GPU 400-100-120-140 Tier III Rev 2

DAVCO MODEL
GPU400-100/120/140
GROUND POWER UNIT
with CUMMINS QSB6.7L
(Tier III) Engine
OPERATION, MAINTENANCE
& PARTS MANUAL
Introduction Davco Model GPU400-100/120/140
NOTE: The information contained in this publication is intended

Note exclusively for the use of TUG and its customers. Disclosure to non-TUG
customers may result in legal action by TUG.
NOTE: The information contained in this document is intended to be

accurate and up to date at the time of original issue. TUG reserves the
Note
right to update the information in this document, without warning, as
deemed prudent or necessary by TUG.
INTRO-ii CD377
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Davco Model GPU400-100/120/140 Introduction
RECORD OF REVISIONS
Property of:
Company:
Address:
City: State: Zip Code:
REVISION DATA
Check each revision received, and insert the revised and supplementary pages in your manual. TUG assumes
no liability for personal injury or equipment failure due to any operation performed without heed to manual
revisions.
Date of original publication: July 2009
Revision Number Date Brief Description
1 May 5, 2010 Rev. Operation Section; New Warranty
2 June, 5, 2013 Changes Chapter 4
CD377 INTRO-iii
Rev 2
LIST OF EFFECTIVE PAGES
INTRO- 1 Rev 1 1-1- 8 Orig

INTRO- 2 Orig 1-1- 9 Orig
INTRO- 10 Orig
INTRO- 17 Rev 1 1-2- 6 Rev 1
INTRO- 20 Rev 1
SAFETY- 1 Orig 1-4- 1 Orig

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MANUAL TABLE OF CONTENTS
INTRODUCTION
Record of Revisions ............................................................................................................... INTRO-iii

List of Effective Pages............................................................................................................ INTRO-iv
Manual Table of Contents ...................................................................................................... INTRO-vii
Copyright Notice ..................................................................................................................... INTRO-xi
Introduction ............................................................................................................................ INTRO-xii
Unit Identification ................................................................................................................... INTRO-xii
Technical Assistance ............................................................................................................ INTRO-xiii
Warranty Policy Statement ................................................................................................... INTRO-xiv
How to Use This Manual ...................................................................................................... INTRO-xxii
SAFETY ............................................................................................................................... SAFETY-I

A. General .......................................................................................................... SAFETY-i
B. Safety Precautions ........................................................................................ SAFETY-i
C. General Responsibilities ............................................................................... SAFETY-ii
D. Warning Statements ..................................................................................... SAFETY-ii
E. Cautionary Statements ................................................................................ SAFETY-iv
CHAPTER 1: GENERAL INFORMATION AND

OPERATING INSTRUCTIONS
TABLE OF CONTENTS
SECTION 1: UNIT DESCRIPTION ........................................................................................... 1-1-1
A. Introduction ........................................................................................................... 1-1-1
B. Unit Description .................................................................................................... 1-1-1
C. Engine Description ............................................................................................... 1-1-1
D. Electrical System .................................................................................................. 1-1-7
E. Chassis .............................................................................................................. 1-1-13
F. 28 VDC System (Optional) ................................................................................. 1-1-15
G. Alarm/Low Fuel Beacon (Optional) ..................................................................... 1-1-16
H. Truck Mounted (Optional) ................................................................................... 1-1-16
CD377 INTRO-vii
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CHAPTER 2: MAINTENANCE
TABLE OF CONTENTS
SECTION 1: SERVICING ......................................................................................................... 2-1-1
A. Introduction ........................................................................................................... 2-1-1
B. General ................................................................................................................. 2-1-1
C. Cleaning ................................................................................................................ 2-1-3
D. Painting ................................................................................................................. 2-1-4
E. Engine Oil Specifications & Recommendations ................................................... 2-1-4
F. Coolant Specifications & Recommendations ....................................................... 2-1-5
G. Fuel Recommendations/Specifications ................................................................ 2-1-6
H. Consumable Materials .......................................................................................... 2-1-6
I. Periodic Maintenance Schedule ........................................................................... 2-1-7
J. Adjusting the Programmable Timer Module .......................................................... 2-1-9
SECTION 2: TROUBLESHOOTING ........................................................................................ 2-2-1

A. General ................................................................................................................. 2-2-1
B. Troubleshooting Chart .......................................................................................... 2-2-1
C. Engine Trouble Codes and Fault Codes ............................................................... 2-2-7
D. Diagnostic Procedure and Wire Diagrams ........................................................... 2-2-7
CHAPTER 3: OVERHAUL
TABLE OF CONTENTS
SECTION 1: OVERHAUL DATA ............................................................................................... 3-1-1

A. Introduction ........................................................................................................... 3-1-1
B. Engine .................................................................................................................. 3-1-1
C. Generator .............................................................................................................. 3-1-1
INTRO-viii CD377
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CHAPTER 4: ILLUSTRATED PARTS LIST

TABLE OF CONTENTS
SECTION 1: DESCRIPTION ..................................................................................................... 4-1-1

A. Introduction ........................................................................................................... 4-1-1
B. Using the Illustrated Parts List .............................................................................. 4-1-2
C. Ordering Spare Parts ............................................................................................ 4-1-4
SECTION 2: ILLUSTRATED PARTS LIST ............................................................................... 4-2-1

A. Introduction ........................................................................................................... 4-2-1
Figure 2-1. Air Intake Assembly ............................................................................. 4-2-2
Figure 2-2. Axle Assembly .................................................................................... 4-2-4
Figure 2-3. Control Box Assembly ........................................................................ 4-2-6
Figure 2-3. Control Box Assembly (Con't.) ........................................................... 4-2-8
Figure 2-4. Control Panel ................................................................................... 4-2-10
Figure 2-5. Cooling System ............................................................................... 4-2-12
Figure 2-6. Engine Assembly/Installation ........................................................... 4-2-14
Figure 2-7. Exhaust System .............................................................................. 4-2-16
Figure 2-8. Axle, Wheels and Tires .................................................................... 4-2-18
Figure 2-9. Fuel System .................................................................................... 4-2-20
Figure 2-10. Generator Assembly (Standard) .................................................... 4-2-22
Figure 2-11. Generator Assembly (28V Option) ................................................. 4-2-24
Figure 2-12. Hood and Doors Installation ........................................................... 4-2-26
Figure 2-12. Hood and Doors Installation (Con't.) .............................................. 4-2-28
Figure 2-13. Rectifier Assembly (Optional) ........................................................ 4-2-30
Figure 2-14. Fuse Installation ............................................................................. 4-2-32
SECTION 3: NUMERICAL INDEX ............................................................................................ 4-3-1
SECTION 4: ALPHABETICAL INDEX ....................................................................................... 4-4-1
CD377 INTRO-ix
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CHAPTER 5: APPENDICES
TABLE OF CONTENTS
SECTION 1: PERIODIC MAINTENANCE CHECKLIST .......................................................... 5-1-1
SECTION 2: ADDITIONAL INFORMATION & VENDOR PUBLICATIONS ............................. 5-2-1

A. Description ........................................................................................................... 5-2-1
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COPYRIGHT NOTICE
This manual is copyrighted as an unpublished work.
This manual contains the confidential and proprietary information of TUG.
Neither this document, nor any information contained herein, may be reproduced or redistributed in any form
whatsoever without the express, written consent of an authorized agent of TUG.
Any attempt by any person other than an authorized agent of TUG to alter the contents of this manual in any
way shall be construed as copyright infringement, punishable by all applicable laws.
All vendor literature contained in this manual is the copyrighted property of the respective vendors, protected
by the same laws governing this operation and maintenance manual.
© Copyright 2010 by TUG. All rights reserved.
CD377 INTRO-xi
Rev 1
INTRODUCTION
The information and instructions in this handbook are intended to acquaint the operator with the important
operating features of the Davco model GPU400-100/120/140. The various controls, gauges, switches, and
operating features are explained and illustrated throughout this handbook. Personnel responsible for operation
of the vehicle should read this manual carefully to become familiar with vehicle operation.
UNIT IDENTIFICATION
To aid the technician in repair or service work on this unit, a TUG identification plate is located on the
operator's compartment of the unit.
815 ALLGOOD RD.

MARIETTA, GA 30062
(770) 422−7230
The serial number identification of each unit will appear on the nameplate along with the date of manufacture.
The mailing address of TUG is also located on the data plate with the TUG logo. This necessary information
will ensure the customer a fast and accurate response to any parts and/or service request.
Please verify the serial number on the identification nameplate of the unit and enter your unit serial number
here:
If applicable, enter your company identification number
here:
INTRO-xii CD377
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TECHNICAL ASSISTANCE
Direct any questions concerning the operation of the Davco GPU400-100/120/140 to:
TUG Technologies Corporation

P.O. Box 3028
Kennesaw, GA 30156
Domestic: 1-800-989-8499
International: (770) 422-8021
Fax: (770) 422-8730
All information in this manual is based on the latest production information available at the time of publication.
Direct any questions concerning the contents or format of this manual to:
TUG Technologies Corporation

ATTN: TUG Shop
P.O. Box 3028
Kennesaw, GA 30156
Domestic: 1-800-989-8499
International: (770) 422-8021
Fax: (770) 422-8730
Email: TugShop@tugtech.com
CD377 INTRO-xiii
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INTRODUCTION
The primary goal of warranty adjustment is to satisfy our customers.

Every satisfied customer strengthens the components of our whole
organization - all aspects of the products themselves and the service that
backs them up. This Manual is directed to TUG Technologies
Distributors, and Customers of TUG Equipment. It should be used to
implement the Warranty Program at every level.
This Warranty Policy and Procedures Manual includes the warranties

of Tug Technologies Products It explains warranty policy and
coverage, and describes the warranty claim process.
Tug Technologies is responsible for handling warranty and policy

adjustments promptly and in accordance with the provisions of the
Sales and Service Agreement, TUG Technologies Warranty Statements
and this Manual. Customers who recognize the Manual as the "heart" of
the warranty system and train their personnel in its use may expect:
Service personnel qualified to submit claims that are properly
completed and fully substantiated, resulting in prompt claims payment.
NOTE: The guidelines and requirements in this Manual apply
to warranty claims submitted to TUG Technologies for reimbursement
to the Customer.
(Continued)
INTRO-xiv CD377
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PRE-DELIVERY PROCEDURES
Establish pre-delivery procedures that ensure the appropriate in-
spections and adjustments are made prior to equipment being
placed in service.
AUTHORIZATION REQUIREMENTS - REPAIRS REQUIRING
PRIOR APPROVAL
Certain repairs and claims require prior approval. Any repair
which will take more then 2 hours labor to complete must have
prior approval.
WARRANTY
A warranty is a specific document that guarantees the quality of goods
to a purchaser within a specified length of time and according to usage
limitations. The TUG Technologies warranty statement defines the con-
ditions of the warranty. A warranty:
Remains in force for the specified period, provided that an occurrence
has not taken place to render the warranty inapplicable.
Assures the owner that if, under the conditions specified, a defect in
factory workmanship or material is encountered, it will be corrected at
no charge or on a pro rata basis.
Extension of coverage by any manufacturer does not change what is
covered in the basic, expressed limited warranty.
WARRANTY STATEMENTS
TUG Technologies Warranty Statements provide detailed information
regarding coverage & usage limitations for TUG products.
CD377 INTRO-xv
Rev 1
WARRANTY POLICY & COVERAGE
SERVICE RECALLS OR OWNER NOTIFICATION PROGRAMS

TUG TECHNOLOGIES may establish a program to resolve extensive customer concern
about a component beyond warranty coverage. Owners are notified to contact TUG
Technologies for replacement/repair. Customers will be notified by TUG TECHNOLOGIES
with information that :
Identifies the component and condition.
Outlines the inspection and repair procedure required to correct the condition.
Defines reimbursement.
WARRANTY CANCELLATION
Certain situations cause a warranty to be canceled. Examples of such situations include, but
are not limited to:
Damaged due to accidents.
Damage due to abuse, improper operation or poor maintenance practices.
Total or partial warranty cancellation is registered in TUG TECHNOLOGIES records.
WARRANTY POLICY & COVERAGE
Shipment:
Shipment is considered acceptable
Freight Charges
To return recalled components is covered when shipped prepaid via least
expensive
Labor for Service :
Reimbursed at the approved hourly warranty labor rate.
Non-TUG Parts
Only covered with prior approval from TUG.
INTRO-xvi CD377
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WARRANTY EXCLUSIONS
x The following items are examples of some of the non-reimbursable items under the
Warranty and Policy Program.
x Non-reimbursable repairs include:
x Any repair to a unit on which the mileage/hours or date of first use reported has been
misrepresented.
x Any repair to a unit on which the odometer/hour meter has been altered so that the true
mileage/hours cannot be determined. (Applies only to cases in which mileage/hours are
a condition of the warranty.)
x Any repair for which the date on the order has been misrepresented or altered to place
an out-of-warranty component within the warranty provisions.
x Any repair made to a product that has been misused or mistreated, or upon which a
conversion, modification or installation of a non-TUG part has been made so as to affect
the performance, reliability or stability of a part. Any failure to a TUG-supplied part
resulting from such action is not covered by the warranty.
x Parts handling charges.
x Parts damaged due to accident. The warranty on parts damaged because of accident or
an act of nature will be canceled.
x NOTE: Repairs on accident claims or conditions that could have contributed to personal
injury or property damage must not begin until approval is obtained.
x Do not scrap allegedly defective parts that may have contributed to injury or damage
until written approval is received.
x Repairs required because of inadequate or incorrect protection in storage and/or
preparation for storage.
x Repairs of damage or failure caused by poor outside workmanship.
x Any repair operation that changes the existing specifications of the equipment or
component.
x Repair techniques beyond the appropriate shop manual limits.
x Labor performed by other than an authorized TUG technician without prior approval,
unless the situation is an emergency.
x Use of other than genuine TUG parts, unless used in an emergency.
x A second or subsequent repair or adjustment necessitated by an incomplete or improper
original repair or adjustment.
x Adjustments made to improve appearance or performance beyond normal standards.
x Maintenance and normal replacement of service items, e.g., replacement of filters and
fluids, tightening of bolts, nuts or fittings. However, minor labor-only repairs are
reimbursable.
x Any repair to a part that is found not to be defective.
x Replacement of assembly rather than repair if replacement costs exceed repair costs, and
parts are available. Replacement requires prior approval.
x Labor operations such as additional diagnostic time, abnormal accessibility or diagnosis
time, hot testing and testing of new parts after repair. Standard labor allowances are
included in warranty labor time standards.
x Replacement parts damaged in shipment (carrier responsibility).
x Towing expense or transportation for moving equipment between the customer's
location and the repair location.
CD377 INTRO-xvii
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Warranty Claim Process

NOTE: No warranty invoice will be accepted unless TUG Technologies has been contacted prior to the
start of work being done to the unit.
Contact TUG Technologies by:

Phone: 1-800-989-8499 Ext. 2 or 770-422-8021
Email (preferred) warranty@tugtech.com
To expedite the claim process please provide the following information:

Unit SN:
Hours of operation:
Description of problem or symptoms.
List of parts required for repairs.
Shipping Address
Contact name
Contact phone numbers
Parts:
TUG Technologies will ship warranty parts out at no charge once the claim has been re-
ceived and accepted.
Return Parts:
Not all failed parts need to be returned to TUG Technologies. If parts are to be returned an
RGA tag will be sent with the replacement warranty parts. The tag must be filled out com-
pletely and attached to the return part(s)
NOTE: Parts not returned within 30 days of claim will be charged to your account.
TUG Technologies reserves the right to invoice for parts being returned for the reasons but
not limited to the reasons listed below.
If deemed if caused by an unwarrantable failure.
If part is damaged due to inadequate packaging.
Part was not supplied by TUG Technologies.
Proper documentation was not provided or sent back with faulty part.
Labor:
TUG Technologies will reimburse labor based on the Standard Labor Rate Chart. Any work
which will exceed the times outlined in this chart requires prior approval. All warranty labor
is subject to TUG Technologies Warranty Approval Process.
INTRO-xviii CD377
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AIRCRAFT GROUND SUPPORT EQUIPMENT

WARRANTY POLICY STATEMENT
This Policy Statement sets forth the terms of the warranty provided by TUG Technologies Corp. with respect to
ground power units, air start units, tow tractors, cargo tractors and other equipment sold for use in the commercial
aviation industry (“Aircraft Ground Support Equipment” “Industrial”).
The foregoing warranty gives Buyer specific legal rights that may vary from state to state. Some states do not
permit the limitation of incidental or consequential damages or limitation of remedies under warranties. The above
limitations apply only to the extent permitted by applicable law.
General Warranty Terms & Conditions

Tug Technologies warrants that each new item of equipment is of good workmanship and is free of mechanical
defects, provided that:
1. The equipment is installed and operated in accordance with the Tug Technologies Operation and Maintenance
Manual.
2. The equipment is used under normal operating conditions, for which it was designed.
3. The equipment is not subject to misuse, negligence or accident.
4. The equipment is properly maintained by qualified technicians in accordance with the Tug Technologies
Operation and Maintenance Manual
This warranty expires, unless otherwise agreed by Tug Technologies in a special provision, 24 months after being
shipped , or after 2000 operating hours.
Tug Technologies warranty does not apply to fluids, oils, fuses, bulbs, accumulators, paint, seals, tires, bumpers,
brake or wearable parts, bulbs, batteries. Etc.
All warranty claims must be sent to the warranty department for processing. All information pertaining to specific
claim must be provided for claim to be processed in a timely manner.
All the expenses related to a warranty claim will be invoiced to the buyer until Tug Technologies have evaluated
the claim. Whatever the circumstances, the buyer should not refuse or delay the payment. If the evaluation
concludes to TUG’s full responsibility, a credit will be issued in the favor of the buyer.
This warranty is extended by Tug Technologies only to the buyer of new products from Tug Technologies or its
authorized distributors. The products purchased under this warranty are intended for use exclusively by the buyer.
There shall be no third party beneficiary of this warranty.
Under no circumstances whatever shall Tug Technologies be liable for any special or consequential damages,
whether based on lost goodwill, lost resale profits, work stoppage, impairment of other goods or otherwise, and
whether arising out of breach of any express or implied warranty, breach of contract, negligence or otherwise,
except only in the case of personal injury as may be required by applicable law.
The warranty is automatically void by Tug Technologies in the following cases:

