
instability develops. Gradually move the
adjustment counterclockwise until stability
returns. Move the adjustment one division
til further counterclockwise to insure stable
performance .
4-1
•
Page 8
TRAINING USE ONLY
MODELT400
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, place the IDLE/RUN switch to "IDLE"
position. The IDLE speed set point is INCREASED
by CLOCKWISE rotation of the IDLE adjustment
control. Adjust idle speed to 800 RPM.
(c) Overspeed Adjustment (See Figure 28).

The electronic governor performs over speed
sensing and will shut down the engine shoUld RPM
exceed approximately 2800. Adjustment for
•:,c. overspeed is located on the electronic governor .
1 Start unit in lAW normal starting procedures.
£ Place IDLE/RUN switch to RUN position.

~"
d Rotate SPEED adjustment potentiometer clockwise

until engine speed reaches 2800 RPM or engine
speed no longer in"creases.
r' . ~ Rotate OVERSPEED adjustment counterclockwise
until engine shuts down. The OVERSPEED
indicators located on the Electronic Governor
module (Upper left corner) and the indicator on
, : the control ~anel will illuminate. Rotate
OVERSPEED adJustment clockwise one half tu:t'n.
The overspeed circuit is now adjusted.
Reset the governor by pressing 'the RESET
pushbutton located on the Electronic Governor.
The Overspeed indicator on the Electronic
Governor and the indicator on the control panel
will go out.
Rotate the speed potentiometer counterclock-
wise one turn to prevent the engine from
reaching overspeed RPM the next time the engine
is started.
1. Start the engine, place the IDLE/RUN switch to

RUN then adjust engine speed down to 2400 RPM.
,:-.--
4-1
Page 9 I
TRAINING USE ONLY
MODELT400
(d) Governor Linkage Installation and Adjustment (See

Figure 29).
Move the actuator lever forward and rearward to
assure freedom apd proper travel.
Attach governor linkage to both the actuator
lever and to the fuel control rod.
Hold fuel control lever to MIN position and
adjust the actuator lever to vertical or 1/8
inch clockwise.
:I
I.
-.,
NOTE.
II rrU]
ADJUST TO FULL
OPEN POSITION FIRST
at'".V
'j"
• i
.
-------'~
I,t.,,,
Gov. ~--(5.19) Approx.--------, ,~
FUE"t Control Rod
Governor Linkage
Figure 29
g Move linkage back and forth to assure full fuel

travel an that there are no points of binding.
/
Additional adjustments to the electronic
gov~+nor may be required to ensure satisfactory /
I
operation under load. Adjust the electronic
governor as required (Gain-/Stability). See
electronic governor adjustments.
4-1
Page 10
TRAINING USE ONLY
MODEL 90T400
PARTSPRQCURENffiNT
For information regarding GSE field parts

procurement, refer to the:
Vehicle Maintenance and Administration
Policy and Procedure Manual.
Subject GSE Field Parts Order Procedures
References No. 2-30
4-2
JUN 15/90 Page 1
MODEL 90T400
NUMERIC INDEX
1. INTRODUCTION
A. The Numeric Index consists of an alphanumeric listing of
part numbers for the parts which comprise the GPU.
B. When a sub-vendor's part number is known, it will appear in

the left column of the numeric index. When a sub-vendors's
part number is unavailable, the prime vendor's number will
appear in the left column.
2. EXPLANATION OF COLUMNS
A. The first column contains the sub-vendor's or prime

vendor's part numbers. The part numbers are arranged in
alpha-numeric order as described in paragraphs 3 and 4.
B. The second column provides the figure number which

identifies the illustration in which the part or the next
higher assembly is shown.
(1) The figure number appears first, followed by a dash,

followed by the item number, When no item number is
~-- shown, the part will not appear on the illustration.
(2) It will, however, appear on the 'detailed parts list,

and descriptive data will be included.
3. ALPHANUMERIC ARRANGEMENT SEOUENCE
Part number arrangement begins at the left and continues to the

right, one position at a time.
NOTE: Numerical digits precede alpha characters.

Alphabetic O's are considered numeric zeros.
Dashes, asterisks, slashed and pounds precede
both alpha and numeric characters.
4. SAMPLE APPLICATION
The following list of part numbers is in correct alphanumeric
sequence:
AA-2702-1 ITLl-7
AA260503 10-24
C-1200-B 102
CDM-35 9-2448-11
FF*43-2 9002
FF1207-3 95
4-3
]UN 15/90 Page 1
MODEL 90T400
PRIMARY FIGURE & PRIMARY FIGURE &

PART NO. INDEX PART NO. INDEX
1-3612 8 6 5904 8 56
1-707-2006 8 20 5908 8 59
1-707-2006-2 8 21 5909 8 60
1-8209 8 37 5910-27 8 58
1-8300-400 8 68 6057 8 13
2-3612 8 24 6057 8 32
3-3502 8 51 6058 8 14
3-3502-03 8 52 6058 8 33
3603 8 7 6151 8 9
3603 8 25 6151 8 27
3712-1 8 46 6152 8 8
3712-2 8 47 6152 8 26
3855 8 17 6251-10 8 10
4-3712 8 44 6251-9 8 29
4-8209 8 38 6311 8 15
4006 8 19 6311 8 34
4600-2 8 3 6312 8 16
4600-2 8 36 6312 8 35
4601-47 8 49 6319-2 8 62
4601-5 8 42 6557 8 45
4601-5 8 65 707-2006F 8 1
4601-5 8 71 707-2006F-2 8 2
4601-6 8 11 8210 8 43
4601-6 8 30 8221 8 28
4700-4 8 41 8225 8 3'9
4700-4 8 50 8300-090 8 63
4700-5 8 12 8300-400 8 69
4700-5 8 31 9054A33 9 9
4702-2 8 4 A02909 2 57
4702-2 8 22 AA0044 10 40
4800-2 8 67 AA0063 3 7
4800-2 8 73 AA0063 4 14
4800-5 8 5 AA0063 5 17
4800-5 8 23 AH5001 21 2
4800-6 8 53 AH5003 21 4
4901-34 8 48 B01756 1 7
4901-7 8 40 B03387 13 27
5000-2 8 61 B03543 1 1
5000-5 8 18 B03546 13 4
5204 8 57 B03548 9 1
5205 8 64 B03549 9 3
5205 8 70 B03550 9 2
5206 8 66 B03558 1 2
5206 8 72 B03604 13 26
5416 8 54 B03608 1 3
5901R 8 55 B03641 2 5
4-3
JUN 15190 Page 2
MODEL 9OT400

B03649 4 1 B3551J 9 7
B03690 3 20 B3640B 3 2
B03692 3 21 B3640C 3 3
B03939 4 28 B3650A 4 3
B04023 2 25 B3650B 4 4
B04024 2 26 B4032A 2 34
B04064 3 22 B4032B 2 36
B04064 4 20 B4130A 2 4
B04069 7 3 B44900 2 55
B04079 11 33 B4490S 2 58
B04129 7 1 B4491A 2 52
B04171 1 11 B4491B 2 53
B04196 7 8 B4498B 11 28
B04201 7 6 B44980 11 29
B04213 4 2 B4498F 2 46
B04274 2 61 B5031M 20 13
B04301 13 3 B5141A 14 37
B04303 2 42 B5141B 14 38
B04303 7 9 B5157A 2 8
B04312 4 6 B5157B 2 31
B04316 1 13 B5158A 2 9
B04363 11 5 B5158A 10 44
B04370 1 5 B5158B 2 9
B04370 11 4 B5158B 10 4,8
B04404 13 37 BAOO09, 12 2
B04406 13 36 BAOO09 12A 2
B04574 2 62 BA5001 7 7
B04683 4 15 BA5001 12 1
B04732 2 44 BA5003 12A 1
B04862 2 47 B03585 17 10
B04888 2 40 B04304 5 1
B04902 2 51 B04306 5 2
B04991 14 45 B04307 5 6
B04992 14 32 B04308 5 12
B05126 14 15 B04309 5 11
B05160 10 41 B04319 5 3
B05161 10 37 B04320 5 21
B05172 2 6 B04384 13 1
B05315 11 35 C04025 3 25
B06041 6 1 C04173 16 1
B3148B 2 50 C04214 4 5
B31491 2 56 C04477 13 31
B33900 14 39 C04490 4 30
B3391C 2 60 C050005 14 27
B3432B 2 54 C05006 14 35
B3551-28 9 11 C05032 14 34
4-3
JUN 15/90 Page 3
TRILECTRON INDUSTRIES INC .
. GROUND POWER GENERATOR
MODEL 90T400