1. The product has received some modification , not authorized or done according to Tug Technologies
requirements.
2. Some original parts have been replaced by parts not provided by Tug Technologies.
CD377 INTRO-xix
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GPU Warranty Labor Flat Rate Guide

28 VDC Magnum 400-100 400-120
Rectifer GPU 400-60 GPU GPU GPU
Body
R&R Hood 0.3 0.3 0.3 0.3 0.3
R&R Radiator Shroud 0.5 0.5 0.5 0.5 0.5
Brakes
R&R Hub Front 1.0 1.0 1.0 1.0 1.0
R&R One Stud 1.0 1.0 1.0 1.0 1.0
Brakes Front Axle

R&R Wheel Bearings 1.0 1.0 1.0 1.0 1.0
R&R Wheel Stud 1.0 1.0 1.0 1.0 1.0
Cooling System
R&R Fan 1.0 1.0 1.0 1.0 1.0
R&R Radiator, transfer shroud 0.8 0.8 0.8 0.8 0.8
R&R Top or Bottom hose 0.5 0.5 0.5 0.5 0.5
R&R Water Pump 1.5 1.5 1.5 1.5 1.5
R&R Thermostat 0.5 0.5 0.5 0.5 0.5
Electrical
Troubleshoot Short or No Power 2.0 2.0 2.0 2.0 2.0
R&R Coolant Temp Sensor 0.5 0.5 0.5 0.5 0.5
R&R Coolant Gauge 0.5 0.5 0.5 0.5 0.5
R&R Hour Meter 0.5 0.5 0.5 0.5 0.5
R&R Ammeter 0.5 0.5 0.5 0.5 0.5
R&R Electric Fuel Gauge 0.5 0.5 0.5 0.5 0.5
R&R Electric Fuel Sender 1.0 1.0 1.0 1.0 1.0
R&R Kysor Coolant Temperature Sen-
sor 0.5 0.5 0.5 0.5 0.5
R&R Kysor Oil Pressure Sensor 0.5 0.5 0.5 0.5 0.5
R&R Kysor Override Switch 0.5 0.5 0.5 0.5 0.5
R&R Light Switch 0.5 0.5 0.5 0.5 0.5
R&R Battery Cable 0.5 0.5 0.5 0.5 0.5
R&R Wire Harness 4.0 4.0 4.0 4.0 4.0
R&R Kysor Warning Light 0.5 0.5 0.5 0.5 0.5
R&R Protecto Start Relay 0.5 0.5 0.5 0.5 0.5
R&R Horn 0.3 0.3 0.3 0.3 0.3
R&R Horn Relay 0.3 0.3 0.3 0.3 0.3
R&R Battery 0.3 0.3 0.3 0.3 0.3
R&R Turn Signal Light 0.3 0.3 0.3 0.3 0.3

R&R Turn Signal Flasher 0.3 0.3 0.3 0.3 0.3
Tighten Battery Cable 0.3 0.3 0.3 0.3 0.3
R&R Glow Plug Switch 0.3 0.3 0.3 0.3 0.3
R&R Brake Switch 0.3 0.3 0.3 0.3 0.3
Adjust Brake Switch
INTRO-xx CD377
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GPU Warranty Labor Flat Rate Guide

28 VDC Magnum 400-100 400-120
Rectifer GPU 400-60 GPU GPU GPU
Engine
R&R Starter Relay 0.3 0.3 0.3 0.3 0.3
R&R Starter 1.0 1.0 1.0 1.0 1.0
R&R Alternator 1.0 1.0 1.0 1.0 1.0
R&R Fuel Pump or Lift Pump 1.0 1.0 1.0 1.0 1.0
R&R Battery 0.5 0.5 0.5 0.5 0.5
R&R Valve Cover Gasket 1.0 1.0 1.0 1.0 1.0
R&R Engine Assembly 4.0 4.0 4.0 4.0
R&R Oil Pan 2.0 2.0 2.0 2.0 2.0
R&R Front Crankshaft Seal 2.0 2.0 2.0 2.0 2.0
Exhaust
R&R Exhaust Pipe 0.5 0.5 0.5 0.5 0.5
R&R Muffler 0.5 0.5 0.5 0.5 0.5
R&R Tail Pipe 0.5 0.5 0.5 0.5 0.5
Fuel System
R&R Fuel Cell 1.0 1.0 1.0 1.0 1.0
R&R Fuel Line Steel 0.5 0.5 0.5 0.5 0.5
GPU
Adjust Voltage Regulator 1.0 1.0 1.0 1.0 1.0
Adjust Speed Control 1.0 1.0 1.0 1.0 1.0
Adjust ECU 1.0 1.0 1.0 1.0 1.0
Adjust Over/Under Frequency Module 1.0 1.0 1.0 1.0 1.0
Adjust Over/Under Voltage Module 1.0 1.0 1.0 1.0 1.0
R&R Voltage Regulator 1.0 1.0 1.0 1.0 1.0
R&R Speed Control 1.5 1.5 1.5 1.5 1.5
R&R ECU 1.5 1.5 1.5 1.5 1.5
R&R Over/Under Frequency Module 1.5 1.5 1.5 1.5 1.5
R&R Over/Under Voltage Module 1.5 1.5 1.5 1.5 1.5
CD377 INTRO-xxi
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HOW TO USE THIS MANUAL
Important Notice: TUG recommends that the vehicle operator thoroughly study the contents of this handbook
before attempting to operate the vehicle.
This handbook is divided into five chapters. Refer to the Table of Contents at the front of this manual for
details of chapter content.
Page numbering system uses a three-part page number. The first number represents the chapter in which the
page appears, the second number indicates the section within that chapter, while the third number is the page
number within that section.
Warnings, Cautions, and Notes are used throughout this handbook. Look for the following symbols, which
point out items of importance to the safety of the individual and protection of equipment.
SAFETY NOTES THAT MUST BE FOLLOWED TO AVOID SERIOUS

INJURY TO PERSONNEL OR EVEN DEATH.
SAFETY NOTES THAT NEED TO BE FOLLOWED TO PREVENT

DAMAGE TO EQUIPMENT.
Note Relevent information for the reader that is not hazard-related.
INTRO-xxii CD377
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Davco Model GPU400-100/120/140 Safety
SAFETY
A. GENERAL
Operator and mechanic safety is so important at TUG that the initial design and build of every product
undergoes a thorough review of all the components to produce the safest equipment available today.
To reinforce this action, this section of the manual is devoted to safety and must be read by every
operator and mechanic that may be involved with this equipment. It is strongly recommended that this
chapter be reproduced and bound to your operator’s book along with your station safety rules.
B. SAFETY PRECAUTIONS
The following safety precautions contained herein should be observed during all phases of operation.
1. Clean or service the unit only when the engine is shut down.
2. When cleaning, use only an approved solvent to prevent damage and/or deterioration to the
equipment.
3. When filling the fuel tank, do not smoke or use an open flame in the vicinity.
4. Prior to starting the unit, ensure that no loose bars, tools, parts, and the like are lying in or on
a part of the unit, as they could cause serious damage to the unit or bodily injury to personnel.
5. When operating in an enclosed area, pipe the exhaust fumes outside.
6. Follow the manufacturer’s recommendations to properly maintain equipment.
7. In case of malfunction, resulting in a shutdown, do not attempt to restart the engine until the
trouble has been corrected. Failure to comply could result in serious damage to the
equipment.
8. In case of accident, shut down the unit immediately.
9. The unit must be safely supported on blocks or other appropriate supporting devices before
personnel may attempt access underneath the tractor. Equipment used to raise and support
the unit must be rated to withstand 150% (1½ times) the unit’s gross weight.
CD377 SAFETY-i
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Safety Davco Model GPU400-100/120/140
10. This equipment uses metric and S.A.E. (inch type) nuts, bolts, and screws that can present
special service requirements. Many metric measurements are very close in dimension to
S.A.E. rated nuts, bolts, and screws. The use of hardware with mismatched threads or
improperly sized components can result in damage, malfunction, or possible personal injury.
Components and hardware removed from tow tractor should be saved for reuse when
possible. If not reusable, care should be taken to select a replacement that matches the
original in dimension, strength, and pitch of threads.
C. GENERAL RESPONSIBILITIES
General rules cannot be written to cover every possible situation that may arise with each job function,
task, or procedure. Therefore, certain definite responsibilities rest with you. These responsibilities
include, protection of yourself, your fellow employees, along with proper care of tools and equipment.
You are also responsible for reporting unsafe conditions, equipment, or operation to the proper
authorities. If unsure of an operating procedure, consult your supervisor for guidance.
D. WARNING STATEMENTS
WARNING: DO NOT ENGAGE EMERGENCY STOP FOR NORMAL

SHUTDOWN. ENGAGING EMERGENCY STOP DURING NORMAL
USE COULD CAUSE DAMAGE TO EQUIPMENT.
WARNING: NEVER SMOKE OR ALLOW AN OPEN FLAME WITHIN

THE IMMEDIATE VICINITY OF THE UNIT WHILE SERVICING
WITH FUEL. NEVER FUEL UNIT WITH ENGINE OPERATING.
WARNING: TO PREVENT SPARKING BETWEEN FILLER NOZZLE

AND FUEL TANK, ALWAYS MAINTAIN METAL-TO-METAL
CONTACT BETWEEN FILLER AND FUEL TANK, AND GROUND
UNIT TO A CERTIFIED GROUND POINT.
WARNING: DO NOT CONNECT LIVE POWER CABLE(S) TO

AIRCRAFT. SEVERE ELECTRICAL ARCING MAY CAUSE SERIOUS
INJURY, DEATH AND/OR DAMAGE TO THE EQUIPMENT.
WARNING: PROLONGED EXPOSURE TO HAZARDOUS NOISE

LEVELS MAY RESULT IN PERMANENT HEARING LOSS. EAR
PROTECTION DEVICES MUST BE WORN WHEN WORKING
WITHIN A CLOSE PROXIMITY OF THIS EQUIPMENT.
WARNING: STARTING THE UNIT IN RUN MODE MAY CAUSE

SERIOUS INJURY AND/OR DAMAGE TO EQUIPMENT.
SAFETY-ii CD377
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Davco Model GPU400-100/120/140 Safety
WARNING: DO NOT CONNECT AN ENERGIZED POWER CABLE

TO AIRCRAFT. SEVERE ELECTRICAL ARCING COULD CAUSE
SERIOUS INJURY, DEATH AND/OR DAMAGE TO THE
EQUIPMENT.
WARNING: DO NOT PLACE THE AC LOAD SWITCH ON OR

MAKE ANY FURTHER SWITCH ADJUSTMENT UNTIL THE UNIT IS
PROPERLY CONNECTED TO THE AIRCRAFT OR LOADBANK.
FAILURE TO COMPLY COULD RESULT IN SEVERE EQUIPMENT
DAMAGE AND/OR SEVERE INJURY TO PERSONNEL.
WARNING: DO NOT PLACE THE DC LOAD SWITCH ON OR

MAKE ANY FURTHER SWITCH ADJUSTMENTS UNTIL THE UNIT
IS PROPERLY CONNECTED TO THE AIRCRAFT OR LOADBANK.
WARNING: NEVER DISCONNECT OUTPUT CABLES WHILE AC

POWER IS BEING DELIVERED.
WARNING: DO NOT TOW UNIT WHILE UNIT IS RUNNING.

DAMAGE, AND/OR SEVERE INJURY TO PERSONNEL.
WARNING: EXTREME CAUTION MUST BE USED WHILE MAKING

SERVICE INSPECTIONS WITHIN THE UNIT WHILE THE UNIT IS
IN OPERATION. WEAR NO LOOSE CLOTHING OR JEWELRY.
NEVER SERVICE THE UNIT ALONE - A SAFETYMAN SHOULD
ALWAYS BE PRESENT DURING SERVICING OPERATIONS.
FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
SERIOUS INJURY OR DEATH.
WARNING: NEVER ENTER THE INTERIOR OF THE UNIT WHILE

UNIT IS IN OPERATION. DO NOT STEP ON OR GRAB HOLD OF
WIRING OR HOSES.
WARNING: FUELS, OILS AND OTHER PETROLEUM PRODUCTS

CAN READILY BE ABSORBED THROUGH THE SKIN AND INTO
THE BLOOD STREAM. WASH IMMEDIATELY AFTER COMING
INTO CONTACT WITH THESE PRODUCTS.
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Safety Davco Model GPU400-100/120/140
E. CAUTIONARY STATEMENTS
CAUTION: BATTERY MUST BE FULLY CHARGED TO SUPPLY

VOLTAGE FOR ENGINE STARTING AND CONTROL.
CAUTION: DO NOT ATTEMPT TO PLACE UNIT INTO SERVICE IF

VOLTAGE AND/OR FREQUENCY IS NOT AT REQUIRED OUTPUT.
SHUT UNIT DOWN AND SERVICE AS REQUIRED.
CAUTION: THE COMBINED LOADS OF AC CABLE 1 AND AC

CABLE 2 CANNOT EXCEED 346 AMPERES CONTINUOUS.
FAILURE TO COMPLY WILL RESULT IN SERIOUS DAMAGE TO
THE GENERATOR.
CAUTION: UNDER NO CIRCUMSTANCES SHOULD THE UNIT BE

ANCHORED BY PASSING BANDS OR CABLES OVER THE AIR
CONDITIONER SUPERSTRUCTURE.
CAUTION: DO NOT ALLOW SOAKING, SPRAYING OR STEAM

CLEANING TO AFFECT ELECTRICAL COMPONENTS OR WIRING.
RUBBER COMPONENTS SHOULD NOT BE CLEANED WITH
SOLUTIONS HAVING A PETROLEUM BASE SUCH AS KEROSENE,
MINERAL SPIRITS, STODDARD SOLVENT OR DRY CLEANING
SOLVENTS.
CAUTION: THE USE OF SYNTHETIC BASE OIL DOES NOT

JUSTIFY EXTENDED OIL CHANGE INTERVALS. EXTENDED OIL
CHANGE INTERVALS CAN DECREASE ENGINE LIFE DUE TO
FACTORS SUCH AS CORROSION, DEPOSITS AND WEAR.
CAUTION: A SULFATED ASH LIMIT OF 1.85% HAS BEEN PLACED

ON ALL ENGINE-LUBRICATING OILS RECOMMENDED FOR USE.
HIGHER ASH OILS MAY CAUSE VALVE AND/OR PISTON DAMAGE
AND LEAD TO EXCESSIVE OIL CONSUMPTION.
NOTE: The warnings and precautions given in this section are general in
Note nature and pertain to any piece of equipment. Specific warnings and
precautions are given as needed in the appropriate sections.
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Chapter 1
Davco Model GPU400-100/120/140 Table of Contents
CHAPTER 1: GENERAL INFORMATION AND

OPERATING INSTRUCTIONS
TABLE OF CONTENTS
SECTION 1: UNIT DESCRIPTION ........................................................................................... 1-1-1
A. Introduction ........................................................................................................... 1-1-1
B. Unit Description .................................................................................................... 1-1-1
C. Engine Description ............................................................................................... 1-1-1
D. Electrical System .................................................................................................. 1-1-7
E. Chassis .............................................................................................................. 1-1-13
F. 28 VDC System (Optional) ................................................................................. 1-1-15
G. Alarm/Low Fuel Beacon (Optional) ..................................................................... 1-1-16
H. Truck Mounted (Optional) ................................................................................... 1-1-16
SECTION 2: OPERATION AND PROCEDURES ..................................................................... 1-2-1
A. General ................................................................................................................. 1-2-1
B. Pre-Operational Inspection ................................................................................... 1-2-1
C. Controls and Indicators ......................................................................................... 1-2-2
D. Operating Procedures .......................................................................................... 1-2-5
SECTION 3: SPECIFICATIONS ................................................................................................ 1-3-1
A. Engine .................................................................................................................. 1-3-1
B. Battery .................................................................................................................. 1-3-1
C. Chassis ................................................................................................................ 1-3-1
D. Instrumentation ..................................................................................................... 1-3-1
E. Controls ................................................................................................................ 1-3-1
F. Fuel Tank .............................................................................................................. 1-3-1
G. Grid Heater ........................................................................................................... 1-3-2
SECTION 4: SHIPPING AND RECEIVING ............................................................................... 1-4-1
A. Shipping ................................................................................................................ 1-4-1
B. Preparation for Shipment ...................................................................................... 1-4-1
C. Receiving .............................................................................................................. 1-4-1
SECTION 5: STORAGE ............................................................................................................ 1-5-1
A. General ................................................................................................................. 1-5-1
B. Preparation for Storage ......................................................................................... 1-5-1
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Table of Contents Davco Model GPU400-100/120/140
(This page intentionally left blank.)
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Chapter 1
Davco Model GPU 400-100/120/140 Section 1
SECTION 1: UNIT DESCRIPTION
A. INTRODUCTION
This manual contains General Specifications, Control and Indicators, Operating Instructions, Service
Requirements, and Parts Information on the Tug Technologies Corporation Davco Model Ground
Power Unit 400-100/120/140 Tier 3.
B. UNIT DESCRIPTION
The Davco Model Ground Power Unit 400-100/120/140 Tier 3 is a self contained, low noise,
weatherproof, diesel-driven generator. This unit is designed to provide 400 Hz, optional 28 VDC
ground power in support of aircraft electrical system. This unit is trailer mounted, designed to be pulled
behind a tow tractor.
C. ENGINE DESCRIPTION
The Ground Power Unit is equipped with a four stroke, in-line six cylinders, turbocharged, electronic
QSB 6.7 liter Cummins diesel engine. Engine horsepower for the GPU 400-100 is rated at 170 HP, the
GPU 400-120 is rated at 203HP, and the GPU400-140 is rated at 240HP. Engine is EPA Tier 3
compliance.
1. Fuel System:
The fuel drawn from one fuel tank by a lift pump and unused fuel is returned back to the other
fuel tank through the low-pressure return line (see Figure 1-1). The fuel tank is equipped with
a 2" crossover hose to equalize fuel level between the two tanks. High pressure common rail
fuel system delivers high injection pressure (1600 bar) for improve performance and fuel
efficiency at every rpm.
a. Pre-Filter Lubricity: The pre-filter includes water separator and water in fuel
(WIF) sensing features (see Figure 1-1). The WIF feature communicates
with the ECM through engine harness and will log a fault code if WIF is not
connected. This adds lubricity for running lighter fuels, i.e. JP8 or Jet A.
b. Primer Pump: A manual priming pump is mounted on the supplied pre-filter

(see Figures 1-1 and 1-2). The fuel system requires manual priming after the
filter changes or when the engine is run out of fuel.
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Chapter 1
Section 1 Davco Model GPU 400-100/120/140
Fuel Tank
Filler Cap
Return Fuel
Hose
Crossover
Fuel Hose
Fuel Tank Filler Cap
Fuel Filter
Fuel Tank,
Right
Water Separator/
Lubricity
Water in Fuel
Sender Supply Fuel
Hose Drain
Petcock
Fuel Tank
Fuel Gauge
Left
Fuel Level Sender
Figure 1-1. Fuel System
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Chapter 1
Turbo Outlet
Air Intake
Turbocharge
Wastegate
Actuator
High Pressure Fuel Lines
Coolant Outlet
Coolant Rail Pressure Sensor
Temperature
Distribution Rail
Sensor
Fuel Injectors
Fuel Filter
Fuel Injector Pump
Fuel Transfer Pump

Fuel Supply Hose
Engine Control Module
Intake Manifold
Fuel Return Hose
Oil Breather
Tube
Turbocharge
Exhaust
Water Temperature
Sensor, Secondary
Coolant Inlet
Figure 1-2. Engine Overview
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Chapter 1
2. Air Intake System: The engine pulls air through a large, single-element air filter into the intake
side of the turbocharger (see Figure 1-3). The exhaust gas-driven turbocharger pressurizes
the intake air which is then directed though a charge air cooler (heat exchanger) before
entering the engines intake manifold and its cylinder.
Air Cleaner
Service Indicator-opt
Air Cleaner Element
Figure 1-3. Air Intake System
3. Cooling System: Coolant is circulated through the engine by a centrifugal-type water pump.
Heat is then removed from the coolant, which circulates in a closed loop system, via the
radiator (see Figures 1-2 and 1-4). Control of the engine temperature is accomplished by the
thermostat that regulates flow of the coolant within the coolant system. The radiator is
mounted directly in front of the motor utilizing a pusher-type fan to push heat through the
updraft.
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Chapter 1
Overflow Bottle
Filler Cap
Coolant Level
Sensor
Overflow
Tube
Figure 1-4. Cooling System
4. Exhaust System: As hot exhaust gas exits the turbocharger (see Figure 1-2), it then travels
through a muffler silencer before being directed out.
5. Electrical System: Engine starting is provided by an electric starting system (see Figure 1-5).
The electric starting motor is energized by the battery. An engine-driven alternator provides
current to charge the battery and power various electrical components.
6. Grid Heater: Allows the fuel chamber to warm for approximately ten seconds prior to engine
start. In addition, the ECM electronically monitors the fuel chamber temperature and cycles
the grid heater, as necessary, until the fuel mixture is at an adequate temperature to reduce
smoke (see Figure 1-5).
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Chapter 1
Grid Heater
Cable
Alternator Engine Grid Heater
Engine Control Module
Alternator to
100 Amp Fuse
Cable
Starter
Starter to
Battery Starter to
Cable Master Switch
Cable
Starter to
Ground
Cable
Figure 1-5. Engine Electrical System
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Chapter 1
D. ELECTRICAL SYSTEM
The Ground Power Unit's electrical system provides power and control circuits for the various
electrical devices installed. Electrical power is provided by a battery, an engine-driven alternator and
an engine-driven generator.
1. Generator: The generator is a brushless, revolving field, three-phase alternating current type
(see Figure 1-6). The front end of the rotor shaft extends forward beyond the stator and is
attached to the engine flywheel by a flexible drive coupling assembly. A brushless exciter is
used to provide excitation current to the rotating field assembly. The generator is rated at 100/
120/140 KVA, 3 phase, 400 Hz, 115 VAC. The generator output produces power to the output
cable through a contactor. The generator output solely depends on the Engine Horse Power.
Contactor, 400HZ, Ground Post

Cable A
Block, 6 pos
Block, Generator
2 pos
Transformer,
Current, (CT)
Jumper Cables
Power Contactor, 400HZ,
Exciter Cable B
Cable A
Fuse, 5AGC,
5 AMP and
Standard
Fuseholder
Main
Harness
Power
Cable B
Block,
2 pos
Figure 1-6. Generator
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Chapter 1
2. Battery Circuit: A battery disconnect switch, located inside next to the batteries of the unit is
use to cut off 12 VDC to the electrical components. Two 12 VDC batteries provide current to
start the engine. The engine alternator will provide current to charge the battery and power
other accessories.
3. Control Panel: The engine control panel (see Figure 1-7) located at the rear of the unit is the
primary control for the operator to start and apply electrical power. The control panel displays
engine and electrical parameters. The control panel consists of:
a. Master Switch: The Master “ON” and “OFF” switch provides power to the control
panel circuits. When the switch is turned off the cool down timer will maintain power
for about 3 minutes 30 seconds.
b. Alarm Light: The alarm light is energized whenever the Deep Sea controller senses a
fault (i.e. engine, generator, low fuel, etc.).
c. Run/Idle Switch: The engine is controlled by this switch. Generator faults are inactive
when switch is in the IDLE position.
d. Reset Switch: The reset switch will clear whatever alarm is present (i.e. under-
voltage/overvoltage). If the alarm condition still exists, the alarm will immediately
energize.
e. Diagnostic Switch: The diagnostic switch energizes the Engine Control Module and
diagnostic input to the engine ECM. Once energized, the water in fuel light will
illuminate and any active engine codes will be flashed out on the engine stop light (see
Chapter 2 Section 2). The master switch must be on for this to activate.
f. Engine Stop Light: This light will illuminate if the engine senses a critical fault that
requires the engine to stop. It will blink the active fault when in diagnostic mode.
g. Water In Fuel Warning Light: This light as three functions. It will illuminate if the
water in fuel sensor, located in the lubricity filter, senses water; the diagnostic switch
is on, and/or there is an engine fault that does not require the engine to stop
immediately.
h. Wait to Start Light: If the air temperature is below 60° F (15.6° C) and the engine
temperature is below 100° F (37.8° C), the grid heater will be energized and the wait
to start lamp will illuminate.
i. Power Cable Switch (28V): Controls the E & F interlock power to the E & F relay.
If the switch is not on, the contactor will not stay closed. If the switch is opened, then
the contactor will open.
j. Contactor Switch (Momentary): This switch closes the output contactor. The switch
will only hold the contactor closed as long as the switch is held in the closed position.
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Chapter 1
k. The Deep Sea Expansion Relay Module (DSERM): The DSERM provides extra
outputs for the Deep Sea controller. The low fuel indicator light and the pre-heater
(grid heater) are controlled.
Diagnostic Switch
Deep Sea Expansion
Light, Pilot Red, 28 Volt, Relay Module
"Engine Stop"
Switch Power
Cable A, 400 HZ
Switch Power
Switch, Contactor, Cable B, 400HZ
400 HZ Cable A
Warning Amber Light
Contactor Closed "Water in Fuel"/Diagnoctic
Green Pilot Light, Switch, Contactor,
28 Volt, Cable A 400 HZ, Cable B
Warning Amber
Light "Wait to Start
Master Switch "Contactor Closed"
Light Pilot Green,
28 Volt, Cable B
Deep Sea, 400 HZ

Controller
"Common Alarm",
Pilot, 28 Volt, Momentary Reset
Amber Light Switch/Alarm
RUN/IDLE, Switch
Figure 1-7. Control Panel
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Chapter 1
4. Electrical Control Box: This houses the electrical relays and fuses (see Figure 1-8).
a. Fuse Panel: The fuses for the GPU are located inside the control panel. The fuses
are ATC.
b. Block, 6 Position: A terminal strip is provided in the control panel to allow multiple
wires to be connected on the same circuit.
c. E & F Relay: The E & F relay is a 24V relay used for the E & F interlock function.
As long as 28VDC power is fed back from the aircraft or the load bank, the contactor
will remain closed until the operator opens the circuit by turning the power cable
switch to OFF.
d. INC/DEC Switch: This switch is a momentary SPDT switch used to increase or

decrease engine speed as required for testing.
e. Diagnostic Plug: The 9-pin diagnostic plug allows Cummins technicians to connect
with the engine's ECM for troubleshooting or programming.
f. Voltage Regulator (AVR): The generator voltage regulator is located in the control
panel for ease of adjustment or replacement. The AVR controls the voltage output of
the generator by varying the voltage supplied to the field winding of the generator.
g. Cool Down Timer: The cool down timer keeps the Timer Relay energized for about 3
minutes plus or minus 30 seconds after the master switch is turned OFF to allow the
engine to cool down before stopping.
h. Alarm Relay: The alarm relay is powered by the Deep Sea controller. The alarm relay
powers the alarm light on the control panel as well as the optional low fuel beacon.
i. Beacon Relay: The beacon relay provides power to the optional "operating" beacon.
j. Frequency Trip Relay: If the Deep Sea controller senses the output frequency to be
above 420 Hz or below 380 Hz, the relay will interrupt power to the E & F relay and
thus open the output contactor.
k. Voltage Trip Relay: The voltage trip relay has the same action as the frequency trip
relay, only opening the circuit for voltage over 122V and below 107V.
l. Timer Relay: This relay is controlled by the cool down timer. It provides power to the
Deep Sea Controller.
m. Starter Relay: The starter relay is controlled by the Deep Sea controller. The relay
provides power to the starter solenoid.
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Chapter 1
5. Engine Fault Circuit: The Deep Sea controller monitors all engine and generator parameters.
Once a fault is detected the controller will automatically shut down the engine, or trip the
generator circuits. (For more information, please refer to the Cummins manual located in
Voltage Trip Relay

Frequency Trip Relay
Starter Relay Beacon Relay
K26
Alarm Relay
K27
K28
K29
Voltage Regulator
Timer Relay
Fuse Panel
EF Relay, A
Block, 6 pos.
EF Relay, B
Timer
INC/DEC Switch
Diagnostic
Plug
Figure 1-8. Electrical Control Box
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Chapter 1
Chapter 5.) Fault codes are as follows:
a. Engine Fault Codes: The Deep Sea controller senses engine fault codes via engine
ECM. If any engine fault code is displayed. The controller will shut down the engine
displaying engine SPN and FMI code. (see Chapter 2 Section 2)
b. Low Oil Pressure: Should the engine oil pressure drop below 15 psi, the Deep Sea
controller will shut down the engine. Low oil pressure will be displayed on the
controller.
c. High Water Temperature: The Deep Sea controller takes a reading from the engine
coolant temperature sensor. Once water temperature exceeds 220° Fahrenheit, the
controller will shut down the engine. High water temperature will be displayed on the
controller.
d. Engine Overcrank: Should the engine fail to start after 3 crank attempts, the Deep
Sea controller will go to Shutdown/Fail To Start mode. The Deep Sea controller has to
be reset to continue operation.
e. Engine Overspeed: If the Deep Sea controller senses the engine speed has exceeded
2250 RPM, the engine will shutdown and the engine overspeed fault will be display on
the controller.
f. Generator High Frequency: Should the generator frequency ever exceed 420 Hz, the
Deep Sea controller will trip the generator frequency relay and the AC cable.
Generator high frequency will be displayed on the deep sea controller.
g. Generator Low Frequency: Should the generator frequency ever drop below 380 Hz,
the Deep Sea controller will trip the generator frequency relay and the AC cable.
Generator low frequency will be displayed on the Deep Sea controller.
h. Generator High Voltage: If the Deep Sea controller senses voltage exceeding 123
VAC, it will trip the generator voltage relay and the AC contactor will be opened.
High voltage will be displayed on the controller.
i. Generator Low Voltage: If the Deep Sea controller senses a voltage drop below 107
VAC, it will trip the generator voltage relay and the AC contactor will be opened.
Low voltage will be displayed on the controller.
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Chapter 1
j. Low Fuel Shutdown: The Deep Sea controller takes a reading frm the fuel level
sender. When only 15 percent fuel level is shown the controller will display an alarm,
and the common alarm light on the control box will light up at the 15 percent fuel
level. Once a 5 percent fuel level is read, the controller will shut down the engine.
k. Low Coolant: The low coolant sensor mounted on the radiator will trip the Deep Sea
controller if the sensor exhibits high resistance in the flow rate indicating no fluid.
When this occurs, the controller will shut down the engine.
WARNING: DO NOT ENGAGE EMERGENCY STOP FOR NORMAL

SHUTDOWN. ENGAGING EMERGENCY STOP DURING NORMAL
USE COULD CAUSE DAMAGE TO EQUIPMENT.
6. Emergency Stop: This red button is located on the left side, between the control box and the
aft door of the unit. In case of an emergency, shut off the unit by simply pressing the button.
Pulling the button back, resetting the switch on the Deep Sea controller, will reset the system.
Use of the Emergency Stop is recorded in the event log of the deep sea controller.
E. CHASSIS
1. Trailer: The unit is mounted on a 4-wheel trailer constructed of 2" x 4" steel rectangular
tubing. All joints and attachments are welded. The front axle has fifth-wheel type steering.
(Refer to the Illustrated Parts List located in Chapter 4 for an illustrated view.) The parking
brakes are drum-type, expanding shoe brakes that are mechanically actuated when the tow
bar is raised into the upright position (see Figure 1-9).
Brake Position
Relieve Brake
Figure 1-9. Brake Position
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2. Enclosure: The enclosure is fabricated from 14-gauge steel. The engine, generator, and
components can be easily accessed by the unique swing-door type design. The removable
doors easily expose the unit for ease of maintenance. Enclosure design has belly pans to keep
mud and dirt from splashing the motor and components. (See Figure 1-10.)
Figure 1-10. Enclosure
3. Fuel Tanks: The unit has two fuel tanks that are constructed of 7-gauge steel mounted on both
side of the trailer (see Figure 1-1). These units have a fuel capacity of 110 gallons, which
allows more than 8 hours of continuous operation at full load.
4. Cable Trays: The unit is equipped with two cable trays mounted on top of each fuel tank. The
cable trays allow the power cables to be stored after use. (Refer to the Illustrated Parts List
in Chapter 4 for more information.)
5. Tire: The unit is mounted on four 6.00" x 9.00" D-rated tires. Tires are of heavy duty
construction.
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F. 28 VDC SYSTEM (OPTIONAL)
The unit model that is equipped with a 28 VDC power supply will provide ground power for aircraft
systems that are capable of operating off a 28 VDC system. This system is capable of operating at
500 DC amp continuous and 2000 DC amp peak. (See Figure 1-11.)
Capacitor, 2.3 MFD

Positive
Diode Positive Cable
Negative Resistor
Diode Shunt
Negative
Diode
Capacitor,
2.3 MFD Capacitor,
2.3 MFD
Rectifier
Negative
Cable
Transformers
Capacitor
Relay, Series 29500
Power Cable
Figure 1-11. Rectifier
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Chapter 1
G. ALARM/LOW FUEL BEACON (OPTIONAL)
The common alarm beacon is mounted directly on top of the enclosure. The common alarm beacon
will turn on when low fuel fault is sensed. Once the fault is sensed, a relay in the control box will
energize thus turning on the common alarm beacon light.
H. TRUCK MOUNTED (OPTIONAL)
The truck-mounted Davco model ground power unit 400-100/120/140 Tier 3 is skid-mounted to the
truck. Controls and functions are identical to the trailer mounted, with the exception that the truck-
mounted unit chassis is different from the trailer-mounted.
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Chapter 1
SECTION 2: OPERATION AND PROCEDURES
A. GENERAL
This section contains information for operating the Davco model Ground Power Unit 400-100/120/140.
The operator must read and understand all instructions before attempting to operate the unit.