C3552-500016 21 6 FLOO02 16 8
C4067-500016 21 7 FLOO04 16 5
C431l-500026 5 13 FLOO19 16 10
C4490A 2 59 FMOOOI 16 6
CB5000 6 28 FMOOOI 16 7
CB5001 6 29 FM5002 16 9
CB5006 6 30 FUOO05 14 36
CY0025 16 14 GEOO02 13 2
CY0025 21 13 HB5007 9 8
CY0026 10 38 HDII00 11 34
CY0026 16 16 HDI175 11 10
CY0035 16 11 HFF050 15 7
CY0036 21 3 HFF075 2 27
CY0037 21 5 HFG075 16 12
CY5020 20 5 HFG088 11 6
CY5021 10 39 HFGI00 4 J1
CY5035 17 9 HFG150 10 42
CY5036 17 8 HFH063 21 8
EB5092 1 15 HFHI00 21 9
EB5092 15 4 HGH075 2 18
EB5094 20 1 HGH088 2 14
EB5095 20 6 HGH088 10 17
EB5100 1 6 HGH088 17 3
EB5100 17 1 HGHI00 2 1,5
EB5101 17 2 HGHI00 20 9
EB5102 17 7 HGH125 10 45
EB5123 17 11 HGH200 2 16
EB5146 1 10 HGH300 2 17
EB5146 20 7 HGI075 16 20
EB5148 20 4 HGII00 2 10
EB5149 20 3 HGQ300 9 4
EB5150 20 2 HGV500 10 31
EC0029 16 17 HGV500 13 12
EC0030 16 18 HPB038 14 46
EC0044 1 14 HPD063 6 17
EC0044 16 16 HPE050 4 17
EC5034 13 21 HROBBI 9 5
EGOO19 13 18 HRBCAI 14 47
EG0051 14 7 HRBCCI 14 49
EG5011 13 22 HRBCJl 14 48
FB0028 13 35 HRDCAI 6 16
FHOO16 14 33 HRDCAI 11 25
FI0028 15 3 HRDCAI 14 25
FI0045 13 28 HRDCBl 6 8
FI0147 16 4 HRDCBl 11 24
FI5119 16 22 HRDCBVI 4 19
4-3
JUN 15190 Page 4
MODEL 9OT400

HRDCC1 6 7 HRHEK1 2 22
HRDCC1 11 23 HRIAA1 11 13
HREAA1 6 33 HRIAB1 11 12
HRECA1 4 21 HRIAC1 11 11
HRECB1 4 18 HRIBA1 2 13
HRECB1 14 30 HRIBA1 10 16
HRECC1 14 29 HRIBB1 2 12
HRFCA1 2 30 HRIBB1 10 15
HRFCA1 5 10 .HRIBB1 16 21
HRFCA1 10 23 HRIBC1 2 11
HRFCA1 11 19 HRIBC1 10 14
HRFCA1 11 20 HRKBB1 10 36
HRFCB1 2 29 HRKBB1 13 33
HRFCB1 5 9 HRKBB1 16 3
HRFCB1 10 22 HRKCB1 9 10
HRFCB1 14 56 HROAA1 9 6
HRFCC1 2 28 HRVBA1 10 34
HRFCC1 4 22 HRVBB1 10 33
HRFCC1 5 8 HRVBB1 13 14
HRFCC1 10 21 HRVBC1 10 32
HRFCC1 11 18 HRVBC1 13 13
HRFCC1 14 19 HRVBK1 13 11
HRGBA1 10 43 HTHBA1 2 21
HRGBA1 11 9 HTHBB1 2 20
HRGBB1 4 33 HTHBC1 2 19
HRGBB1 11 8 HV5064 2 24
HRGBB1 15 8 HWD038 14 18
HRGBB1 16 13 HWD063 14 24
HRGBB1 17 5 HWD075 11 22
HRGBC1 3 14 HWE038 14 28
HRGBC1 4 32 HWF050 10 20
HRGBC1 11 7 HWF050 14 55
HRGCB1 7 11 HWF063 11 21
HRGCC1 7 10 HWF075 2 43
HRGEK1 2 32 HWF075 14 9
HRHBA1 17 6 HWF088 5 7
HRHBA1 20 12 HWF100 11 17
HRHBA1 21 12 ILOO04 6 11
HRHBB1 10 19 IL0016 6 2
HRHBB1 13 29 IL0072 6 10
HRHBB1 20 11 IL5012 6 13
HRHBB1 21 11 IL5012 6 26
HRHBC1 10 18 IL5014 4 16
HRHBC1 17 4 IN0026 3 24
HRHBC1 20 10 IN0026 4 26
HRHBC1 21 10 IN0033 5 18
4-3
JUN 15/90 PageS
MODEL 90T400

IN0033 7 2 L010523 14 4
IN5006 3 6 L01054 14 2
IN5006 3 28 L01154 14 11
IN5006 4 12 L01324 14 5
IN5006 5 16 L01492 14 10
IN5007 5 5 L01901 14 6
IN5007 5 15 L01921 14 8
IWFBBl 11 32 L1429B 14 14
IWFBCl 11 31 LF3546 10 13
IWHBBl 10 28 LF3604 10 9
IWHBBl 13 10 LF3699 15 5
IYD080 13 30 LF3916 3 4
IYF035 10 35 LF4010 10 3
IYF035 13 34 LF4027 10 7
IYF035 16 2 LF4046B 10 2
IYF036 11 30 LF4065 2 1
IYH090 10 27 LF4128 10 11
IYH090 13 9 LF4131 2 7
KH0034 3 23 LF4212 2 2
KH0118 3 18 LF4215 10 12
KH0118 4 25 LF4300 10 5
KH0118 5 19 LF4343 11 3
KH0119 4 10 LF4423 10 8
KH0131 3 5 LF4496 10 10
KHOl31 4 7 LF4498-6 12 '3
KH0134 7 5 LF449S-6 12 4
KH0139 4 8 LF4498-6 12A 3
KH0150 14 54 LF4498-6 12A 4
KH5006 7 4 LF4498-6 12A 5
KH5015 14 17 LF4498-6 12A 6
KH5040 2 39 LF4724 15 1
KH5050 14 1 LF4725 10 6
KH5059 14 53 LF5256 2 63
KH5064 2 49 LF5261 2 64
KH5069 13 32 LF5442 11 2
KH5076 14 52 LF6005 10 1
KH5096 2 33 LF6006 10 4
KH5097 2 35 LF6010 11 1
KH5099 2 37 LF6011 2 3
KH5100 2 38 LF6040B 14 50
KH5102 4 27 L01055 14 3
KH5102 14 41 LOF3636 3 1
KH5112 5 22 MA0052 6 6
KH5127 3 29 MEOO03 6 22
KH5127 4 9 MEOO05 6 35
KH5135 14 31 MEOO07 13 19
4-3
JUN 15190 Page 6
MODEL 90T400

MEOO08 15 2 VMOO02 10 24
MEOO09 13 25 VM0010 10 2~
MEOO12 6 34 VM00102 13 ~
MEOO13 6 15 VM0011 10 2E
MEOO14 6 21 VM0011 13 6
MEOO16 6 32 VMOO13 10 29
MFOO02 6 20 VMOO13 13 7
MS1106 11 27 VMOO14 10 3C
MS1118 14 13 VMOO14 13 8
MV0032 6 18 WI0050 4 13
MV0041 6 19 WL0091 4 11
NVOO05 1 8
NVOO05 21 1
RA2152 14 26
SA0024 14 23
SA5014 2 23
SA5021 14 51
SL5033 4 23
SPOO19 6 31
SP0021 4 29
SP5008 6 23
SP5008 14 42
SP5012 14 43
SP5013 6 4
SP5014 6 3
SP5012 6 24
SPOO21 6 12
SPOO21 14 44
SROO19 13 24
SR0069 13 23
SR5005 13 20
SR5012 15 6
SR0061 6 5
ST0011 6 9
ST0020 14 40
ST0049 6 25
ST0049 14 16
ST5017 6 14
STOO23 6 27
TB1116 11 26
TB1119 14 12
TR5003 1 12
TR5050 1 16
TR5112 1 9
TSOO07 15 9
VA5000 21 14
4-3
JUN 15/90 Page 7
.
..•.'
. TRILECTRON INDUSTRIES INC.

MODEL 9OT400
DETAILED PARTS LIST
GENERAL
This section contains an explanation of each column in the
detailed parts list. Illustrations and detailed parts lists of
all assemblies used in the Ground Power unit are contained in
sequence. (Refer to Chapter 4, Table of Contents for assemblies
and sections).
1. FIGURE AND ITEM NUMBER
This column provides a cross-reference between the parts
listed and the illustrations. To find a view of the parts
listed and its visual relationship to the assembly, locate
the figure and item number. To find a part number and
description in the parts list, locate the part on an
illustration, note the item number then refer to the parts
list and locate the applicable part number and description.
2. PART NUMBER
This column lists the part number necessary for ordering
repair parts, For ordering instructions, refer to
Chapter/Section 4-2 Parts Procurement.
3. NOMENCLATURE
This column lists the description of each item in the parts
lists. The identifying noun or key word is the first word
in the nomenclature column. The remainder of the column
contains an expanded description to assist in completely
identifying the item. The vendor's code preceded by the
letter "V" is found in parentheses after the nomenclature.
Those vendor codes preceded by the letter "V" followed by
five alphabetic characters are abbreviation of vendors
which are listed in detail in Chapter 4-4, "Index To Vendor
Codes".
4. UNITS PER ASSEMBLY
This column indicates the quantity of each part required to
complete the next higher assembly. The abbreviation REF
indicates a part number referenced to another list. This
ensures the quantity shown on the list does not exceed the
quantity used on the unit.
4-4
JUN 15/90 Page 1
MODEL 9OT400
INDEX TO VENDOR COPES
The following index provides information for vendor codes found

in the parts lists and whose nomenclature begin with the letter
"V" and are followed by five alphabetic characters. These
supply codes are abbreviation of vendors which are listed in
detail with their most current addresses and telephone numbers
available at the time of writing.
VENDORS NAMES AND ADPRESS