MAY RESULT IN PERMANENT HEARING LOSS. EAR
B. PRE-OPERATIONAL INSPECTION
Prior to the first operation of the day, the unit must be inspected to ensure safe and reliable operation.
The engine should be operated from the engine service panel to observe that the engine oil pressure
and generator system is functioning properly. Perform the preoperational inspection as follows.
NOTE: If the unit is being operated for the first time, refer to Section 4,
Note Shipping/ Receiving, for initial inspection and preparation for use
procedure, or if it has been in extended storage, refer to Section 5,
Storage, before performing the preoperational inspection.
1. Check engine oil level: Open the engine access doors. Remove engine oil dipstick and check
oil level mark on dipstick. Add oil to bring level up to “H” (full) mark.
2. Enclosure: Visually inspect for obvious defects, i.e., security of common hardware.
3. Towbar: Inspect for excessive movement.
4. Brakes: Check brakes for proper operation.
5. Tires: Inspect tread wear, and check tire inflation (75 psig/517.11 kPa).
6. Engine hoses and clamps: Inspect for leaks and security.
7. Radiator coolant: Open radiator access door; remove radiator cap. Observe that coolant is
visible at top of radiator. Service as required.
8. Engine assembly: Visually inspect fuel lines and fittings for evidence of fuel leakage. Inspect
valve covers, oil pan, and cylinder block for evidence of oil leakage.
9. Fan belt: Visually inspect for wear and cracking. Check belt for proper tension.
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WARNING: NEVER SMOKE OR ALLOW AN OPEN FLAME WITHIN

THE IMMEDIATE VICINITY OF THE UNIT WHILE SERVICING
WITH FUEL. NEVER FUEL UNIT WITH ENGINE OPERATING.
WARNING: TO PREVENT SPARKING BETWEEN FILLER NOZZLE

AND FUEL TANK, ALWAYS MAINTAIN METAL-TO-METAL
CONTACT BETWEEN FILLER AND FUEL TANK, AND GROUND
UNIT TO A CERTIFIED GROUND POINT.
10. Check fuel level and service with diesel fuel as required.
C. CONTROLS AND INDICATORS
1. Table 2-1 lists the controls, indicators, and equipment found on the engine control panel for the
GPU400-60, and explains the specific function of each.
2. Table 2-2 lists the controls, indicators, and equipment found on the Deep Sea controller, and
explains the specific function of each.
Diagnostic Switch 6
Light, Pilot Red, 28 Volt,
"Engine Stop"
7
14
Switch Power Switch Power
Cable A, 400 HZ 12 Cable B, 400HZ
Switch, Contactor,
400 HZ Cable A 15
9
Warning Amber Light
Contactor Closed "Water in Fuel"/Diagnoctic
Green Pilot Light,
16 Switch, Contactor,
28 Volt, Cable A 4 400 HZ, Cable B
Warning Amber
8 Light "Wait to Start
Master Switch 1 "Contactor Closed"

13 Light Pilot Green,
28 Volt, Cable B
5 Deep Sea, 400 HZ

"Common Alarm", Controller
Pilot, 28 Volt, 2
Amber Light
4 Momentary Reset
Switch/Alarm
3 RUN/IDLE, Switch
Figure 2-1. Engine Control Panel
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Chapter 1
Table 2-1. Engine Control Panel
ITEM NAME DESCRIPTION

This switch connects and disconnect electrical power to control box
1 Master ON/OFF Switch components.
2 Common Alarm Light (Amber) This light illuminates when low fuel or another fault code is sensed.
This switch cycles the engine speed from idle (800 RPM) to full speed
3 RUN/IDLE Switch (2000 RPM).
4 Momentary Reset Switch This switch will reset a fault code on the Deep Sea controller.
This is the main control of the control box. (See next table for
5 Deep Sea Controller functions.)
6 Diagnostic Switch This switch will allow a flashing fault code to be read by operator.
7 Engine STOP Light (Red) This light illuminates when an engine fault is read.
This light illuminates during the preheat cycle, before initial engine
8 "Wait to Start" Light (Amber) start.
9 "Water in Fuel" Light (Amber) This light illuminates if water is present in the fuel system.
10 Voltmeter (28 VDC) - Opt. This gauge displays 28 VDC power from transformer/rectifier.
11 Ammeter (28 VDC) - Opt. This gauge display the amp load on 28 volt system.
Power Cable Switch (28 VDC) -
12 Opt. This switch will apply power to 28 VDC power cable.
Pilot Light (28 VDC, Green) -
13 Opt. This light illuminates when 28 VDC loop is closed.
14 Power Cable 1 Switch This switch will apply power to Power Cable 1.
15 Contactor 1 Switch This switch will engage Contactor 1.
Power Cable 1 Pilot Light
16 (Green) This light illuminates when the Contactor 1 loop is closed.
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Chapter 1
Figure 2-2. Deep Sea Controller Panel
Main Display
7
Next Page
8
Information Button 9
Warning Indicator
6 Light "Over Voltage"
5 Warning Indicator
Light "Under Voltage"
4 Warning Indicator Light

"Over Frequency"
(Not in Use)
3 Warning Indicator Light
Start Button 1 "Under Frequency"
Mute/Lamp 2
Test Button
10 Generator Available
Light
(Not in Use)
Table 2-2. Deep Sea Controller Panel
ITEM NAME DESCRIPTION

This button will automatically start the engine once Remote Start
1 Start Button condition is signaled.
2 Mute/Lamp Test Button This button will silence the alarm and illuminates all the LED lights.
Warning Indicator Light This light illuminates when generator frequency drops below 107
3 "Under Frequency" VAC.
Warning Indicator Light
4 "Over Frequency" This light illuminates when generator frequency exceeds 122 VAC.
Warning Indicator Light This light illuminates when generator voltage drops below 107
5 "Under Voltage" VAC.
Warning Indicator Light
6 "Over Voltage" This light illuminates when generator voltage exceeds 122 VAC.
7 Main Display This displays engine and generator parameters.
8 Next Page Button This button allows operator to scroll through parameters.
9 Information Button This button activates the parameter menus.
10 Generator Available Light This light illuminates when the generator is available for loading.
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Chapter 1
D. OPERATING PROCEDURES
1. Engine Start Procedure

The following steps must be performed in the sequence in which they are presented.
WARNING: DO NOT CONNECT LIVE POWER CABLE(S) TO

AIRCRAFT. SEVERE ELECTRICAL ARCING MAY CAUSE SERIOUS
INJURY, DEATH AND/OR DAMAGE TO THE EQUIPMENT.

LEVELS MAY RESULT IN PERMANENT HEARING LOSS. EAR
WARNING: STARTING THE UNIT IN RUN MODE MAY CAUSE

SERIOUS INJURY AND/OR DAMAGE TO EQUIPMENT.
(a) Check and make sure RUN/IDLE switch is in IDLE.
(b) Set master switch to ON. The Deep Sea controller will light up. Push the START
button on the controller. The controller will automatically control the starting function
and cycle the engine to idle speed (750 rpm).
(c) Observe the Deep Sea controller and make sure no fault is present. If no fault is
present, continue operation. If fault is present, discontinue operation until malfunction
is repaired.
CAUTION: BATTERY MUST BE FULLY CHARGED TO SUPPLY

VOLTAGE FOR ENGINE STARTING AND CONTROL.
(d) Set RUN/IDLE switch to RUN. The unit will cycle to full speed (2000 rpm).
CAUTION: DO NOT ATTEMPT TO PLACE UNIT INTO SERVICE IF

VOLTAGE AND/OR FREQUENCY IS NOT AT REQUIRED OUTPUT.
SHUT UNIT DOWN AND SERVICE AS REQUIRED.
(e) Observe generator voltage (115 VAC) and generator frequency (400 Hz) on the Deep
Sea controller.
(f) Observe the generator power available light on the Deep Sea controller. When light
illuminates electrical power is now available for loading.
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2. Generator Operation (AC power)

WARNING: DO NOT CONNECT AN ENERGIZED POWER CABLE

TO AIRCRAFT. SEVERE ELECTRICAL ARCING COULD CAUSE
SERIOUS INJURY, DEATH AND/OR DAMAGE TO THE
EQUIPMENT.
CAUTION: THE COMBINED LOADS OF AC CABLE 1 AND AC

CABLE 2 CANNOT EXCEED 346 AMPERES CONTINUOUS.
FAILURE TO COMPLY WILL RESULT IN SERIOUS DAMAGE TO
THE GENERATOR.
(a) Make sure that the Engine Starting Procedures (Step 1) have been followed.
(b) Connect AC cable(s) to aircraft.
(c) Check voltage (115 VAC) on the Deep Sea controller.
WARNING: DO NOT PLACE THE CONTACTOR ON OR MAKE ANY

FURTHER SWITCH ADJUSTMENT UNTIL THE UNIT IS PROPERLY
CONNECTED TO THE AIRCRAFT OR LOADBANK. FAILURE TO
COMPLY COULD RESULT IN SEVERE EQUIPMENT DAMAGE
AND/OR SEVERE INJURY TO PERSONNEL.
(d) Set Power Cable switch to ON; set Contactor switch to ON for a minimum of 1
second to provide AC power to the aircraft on Power Cable 1.
(e) Upon completion of use, set Power Cable 1 switch to OFF, also repeat for Cable 2 if
present.

(f) Disconnect cable(s) from aircraft.
(g) Skip to Step 4 (Shut Down Procedure).
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Chapter 1
3. 28 Volt Operation (DC Power)

(a) Make sure that the Engine Starting Procedures (Step 1) have been followed.
(b) Connect DC power cable to the aircraft.
(c) Check DC voltmeter (28 VDC).
WARNING: DO NOT PLACE THE CONTACTOR ON OR MAKE ANY

FURTHER SWITCH ADJUSTMENTS UNTIL THE UNIT IS
PROPERLY CONNECTED TO THE AIRCRAFT OR LOADBANK.
(d) Set DC contactor switch to “ON” to provide DC power to the aircraft.
(e) Upon completion of use, set DC LOAD switch to OFF.

(f) Disconnect cable from aircraft.
(g) Skip to Step 4 (Shut Down Procedure).
4. Shut Down Procedures
(a) Set RUN/IDLE switch to IDLE. Engine will cycle down to 1000 rpm.
(b) Set master switch to OFF.
Note NOTE: The unit is equipped with a 3 minute cool down timer.
WARNING: DO NOT TOW UNIT WHILE UNIT IS RUNNING.

DAMAGE, AND/OR SEVERE INJURY TO PERSONNEL.
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SECTION 3: SPECIFICATIONS
A. ENGINE
The prime mover is a 4 cycle, water-cooled, 6-cylinder diesel engine. Engine accessories include fuel
filter, oil filters, heavy-duty air cleaner and radiator, capable of operation in sandy, dusty desert
environments as well as cold weather environments.
B. BATTERY
TUG Technologies uses 2 group 31, 12-volt, batteries for starting. This battery requires no
maintenance.
C. CHASSIS
The unit is mounted on a 4-wheel trailer constructed of 2" x 4" steel rectangular tubing. All joints
and attachments are welded. All metal parts are powder-coat painted. The front axle has fifth wheel
type steering. The two-wheel front trailer brakes are activated when the towbar is in the up and
locked position.
D. INSTRUMENTATION
The Davco Model Ground Power Unit 400-100/120/140 is equipped with the following instrumentation:
1. Engine hour meter

2. Ammeter
3. Oil pressure gauge
4. Temperature gauge
E. CONTROLS
The Davco Model Ground Power Unit 400-100/120/140 is equipped with the following controls:
1. Master on/off switch which enables the engine Deap Sea Control unit (ECU)
2. Contactor on/off
F. FUEL TANK
The fuel tank shall be sized to permit in excess of 8-hour minimum operation without refueling.
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G. GRID HEATER
Units furnished with grid heaters allow the air intake manifold to warm for approximately 10 seconds
prior to the Deep Sea cycle to start. In addition, the grid heater electronics will monitor the engine
temperature and cycle, as necessary, until the air/fuel mixture is at an adequate temperature.
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SECTION 4: SHIPPING AND RECEIVING
A. SHIPPING
When shipped domestically, the Davco Model Ground Power Unit 400-100/120/140 may be shipped
completely assembled. When deemed advisable by the shipping activity, the ground power unit 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.
The application of the covering material should be accomplished in such a manner as to avoid the
formation of water pockets or interference 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.
B. PREPARATION FOR SHIPMENT

To prepare the GPU for shipment, perform the following procedures:
1. Ensure covers are closed and securely fastened.
2. Ensure output cable(s) is secured.
CAUTION: UNDER NO CIRCUMSTANCES SHOULD THE UNIT BE

ANCHORED BY PASSING BANDS OR CABLES OVER THE AIR
CONDITIONER SUPERSTRUCTURE.
C. RECEIVING
1. Initial Inspection
(a) If the unit has been encased in an envelope of weather resistant material, remove the
covering.
(b) Thoroughly inspect the exterior of the housing for any damage that may have
occurred during shipment. Open all covers and re-close, checking latches for proper
operation.
(c) Inspect all instrument glasses and indicator light lenses for evidence of cracks or
damage.
(d) Inspect interior of unit for security of components. Check fuel system for leaks.
Check electrical wiring for brakes or exposed wiring.
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(e) Check the entire unit for loose connections, parts, bolts, nuts or other hardware that
may have been loosened during transit. Tighten or repair all found discrepancies.
(f) Unroll the cable(s). Inspect for damage.
2. Initial Servicing
(a) Remove the engine oil level dipstick. Do not operate if oil level is below the “l” mark
on the dipstick. Service with oil until oil level is at the “H” mark.
(b) Remove radiator cap and inspect coolant level. Service as required bringing level to
within 1 inch (25 mm) of filler neck.
(c) Perform preoperational inspection.
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SECTION 5: STORAGE
A. GENERAL
This section provides instructions for preparing the ground power unit for both short and long term
storage. When the ground power 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.
B. PREPARATION FOR STORAGE
1. Short term storage (less than three months): The following steps are recommended if the
ground power 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.
(a) Check engine coolant level by removing the radiator cap and observing the coolant
level. If needed, service to within one inch form the top of the radiator filler with the
proper mixture of coolant.
(b) Add oil to the “H” (full) mark level on dipstick.
Note NOTE: Do not drain the fuel system or crankcase.
(c) Install new fuel filters.
(d) Close all access doors and covers to minimize buildup of foreign particles in the unit.
(e) Store unit in a building that is dry.
(f) If the storage area has high humidity levels, place moisture-absorbing chemicals inside
the unit.
2. Long term storage: Special precautions are necessary to protect the ground power unit from
rust and corrosion. It is recommended that the unit be stored in a building that is heated during
winter months. Moisture absorbing chemicals should be placed inside the unit in climates
where there is excessive dampness. Parts of the diesel engine requiring special attention are
given below. The unit should be prepared for storage as soon as possible after being removed
from service.
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(a) Drain the cooling system and flush with clean water.
(b) Refill with a pre-mixed solution of 50 percent water and 50 percent antifreeze and
add a rust inhibitor.
(c) Circulate the coolant and additives by operating the engine until the normal operating
temperature is reached.
(d) Stop the engine.
(e) Drain the engine crankcase.
(f) Reinstall the drain plug.
(g) Install new lubricating oil filter elements and gaskets.
(h) Refill with high quality lubricating oil 15W-40 CE/SG multi-viscosity oil.
(i) Remove the spin-on fuel filters, discard, fill new filters with no. 1 diesel fuel and
reinstall on the engine.
(j) Seal all engine openings, including the exhaust outlet, with moisture resistant tape.
Use cardboard, plywood, or metal covers where practical.
(k) Place a tag on the ground power unit control panel that states, “DO NOT RUN,
STORAGE READY.”
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Chapter 2
CHAPTER 2: MAINTENANCE
TABLE OF CONTENTS
SECTION 1: SERVICING ......................................................................................................... 2-1-1
A. Introduction ........................................................................................................... 2-1-1
B. General ................................................................................................................. 2-1-1
C. Cleaning ................................................................................................................ 2-1-3
D. Painting ................................................................................................................. 2-1-4
E. Engine Oil Specifications & Recommendations ................................................... 2-1-4
F. Coolant Specifications & Recommendations ....................................................... 2-1-5
G. Fuel Recommendations/Specifications ................................................................ 2-1-6
H. Consumable Materials .......................................................................................... 2-1-6
I. Periodic Maintenance Schedule ........................................................................... 2-1-7
J. Adjusting the Programmable Timer Module .......................................................... 2-1-9
SECTION 2: TROUBLESHOOTING ........................................................................................ 2-2-1

A. General ................................................................................................................. 2-2-1
B. Troubleshooting Chart .......................................................................................... 2-2-1
C. Engine Trouble Codes and Fault Codes ............................................................... 2-2-7
D. Diagnostic Procedure and Wire Diagrams ........................................................... 2-2-7
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Chapter 2
SECTION 1: SERVICING
A. INTRODUCTION
This section contains instructions for servicing, inspecting, and preventive maintenance on the Davco
model Ground Power Unit 400-100/120/140.
B. GENERAL
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 would
prevent damage or failure of unit, and provide optimum performance.
1. Service Intervals
Under normal operating conditions and with proper preventive maintenance practices, the unit
will provide years of excellent service; typically, 20,000 to 30,000 hours (depending upon local
conditions). At that time, major component overhaul, i.e., diesel engine, generator, may be
required.
2. Engine Oil Change Schedule
Time schedules indicated in Paragraph I of this section 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), and 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. (Also refer to the Periodic Maintenance Chart in Chapter 5.)
(a) Always clean around oil filler openings before removing caps or plugs (see Figure 1-
1).
(b) Do not over-lubricate or overfill the engine crankcase. Use the engine oil level
dipstick to check oil level (see Figure 1-1).
(c) Prevent dust, dirt, or water from contaminating lubricants or lubricated equipment.
(d) Do not mix brands, weights, or types of oil when servicing unit.
(e) Check engine oil level daily, adding oil as required bringing level to “h” (full) mark on
the oil level dipstick (see Figure 1-1).
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Chapter 2
Oil Pressure
Sender
Oil Filter
Oil Fill Cap
Oil Pressure Oil Pan

Switch Dipstick Drain Plug
Figure 1-1. Engine Oil System
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Chapter 2
3. Chassis Lubrication
The bearings in the wheel hubs and fifth-wheel steering should be inspected and greased
yearly. (See Figure 1-2.)
GREASE YEARLY
GREASE YEARLY
GREASE YEARLY
Figure 1-2. Chassis Lubrication
C. CLEANING
CAUTION: DO NOT ALLOW SOAKING, SPRAYING OR STEAM

CLEANING TO AFFECT ELECTRICAL COMPONENTS OR WIRING.
RUBBER COMPONENTS SHOULD NOT BE CLEANED WITH
SOLUTIONS HAVING A PETROLEUM BASE SUCH AS KEROSENE,
MINERAL SPIRITS, STODDARD SOLVENT OR DRY CLEANING
SOLVENTS.
Cleanliness of the unit not only adds to the general appearance, but it is also a factor in reducing the
maintenance upkeep. A unit maintained with periodic cleaning will require less repainting, and will also
help prevent the accumulation of abrasive grit on moving parts and surfaces. Cleaning schedules
should be devised by the user according to his environmental and operating conditions. Painted
surfaces require washing with a mild detergent and rinsing with clean water. A bristle brush (never
wire) or spray gun may be used. Unpainted surfaces are cleaned using plain water and brush,
approved solvents, or steam cleaning equipment. Degreasers may be used to remove grease
accumulations from non-lubricated metal parts. Care should be taken with degreasers, as some
brands will also remove or damage painted surfaces. Clean electrical parts with a lint-free cloth,
moistened with approved solvents for electrical equipment.
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D. PAINTING
Painted surfaces, in addition to presenting a good appearance, etc., protect the unit from deterioration.
Paint should be maintained on a nonscheduled, as required, basis. Depending upon environmental and
operational conditions, repaint the entire unit whenever it becomes necessary. Powder-coated units
may never need to be repainted as long as they are kept clean and undamaged.
E. ENGINE OIL SPECIFICATIONS & RECOMMENDATIONS
The use of quality engine lubricating oils combined with appropriate oil drain and filter change intervals
is a critical factor in maintaining the engine performance and durability.
1. A high quality SAE 15W-40 heavy-duty engine oil, which meets the American Petroleum
Institute (API) performance classification CE/SG, is recommended.
NOTE: CC/CD or CD/SG engine oils can be used in areas where CE oil
Note is not yet available, but the oil change schedule must be reduced to one
half the interval given in the maintenance schedule.
2. Arctic Operation: If an engine is operated in ambient temperatures consistently below -10of

(23o C) and there are no provisions to keep the engine warm when it is not in operation, use a
synthetic CC/CE engine oil with adequate low temperature properties such as 5W-20 or 5W-
30. The oil supplier must be responsible for meeting the performance service specifications.
CAUTION: THE USE OF SYNTHETIC BASE OIL DOES NOT

JUSTIFY EXTENDED OIL CHANGE INTERVALS. EXTENDED OIL
CHANGE INTERVALS CAN DECREASE ENGINE LIFE DUE TO
FACTORS SUCH AS CORROSION, DEPOSITS AND WEAR.
CAUTION: A SULFATED ASH LIMIT OF 1.85% HAS BEEN PLACED

ON ALL ENGINE-LUBRICATING OILS RECOMMENDED FOR USE.
HIGHER ASH OILS MAY CAUSE VALVE AND/OR PISTON DAMAGE
AND LEAD TO EXCESSIVE OIL CONSUMPTION.
NOTE: Additional information regarding lubricating oil availability

throughout the world is available in the “E.M.A. Lubricating Oils Data
Note Book for Heavy Duty Automotive and Industrial Engines.” The data
book may be ordered from the Engine Manufacturers Association, One
Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A. 60601.
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F. COOLANT SPECIFICATIONS & RECOMMENDATIONS
1. Specifications
Use low-silicate antifreeze that meets ASTM4985 Test (GM6038M spec.) Criteria.
2. Concentration
Antifreeze must be used in all climates for both freeze and boiling point protection. A 50
percent concentration level (40 to 60 percent range) of ethylene glycol/propylene glycol in
most climates is recommended. Antifreeze at 68 percent concentration provides the
maximum freeze protection and must never be exceeded under any conditions. Antifreeze
protection decreases above 68 percent. For tropical climates, 10% glycol is sufficient for
corrosion protection. (See Table 1-3.)
3. Concentration Testing
Antifreeze concentration must be checked using a refractometer (such as Fleetguard part no.
CC2800). “Floating ball” type density testers or hydrometers are not accurate enough for use
with heavy-duty diesel engine cooling systems.
4. Coolant Change Recommendations
TUG recommends the cooling system be drained and the coolant replaced every 3000 hours,
or yearly (whichever occurs first), to eliminate buildup of harmful chemicals. Cooling System
Capacity: 8.75 U.S. gal. (33 liters).
Table 1-3. Antifreeze Concentration Protection
Antifreeze Percentage of Protection to

Type Antifreeze Temperature
40% -10 °F (-23 °C)
Ethylene Glycol
50% -34 °F (-37 °C)
60% -65 °F (-54 °C)
68% -90 °F (-71 °C)
40% -6 °F (-21 °C)
Propylene
Glycol 50% -27 °F (-33 °C)
60% -56 °F (-49 °C)
68% -82 °F (-63 °C)
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G. FUEL RECOMMENDATIONS/SPECIFICATIONS
ASTM No. 2 D fuel is recommended. The use of No. 2 diesel fuel will result in optimum engine
performance, however the unit is rated for use with JP8 and Jet A fuel. At operation temperatures
below 32 °F (0 °C), acceptable performance can be obtained by using blends of No. 2 D And No. 1
D. The use of lighter fuels can reduce fuel economy.
H. CONSUMABLE MATERIALS
Consumable items are items such as lubricants, fuels, filters, and other disposable items that are
consumed during operation, used to service the air conditioner, or replaced at timed intervals. (See
Table 1-4.)
Table 1-4. Consumable Materials
Application Description Quantity

Coolant, Radiator Coolant Capacity 6 gal. (22.7 lt.)
Ethylene Glycol/Water Mix, Radiator Ethylene Glycol/Water 50% mixture
Filter, Air (p/n GPU-10269-1) Canister 1 ea.
Filter, Fuel (p/n ENG-GPU-QSB4.5-130-2) Filter 1 ea.
Filter, Oil (p/n ENG-GPU-QSB4.5-130-1) Cartridge 1 ea.
Pre-Filter, Lubricity (p/n FS20000) Filter 1 ea.
Fuel Fuel Oil, Diesel, Jet-A 26 gal. (98.4 lt.)
Lubricant, Door Hinge Oil Can, OE30 As required
Lubricant, Engine Crankcase 15-40 CE/SG 15 quarts (14.2 lt.)
Lubricant, Running Gear Grease, Lithium Base As required
Propylene Glycol/Water Mix, Radiator Propylene Glycol/Water 50% mixture
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I. PERIODIC MAINTENANCE SCHEDULE
A suggested inspection/check schedule is provided in Chapter 5. A periodic inspection schedule should

be established and maintained. 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.
WARNING: EXTREME CAUTION MUST BE USED WHILE MAKING

SERVICE INSPECTIONS WITHIN THE UNIT WHILE THE UNIT IS
IN OPERATION. WEAR NO LOOSE CLOTHING OR JEWELRY.
NEVER SERVICE THE UNIT ALONE - A SAFETYMAN SHOULD
ALWAYS BE PRESENT DURING SERVICING OPERATIONS.
FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
SERIOUS INJURY OR DEATH.
WARNING: NEVER ENTER THE INTERIOR OF THE UNIT WHILE

UNIT IS IN OPERATION. DO NOT STEP ON OR GRAB HOLD OF
WIRING OR HOSES.
1. Daily
(a) Inspect lubrication system for leaks.
(b) Check oil level.
(c) Inspect engine cooling system for leaks.
(d) Inspect the condition of belts in engine cooling system.
(e) Check coolant level; add coolant as required.
(f) Inspect air intake system for leaks.
(g) Inspect air intake system for air restrictions.
(h) Inspect exhaust system for leaks.
(i) Inspect exhaust system for restrictions.
(j) Inspect clamps for tightness.
(k) Inspect exhaust system for corrosion.
(l) Inspect oil line to turbocharger for leaks and chafing.
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Chapter 2
(m) Inspect turbocharger for excessive noise.
(n) Inspect battery: ensure electrolyte level covers plates.
(o) Inspect battery hold-down.
(p) Inspect battery terminals for security and corrosion.
(q) Inspect unit for any loose nuts, bolts and/or missing hardware.
2. Every 125 Hours
(a) Inspect radiator core for cleanliness.
(b) Inspect air intake system for corrosion.
(c) Inspect muffler for security.
(d) Check battery state of charge.
(e) Inspect doors and hinges for defects: lubricate hinges.
(f) Inspect drawbar for cracks, corrosion and excessive wear.
(g) Inspect drawbar latch for proper operation.
(h) Inspect axles for security.
(i) Inspect tires for wear.
(j) Inspect wheel bearings for looseness.
3. Every 250 Hours
(a) Change fuel filters (2), engine-mounted and frame.
(b) Change oil and filter.
NOTE: Change engine oil and filter after first 50 hours and then every
Note 250 hours or six months, whichever occurs first.
(c) Change air filter element.
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4. Every 750 Hours
The bearings in the wheel hubs and the fifth-wheel steering should be inspected and greased
every 750 hours or yearly, whichever occurs first.
5. Every 3000 Hours
Change antifreeze solution every 3000 hours or yearly, whichever occurs first.
J. ADJUSTING THE PROGRAMMABLE TIMER MODULE
See the Figure 1-5 for the specifications on how to adjust the programmable timer module.
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Figure 1-5. PMTN Adjustment Specifications
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Chapter 2
SECTION 2: TROUBLESHOOTING
A. GENERAL
This section contains troubleshooting information to assist in locating and correcting operating troubles
which may develop in the ground power unit. Each malfunction for an individual component, unit or
system is followed by a list of tests or inspections that will help the technician to determine probable
causes and corrective action to take.
The tests/inspections and corrective actions should be performed in the order listed. Troubleshooting
is a logical and systematic process of determining and correcting the cause of a malfunction. The
process begins with verification of the malfunction. This may often involve an operational checkout of
the unit. After the trouble has been verified, identify all components in the circuit whose failure could
cause the symptoms observed during the operational checkout. The technician should start by
checking those items that are highest in probability of causing the problem. Inspect and test each
component, until the exact cause of the problem is determined and corrected.

MAY RESULT IN PERMANENT HEARING LOSS. EAR
WARNING: FUELS, OILS AND OTHER PETROLEUM PRODUCTS

CAN READILY BE ABSORBED THROUGH THE SKIN AND INTO
THE BLOOD STREAM. WASH IMMEDIATELY AFTER COMING
INTO CONTACT WITH THESE PRODUCTS.
B. TROUBLESHOOTING CHART
1. Use of Troubleshooting Chart (see Table 2-1)
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 or proper operation. Then proceed by
checking each component in the circuit/system thoroughly.
2. Support Test Equipment Required
Multimeter (Fluke 179 or equivalent): Required for basic troubleshooting. At least two jumper
leads with alligator clips and test prods are required.
CD377 2-2-1
Orig
Chapter 2
3. Component Failure
Stop the engine immediately should any component fail. Practically all engine failures give
some warning to the operator before the component fails and ruins the engine. Equipment has
been saved because alert operators heed warning signs such as a sudden drop in oil pressure,
unusual noises, etc., and immediately shutdown the engine.
Table 2-1. Troubleshooting
Fault and Condition Probable Cause Test, Check, Remedy

1 Excessive fuel consumption. (a) Fuel leak. (a) Check/correct the source of the
leak.
(b) Additional loading from (b) Check/repair accessories and unit
malfunctioning accessories. components, i.e., water pump,
alternator, etc.
(c) Poor quality fuel. (c) Check fuel for contamination.
(d) Inadequate intake air or (d) Check/change air intake filter, and
exhaust restriction. remove any restrictions found in the
exhaust.
2 Engine hard to start or will not (a) Engine cranking speed too (a) Check engine-cranking RPM. Refer
start (exhaust smoke present.) slow. to engine will not crank or cranks
slowly.
(b) Air in the fuel system. (b) Prime the fuel pump.
(c) Fuel supply restricted. (c) Clean or replace prefilters or
screens. Check fuel lines for
restrictions.
(d) Intake air system restricted. (d) Check intake system.
3 Engine cranks but will not start (a) No fuel in tank. (a) Add fuel.
(no smoke from exhaust). (b) Fuel filter clogged with water (b) Replace fuel filters Check fuel for
or other contaminates. contamination
(c) Key Switch signal not present (c) Check fuses, Check Pin # 39 at
engine ECM for 12 volt DC during
cranking
(d) Fuel system not primed (d) Prime fuel system using hand
pump on fuel/water separator
2-2-2 CD377
Orig
Chapter 2
Table 2-1. Troubleshooting (Cont'd)

4 Engine starts but will not keep (a) Air in the fuel system. (a) Prime fuel system using priming
running. pump on fuel/water separator
(b) Fuel filter clogged or fuel waxing (b) Replace fuel filters. Check Fuel
due to cold weather. Heater (if installed) for correct
operation
(c) Fuel supply restricted. (c) Clean or replace pre-filters and
screens and check for fuel line
restrictions.
(d) Fuel contaminated. (d) Verify by operating engine from a
temporary supply tank.
5 Engine surges. (a) Low fuel in tank. (a) Fill supply tank.
(b) Air in the fuel system. (b) Prime fuel system using priming
pump on fuel/water separator
(c) Restricted fuel supply. (c) Clean/replace prefilters and screens
and check fuel lines for restrictions.
6 Black Smoke from exhaust. (a) Intake air restriction. (a) Check/replace filter element. Review
operation for excessive idling.
(b) Injector needle valve stuck open. (b) Locate and replace malfunctioning
injector.
7 Engine will not reach rated (a) Fuel supply restricted. (a) Change the fuel filter and check fuel
speed when loaded. line, pre-filter and screens for
restrictions.
(b) Charge Air Leak (Turbo Outlet) (b) Check Piping and connection
fromTurbo to CAC and CAC to
intake manifold.
8 Low power. (a) Lubricating oil level too high. (a) Drain oil to proper level.
(b) Charge Air Leak (Tubo Outlet) (b) Check Charge Air piping for leaks
9 Engine misfiring. (a) Contaminated fuel. (a) Verify by operating from a temporary
supply tank.
(b) Air in the fuel system. (b) Bleed fuel system and check for
suction leaks.
(c) Fuel injection lines leaking. (c) Inspect and replace broken lines.
CD377 2-2-3
Orig
Chapter 2

10 Fuel knock. (a) Poor quality fuel. (a) Drain tank, fill with correct diesel
fuel.
(b) Air in fuel system. (b) Bleed fuel system and check for
suction leaks.
11 Engine will not crank or (a) Battery voltage low. (a) Remove and load test battery.
cranks too slowly. Recharge battery.
(b) Starting circuit connections (b) Check and tighten connections.
loose or corroded.
(c) No voltage to solenoid. (c) Check wiring, perform voltage check
at solenoid.
(d) Solenoid or starting motor (d) Replace starting motor.
malfunctioning.
(e) Starting motor operating but not (e) Remove the starting motor and
cranking the engine. check for broken teeth on the
flywheel or starting motor spring.
12 Alternator not charging or (a) Loose or corroded battery (a) Clean/tighten battery connections.
charging is not sufficient. connections.
(b) Alternator belt slipping. (b) Check/replace belt tensioner.
(c) Alternator pulley loose. (c) Tighten pulley.
(d) Malfunctioning alternator. (d) Replace alternator.
13 Engine will not start. No (a) Low battery voltage. (a) Check battery connections. Tighten
fault indicators on. if necessary. Perform load test on
battery, recharge if necessary.
(b) No output from Deep Sea (b) Check Fuses, Chaeck Pin #4 of Deep
Controller Sea Controller for 12 Volt output.
(c) No 12 volt signal to Engine (c) Check pin # 39 on engine ECM for
ECM 12Volt check fuses
(d) Defective starter solenoid. (d) Check starter solenoid; replace if
defective.
(e) Defective starter. (e) Check starter; replace if determined
it is defective.
14 Engine will not start, no (a) Low fuel. (a) Check fuel gauge. Fill fuel tank.
reading on fuel gauge.
15 High water temperature (a) High water temperature. (a) Check water temperature level gauge
indicator on. & fluid level in radiator.
(b) High water temperature switch (b) Check high water temp. Switch for
defective. short, replace if defective.
2-2-4 CD377
Orig
Chapter 2