CODE
TELEPHONE
131532 BROWNELL ELECTRO 800-365-3343

307 25TH ST
ORLANLDO, FL 32806
237414 CUMMINS SOUTHEASTERN 813-626-1101

P.O. BOX 23474
TAMPA, FL. 33623
248088 DATCON INSTURMENTS 717-569-5713

P.O. BOX 128
EAST PETERSBURG, PENN
17520
351792 GENERAL BATTERY CORP: 800-235-2261

P.O.BOX 8500
PHILADELPHIA, PA. 19178
406081 HOYT ELECTRIC 603-753-6321

19 LINDEN ST
PENACOOK N.H. 03303
456853 KATO ENGINEERING 507-625-4011

DRAWER
ATLANTA, GA. 30384-8210
566861 NELSON DIVISION 608-873-4200
HYW 51 WEST
STOUGTON, WI. 53589
583707 NEWARK ELECTRIC 813-442-2057

1100 CLEVELAND AVE
SUITE 106
CLEARWATER, FL 34615
633895 PROTECTO SEAL 312-595-0800

P.O. BOX 95588
CHICAGO, IL. 60694
4-4
JUN 15190 Page 2
MODEL 9OT400
INDEX TO VENDOR CODES
VENDORS NAMES AND ADDRESS

CODE
TELEPHONE
681431 SOUTHCO FASTNERS 215-459-4000

P.O. BOX 7780-1316
PHILADELPHIA, PA. 19182
688819 SPRAGUE ELECTRIC

P.O. BOX 3595
BOSTON, MA. 02241
749394 TRILECTRON IND. INC. SOUTH 813-723-1841

12297 US HWY 41 NORTH
PALMETTO, FL 34221-2505
749389 TRILECTRON IND. INC. NORTH 201-423-4005

300 NINTH AVE
HAWHORNE, NJ 07506
799394 STEWART WARNER 305-271-3685'

5246 SNAPFINGER WOODS DR.
DECATER, GA 30035
816426 WOODWARD GOVERNOR 303-482-5811

P.O. BOX 751181
CHARLOTTE, NC.28275
4-4
JUN 15/90 Page 3
MODEL 90T400
14
15
MaJor Components Left S1de

Figure 1
JUN 15190 4-4

Page 4
MODEL 9OT400
FIG ~ PRIMARY SUB VENDOR NOMENCLATURE UNIT

ITEM PART NO. PART NO. En PER
1234567 ASSY
1-1 B03543 PANEL, ENG. CTRL. FIG 18 REF
2 B03558 PANEL, GEN. CTRL. FIG 19 REF
3 B03608 ENCLOSURE, DRAWER FIG REF
4 DRAWER, ASSEMBLY FIG 16 REF
5 B04370 BOARD, CABLE CONNECTING 1

6 EB5100 FILTER, AIR CLEANER 1
7 B01756 ENGINE, WITH FAN FIG 20 REF
8 NVOO05 RADIATOR, WI SHROUD FIG 8 REF
9 TR5112 LEVER, HAND BRAKE FIG 6 REF

10 EB5146 MUFFLER, MOD. FIG 9 REF
11 B04171 TANK, FUEL FIG 10 REF

12 TR5003 DRAWBAR FIG 2 REF
13 B04316 PANEL, CONTACTOR FIG 11 REF

14 EC0044 FILTER, FUEL FIG 2 REF
15 EB5092 CAP, FUEL FILLER 1
16 TR5050 AXLE, REAR FIG 3
LMF1234
JUN 15/90 4-4

Page 5
MODEL 90T400
o
19
17
15
26
,"
t.
"
"
~,.
"
to .• II· W ..
" '.
"
. I}! U ..
" '.
S026-5K77 Chass~s Assembly
Figure 2
JUN 15/90 4-4

Page 6
- :.:.~

MODEL 90T400
FIG & PRIMARY SUB VENDOR NOMENCLATURE UNIT

ITEM PART NO. PART NO. EFF PER
1234567 ASSY
2-1 LF4065 CANOPY, FRONT 1
2 LF4212 CANOPY, REAR 1
3 LF6011 ELECTRICAL ASSY, CHASSIS 1
4 B4130A FENDER, BOX LEFT HAND 1
5 B03641 FENDER, REAR 2
6 B05172 BRACE, FENDER REAR 2
7 LF4131 FENDER ASSEMBLY, BOX R.H. 1
8 B5157A FENDER, FRONT R. H. 1
9 B5158A BRACKET, FENDER FRONT R.H. 1

B5158B BRACKET, FENDER FRONT L.H. 1
10 HGI100 BOLT, HEX HD 3/8-16Xl. 00 16
11 HRIBC1 WASHER, FLAT 3/8 ~2
12 HRIBB1 WASHER, LOCK 3/8 16
13 HRIBA1 NUT, HEX HD, 3/16-16 THD. 16
14 HGH088 BOLT, HEX HD. 3 .16-18X. 875 16
15 HGH100 BOLT HEX HD. 3/ 16-18Xl. OC 6
16 HGH200 BOLT, HEX HD. 5/16-18X2.0C 1
17 HGH300 BOLT, HEX HD. 5/16-18X3.00 4
18 HGH075 BOLT, HEX HD. 5/16-18X.75 16
19 HTHBC1 WASHER, FLAT 5/16 62
20 HTHBB1 WASHER, LOCK 5/16 38
21 HTHBA1 NUT, HEX 5/16-18 THD. 24
22 HRHEK1 NUT, HEX 5/16 THD. 8
23 SA5014 SPACER, NYLON, ROUND .75 4
JUN 15/90 4-4

Page 7
MODEL 90T400
FIG 6 PRIMARY SUB VENDOR NOMENCLATURE UNIT

ITEM PART NO. PART NO. EFE PER
1234567 ASSY
2-24 HV5064 WASHER, FLAT .312 D. 4
25 B04023 C4023-500022 WELDMENT, ROD RETAINING 4
26 B04024 B4024-500022 BRACKET, RETAINING 4
27 HFF075 SCREW, PAN HD. 10-32X.75 4
28 HRFCC1 WASHER, FLAT #10 SS 30
29 HRFCB1 WASHER, FLAT #10 SS 16
30 HRFCA1 NUT, HEX 10-32 THD. SS 16
31 B5157B FENDER, FRONT L.H. 1
32 HRGEK1 NUT, LOCK ELASTIC 1/4-20 4
33 KH5096 TL200B LATCH, TOGGLE DZUS 2
34 B4032A C4032-500022-22 BRACKET, LATCH SUPPORT 2
35 KH5097 TL200-5 LATCH, TOGGLE DZUS 2
36 B4032B C4032-500022-2 BRACKET, LATCH SUPPORT 2
37 KH5099 PIN, QUICK RELEASE 2
38 KH5100 LANYARD, TYPE B 2
39 KH5040 C4936-500069 HINGE, ASSEMBLY SLIP 4
40 B04888 B4888-500036 STOP, HINGE 2
41 NOT SHOWN
42 B04303 B4303-500030 ROD AND WASHER ASSEMBLY 2

43 HWF075 SCREW, PAN HD. 10-32X.75 2
44 B04732 C4732-500036 HOOK, LIP CABLE BOX 1
45 NOT SHOWN
46 B4498F C4498-500040-6 BATTERY AND CABLES 2
JUN 15/90 4-4

Page 8
MODEL 9OT400

1234567 ASSY
2-47 B04862 B4862-500037 CABLE, AC OUTPUT 1
48 NOT SHOWN
49 KH5064 B3148-4347-1 RIVET, DRIVE #4 .114X.25 28
50 B3148B C4902-500016 1.0. PLATE TRILECTRON 2
51 B04902 C4902-500016 1.0. PLATE, GROUND POWER 1
52 B4491A C4491-500040-1 1.0. PLATE, OPEN THIS FIRS rr 1
53 B4491B C4401-500040-2 1.0. PLATE, OPEN OTHER EN!: 1
54 B3432B C3432-4347-1 1.0. PLATE, HAND BRAKE 1

55 B4490D C4490-500040-4 1.0. PLATE, ENGINE COOLAN'I 1
56 B31491 C3149-4347-8 1.0. PLATE, CAUTION ROTAT. 2
57 A02909 C0476-2909 1.0. PLATE, WARNING HIGH \ pLT 2
58 B4490S C4490-500040-19 1.0. PLATE, DIESEL FUEL 1
59 C4490A C4490-500040-1 1. D. PLATE, A.C. CABLE 1

60 B3391C B4491-500040-3 1. D. PLATE, TOW BAR HOT 1
61 B04274 B4274-500039 1. D. PLATE, BATTERY BOX 1
62 B04574 B4574-500029 1.0. PLATE, CAUTION MAINT. 1

63 LF5256 LM-F5256 TAPE, ANTI-SLIP 2
64 LF5261 LM-F5261 TAPE, ANTI-SLIP 2
JUN 15/90 4-4

Page 9
MODEL 9OT400
,,--------_ ... _--- -,,

I I 1..
I
- I}
. , ,I •
I I
, I
I L[_________ ~_J
(
-.------,--.- ; - ' - - -..--.- .I-rl
. ...
11
~
M ,
15
•
16 I
.1 ,.
,I
I
1 • • I
1 I
.,
1 I
1• • I"
,I I
.,I . , I
r
I
I I
.J •
, . 1--,-====,===1. J
• • • ·co 0 (> ••
"
I!
Front Canopy Assembly

Figure 3
JUN 15190 4-4

Page 10
MODEL 9OT400

1234567 ASSY
3-1 LOF3636 PANEL, FRONT CANOPY ASSY 1
2 B3640B WALL, FRONT CANOPY LEFT 1
3 B3640C WALL, FRONT CANOPY RIGHT 1
4 LF3916 ROOF, CANOPY ASSY 1
5 KHOl31 RIVET 33
6 IN5006 SPONGE, 11/8X1.00X140" 1
7 AA0063 ADHESIVE, 1/2 PINT AR

8 NOT SHOWN
9 NOT SHOWN
10 NOT SHOWN
11 NOT SHOWN
.
12 NOT SHOWN
13 NOT SHOWN
14 HRGBC1 WASHER, FLAT 1/4 12
15 NOT SHOWN
16 NOT SHOWN
17 NOT SHOWN
18 KH0118 RIVET, POP 1

19 NOT SHOWN
20 B03690 TRIM, INSP. DOOR 2

21 B03692 DOOR, INSPECTION 2
22 B04064 WELDMENT, CANOPY SUPPORT 1
-
"'--..
JUN 15/90 4-4

Page 11
.",-

MODEL 9OT400

1234567 ASSY
3-23 KHOO34 HANDLE 2

24 INOO26 INSULATION, SOUND ADHESIVE AR
25 C04025 BRACKET, WEATHER SEAL 1
26 NOT SHOWN
27 NOT SHOWN
28 IN5006 SPONGE, CLOSED CELL 1/8X.50 AR
29 KH5127 RIVET, DRIVE 2
JUN 15/90 4-4

Page 12
MODEL 9OT400
11
~.~.~.~.
I.
,
3 ZO
• "
DWG 5026-51::77 Rear canopy Assembly

Figure 4
JUN 15190 4-4

Page 13
·~-

MODEL 90T400

1234567 ASSY
4-1 B03649 ROOF, CANOPY ASSEMBLY 1
2 B04213 PANEL, REAR CANOPY 1
3 B3650A WALL, REAR CANOPY RT. 1
4 B3650B WALL, REAR CANOPY LT. 1
5 C04214 FUEL FLAP ASSEMBLY 1

6 B04312 DUST COVER ASSEMBLY 1
11 WL0091 INSULATION, SPLICE 22-18 4

'.
12 IN5006 SPNG, CLSD CELL 1/8X1 I X14" 2
13 WI0050 WIRE 18 GA. TYPE "B" 72" 1

14 AA0063 ADHESIVE 1/2 PT. 1
15 B04683 BRACKET, INST. PANEL LT. 1
16 IL5014 LIGHT, INST. PANEL 12V 1
17 HPE050 SCREW, PAN HD,. S.S. 4
18 HRECB1 WASHER, FLAT S.S. 4

19 HRDCBV1 WASHER, LOCK S.S. 2
20 B04064 WLMT, CANOPY AND SPRT. 1
21 HRECA1 NUT, HEX HD 8-32 S.S. 2

22 HRFCC1 WASHER, FLAT 1/4 39
23 SL5033 PROTECTOR, HARNESS 1
JUN 15190 4-4

Page 14
MODEL 90T400

1234567 ASSY
4-24 NOT USED
25 KH01l8 RIVET, POP 3/16 8
26 IN0026 INSULATION, ADH. 1/2" FO~ AR
27 KH5102 HANDLE 2
28 B03939 DEFLECTOR, WATER ALUM. 1
29 spoon SWITCH, PUSH BUTTON 1
30 C04490 PLATE, INFO. ETHER P.B. 1
31 HFG100 BOLT, H.H. • 250-20Xl. 00" 3
32 HRGBC1 WASHER, FLAT 6
33 HRGBB1 WASHER, LOCK 3
34 HRGBA1 NUT, HEX • • 250-20 2

,
JUN 15/90 4-4

Page 15
MODEL 90T400
. . - . . - . . -=-.. .- . . ~
I
Bl=i
I
,,
I
@
@, ,
i ..~
~O( lilt -.,
ASStllll)LV
Rtf RtF .
7)--_ _ _---/
a
9
~.
18
6 Rtf
DUAIL VllN·C
rUlL !>C'L(
Wl.ndow Frame
Figure 5
JUN 15/90 4-4

Page 16
MODEL 90T400
UNIT
FIG & PRIMARY SUB VENDOR NOMENCLATURE iEFF PER
ITEM PART NO. PART NO. ASSY
5-1 B04304 SIDE PLATE, GAUGE WINDOW 2
2 B04306 HINGE, GAUGE WINDOW 1
3 B04319 WELDMENT-HINGE SPRT. WIND. 1
4 NOT USED
5 IN5007 CLOSE CELL RUBBER 3/16 THI< 2
X3/4" 20"
6 B04307 WINDOW GAUGE 1
7 HWF088 SCREW PHIL HD.#10-32 X 7/8 6
8 HRFCC1 WASHER FLAT 12
9 HRFCB1 WASHER LOCK 6
10 HRFCA1 NUT, HEX 6
11 B04309 COVER DUST, GAUGE WINDOW 1
12 B04308 SUPPORT FRAME, GAUGE WIND. ·1
13 C4311-500026 WELDMENT SPACER HINGE 1
14 NOT USED
15 IN5007 CLOSED CELL RUBBER 3/16" 1

3/4" X 31 3/4" LG.
16 IN5006 CLOSED CELL RUBBER 1/8" 2
THK X 3/4X10.562 LG.
17 AA0063 ADHESIVE AR
18 IN0033 NEOPRENE RUBBER 1/8" THK 1

X 3/4 X 31.75 LG.
19 KH0118 POP RIVET 3/16" (1/8" -1/4 16

GRIP) 4-639
20 NOT USED
21 B04320 HINGE GAUGE WINDOW 1

22 KH5112 VISE ACTION LATCH 2
JUN 15/90 4':4

Page 17
MODEL 90T400
+
'f
'"
'"
('I 0
(I v
('i 0
+ a
m
~
CiJ I-IJ::-.JWO .... O:oz
v
• III.
I iI!lIIJ
i II I',iII Ii
" I gIl
~ II,
.... v
.~ ~:! r~ ~III
I
I oIIP·
I pd. 1
00! III! Iq: p'II n 'r ,I. v
Ij ;1I1111~ Ii r'!1 ,~I iI '~l

rI',
n I!lh
~ ~ ~ 4 •
Ii I: II!
~ ~.
+ + +
GPU CONTROL PANEL
Figure 6
JUN 15/90 4-4

Page 18
· TRILECTRON INDUSTRIES. INC.
MODEL 9OT400
UNIT
FIG & PRIMARY SUB VENDOl; NOMENCLATURE IEFF PER
6-1 B06041 PANEL, CONTROL ENG & AC 1
2 ILOO16 LAMP 8
3 SP5014 SWITCH P.B. GREEN LENS 1
4 SP5013 SWITCH, P.B. RED LENS 1
5 SR0061 SWITCH AMMTER W/HANDLE 1
6 MA0052 AMMETER 1
7 HRDCC1 WASHER, FLAT S.S. 8
8 HRDCB1 WASHER, LOCK S.S. 8
9 STOO11 SWITCH, TOGGLE RUN/IDLE 1
10 IL0072 HOLDER, LAMP 1
11 ILOO04 LENS, AMBER IGNITION ON 1

,
12 SPOO21 SWITCH P.B •. SPNO 1
13 IL5012 BULB, 12 VOLT 1
14 ST5017 SWITCH, SPOT OFF/MOM 1
15 MEOO13 GAUGE, WATER TEMPERATURE 1
16 HRDCA1 NUT, HEX S.S. 8

17 HPD063 SCREW, FLAT HD. S.S. 8
18 MV0032 SWITCH, VOLTMETER W/HANDLE 1

19 MV0041 VOLTMETER, 0-150 VOLTS 1
20 MFOO02 METER, FREQ. 380-420 Hz 1
21 MEOO14 GAUGE, OIL PRESSURE 1
22 MEOO03 HOURMETER 1
23 SP5008 WASHER, LOCK 8
JUN 15/90 4-4

Page 19
TRILECfRON INDUSTRIES. INC.
MODEL 90T400
UNIT
FIG & PRIMARY SUB VENDOR NOMENCLATURE En PER
6- 24 SP5012 NUT, KNURLED 5
25 ST0049 SWITCH, TOGGLE PANEL LIGHT 1
26 IL5012 BULB 12 VOLT 1
27 STOO23 SWITCH, TOGGLE IGN. ON/OFF 1

28 CB5000 CIRCUIT BKR, 15 AMP IGN. 1
29 CB5001 CIRCUIT BKR, 5 AMP INSTRU. 1
30 CB5006 CIRCUIT BKR, 10 AMP GOV. 1

31 SPOO19 SWITCH, P.B. N.O. START 1
32 MEOO16 LIGHT KIT 4
33 HREAA1 NUT, HEX BRASS 8
34 MEOO12 GAUGE, FUEL 1
,
35 MEOO05 VOLTMETER 1
ruN 15/90 4-4

Page 20
,'.