16 Overspeed indicator on. (a) Speed Adjustment switch (a) Check Speed adjustment switch on
defective back panel of control box.
17 Low oil pressure indicator on. (a) Low oil pressure. (a) Check oil dipstick. Add oil as
required.
(b) Low oil pressure switch (b) Check low oil pressure switch for
defective. binding or short. Replace if
defective.
18 Engine will not go to run (a) Run Idle switch (a) Check run/Idle switch for operation
speed. (b) Charge Air leak (b) Check piping for leaks.
(c) Fuel Restriction (c) Check fuel hose for restriction or air
leak.,
19 Engine will not shut off. (a) Diagnostic Switch ON (a) Turn diagnostic switch OFF
(b) Cool Down Timer defective (b) Check programming of Timer See
page XXXX
20 No AC voltage. Engine at (a) Voltage regulator fuse blown or (a) Replace fuses
run speed, Undervoltage fault (b) Defective generator exciter field. (b) Perform continuity test. 20 -29 ohm
between wires F1(+) and F2 (-) with
one lead removed from voltage
reulator.
(c) Residual Magnetism not enough (c) Field Flash the exciter by removing
in exciter the wires F1 and F2 and applying 12
vdc to the wires (+) to F! and (-) to
F2 for 10 seconds with generator not
running. Replace wires and restart.
(d) Defective diodes in generator (d) Check diodes for open; replace if
field exciter defective.
21 No AC output voltage at (a) Contactor switch not closing (a) Check check contactor switch for
cable connector. proper operation. Replace if
defective..
(b) Contactor/wiring bad (b) check for 115 VAC on Red/White
wire on contactor switch with engine
running at full speed. If voltage not
present check wiring, If voltage
present replace contactor.
(c) Cable head bad (c) Check for continuity of cable to

head from contactor out put
CD377 2-2-5
Orig
Chapter 2

22 Over or under (o/u) frequency (a) Engine not running at rated (a) check Run/idle switch for proper
indicator on. spoeed operation
(b) Defective or binding actuator. (b) Check actuator for binds. Replace if
defective.
(c) Defective over frequency (c) If indicator stays on, but frequency
module. is correct, replace over/under
frequency module.
23 Over voltage indicator on. (a) Overvoltage condition. Voltage (a) Adjust to obtain proper voltage.
(b) Over/under voltage module (b) Reset AC. If voltage stabilizes at
defective. 115 VAC and after 5 to 7 seconds
the overvoltage indicator turns on,
change the module.
(c) Defective power supply. (c) Check condition of transformer. If
transformer checks good, change
power supply.
(d) Defective voltage regulator. (d) Replace voltage regulator.
(e) Supply/sensing transformer. (e) Replace supply/sensing transformer.
(f) Defective voltage adjust (f) Replace voltage adjust

(g) 7. Defective generator exciter (g) Check diodes.
field diodes.
24 Under voltage indicator on. (a) Undervoltage condition exists. (a) Adjust to correct voltage.
Voltage adjustment
potentiometer is incorrectly
adjusted.
(b) Over/under voltage (o/u) (b) Reset AC. If AC voltage stabilizes
at 115 VAC and after 5-7 seconds
the indicator illuminates, change o/u
voltage module.
25 Ac output voltage adjustment (a) Defective voltage adjust (a) Check for opens or intermittent
range limited. Voltage potentiometer. readings. Replace if defective.
cannot be adjusted to 115 (b) Voltage regulator potentiometer (b) Set voltage adjust potentiometer on
VAC line to neutral or 200 incorrectly adjusted. control panel at midpoint. Adjust
VAC line to line. potentiometer on voltage regulator
module for a reading of 200 VAC
line to line on the AC output
voltmeter.
2-2-6 CD377
Orig
Chapter 2

26 No DC Voltage Present ( (a) Defective Voltmeter (a) Check voltage at plates on rectifier
Engine idles) (Positive is TOP and Negative is Bottom)
(b) Circuit Breaker open (b) Check circuit breaker for tripped or
open condition
27 No Dc output (engine does No AC output from generator Check H1.H2. H3 terminals on
not idle) transformer for200 VAC input from
generator
28 No DC output voltage at (a) Contactor switch not closing (a) Check check contactor switch for
cable connector. (b) Contactor/wiring bad (b) check for 28.5 VDC on Yellow/Grey
wire on contactor switch with engine
running at full speed. If voltage not
present check wiring, If voltage
present replace contactor.
(c) Cable head bad (c) Check for continuity of cable to head
from contactor out put
C. ENGINE TROUBLE CODES AND FAULT CODES
This troubleshooting section contains the diagnostic trouble and fault codes that Cummins has
provided. Please see Table 2-2 for fault codes relating to the engine.
D. DIAGNOSTIC PROCEDURE AND WIRE DIAGRAMS
To access trouble codes from engine complete the diagnostic list in numerical order.
1. Turn master switch to the on position.
2. Switch the diagnostic switch to the on position.
3. Code will be displayed by a sequential flashing of the "engine stop lamp".
4. Codes are also displayed on the Deep Sea Controller in SPN/FMI format.
CD377 2-2-7
Orig
Chapter 2
Table 2-2. Engine Trouble Codes and Fault Codes
Lamp Color
Fault Code
J1939 FMI
J1939 SPN
J1939 SPN Description Cummins Description

Engine Control Module Critical internal failure - Bad
111 629 12 Red Controller #1 intelligent Device or Component
Engine Speed/Position Sensor Circuit lost both of two
signals from the magnetic pickup sensor -Data
115 612 2 Red System Diagnostic Code # 2 Erratic, Intermittent, or incorrect
Intake Manifold Pressure Sensor Circuit – Voltage
122 102 3 Amber Boost Pressure Above Normal, or Shorted to High Source
Intake Manifold Pressure Sensor Circuit – Voltage
123 102 4 Amber Boost Pressure Below Normal, or Shorted to Low Source
Intake Manifold 1 Pressure - Data Valid but Above

124 102 16 Amber Boost Pressure Normal Operational Range - Moderately Severe Level
Accelerator Pedal or Lever Position Sensor Circuit -

131 91 3 Red Accelerator Pedal Position Voltage Above Normal, or Shorted to High Source
Accelerator Pedal or Lever Position Sensor Circuit -

132 91 4 Red Accelerator Pedal Position Voltage Below Normal, or Shorted to Low Source
Remote Accelerator Pedal or Lever Position Sensor
Circuit – Voltage Above Normal, or Shorted to High
133 974 3 Red Remote Accelerator Source
Remote Accelerator Pedal or Lever Position Sensor
Circuit – Voltage Below Normal, or Shorted to Low
134 974 4 Red Remote Accelerator Source
Oil Pressure Sensor Circuit - Voltage Above Normal,
135 100 3 Amber Engine Oil Pressure or Shorted to High Source
Oil Pressure Sensor Circuit - Voltage Below Normal,
141 100 4 Amber Engine Oil Pressure or Shorted to Low Source
Oil Pressure Low – Data Valid but Below Normal
143 100 18 Amber Engine Oil Pressure Operational Range -Moderately Severe Level
Coolant Temperature Sensor Circuit – Voltage Above
144 110 3 Amber Engine Coolant Temperature Normal, or Shorted to High Source
Coolant Temperature Sensor Circuit – Voltage Below
145 110 4 Amber Engine Coolant Temperature Normal, or Shorted to Low Source
Coolant Temperature High - Data Valid but Above

146 110 16 Amber Engine Coolant Temperature Normal Operational Range - Moderately Severe Level
Accelerator Pedal or Lever Position Sensor Circuit –

147 91 1 Red Accelerator Pedal Position Abnormal Frequency, Pulse Width, or Period
Accelerator Pedal or Lever Position Sensor Circuit –

148 91 0 Red Accelerator Pedal Position Abnormal Frequency, Pulse Width, or Period
Coolant Temperature Low - Data Valid but Above
151 110 0 Red Engine Coolant Temperature Normal Operational Range - Most Severe Level
Intake Manifold Air Temperature Sensor Circuit -
153 105 3 Amber Intake Manifold #1 Temp Voltage Above Normal, or Shorted to High Source
2-2-8 CD377
Orig
Chapter 2
Table 2-2. Engine Trouble Codes and Fault Codes (Cont'd.)

Intake Manifold Air Temperature Sensor Circuit -
154 105 4 Amber Intake Manifold #1 Temp Voltage Below Normal, or Shorted to Low Source
Intake Manifold Air Temperature High – Data Valid
but Above Normal Operational Range -Most Severe
155 105 0 Red Intake Manifold #1 Temp Level
Sensor Supply Voltage #2 Circuit – Voltage Below
187 3510 4 Amber 5 Volts DC Supply Normal, or Shorted to Low Source
Cruise Control (Resistive) Signal Circuit - Voltage
193 520199 3 Amber Cruise Control Above Normal, or Shorted to High Source
Cruise Control (Resistive) Signal Circuit - Voltage
194 520199 4 Amber Cruise Control Below Normal, or Shorted to Low Source
Coolant Level Sensor Circuit - Voltage Above Normal,
195 111 3 Amber Coolant Level or Shorted to High Source
Coolant Level Sensor Circuit - Voltage Below Normal,
196 111 4 Amber Coolant Level or Shorted to Low Source
Coolant Level -Data Valid but Below Normal
197 111 18 Amber Coolant Level Operational Range -Moderately Severe Level
Engine Automatic Start Lamp Driver Circuit - Voltage
199 1661 4 Amber Engine Automatic Start Lamp Above Normal, or Shorted to High Source
Additional Auxiliary Diagnostic Codes logged -
211 1484 31 None J1939 Error Condition Exists
Engine Oil Temperature Sensor 1 Circuit - Voltage
212 175 3 Amber Oil Temperature Above Normal, or Shorted to High Source
Engine Oil Temperature Sensor 1 Circuit - Voltage
213 175 4 Amber Oil Temperature Below Normal, or Shorted to Low Source
Engine Oil Temperature - Data Valid but Above
214 175 0 Red Oil Temperature Normal Operational Range - Most Severe Level
Barometric Pressure Sensor Circuit – Voltage Above
221 108 3 Amber Barometric Pressure Normal, or Shorted to High Source
Barometric Pressure Sensor Circuit – Voltage Below
222 108 4 Amber Barometric Pressure Normal, or Shorted to Low Source
Sensor Supply Voltage #2 Circuit – Voltage Above
227 3510 3 Amber 5 Volts DC Supply Normal, or Shorted to High Source
Coolant Pressure Sensor Circuit - Voltage Above
231 109 3 Amber Coolant Pressure Normal, or Shorted to High Source
Coolant Pressure Sensor Circuit - Voltage Below
232 109 4 Amber Coolant Pressure Normal, or Shorted to Low Source
Coolant Pressure - Data Valid but Below Normal
233 109 18 Amber Coolant Pressure Operational Range -Moderately Severe Level
Engine Speed High -Data Valid but Above Normal
234 190 0 Red Engine Speed Operational Range -Most Severe Level
Coolant Level Low -Data Valid but Below Normal
235 111 1 Red Coolant Level Operational Range -Most Severe Level
External Speed Input (Multiple Unit Synchronization) -

237 644 2 Amber External Speed Input Data Erratic, Intermittent, or Incorrect
238 3511 4 Amber System Diagnostic code # 1 Normal, or Shorted to Low Source
Sensor Supply Voltage #3 Circuit -Voltage Above
239 3511 3 Amber System Diagnostic code #2 Normal, or Shorted to High Source
Vehicle Speed Sensor Circuit - Data Erratic,
241 84 2 Amber Wheel-based Vehicle Speed Intermittent, or Incorrect
Vehicle Speed Sensor Circuit tampering has been
242 84 10 Amber Wheel-based Vehicle Speed detected – Abnormal Rate of Change
CD377 2-2-9
Orig
Chapter 2

Red Stop Lamp Driver Circuit -Voltage Below Normal,
244 623 4 Amber Red Stop Lamp or Shorted to Low Source
Fan Control Circuit - Voltage Below Normal, or
245 647 4 Amber Fan Clutch Output Device Driver Shorted to Low Source
Ambient Air Temperature Sensor Circuit - Voltage
249 171 3 Amber Ambient Air Temperature Above Normal, or Shorted to High Source
Ambient Air Temperature Sensor Circuit - Voltage
256 171 4 Amber Ambient Air Temperature Below Normal, or Shorted to Low Source
Engine Fuel Temperature - Data Valid but Above

261 174 16 Amber Fuel Temperature Normal Operational Range - Moderately Severe Level
Engine Fuel Temperature Sensor 1 Circuit - Voltage
263 174 3 Amber Fuel Temperature Above Normal, or Shorted to High Source
Engine Fuel Temperature Sensor 1 Circuit - Voltage
265 174 4 Amber Fuel Temperature Below Normal, or Shorted to Low Source
Fuel Pressure Sensor Circuit - Data Erratic,
268 94 2 Amber Fuel Delivery Pressure Intermittent, or Incorrect
High Fuel Pressure Solenoid Valve Circuit – Voltage
271 1347 4 Amber Fuel Pump Pressurizing Assembly #1 Below Normal, or Shorted to Low Source
High Fuel Pressure Solenoid Valve Circuit – Voltage
272 1347 3 Amber Fuel Pump Pressurizing Assembly #1 Above Normal, or Shorted to High Source
High Fuel Pressure Solenoid Valve #1 – Mechanical
System Not Responding Properly or Out of
281 1347 7 Amber Fuel Pump Pressurizing Assembly #1 Adjustment
Engine Speed/Position Sensor (Crankshaft) Supply
Voltage Circuit -Voltage Below Normal, or Shorted to
284 1043 4 Amber Internal Sensor Voltage Supply Low Source
SAE J1939 Multiplexing PGN Timeout Error -
285 639 9 Amber SAE J1939 Datalink Abnormal Update Rate
SAE J1939 Multiplexing Configuration Error – Out of
286 639 13 Amber SAE J1939 Datalink Calibration
SAE J1939 Multiplexing Accelerator Pedal or Lever
Sensor System Error - Received Network Data In
287 91 19 Red Accelerator Pedal Position Error
SAE J1939 Multiplexing Accelerator Pedal or Lever
Sensor System Error - Received Network Data In
288 974 19 Red Remote Accelerator Error
Auxiliary Temperature Sensor Input 1 - Special
292 441 14 Red Auxiliary Temperature 1 Instructions
Auxiliary Temperature Sensor Input # 1 Circuit -
293 441 3 Amber OEM Temperature Voltage Above Normal, or Shorted to High Source
Auxiliary Temperature Sensor Input # 1 Circuit -
294 441 4 Amber OEM Temperature Voltage Below Normal, or Shorted to Low Source
Barometric Pressure Sensor Circuit - Data Erratic,
295 108 2 Amber Barometric Pressure Intermittent, or Incorrect
Auxiliary Pressure Sensor Input 1 -Special
296 1388 14 Red Auxiliary Pressure Instructions
Auxiliary Pressure Sensor Input # 2 Circuit -Voltage
297 1388 3 Amber Auxiliary Pressure Above Normal, or Shorted to High Source
Auxiliary Pressure Sensor Input # 2 Circuit -Voltage
298 1388 4 Amber Auxiliary Pressure Below Normal, or Shorted to Low Source
Real Time Clock Power Interrupt - Data Erratic,
319 251 2 Maint Real Time Clock Power Intermittent, or Incorrect
2-2-10 CD377
Orig
Chapter 2

Injector Solenoid Cylinder #1 Circuit – Current Below
322 651 5 Amber Injector Cylinder #01 Normal, or Open Circuit
Coolant Temperature Sensor Circuit – Data Erratic,
334 110 2 Amber Engine Coolant Temperature Intermittent, or Incorrect
Idle Shutdown Vehicle Accessories Relay Driver
Circuit -Voltage Above Normal, or Shorted to High
338 1267 3 Amber Vehicle Accessories Relay Driver Source
Idle Shutdown Vehicle Accessories Relay Driver
Circuit -Voltage Below Normal, or Shorted to Low
339 1267 4 Amber Vehicle Accessories Relay Driver Source
Engine Control Module data lost - Data Erratic,
341 630 2 Amber Calibration Memory Intermittent, or Incorrect
Electronic Calibration Code Incompatibility - Out of
342 630 13 Red Calibration Memory Calibration
Engine Control Module Warning internal hardware
343 629 12 Amber Controller #1 failure - Bad Intelligent Device or Component
Transmission Output Shaft Speed - Data Valid but
Above Normal Operational Range -Moderately
349 191 16 Amber Transmission Output Shaft Speed Severe Level
Injector Power Supply - Bad Intelligent Device or
351 627 12 Amber Controller #1 Component
352 3509 4 Amber 5 Volts DC Supply Normal, or Shorted to Low Source
386 3509 3 Amber 5 Volts DC Supply Normal, or Shorted to High Source
Oil Pressure Low – Data Valid but Below Normal
415 100 1 Red Engine Oil Pressure Operational Range -Most Severe Level
Water in Fuel Indicator High - Data Valid but Above

418 97 15 Maint. Water in Fuel Indicator Normal Operational Range – Least Severe Level
422 111 2 Amber Coolant Level Coolant Level - Data Erratic, Intermittent, or Incorrect
Engine Oil Temperature - Data Erratic, Intermittent, or
425 175 2 Amber Oil Temperature Incorrect
Water in Fuel Sensor Circuit - Voltage Above Normal,
428 97 3 Amber Water in Fuel Indicator or Shorted to High Source
Water in Fuel Sensor Circuit - Voltage Below Normal,
429 97 4 Amber Water in Fuel Indicator or Shorted to Low Source
Accelerator Pedal or Lever Idle Validation Circuit -
431 558 2 Amber Accelerator Pedal Low Idle Switch Data Erratic, Intermittent, or Incorrect
432 558 13 Red Accelerator Pedal Low Idle Switch Out of Calibration
Oil Pressure Sensor Circuit - Data Erratic,
435 100 2 Amber Engine Oil Pressure Intermittent, or Incorrect
CD377 2-2-11
Orig
Chapter 2

Battery #1 Voltage Low - Data Valid but Below
Normal Operational Range – Moderately Severe
441 168 18 Amber Electrical Potential (Voltage) Level
Battery #1 Voltage High - Data Valid but Above
442 168 16 Amber Electrical Potential (Voltage) Level
Fuel Pressure High - Data Valid but Above Normal

449 157 0 Red Injector Metering Rail 1 Pressure Operational Range – Moderately Severe Level
Injector Metering Rail #1 Pressure Sensor Circuit -
451 157 3 Amber Injector Metering Rail 1 Pressure Voltage Above Normal, or Shorted to High Source
Injector Metering Rail #1 Pressure Sensor Circuit -
452 157 4 Amber Injector Metering Rail 1 Pressure Voltage Below Normal, or Shorted to Low Source
Intake Manifold 1 Temperature - Data Valid but Above

488 105 16 Amber Intake Manifold Normal Operational Range -Moderately Severe Level
Transmission Output Shaft Speed - Data Valid but
Below Normal Operational Range -Moderately Severe
489 191 18 Amber Transmission Output Shaft Speed Level
Multiple Unit Synchronization Switch Circuit - Data
497 1377 2 Amber Switch Circuit Erratic, Intermittent, or Incorrect
OEM Intermediate (PTO) Speed switch Validation -
523 611 2 Amber System Diagnostic code # 1 Data Erratic, Intermittent, or Incorrect
Auxiliary Input/Output 2 Circuit -Voltage Above
527 702 3 Amber Circuit -Voltage Normal, or Shorted to High Source
Auxiliary Alternate Torque Validation Switch - Data
528 93 2 Amber Switch - Data Erratic, Intermittent, or Incorrect
Auxiliary Input/Output 3 Circuit -Voltage Above
529 703 3 Amber Circuit -Voltage Normal, or Shorted to High Source
Fuel Delivery Pressure Sensor Circuit - Voltage
546 94 3 Amber Fuel Delivery Pressure Above Normal, or Shorted to High Source
Fuel Delivery Pressure Sensor Circuit - Voltage
547 94 4 Amber Fuel Delivery Pressure Below Normal, or Shorted to Low Source
551 558 4 Amber Accelerator Pedal Low Idle Switch Voltage Below Normal, or Shorted to Low Source
Injector Metering Rail #1 Pressure High – Data Valid
but Above Normal Operational Range -Moderately
553 157 16 Amber Injector Metering Rail 1 Pressure Severe Level
Fuel Pressure Sensor Error - Data Erratic,
554 157 2 Amber Injector Metering Rail 1 Pressure Intermittent, or Incorrect
Injector Metering Rail #1 Pressure Low – Data Valid
but Below Normal Operational Range -Moderately
559 157 18 Amber Injector Metering Rail 1 Pressure Severe Level
Starter Solenoid Lockout Relay Driver Starter Relay Circuit - Voltage Above Normal, or
584 677 3 Amber Circuit Shorted to High Source
Starter Solenoid Lockout Relay Driver Starter Relay Circuit - Voltage Below Normal, or
585 677 4 Amber Circuit Shorted to Low Source
Turbocharger #1 Speed High -Data Valid but Above
595 103 16 Amber Turbocharger 1 Speed Level
Electrical Charging System Voltage High – Data Valid
but Above Normal Operational Range -Moderately
596 167 16 Amber Alternate Potential (voltage) Severe Level
2-2-12 CD377
Orig
Chapter 2

Electrical Charging System Voltage Low – Data Valid
but Below Normal Operational Range -Moderately
597 167 18 Amber Alternate Potential (voltage) Severe Level
Electrical Charging System Voltage Low – Data Valid
but Below Normal Operational Range - Most Severe
598 167 1 Red Alternate Potential (voltage) Level
Auxiliary Commanded Dual Output Shutdown -
599 640 14 Red Engine External Protection Input Special Instructions
649 1378 31 Maint Engine Oil Change Interval Change Lubricating Oil and Filter – Condition Exists
Turbocharger #1 Speed Low - Data Valid but Below
687 103 18 Amber Turbocharger 1 Speed Level
Primary Engine Speed Sensor Error – Data Erratic,
689 190 2 Amber Engine Speed Intermittent, or Incorrect
Turbocharger #1 Compressor Inlet Temperature
Turbocharger #1Compressor Inlet Sensor Circuit – Voltage Above Normal, or Shorted to
691 1172 3 Amber Temp. High Source
Turbocharger #1 Compressor Inlet Temperature
Turbocharger #1Compressor Inlet Sensor Circuit – Voltage Below Normal, or Shorted to
692 1172 4 Amber Temp. Low Source
ECM Internal Temperature Sensor Circuit - Voltage
697 1136 3 Amber Sensor Circuit -Voltage Above Normal, or Shorted to High Source
ECM Internal Temperature Sensor Circuit - Voltage
698 1136 4 Amber Sensor Circuit -Voltage Below Normal, or Shorted to Low Source
Extended Crankcase Blow-by Pressure Circuit -
719 22 3 Amber Crankcase Pressure Voltage Above Normal, or Shorted to High Source
Extended Crankcase Blow-by Pressure Circuit -
729 22 4 Amber Crankcase Pressure Voltage Below Normal, or Shorted to Low Source
Engine Speed/Position #2 mechanical misalignment
between camshaft and crankshaft sensors -
Mechanical System Not Responding Properly or Out
731 723 7 Amber Engine Speed Sensor #2 of Adjustment
757 2802 31 Amber Electronic Control Module Electronic Control Module data lost - Condition Exists
Engine Speed Sensor (Camshaft) Error – Data
778 723 2 Amber Engine Speed Sensor #2 Erratic, Intermittent, or Incorrect
Warning Auxiliary Equipment Sensor Input # 3 (OEM
779 703 11 Amber Auxiliary Equipment Sensor Input Switch) - Root Cause Not Known
Cylinder Power Imbalance Between Cylinders -Data
951 166 2 None Cylinder Power Erratic, Intermittent, or Incorrect
Power Lost With Ignition On - Data Erratic,
1117 627 2 None Power Supply Intermittent, or Incorrect
Injector Cylinder #1 -Mechanical System Not
1139 651 7 Amber Injector Cylinder # 01 Responding Properly or Out of Adjustment
CD377 2-2-13
Orig
Chapter 2

Accelerator Pedal or Lever Position Sensor 2 Circuit -

1239 2623 3 Amber Accelerator Pedal Position Voltage Above Normal, or Shorted to High Source
Accelerator Pedal or Lever Position Sensor 2 Circuit -

1241 2623 4 Amber Accelerator Pedal Position Voltage Below Normal, or Shorted to Low Source
Accelerator Pedal or Lever Position Sensor 1 and 2 -
1242 91 2 Red Accelerator Pedal Position Data Erratic, Intermittent, or Incorrect
Control Module Identification Input Control Module Identification Input State Error -Data
1256 1563 2 Amber State Erratic, Intermittent, or Incorrect
Control Module Identification Input Control Module Identification Input State Error -Data
1257 1563 2 Red State Erratic, Intermittent, or Incorrect
Water in Fuel Indicator - Data Valid but Above Normal

1852 97 16 Amber Water in Fuel Indicator Operational Range - Moderately Severe Level
Injector Metering Rail 1 Pressure - Data Valid but

1911 157 0 Amber Injector Metering Rail Above Normal Operational Range -Most Severe Level
Coolant Temperature 2 Sensor Circuit - Voltage
2111 52 3 Amber Coolant Temperature Above Normal, or Shorted to High Source
Coolant Temperature 2 Sensor Circuit - Voltage
2112 52 4 Amber Coolant Temperature Below Normal, or Shorted to Low Source
Coolant Temperature 2 - Data Valid but Above

2113 52 16 Amber Coolant Temperature Normal Operational Range - Moderately Severe Level
Coolant Temperature 2 - Data Valid but Above
2114 52 0 Red Coolant Temperature Normal Operational Range - Most Severe Level
Coolant Pressure 2 Circuit - Voltage Above Normal,
2115 2981 3 Amber Coolant Pressure or Shorted to High Source
Coolant Pressure 2 Circuit - Voltage Below Normal, or
2116 2981 4 Amber Coolant Pressure Shorted to Low Source
Coolant Pressure 2 - Data Valid but Below Normal

2117 2981 18 Amber Coolant Pressure Operational Range -Moderately Severe Level
Engine Brake Actuator Driver 1 Circuit - Voltage
2182 1072 3 Amber Engine Brake Output # 1 Above Normal, or Shorted to High Source
2183 1072 4 Amber Engine Brake Output # 1 Below Normal, or Shorted to Low Source
2185 3512 3 Amber System Diagnostic code # 1 Normal, or Shorted to High Source
2186 3512 4 Amber System Diagnostic code # 1 Normal, or Shorted to Low Source
Auxiliary Equipment Sensor Input 3 Engine Protection
2195 703 14 Red Auxiliary Equipment Sensor Critical - Special Instructions
Fuel Pump Delivery Pressure - Data Valid but Below

2215 94 18 Amber Fuel Delivery Pressure Normal Operational Range - Moderately Severe Level
Fuel Pump Delivery Pressure - Data Valid but Above
2216 94 1 Amber Fuel Delivery Pressure Level
ECM Program Memory (RAM) Corruption -Condition
2217 630 31 Amber Calibration Memory Exists
2-2-14 CD377
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Chapter 2
Injector Metering Rail 1 Pressure - Data Valid but

2249 157 1 Amber Injector Metering Rail 1 Pressure Below Normal Operational Range -Most Severe Level
Fuel Pump Delivery Pressure - Data Valid but Above

2261 94 15 Maint Fuel Delivery Pressure Normal Operational Range - Least Severe Level
Fuel Pump Delivery Pressure - Data Valid but Below

2262 94 17 Maint Fuel Delivery Pressure Normal Operational Range -Least Severe Level
Battery Temperature - Data Valid but Above Normal

2263 1800 16 Amber Battery Temperature Operational Range -Moderately Severe Level
Battery Temperature - Data Valid but Below Normal

2264 1800 18 Amber Battery Temperature Operational Range -Moderately Severe Level
Fuel Priming Pump Control Signal Circuit – Voltage
2265 1075 3 Amber Electric Lift Pump for Engine Fuel Above Normal, or Shorted to High Source
Fuel Priming Pump Control Signal Circuit – Voltage
2266 1075 4 Amber Electric Lift Pump for Engine Fuel Below Normal, or Shorted to Low Source
Fuel Inlet Meter Device - Data Valid but Above
2292 611 16 Amber Fuel Inlet Meter Device Normal Operational Range - Moderately Severe Level
Fuel Inlet Meter Device flow demand lower than
expected -Data Valid but Below Normal Operational
2293 611 18 Amber Fuel Inlet Meter Device Range - Moderately Severe Level
2311 633 31 Amber Fuel Control Valve #1 Fueling Actuator #1 Circuit Error – Condition Exists
Engine Speed / Position Sensor #1 - Data Erratic,
2321 190 2 None Engine Speed Intermittent, or Incorrect
Engine Speed / Position Sensor #2 - Data Erratic,
2322 723 2 None Engine Speed Sensor #2 Intermittent, or Incorrect
Turbocharger speed invalid rate of change detected -
2345 103 10 Amber Turbocharger 1 Speed Abnormal Rate of Change
Turbocharger Turbine Inlet Temperature (Calculated) -
Data Valid but Above Normal Operational Range –
2346 2789 15 None System Diagnostic Code #1 Least Severe Level
Turbocharger Compressor Outlet Temperature
(Calculated) - Data Valid but Above Normal
2347 2790 15 None System Diagnostic Code #1 Operational Range – Least Severe Level
Engine Brake Actuator Circuit #2 – Voltage Below
2363 1073 4 Amber Engine Compression Brake Output # 2 Normal, or Shorted to Low Source
Engine Brake Actuator Driver Output 3 Circuit -
2365 1112 4 Amber Engine Brake Output # 3 Voltage Below Normal, or Shorted to Low Source
Engine Brake Actuator Circuit #2 – Voltage Above
2367 1073 3 Amber Engine Compression Brake Output # 2 Normal, or Shorted to High Source
2368 1112 3 Amber Engine Brake Output # 3 Above Normal, or Shorted to High Source
Fuel Filter Differential Pressure - Data Valid but
Above Normal Operational Range -Moderately
2372 95 16 Amber Engine Fuel Filter Differential Pressure Severe Level
Exhaust Gas Pressure Sensor Circuit - Voltage
2373 1209 3 Amber Exhaust Gas Pressure Above Normal, or Shorted to High Source
Exhaust Gas Pressure Sensor Circuit - Voltage Below
2374 1209 4 Amber Exhaust Gas Pressure Normal, or Shorted to Low Source
CD377 2-2-15
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Chapter 2

Exhaust Gas Recirculation Temperature Sensor
Exhaust Gas Recirculation Circuit -Voltage Above Normal, or Shorted to High
2375 412 3 Amber Temperature Source
Exhaust Gas Recirculation Temperature Sensor
Exhaust Gas Recirculation Circuit -Voltage Below Normal, or Shorted to Low
2376 412 4 Amber Temperature Source
Fan Control Circuit -Voltage Above Normal, or
2377 647 3 Amber Fan Clutch Output Device Driver Shorted to High Source
Intake Air Heater 2 Circuit - Voltage Below Normal, or
2425 730 4 Intake Air Heater # 2 Shorted to Low Source
Intake Air Heater 2 Circuit - Voltage Above Normal, or
2426 730 3 Intake Air Heater # 2 Shorted to High Source
Intake Air Heater #1 Circuit - Voltage Above Normal,
2555 729 3 Amber Inlet Air Heater Driver #1 or Shorted to High Source
Intake Air Heater #1 Circuit - Voltage Below Normal,
2556 729 4 Amber Inlet Air Heater Driver #1 or Shorted to Low Source
Auxiliary PWM Driver #1 - Voltage Above Normal, or
2557 697 3 Amber Auxiliary PWM Driver #1 Shorted to High Source
Auxiliary PWM Driver #1 - Voltage Below Normal, or
2558 697 4 Amber Auxiliary PWM Driver #1 Shorted to Low Source
Engine Coolant Temperature High - Data Valid but
Above Normal Operational Range - Least Severe
2963 110 15 None Engine Coolant Temperature Level
Intake Manifold Pressure Sensor Circuit - Data
2973 102 2 Amber Boost Pressure Erratic, Intermittent, or Incorrect
2-2-16 CD377
Orig
Chapter 2
Figure 2-3. Electrical Schematic (1 of 4)
CD377 2-2-19
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Chapter 2
2-2-20 CD377
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Chapter 2
CD377 2-2-21
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Chapter 2
30FT
CABLE "A"
C1 C2
L3 C
T3
T9
T4 T5 L0 B1 B2
B
T6 T10 L2
T2
T8
A1 A2
L1 A
T1
T7 W/BN
(X)
F2 F1
(Y)
30FT
CABLE "B"
C1 C2
C
B1 B2
B
A1 A2
A
W/BN
(X)
(Y)
2-2-22 CD377
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Chapter 2
L3
T3
T9
T4 T5 L0
T6 T10 L2
T2
T8
L1
T1
T7
Figure 2-4. 28V Electrical Schematic
CD377 2-2-23
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Chapter 2
2-2-24 CD377
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Chapter 3
CHAPTER 3: OVERHAUL
TABLE OF CONTENTS
SECTION 1: OVERHAUL DATA ............................................................................................... 3-1-1

A. Introduction ........................................................................................................... 3-1-1
B. Engine .................................................................................................................. 3-1-1
C. Generator .............................................................................................................. 3-1-1
CD377 3-TOC-i
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Chapter 3
3-TOC-ii CD377
Orig
Chapter 3
SECTION 1: OVERHAUL DATA
A. INTRODUCTION
The Davco Model GPU 400-100/120/140 has many components that must be maintained by a flexible
program of preventive maintenance, repair, and/or overhaul. Overhaul is normally conducted on a
periodic basis or during unscheduled down time. Proper servicing, maintenance, manufacturer’s
recommendations, and record keeping are important in establishing overhaul periods.
Preventive maintenance recommendations have been provided Tug Technologies Corporation

(Chapter 2, Section 1). Troubleshooting tables (Chapter 2, Section 2), specific to this equipment, have
also been provided to assist the operator and maintenance personnel in quickly isolating and correcting
most common malfunctions.
B. ENGINE
For engine maintenance procedures, refer to the Cummins Operation and Maintenance Manual
located in Chapter 5 of this manual. An engine overhaul manual is not included in this publication. A
workshop manual is available from Cummins or Tug Technologies Corporation.
C. GENERATOR
For generator maintenance procedures, refer to the Marathon Electric Installation, Operation and
Maintenance Manual located in Chapter 5 of this manual. A generator overhaul manual is not
included in this publication. A workshop manual is available from Marathon Electric or TUG.
CD377 3-1-1
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Chapter 3
3-1-2 CD377
Orig.
Chapter 4
Davco Model GPU400-100/120/140 Contents
CHAPTER 4: ILLUSTRATED PARTS LIST