MODEL 90T400
.J;
Fender Box Assembly

Figure 7
UN:j:T
FIG & PRIMARY SUB VENDOR NOMENCLATURE EFF PER
7-1 B04129 BOX, FENDER ASSY.-R.H. 1
2 IN0033 NEO.125X1.00X125.7 1
3 B04069 COVER, BOX-FENDER ASSY. 1
4 KH5006 LATCH, FLEXIBLE "Tn 2
5 KH0134 RIVET, POP. 125 DIA. a

6 B04201 PADDED BATTERY HOLDER 1
7 BA5001 BATTERY 12V 6 CELLS H.D. 1
a B04196 ASSY. BATTERY HOLD DOWN 1
9 B04303 ROD AND WASHER ASSY. 2
10 HRGCC1 WASHER, FLAT .250 S.S. 2
11 HRGCB1 WASHER, LKG. 250 S.S. 4
JUN 15190 4-4

Page 21
TRILECTReON INDUSTRIES INC.
MODEL 90T400
-'.- ~
----------'eI
o
Four Wheel Runn1ng Gear, 5th Wheel
Figure 8
JUN 15190 4-4

Page 22
MODEL 9OT400
UNIT
8-1 707-2006F FRONT AXLE ASSEMBLY 1
2 707-2006F-2 FRONT AXLE 1
3 4600-2 SPINDLE NUT 2
4 4702-2 SPINDLE WASHER 2
5 4800-5 SPINDLE COTTER 2
6 1-3612 HUB, ASSEMBLY 2
7 3603 HUB 2
8 6152 INNER BEARING CUP 2
9 6151 OUTER BEARING CUP 2
10 6251-10 WHEEL STUD 10
11 4601-6 NUT, STUD 1
12 4700-5 WASHER, LOCK 10
13 6057 INNER BEARING CONE 2
14 6058 OUTER BEARING CONE 2
15 6311 SEAL, GREASE 2
16 6312 CAP, GREASE 2
17 3855 LATCH, PEDAL 1
18 5000-5 PIN, ROLL 1
19 4006 SPRING 1
20 1-707-2006 AXLE ASSEMBLY, REAR 1
21 1-707-2006 AXLE, REAR
-2 1
22 4702-2 SPINDLE WASHER 2
23 4800-5 SPINDLE COTTER 2
24 2-3612 HUB AND DRUM ASSEMBLY 2
JUN 15/90 4-4

Page 23
li-:;., ' .;~

MODEL 9OT400
UNIT
8-25 3603 HUB 2
26 6152 INNER BEARING CUP 2
27 6151 OUTER BEARING CUP 2
28 8221 BRAKE DRUM 2
29 6251-9 WHEEL STUD 10
30 4601-6 NUT, STUD 10
32 6057 INNER BEARING CONE 2
33 6058 OUTER BEARING CONE 2
34 6311 SEAL, GREASE 2
35 6312 CAP, GREASE 2
36 4600-2 NUT, SPINDLE 2
37 1-8209 BRAKE ASSEMBLY KIT 2
38 4-8209 BRAKE ASSEMBLY 2
39 8225 LEVER ASSEMBLY 2
40 4901-7 CAPSCREW, HEX. HD. 8
42 4601-5 NUT, HEX 8
43 8210 SHIELD, DUST 2
44 4-3712 WHEEL AND TIRE ASSEMBLY 4
45 6557 TIRE, TUBE AND FLAP 4
46 3712-1 WHEEL DISC WIVALVE HOLE 4
47 3712-2 WHEEL DISC WIO VALVE HOLE 4
JUN 15/90 4-4

Page 24
· TRILECTRON INDUSTRIES, INC.,
MODEL 90T400
UNIT
8-48 4901-34 WHEEL DISC BOLT 32
49 4601-47 WHEEL DISC NUT 32
50 4700-4 WHEEL DISC LOCKWASHER 32
51 3-3502 DRAWBAR ASSEMBLY 1
52 3-3502-03 DRAWBAR 1
53 4800-6 PIN, COTTER 2
54 5416 PIN, HINGE 1
55 5901R HANDBRAKE AND CROSS SHAF1 1
56 5904 HANDBRAKE LEVER 1
57 5204 SPACER 1
58 5910-27 CROSS SHAFT 1

,
59 5908 SHAFT BEARING 2
60 5909 SHAFT LEVER 3
61 5000-2 PIN, ROLL 3
62 6319-2 SETSCREW, COLLAR 1
63 8300-090 BRAKE ROD 1
64 5205 YOKE 4
65 4601-5 NUT, YOKE 4
66 5206 PIN, YOKE 3
67 4800-2 PIN, COTTER 3
68 1-8300-400 BRAKE ROD KIT 1

69 8300-400 BRAKE ROD 2
70 5205 YOKE 2
JUN 15/90 4-4

Page 25
,-.- .

MODEL 90T400
UNIT
FIG & PRIMARY SUB VENDOR NOMENCLATURE EFE PER
8-71 4601-5 NUT, YOKE 2
72 5206 PIN, YOKE 2
73 4800-2 PIN, COTTER 2
JUN 15190 4-4

Page 26
MODEL 9OT400
(2)
@
1 I
I•1
1\
II
I, I
I !.
I
~=".f1'1
,I
I I
I I
I I
1 , I
I I
I I
1 I 2
I,
I
I
I I 3
,-
I .• ~,k-J.----. _. _____.1-- __ -,-1_ _
5TH Wheel Assembly

Figure 9
JUN 15/90 4-4

Page 27
MODEL 90T400
UNIT
9- B03548 TRUNION, 5TH WHEEL, ASSY 1
2 B03550 CONNECTION ASSEMBLY 1
3 B03549 BEARING, BRASS, MODIFIED 1
4 HGQ300 SCREW, HEX HD. 3/4-10X2.00 4
~ HROBB1 WASHER, SPLIT 3/4-10 4
E HROAA1 NUT, HEX 3/4-10 4
7 B3551J GUSSET, TOP 1

8 HB5007 PIN, COTTER 1/8X1-1/4 1
9 9054A33 NUT, CASTLE 1/2-13 1
10 HRKCB1 WASHER, FLAT 1/2 1
11 B3551-28 WASHER, NEOPRENE 1
JUN 15/90 4-4

Page 28
, TRILECTRON INDUSTRIES INC.
MODEL 90T400
0)
Ir-~----i-
~I------------H--t--------I
8-----
@:@)--I--_____ O'
F===~II
Eng1ne and Chass1s Assembly

Figure 10 (1 of 2)
JUN 15190 4-4

Page 29
,.

MODEL 90T400
"8
. d
rJ -'
.' - r...'
'--'
o
", 0 :q
DWG 5026-SlC77 Eng1ne and Chass1s Assembly

Figure 10 (2 of 2)
JUN 15/90 4-4

Page 30
· TRILECfRON INDUSTRIES INC.
MODEL 9OT400

1234567 ASSY
10-1 LF6005 WELDMENT, FRAME 5TH WHEEL 1
2 LF4046B ENGINE/GENERATOR ASSEMBLY 1
3 LF4010 COOLING SYSTEM ASSEMBLY 1
4 LF6006 EXHAUST, SYSTEM ASSEMBLY 1

5 LF4300 AIR CLEANER ASSEMBLY 1
6 LF4725 FUEL TANK ASSEMBLY 1
7 LF4027 FUEL FILTER ASSEMBLY 1
8 LF4423 TRAILER AND BRAKE ASSEMBLY 1
9 LF3604 BRIDGE, CONTACTOR PANEL 1

10 LF4496 DRAWER, ENCLOSURE ASSEMBLY 1
11 LF4128 PAD-STRAP, FUEL TANK 2

,
12 LF4215 SPACER, PADDED 2
13 LF3546 WELDMENT, ENG. SUPP. REAR 2

14 HRIBC1 WASHER, FLAT 3/8 4
15 HRIBB1 WASHER, LOCK 3/8 4
16 HRIBA1 NUT, HEX, 3/8-16 4
17 HGH088 BOLT, HEX HD 5/16X18X.88 22
18 HRHBC1 WASHER, FLAT 5/16 22
19 HRHBB1 WASHER, LICK T/16 22
20 HWF050 SCREW, PAN HD 10-32X.50 11
21 HRFCC1 WASHER, FLAT #10 S.S 21
22 HRFCB1 WASHER, LOCK #10 21

23 HRFCA1 NUT, HEX #10-32 S.S. 10
JUN 15190 4-4

Page 31
·~'- .
• TRILECTRON INDUSTRIES, INC.

MODEL 90T400

1234567 ASSY
10-24 VMOO02 ZB6109 BUMPER 10
25 VM0010 MOUNT, ENGINE FRONT 1
26 VMOOll WASHER, SNUBBING FRONT 1
27 IYH090 BOLT" HEX, HD M16-20X90MJI 1
28 IWHBB1 WASHER, LOCK 16MM 1
29 VMOO13 MOUNT, ENGINE REAR 2
30 VMOO14 WASHER, SNUBBING REAR 2
31 HGV500 BOLT, HEX HD 7/8-9X.50 2
32 HRVBC1 WASHER, FLAT 7.8 4
33 HRVBB1 WASHER, LOCK 7/8 2
34 HRVBA1 NUT, LOCK HEX 7/8-9 THD. 2
35 IYF035 BOLT, HEX HD M12-1. 75X35MI' 8
36 HRKBB1 WASHER, LOCK 1/2 8
37 B05161 SPLASH GUARD, FRONT 1
38 CY0026 CLAMP, HEX 3/4 1
39 CY5021 CALMP, HOSE 1
40 AA0044 HOSE, 3/4 10 X 32.0 LG 1
41 B05160 SPACER, PARKING BRAKE 1
42 HFG150 BOLT, HEX HD 1/4-20X1.5 1
43 HRGBA1 NUT, HEX HD 1/4-20 1
44 B5158A FENDER, BRACKET, FRONT R.lI 1
45 HGH125 BOLT, HEX HD 5/16-18X1.25 2
46 NOT USED
47 NOT USED
48 B5158B FENDER, BRACKET, FRONT L.ll 1
JUN 15190 4-4

Page 32
MODEL 9OT400
N.OTE: ALL FINO NO·S

S~OW~ BELOW ARE
FOR REFERENCE.
~'------- CABLE ASS Y I£RM

RE.F,
OoTAIL VIEW- 4
SCALE: FUll
!-JOT(: ~"I!) hO .!.3 15

lOCATc.CI ON OP"O~IT~ ~IO;::
%,\4 n'~" •. ::0

18 '0
\I
0' " " " " '"
11 10
12
\I
\ 'rl\--n-.
ChaSS1S and Electr1cal Assembly

Figure 11
JUN 15190 4-4

Page 33
· TRILECTRON INDUSTRIES, INC.
MODEL 9OT400

ITEM PART NO. PART NO. FF PER
1234567 ASSY
11-1 LF6010 ENGINE AND CHASSIS ASSY 1
2 LF5442 PANEL, CONTACTOR ASSY 2
3 LF4343 DRAWER ASSEMBLY 1
4 B04370 BOARD, CABLE CONNECTING 1
5 B04363 BRACKET, TERMINAL BOARD 2
6 HFG088 BOLT, HEX, HD. 1/4-20X.87~ 4
7 HRGBC1 WASHER, FLAT 1/4 8
8 HRGBB1 WASHER, LOCK 1/4 4
9 HRGBA1 NUT, HEX 1/4-20 4
10 HDI175 BOLT, HEX HD. 3 .8-16Xl. 75 2
11 HRIAC1 WASHER, FLAT 3/8 BRASS 9

,
12 HRIAB1 WASHER, LICK 3/8 BRASS 5
13 HRIAA1 NUT, HEX 3/8-16 BRASS 4
14 NOT USED
15 NOT USED
16 NOT USED
17 HWF100 SCREW, PAN HD. 10-32Xl.OO 4
18 HRFCC1 WASHER, FLAT #10 29
19 HRFCA1 WASHER, LOCK #10 25
20 HRFCA1 NUT, HEX #10-32 S.S. 4
21 HWF063 SCREW, PAN HD. #10-32X.63 21
22 HWD075 SCREW, PAN HD. #6-32X.75 2

23 HRDCC1 WASHER, FLAT #6 4
JUN 15190 4-4

Page 34
MODEL 90T400
FIG t PRIMARY SUB VENDOR NOMENCLATURE UNIT

ITEM PART NO. PART NO. EFI PER
1234567 ASSY
11-24 HRDCB1 WASHER, LOCK #6 S.S. 2

25 HRDCA1 NUT, HEX #6-32 S.S. 2
26 TB1116 TERMINAL BLOCK 6 1
27 MS1106 MARKING STRIP 6 1
28 B4498B CABLE, STARTER TO POS. 1
29 B4498D CABLE, GROUND STRAP 1
30 IYF036 BOLT, HEX HD M12-1. 75X5MM 2
31 IWFBC1 WASHER, FLAT M12 2
32 IWFBB1 WASHER, LOCK M12 2
33 B04079 WIRING DIAGRAM 1
34 HDIlOO BOLT, HEX HD 3/8-16 X 1.00 1
,
35 B05315 GROUNDING STUD. 1
JUN 15190 4-4

Page 35
MODEL 90T400
o o o 1
o o o
BATTERY AND CABLE ASSY

Figure 12

1234567 ASSY
12-1 BA5001 BATTERY 12 VOLT 6 CELL 1
2 BAOO09 BATTERY CONNECTOR 2
3 LF4498-6 CABLE ASSEMBLY POS. 60" 1

4 LF4498-6 CABLE ASSEMBLY NEG. 60" 1
JUN 15/90 4-4

Page 36
MODEL 90T400
-~\
CABLE TO BATT.
POS. TERMIUAL . . L - - -
ON CONTACTOR ENGI,IE HOUSING
PANEL ASSY.
IZ. VOC
Battery anc Cable Assy

F'Igure 12A
1234567 ASS
12A-1 BA5001 BATTERY 12 VOLT 6 CELL 1
2 BAOOO9 BATTERY CONNECTOR 2
3 LF4498-6 CABLE ASSEMBLY POS. 60" 1
4 LF4498-6 CABLE ASSEMBLY NEG. 60" 1
AUG 01189 4-4

Page 37
MODEL 90T400
~
,
Eng1ne and Generator Assembly

Figure 13
JUN 15190 4-4

Page 38
·:--: -.; __,;;:::;:r,:
. TRILECTRON INDUSTRIES' INC.

MODEL 90T400
UNIT
ITEM PART NO. PART NO. 1234567 ASSY
13-1 B04384 ENGINE WITH FAN SPACER 1
2 GEOO02 101-2039-00 GENERATOR ASSY 1
3 B04301 AIR CLEANER W/MTG BRACKET 1
4 B03546 WELDMENT ENG. SPT REAR 2
5 VM00102 ENGINE MOUNT FRONT 1
6 VM0011 SNUBBING WASHER FRONT 1
7 VMOO13 ENGINE MOUNT REAR 2
8 VMOO14 SNUBBING WASHER REAR 2
9 IYH090 BOLT HH M16-2.0X90MM 1
10 IWHBB1 WASHER LOCK 16MM 2
11 HRVBK1 LOCKNUT .875-9 GR.8 2

,
12 HGV500 BOLT HEX HD .875-9X5.0 2
13 HRVBC1 WASHER FLAT 4
14 HRVBB1 WASHER LOCK 2
15 NOT USED
16 NOT USED
17 NOT USED
18 EGOO19 3040AN25 MAGNETIC PICKUP 1

19 MEOO07 02505-00 OIL PRESSURE SENDER 1
20 SR5005 364L OIL PRESSURE SWITCH 1
21 EC5034 3903575 FUEL SOLENOID 1

22 EG5011 8256-022 ACTUATOR 1
23 SR0069 GOM OVERSPEED SWITCH 1
JUN 15190 4-4

Page 39
MODEL 9OT400
UNIT
ITEM PART NO. PART NO. 1234567 ASSY
13-24 SROO19 1631002526 WATER TEMP SWITCH 1
25 MEOO09 02025-00 WATER TEMP SENDER 1
26 B03604 BRIDGE ASSEMBLY, CTRL PNL 1
27 B033B7 BUSHING 1
2B FI0045 2040-2-2S ADAPTER 2
29 HRHBB1 WASHER, LOCKING .312 4
30 IYDOBO BOLT, H.H. MBX1.25XBOMM 4
31 C04477 BRACKET, OVERPSPEED SWITCH 1
32 KH5069 TY RAP 1
33 HRKBB1 LOCKWASHER, SPLIT .500 B
34 IYF035 BOLT, H.H.M12, 1. 75X35MM B

,
35 FB002B B4503B1 FAN, BLOWER ENG. 18" DIA. 1

36 B04406 WELDMENT, BKT. ACTUATOR 1
37 B04404 LINKAGE ACTUATOR ASSY 1
ruN 15190 4-4

Page 40
TRlLECTRON INDUSTRIES INC.
MODEL 90T400
Component Drawer Assembly

Figure 14 (1 of 2)
JUN 15/90 4-4

Page 41
. ,
MODEL 90T400
Component Drawer Assembly

Figure 14 (2 of 2)
JUN 15190 4-4

Page 42
· S:. "
.,-.-~ .. ~.-.
.
-~--

MODEL 9OT400

1234567 ASSY
14-1 KH5050 INSERT, THREADED #10-32 10
2 L01054 BOARD, OVER/UNDER FREQ. 1
3 L01055 BOARD, OVER/UNDER VOLTAGE 1
4 L010523 BOARD, A.C. OVERLOAD 1
5 L01324 BOARD, A.C. VOLTAGE REG. 1
6 L01901 BOARD, REMOTE SENSING 1
7 EG0051 GOV. SPEED CONTROL (GOA) 1
8 L01921 BOARD, RELAY MODULE 1
9 HWF075 SCREW, PHIL #10-32X.75 10
10 L01492 BOARD, DIODE LOGIC 1
11 L01l54 TRANSFORMER ASSEMBLY 1

,
12 TBl119 TERMINAL BLOCK, 10 PT. 1
13 MS1l18 MARKER STRIP 18 POS. 1
14 L1429B BOARD, POWER SUPPLY 1
15 B05126 BRACKET, MOUNTING SWITCH 1

16 ST0049 SWITCH, TOGGLE SPDT 1
17 KH5015 INSERT, THREADED #6-32 4
18 HWD038 SCREW, PHIL. #6-32X.375 88
19 HRFCC1 WASHER, FLAT #10- 14
23 SA0024 STANDOFF #6-32 29
24 HWD063 SCREW, PHIL #6-32 27
25 HRDCA1 NUT, HEX #6-32 27

26 RA2152 VOLTAGE ADJ. POT. 1.5D 2W. 1
JUN 15190 4-4

Page 43
TRILECTRON INDUSTRIES INC. , ,
MODEL 90T400

1234567 ASSY
14-27 C050005 RECEPTACLE CONNECTOR 1
28 HWE038 SCREW, PHIL #8-32X.375 4
29 HRECC1 WASHER, FLAT #8 S.S. 4
30 HRECB1 LOCKWASHER, SPLIT #8 S.S. 4
31 KH5135 DRAWER SLIDES PR
32 B04992 WELDMT. , DRAER CTL PANEL 1
33 FHOO16 BLOCK, FUSE 8
34 C05032 RECEPTACLE, CONNECTOR 1
35 C05006 RECPTACLE, CONNECTOR 1
36 FUOO05 FUSE, 5 AMP AGC-5 8
37 B5141A PLATE, SWITCH DESCRIPTIONS 1
38 B5141B PLATE, ON/OFF POSITIONS 1
39 B33900 PLATE, CAUTION DO NOT SW. 1

40 ST0020 SWITCH, TOGGLE SPDT 1
41 KH5102 HANDLE. DRAWER 2
42 SP5008 WASHER, LOCK 7
43 SP5012 NUT, KNURLED 5
44 SPOO21 SWITCH P.B. SPNO 5

45 B04991 PLATE, TEST BUTTONS 1
46 HPB038 SCREW, PAN HD. #4-40X.375 4
47 HRBCA1 NUT, HEX HD. #4-40 S.S. 4
48 HRBCJ1 WASHER, LOCK #4 4
49 HRBCC1 WASHER, FLAT #4 S.S. 8
JUN 15190 4-4

Page 44
TRILECTRON INDUSTRIES INC. .,
MODEL 90T400

1234567 ASSY
14-50 LF6040B ENGINE CONTROL PANEL ASSY 1

51 SA5021 STANDOFF #6-32X1.375 8
52 KH5076 WASHER, WEAR 2
53 KH5059 SCREW, CATIVE .250-20X.812 2

54 KH0150 RETAINER 3
55 HWF050 SCREW, PHIL. #10-32X.50 4
56 HRFCB1 WASHER, LOCK SPLIT #10 14
JUN 15190 4-4

Page 45
TRILECTRON INDUSTRIES' INC. .\
MODEL 9OT400
Fuel Tank Assembly

Figure 15
JUN 15/90 4-4

Page 46
MODEL 90T400

1234567 ASSY
15-1 LF4724 TANK, FUEL 1
2 MEOO08 SENDER, FUEL 1
3 FI0028 2024-6-6S ADAPTER 900 1

4 EB5092 398 CAP, FUEL FILL 1
5 LF3699 PICKUP, FUEL 1
6 SR5012 LS700 SWITCH, FUEL LEVEL SHUTOFF 2
7 HFF050 BOLT, HEX HD . . 4-20X.50 6
8 HRGBB1 WASHER, LOCK 1/4 6
9 TSOO07 PLUG, SQ. HD. 1/2-14 NPT 1
JUN 15190 4-4

Page 47
MODEL 90T400
Flltar. Fuel
3903640
. ~o
-
~.
RETURN
eo· EL"
~. ~ .
(~~~\.
'FUEDI\NK~
.~-"/
.DeTlltL VIEW.
A
Fuel Fllters and Hoses

Figure 16
JUN 15/90 4-4

Page 48
.I".,

MODEL 90T400

1234567 ASS
16-1 C04173 BRACKET, FUEL FILTER 1
2 IYF035 BOLT, H.H. 12MM-1. 75X35MM 2
3 HRKBBI WASHER, SPLIT LOCK 1/2 2
4 FI0147 ADAPTER, 900 EL 1
5 FLOO04 FITTING, 900 EL SWL. 1
6 FMOOOI HOSE, #6X6.0" 1
7 FMOOOI HOSE, #6XI08.0" 1
8 FLOO02 FITTING SWL 9/16-18 THD #6 2
9 FM5002 HOSE, .19 LD.X90.0 1
10 FLOO19 FITTING, 7/l6-20 #4 1
11 CY0035 705-1107 CLAMP, HOSE #4 1

12 HFG075 BOLT, HOSE 1/4 #4 1
13 HRGBBI WASHER, LOCK SPLIT 1/4 2

14 CY0025 CLAMP, HOSE 2
15 CY0026 CLAMP, HOSE 2
16 EC0044 FS1212 FILTER, FUEL 1
17 EC0029 1427845 FILTER, FUEL 1
18 EC0030 GASKET, FUEL FILTER 1
19 NOT USED
20 HGI075 BOLT, HEX HD. 3.8-16X.75 4

21 HRIBBI WASHER, LOCK 3/8 DIA. 4
22 FI5119 ADAPTER 7/8-14-9/19-18 2
JUN 15/90 4-4

Page 49
TRILECTRON INDUSTRIES INC ..
MODEL 90T400
Q 0
Air Cleaner Assembly

F'1 ure 17
UNIT
17-1 EB5100 78058N Cleaner, Air 1
2 EB5101 Q27370 Mounting Band 2
3 HGH088 Bolt, Hex HD 4
4 HRHBC1 Washer, Flat 8
5 HRGBB1 Washer, Lock 4
6 HRHBA1 Nut, Hex 4
7 EB5102 Hump, Reducer 1
8 CY5036 89843K Clamp 3.5" 1
9 CY5035 89581K Clamp 3.0" 1
10 B03585 89580K Bracket, Air Filter 1
11 EB5123 70334N ELEMENT, AIR CLEANER 1
JUN 15190 4-4

Page 50
MODEL 90T400
II
10
3
®
----------_.. --'
G @ 7
Exhaust system
Figure 18
JUN 15/90 4-4

Page 51
MODEL 90T400

ITEM PART NO. PART NO. EF~ PER
1234567 ASSY
18-1 EB5094 89090-A ELBOW 900 SHORT RAD. 3.0" 1
2 EB5150 89102-A ELBOW 900 3.0' MOD. 1
3 EB5149 89211-A STACK PIPE 3.0" MOD. 1
4 EB5148 89153-A TAIL SPOUT, 3.0 DIA. 1
5 CY5017 89545K CLAMP, GUILLOTINE 3.0" 4
6 EB5095 98101-A ELBOW 900 3.0" 1
7 EB5146 96187M MUFFLER, MOD. 1
9 HGH100 BOLT, HEX HD. 5/16 3

10 HRHBC1 WASHER, FLAT 5/16 4
11 HRHBB1 WASHER, LOCK 5/16 3
12 HRHBA1 NUT, HEX 5/16 1

13 B5031M BRACKET, ANGLE 1
JUN 15190 4-4

Page 52
MODEL 90T400
I
I
I
I
I
1'1
_J
I "'WWV'-'":'ll; - = = -I
, I
L...?"""",,~""-f' ~ ~V .
(I tl.
II
I I j
1,.1 I..I.!
,--_+",~",.D) 1
Radiator Assembly
Figure 19
JUN 15190 4-4

Page 53
MODEL 90T400
UNIT
19-1 NVOOO5 RADIATOR WITH SHROUD 1

2 AH5001 HOSE RADIATOR 1
3 CYOO36 CLAMP HOSE 2
4 AH5003 HOSE RADIATOR 1
~ CYOO37 CLAMP HOSE 2

E C3552-500016 BRACKET RADIATOR 2
7 C4067-500016 SPACER RADIATOR 2
8 HFH063 BOLT HEX HD 6
9 HFH100 BOLT HEX HD 15
1C HRHBC1 WASHER FLAT 28
11 HRHBB1 WASHER LOCK 21
12 HRHBA1 NUT HEX 7
13 CYOO25 CLAMP HOSE OVERFLOW 2
14 VA5000 PET COCK RADIATOR DRAIN 1
JUN 15190 4-4

Page 54
MODEL 90T400
I •
lr
. - \ ' { \ 1--- L C{X-. ,,;
~)
D
MIN II . .
\ l
Electron1C Governor Installat10n

Figure 20
JUN 15190 4-4

REV 2 Page 55
- ----- --~- ------~-----;----- - - ----- -- - --- - ----

MODEL 9OT400
UNIT
21-1 EG0046 GOVERNOR SPEED CONTROL

,-
1
(WOODWARD)
EG0051 ESD5221 GOVERNOR SPEED CONTROL 1

(TI)
2 EG5011 8256-022 ACTUATOR, SPEED CONTROL 1
(WOODWARD)
EG0052 ACC-120-12V ACTUCATOR, SPEED CONTROL 1

(TI)
3 EGOO19 MAGNETIC PICKUP (WOODWARD) 1

EG0053 MSP671B MAGNETIC PICKUP (TI) 1
4 B04404 LINKAGE GOV. ACTUATOR ASSY REF
(WOODWARD) (SEE FIG 13)
5 EG5054 KT103T GOV. INSTALLATION KIT 1

(TI GOV. INST. MOD. KIT)
JUN 15190 4-4

REV 2 Page 56
---------, , ..

MODEL 90T400
CHAPTERS
MANUFACTURERS APPENDICES
TABLE OF CONTENTS
1 . • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
2. Governor Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
3. KATO ENGINEERING Instruction Manual, AC Generator •••••••• 5-3
4. cummins Troubleshooting and Repair Manual •..•...•.•••..•• 5-4
5. Cummins Parts Catalog 6B, 6BT, 6BTA5.9 Engines •••..••.••• 5-5
6. Cummins operation and Maintenance Manual •.••••••.••••••• 5-6
JUN 15/90 S-CONTENTS

REV 2 Page 1
MODEL 90T400
INTRODUCTION
This chapter has been assembled to furnish the service person

with the various equipment manufacturer's descriptions,
specifications and procedures for removal, installation and
adjustment not covered in the proceeding four chapters.
The size of these manuals may require they be kept in a

separate binder.
The contents of these manuals contain a wide range of

disciplines including:
Specifications
Installation Instructions
Removal Instructions
Operating Procedures
Calibration Procedures
servicing
Repair
Maintenance
Storage Instructions
- Parts Lists
5-1
JUN 15/90 Page 1
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wi r.u£ 90~()A- 20P2- DG5()

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.KATO -/;~1 - 0.FJ~
JIMENSIONAL DRAWINGS
ENGINE - GENERATOR MATCH CHART
KATO'S FLEXIBILITY ENABLES US TO MATCH SINGLE BEARING GENERATORS TO MOST
INDUSTRIAL ENGINES.
ENGINE FLYWHEEL HOUSING
s.A.E. Ho.
He. "- D C E Hoi.. Slu
00 31000 34 3/4 33112 3 15/16 16 112· 13
0 25500 2B 263/. 315/16 16 112·13
.~ . 1.'2 23.000 251/2 2' J/8 315/.16 12 112· 13
1t' 20125 21 J/' 20718 3 15116 12 7116·104

~ 17.625 19 1 f" lB 3/B 315/16 12 J/8'16
] 16.125 11 3/' 161/B 315116 12 3/8·16
•5 ".250
12.375
157/8
,. 131/8
15 3151\6
2 13116
12
B
3/B· '6
3/B·· 16
S.A.E.
6 10.500 12118 11 ".c 2 13116 B 3/B . 16
E-I STANDARD
FLYWHEELS FOR INDUSTRIAL ENGINES
,
Nom.
Clutch
01.. A B C E G
H_ Ho.
SI..
61/2 711. 81/2 17/8 213116 13116 6 5116·1B
11/2 81/8 91/2 83/4 213/16 13/16 8 5116·18
f+. 8 87/8 103/8 95/8 315/16 21/16 6 3/8-16
;):tJ 10718 123/8 11 5/8 3 15/1.6 21/8 8 3/8-16
i1'I1I2 123/8 13718 131/8 315/16 19/16 8 3/8-16
I' 16118 18318 17 1/4 3 15116 I 8 1/2·13
16 18118 203/8 191/' 315/16 SIB 8 1/2·13
S.A.E. STANDARD 18 19 SIB 22 112 21 31B 315/16 518 6 5/B-ll
21 23 261/2 251/' 315116 0 12 51 B·"
2' 25318 287/B 211/' 315116 0 12 3/4.10
RECOMMENDED FLYWHEEL 0 MATCH HOUSING

DELCO l'TANDARD FLYWHEELS
NOMINAL $.A.£.
CLUTCH DIA. 6 5 • PIlot Bon No. Hot.. Flywhool
61: - •
Dw-to< Clrclo 8(N1dng Sll>t Spodng • 3 2 1 'I; o 00
7': - •
12.750
" 4·Equal 17/32 FluSh • •
4 Groups
B •
I
I
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Ilt r desc:riction - T date TaPPd
PU A ADDED TDI 130/10/90 1JCW
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NOTES : 1) ~OR UNITS WITH LOW F1JEL
BEACON OPTION. TRILECTRON INDUSTRIES INC .
2) ~OR UNITS WITH ETHER START PAl../'\crTO~ fLORIDA, U.S .A .
50106ENC
)PTION. SCHEMATIC
ENGINE CONTROLS
:3) °OR UNITS I.IITH ANTICOLUSION AND
-1GHT OPTION . PROTECTIVE CIRCUITS
If) COR UNITS WITH LOW FUEL ENGINE SINGLE AC ,12v ,EUROPANEL,GAC GOlJ .
;UT -OFF" OPTION . dr auin<;1 no. rev .
~) COR UNITS WITH WOOWARD GOVERNOR next assy I used on 6029-500106 C
DATE 9/1'+/90
application sheet 1 of 1
JUN 15190 Engine Controls and Protective Circuits Schematic 1-1

REV 2 fl~re6 Page 10
--- _. _ - - - -~.- . - ..--,-,--
1-
I - -------------
II MAG -- ACTUATOR - - -- - - - - - - - - - - - - - - - - revisions
hr I descriPtIon date lappd
PU A I ADDED TDI 30/10/90 I JCW
B I REV PER ECR# 1"051'+, 1"05'+7, 12/17/<)01 KHW
F05'+9, F0550
REV PER CHECK PRINTS 01.'07/91 I KHW
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FUEL SW NOTES : 1) ~OR UNITS WITH LOW FUEL
8EACON OPTION . TRILECTRON INDUSTRIES INC.
O!) COR UNITS IoIITH ETHER START PALMETTO, FLORIDA, U.S.A .
S0106ENC
)PTIOH. SCHEMATIC
ENGINE CONTROLS
3) ~OR UNITS WITH ANTICOLLISION AND
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application DATE 8/1'+/90
sheet 1 of 1
JUN 15190 Engine Controls and Protective Circuits Schematic 1-1

REV 2 fi~re6 Page 10

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TRlLECTRON INDUSTRIES INC.

GROUND POWER GENERATOR

The operating Instructions are designed for new, or experienced

A set-up preparation section shows all necessary details on how

The functional description and theory of operation fully describe

The maintenance portion of this manual provides a maintenance

The illustrated parts list is intended for use in provisioning

TRILECTRON INDUSTRIES INC. (The company) guarantees to the original

If said part is supplied previous to the return of the suspected

If this unit has malfunctioned during warranty period, and the

a. Request for return authorization. Unit to be returned to the

b. Request field service for which travel and expenses, plus a

This Warranty or Guarantee is expressly made in lieu of all other

TRILECTRON INDUSTRIES INC.

Safety summary Chapter/Section

General.In~ormation and operating Instructions 1

Illustrated Parts List ..•.•••••...........•.•••................. 4

TRILECTRON INDUSTRIES INC.

ALL SPECIFIC CAUTIONS AN WARNINGS IN THIS MANUAL SHALL BE

WARNING: THIS GROUND POWER UNIT PRODUCES DANGEROUS HIGH VOLTAGE

WARNING: THIS UNIT FEATURES A CABLE INTERLOCK SAFETY CIRCUIT

WARNING: DO NOT ATTEMPT TO SERVICE OR OTHERWISE MAKE ANY

WARNING: PROLONGED EXPOSURE TO HAZARDOUS NOISE CAN CAUSE

WARNING: DO NOT SMOKE OR ALLOW OPEN FLAME WITHIN THE IMMEDIATE

TRILECTRON INDUSTRIES INC.

WARNING: TO PREVENT SPARKING BETWEEN FILLER NOZZLE AND FUEL

WARNING: ETHER QUICK START SYSTEM IS HIGHLY EXPLOSIVE. DO NOT

WARNING: ADEQUATE SUPPORT OF HEAVY ITEMS SUCH AS THE ENGINE

General InfOrmation & Operating Instructions

Specifications and Capabilities

TRILECTRON INDUSTRIES INC.

2. MAJOR COMPONENTS (See Figure 2)

A. The power plant, designated as Model 90T400. has the overall

B. The main generator is directly coupled to the diesel engine.

C. The power plant is trailer mounted, self contained, requiring

D. All components of the power plant are protected by a weather

E. The unit is equipped with one hard-wired AC power cable.

F. The chassis is equipped with a turntable steering front axle

L"oo~ All dimensions are in

RADIATOR CONTACTOR PANEL

Locations of Major Components

(c) Temperature Sensing switch: This switch is activated

(d) Low oil Pressure Switch:

1. Water Temp. Sender 5. Fuel Solenoid

Engine Sensing Components

JUN 15/90 1-1

PRIMARY/SECONDARY FUEL TANK

Fuel Flow schemat1c

Engine Controls and Indicators

TRILECTRON INDUSTRIES INC.

ITEM CONTROL/INDICATOR FUNCTIONAL DESCRIPTION

1 OIL PRESSURE GAUGE Indicates engine oil pressure

2 FAULT INDICATORS Indicates to operator the

(red): protective system that caused

3 IGN. ON Indicator Lights when the ENGINE CONTROL

5 BATTERY VOLTMETER Indicates battery voltage

6 FUEL LEVEL GAUGE Indicates amount of fuel

7 START switch Starts engine, Pushbutton,

8 IGNITION switch On position supplies starting

9 GOVERNOR CIRCUIT Protects the electronic governor

10 INSTRUMENT CIRCUIT Protects the instrument elect.

11 IGNITION CIRCUIT Protects engine ignition system

12 RUN/IDLE switch Two position switch. Controls