TABLE OF CONTENTS
CHAPTER 4: ILLUSTRATED PARTS LIST ...................................... 4-TOC-I
SECTION 1: DESCRIPTION ..................................................................................................... 4-1-1
A. Introduction ........................................................................................................... 4-1-1
B. Using the Illustrated Parts List .............................................................................. 4-1-2
C. Ordering Spare Parts ............................................................................................ 4-1-4
SECTION 2: ILLUSTRATED PARTS LIST ............................................................................... 4-2-1
A. Introduction ........................................................................................................... 4-2-1
Figure 2-1. Air Intake Assembly ............................................................................. 4-2-2
Figure 2-2. Axle, Wheels, and Tires ...................................................................... 4-2-4
Figure 2-3. Battery Assembly (Up to S/N 10555) .................................................. 4-2-6
Figure 2-4. Battery Assembly (S/N 10555 & Up) ................................................... 4-2-8
Figure 2-5. Control Box Assembly (Up to S/N 10533) ......................................... 4-2-10
Figure 2-5. Control Box Assembly (Up to S/N 10533) - Con't. ............................ 4-2-12
Figure 2-6. Control Box Assembly (S/N 10533 & Up) ......................................... 4-2-14
Figure 2-6. Control Box Assembly (S/N 10533 & Up) - Con't. ............................. 4-2-16
Figure 2-7. Control Panel (Up to S/N 10533) ...................................................... 4-2-18
Figure 2-8. Control Panel (S/N 10533 & Up) ....................................................... 4-2-20
Figure 2-9. Enclosure Assembly ......................................................................... 4-2-22
Figure 2-10. Engine Assembly ............................................................................ 4-2-24
Figure 2-11. Engine Installation ........................................................................... 4-2-26
Figure 2-12. Exhaust System (Up to S/N 10552) ............................................... 4-2-28
Figure 2-13. Fuel System ................................................................................... 4-2-30
Figure 2-14. Fuel System (with Fuel Heater Option) .......................................... 4-2-32
Figure 2-15. Gauge Panel ................................................................................... 4-2-34
Figure 2-16. Generator Assembly - Standard (GPU400-100) ............................. 4-2-36
Figure 2-17. Generator Assembly - 28V Option with One Cable (GPU400-100) 4-2-38
Figure 2-18. Generator Assembly - Two Cables (GPU400-100) ........................ 4-2-40
Figure 2-19. Generator Assembly - Two Cables with 28V Option (GPU400-100) 4-2-42
Figure 2-20. Generator Assembly - Standard (GPU400-120/140) ...................... 4-2-44
Figure 2-21. Generator Assembly - 28V Option (GPU400-120/140) ................... 4-2-46
Figure 2-22. Radiator Assembly ......................................................................... 4-2-48
Figure 2-23. Cooling System .............................................................................. 4-2-50
CD377 4-TOC-i
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Chapter 4
Contents Davco Model GPU400-100/120/140
Figure 2-24. Rectifier Assembly .......................................................................... 4-2-52

Figure 2-25. Exhaust System (S/N 10552 & Up) ................................................ 4-2-54
SECTION 3:
NUMERICAL INDEX ............................................................................................................. 4-3-1
SECTION 4:
ALPHABETICAL INDEX ....................................................................................................... 4-4-1
4-TOC-ii CD377
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Chapter 4
Davco Model GPU400-100/120/140 Section 1
SECTION 1: DESCRIPTION
A. INTRODUCTION
The Illustrated Parts List contained in this manual furnishes spare parts and replacement parts
information as well as general part and assembly information necessary for maintenance of the Davco
Model GPU400-100/120/140.
CAUTION: FOR YOUR OWN PROTECTION, DO NOT USE

SUBSTITUTE PARTS WITHOUT THE APPROVAL OF TUG.
CD377 4-1-1
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Chapter 4
Section 1 Davco Model GPU400-100/120/140
B. USING THE ILLUSTRATED PARTS LIST
The Illustrated Parts List (IPL) provides an illustrated breakdown of components and systems which
comprise the GPU400-100/120/140. Each IPL consists of a figure illustrating a group of related parts
and a corresponding list identifying the parts by part number(s) and description. The quantity given in
the list is for the particular assembly shown in the illustration and is not necessarily the quantity for the
entire unit.
1. Figure and Index Number
The figure and index number refers to the figure on which the part is depicted. The index
number refers to the individual part shown on the illustration. See the following example for
further explanation of the Figure and Index Number.
Refers to the figure number, and the Fig & Vendor Part Tug Part
Code Descriptio
item's number on that figure. Ind Number Number
89-1 372750 ------ TM1-4-8168 Spindle, R
No Index Number: This item is 89- 372750 ------ TM1-4-8166 Spindle, L/
related to the components or
89-2 ------ ------ TM1-1-8264 Pin, King,
system in the illustration, but is
89-3 373090 CB2430-16 TM1-1-8084 Bushing, S
not actually shown. In certain
89-4 372750 ------ TM1-2-8198 Cover, Du
cases, such items are shown in
89-5 403166 ------ MI-ND-813 Bearing, T
other figures in section 4-2.
89-6 403166 CR21208K T6-3001-60022 Seal, Grea
89-7 372739 ------ MI-ND-817 Bearing, H
Figure and index number blank: 89-8 373090 24720 T6-3001-60024 Race, Inne
This item is one of possibly many 89-9 ------ ------ TM1-ND-5287 Hub, Front
items designated by a single 372750 ------ TM1-4-8196 Rotor, Cas
Figure and Index Number. The first 89-10 450238 ------ T6-8015-103 Stud, Whe
item in such a group is assigned a 89-11 ------ ------ TM1-ND-5287 Hub, Front
number; the rest of these items are 89 12 373317 T6 3003 105 N t L ½
listed directly below. These items
are generally similar in function,
but have different applicabilities or
effectivities.
Note NOTE: Sample tables in this section are intended to illustrate table
structure and format, and should not be used for reference of actual data.
Refer to applicable figure for specific required part information.
4-1-2 CD377
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Chapter 4
2. Part Numbers and Vendor Codes
Parts are identified by part numbers assigned by TUG or, in the case of fasteners and related
materials, by industry standard specification. When applicable, vendors’ part numbers are also
included and the individual vendor for each item identified. In a few instances, TUG part
numbers are not available and only the vendor numbers are indicated. These parts can be
ordered directly from TUG using the vendor part number in lieu of a TUG part number.
Vendor codes are provided for quick, easy reference to an individual vendor. The vendor can
be identified by referring to the Vendor Code Reference List in this section. Vendor codes are
not in any way related to the part number. They should not be used when ordering
replacement parts. They are for use as a reference only when using this manual. See the
following illustration for further explanation of Part Numbers and Vendor Codes.
Part number assigned by

TUG.
No vendor code or vendor
part number indicates that
the part is designed,
Fig & Vendor Part Tug Part
manufactured or modified Code Descriptio
Ind Number Number
by TUG.
89-1 372750 ------ TM1-4-8168 Spindle, R
89- 372750 ------ TM1-4-8166 Spindle, L/
89-2 ------ ------ TM1-1-8264 Pin, King,
89-3 373090 CB2430-16 TM1-1-8084 Bushing, S
89-4 372750 ------ TM1-2-8198 Cover, Du
89-5 403166 ------ MI-ND-813 Bearing, T
89-6 403166 CR21208K T6-3001-60022 Seal, Grea
89-7 372739 ------ MI-ND-817 Bearing, H
89-8 373090 24720 T6-3001-60024 Race, Inne
89-9 ------ ------ TM1-ND-5287 Hub, Front
372750 ------ TM1-4-8196 Rotor, Cas
89-10 450238 ------ T6-8015-103 Stud, Whe
89-11 ------ ------ TM1-ND-5287 Hub, Front
89-12 373317 ------ T6-3003-105 Nut, Lug ½
89-13 403166 15245 T6-3001-60026 Race, Out
89-14 403166 15123 T6-3001-60027 Bearing, O
89-15 261788 613108 T6-3001-60028 Washer, S
89-16 261788 ------ T6-3001-60030 Pin, Cotter
89-17 373059 ------ T6-3001-60029 Nut, Spind
89-18 261788 06-12016 T6-3001-60031 Cap, Grea
89-19 372739 EW244002 TM1-1-3508
------ Washer, T
No TUG part number indicates that TUG has not assigned a part
number to the part, and that the part is inventoried and supplied
under the vendor part number.
CD377 4-1-3
Orig
Chapter 4
3. Description and Quantity
A description and quantity is provided for each part listed in the IPL. The quantity given for
subassemblies and subparts is the number of subassemblies/parts contained in the component
or system depicted by the associated illustration, not necessarily the entire vehicle.
4. Effectivity
The effectivity of each item in the parts list is given in part or in whole in the “Effective”
column of the IPL. Information concerning the effectivity of a particular part may also be
found in the description column, the figure title or in notes located at the bottom of the IPL
page. Effectivity is usually (but not always) associated with the serial number.
C. ORDERING SPARE PARTS
To ensure that proper spares and replacement parts are obtained, it is recommended that all major
components be procured directly from TUG. Use of parts not manufactured or supplied by TUG may
void the warranty on the vehicle. When replacing structural fasteners, use Grade 8 or higher material.
Spare parts can be ordered directly from TUG by telephoning TUG SHOP at
1-800-989-8499 (toll free in U.S. and Canada) or 770-422-8021 (outside U.S. or Canada). Ask for
TUG SHOP when calling. FAX messages can be sent to (U.S.A.) 770-422-8730.
When ordering parts, please be prepared with TUG part numbers (vendor part number and code if no
TUG part number is available), part description, figure and index number and the revision of the IPL
page (located in the footer of each page, directly under each page number).
TUG SHOP business hours are from 8:00 a.m. until 5:00 p.m. Eastern time, Monday through Friday.
Answering machines are ready to receive calls after regular business hours. All calls received after
hours will be returned during the next regular business day.
4-1-4 CD377
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Chapter 4
Vendor Code Vendor Name Address City, State, Zip

15376 Tug Kennesaw Production 2652 South Main St. Kennesaw, GA 30144
223505 Crum Electric Supply Co 1165 English Ave Casoer, WY 82601
230042 Fleetpride/Truck & Industrial 200 Pendell Blvd. Mills, WY 82644
238715 DW Industries Inc. 6326 Long Drive Houston, TX 77087
239209 Quality Trailer Products Inc PO Box 1919 Azle, TX 76020
239337 Juliana Company - Colony Tx 4304 Boca Raton Drive The Colony, TX 75056
239602 Donaldson Co., Inc. 1400 West 94th Street Minneapolis, MN 55431
239848 The Protectoseal Company 225 West Foster Avenue Bensenville, IL 60106
240012 Cummins Filtration - Nelson Muffler P O Box 590 Ontario, CAN.POA 1 CO
240950 Stasco Inc 1140 Rothwell Houston, TX 77002
241776 Komatsu American International Co 108 Industrial Drive Ripley, TN 38063
242056 Marathon Electric Victoria Bin# 10560 Milwaukee, WI 53288
242316 Cignys Mfg 68 Williamson St Saginaw, MI 48601-3246
242341 Fleming Metal Fabricators 2810 South Tanager Avenue Los Angeles, CA 90040
242714 Delta Fastener Corp 7122 Old Katy Road Houston, TX 77024
248660 Continental Automotive Systems - VDO 188 Brooke Rd. Winchester, VA 22604
252224 Waytek Inc 2440 Galpin Court Chanhassen, MN 55317
253741 Nabson Inc 480 Neponset St. Unit 10-C Canton, MA 02021
254605 Centroid Products Inc 2104 Hibiscus Drive Edgewater, FL 32141
262861 Grand Bending and Distributors, Inc. 1607 South Cobb Drive Marietta, GA 30060
263540 Peerless Electronics 9600 W. Sample Rd. Coral Springs, FL 33065
263913 Trim-Lok Inc 6855 Hermosa Circle Buena Park, CA 90620
268654 Wear Parts - Casper 455 S Poplar Street Casper, WY 82601
268860 Engineering Concepts Unlimited 8950 Technology Drive Fishers, IN 46038
275689 Wilson Supply Company 6577 West Yellowstone Casper, WY 82604
276841 Process Measurement Denver 2475 West 2nd Avenue #34A Denver, CO 80223
279412 Century Wheel & Rim P O Box 513660 Los Angeles, CA 90051
281660 EWH Spectrum, Inc. 221 West Chillicothe Avenue Bellefontaine, OH 43311
282851 Julian Electric Inc 406 Plaza Drive Westmont, IL 60559
289626 Cummins Generator Technologies P O Box 99337 Chicago, IL 60693-9337
296576 Ladd Industrial Sales Inc 4849 Hempstead Station Drive Deyton, OH 45429
372196 Cummins South Inc. 5125 Hwy 85 Atlanta, GA 30349
372298 Turbo Diesel & Electric Systems, Inc 231 Main Street Forest Park, GA 30297
372736 BSA Machine Shop 2771 Winston Indust. Pkwy Winston, GA 30187
372739 Motion Industries 8145 Troon Circle Austell, GA 30001
372750 Tech Craft Inc. 462 Roswell Street NE Marietta, GA 30060
373089 Laserform & Machine Inc. 10010 Farrow Road Columbia, SC 29203
373094 Grainger, Inc. 2255 Northwest Parkway SE Marietta, GA 30067
373102 Georgia Control Center 3645 Zip Indust. Blvd. Atlanta, GA 30354
373317 Fastenal 1000 Cobb International Blvd. Marietta, GA 30152
373326 Voltex/Bartow Batteries 135 East Felton Rd. Cartersville, GA 30120
402530 Napa Auto Parts 2590 Keene Street Kennesaw, GA 30144
402641 Newark Electronics 22 Technology Parkway South Norcross, GA 30092
402645 Carlton Bates Company 125 Royal Woods Court Tucker, GA 30084
426744 Royal Brass & Hose 1002 Williams Drive NE Marietta, GA 30066
440230 AMS, Incorporated 824 Bill Rutlege Road Winder, GA 30680
524161 Galco Industrial Electronics 1001 E Lincoln Avenue Madison Hghts, MI 48071
CD377 4-1-5
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Chapter 4
Vendor Code Vendor Name Address City, State, Zip

629283 Selecta Switches 1200 E. Tehachapi Blvd. Tehachapi, CA 93561
634120 Anderson Airmotive Products 994 Jefferson Street Fall River, MA 02721
643893 Deltec Co 13065 Tom White Way #G Norwalk, CA 90650
656221 Angel Capacitors Mfg 45011 N Yucca Ave Lancaster, CA 93534
712103 Kissling Electrotech Inc 320 A BUSINESS PARKWAY Greer, SC 29651
712577 Contact Industries Lexington 25 Lex Industrial Dr Mansfield, OH 44904
933325 C & H Technology Inc 6121 Baker Road Suite 108 Minnetonka, MN 55345
963191 Benchmark Power Solutions 800 Prickett Rd. Douglasville, GA 30134
1180420 Marelco Power Systems Inc 327 Catrell Drive, Howell, MI 48843
1180572 Waymatic, Inc. P.O. BOX 5320 South Fulton, TN 38257
1181169 Cable Quest 105 HEATHER CT Ball Ground, GA 30107
1182549 NAPA IBS Store P O Box 102155 Atlanta, GA 30368-2127
4-1-6 CD377
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Chapter 4
SECTION 2: ILLUSTRATED PARTS LIST
A. INTRODUCTION
The following illustrations and corresponding tables comprise the Illustrated Parts List (IPL) for the
Davco model GPU400-100/120/140. Refer to Section 1 of this Chapter for instructions on using the
IPL to identify spare parts and replacement parts information. The IPL can also be used to obtain
general part and assembly information necessary for maintenance of the vehicle.
CD377 4-2-1
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Chapter 4
8 9
1
2
6 3
5
2
2
4
10
Figure 2-1. Air Intake Assembly
4-2-2 CD377
Orig
Chapter 4
Table 2-1. Air Intake Assembly

Code Description Qty Effective
Ind Number Number
1-1 372196 ------ ------ Turbo, Air Intake 1 10435 & Up

1-2 373317 62022 ------ Clamp, Hose, IDEAL 5056 3 "
1-3 426744 ------ 12912045 Hose, Turbo, Ø 4" x 4" Long 1 "
1-4 262861 ------ GPU-10261 Tube, Intake 1 "
1-5 230042 R2 RH540 2000119 Hose, Hump, 5" x 4" 1 "
1-6 373317 62025 ------ Clamp, Hose, IDEAL 5072 1 "
1-7 372196 3932495-S GPU-10089 Clamp, Air Filter, GPU 400/100 2 "
1-8 372196 AH19333 GPU-10248 Cleaner Assembly, Air 1 "
1-9 372196 AF25962 GPU-10248-1 Element, Air Cleaner 1 "
1-10 372750 ------ GPU-10280 Plate, Battery Mount 1 "
CD377 4-2-3
Orig
Chapter 4
16
3d
3c
3b
3a
2o 2p 2q 2r 15
1 2n 2m 14
2l
2s 12
2k 2j 2i 2h 11
2p
2g
2f 2e 2d 8
2c
13
7
10
2a 2b
9
2t 6
5
Figure 2-2. Axle, Wheels, and Tires
4-2-4 CD377
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Chapter 4
Table 2-2. Axle, Wheels, and Tires

Ind Number Number
2-1 242316 55644 AS-10102 Assembly, 5th Wheel 1 10435 & Up

2-2 242316 ------ 05-052783 Axle Assembly, Front (2 Piece Axle) 1 "
2-2a 242316 ------ 05-051009 Latch, Pedal 1 "
2-2b 242316 ------ LC-063F-7 Spring, Comp. 1 "
2-2c 242316 ------ 05-048332 Cable Assembly, Lever 1 "
2-2d 373317 18846 3/8-24x3¼ Bolt, Hex Head Ø 3/8-24 x 3¼" Long 1 "
2-2e 242316 ------ 90-034050-8 Nut, Self-Locking, 3/8-24 2 "
2-2f 242316 ------ 05-048336 Roller 1 "
2-2g 242316 ------ 05-052768 Axle Weldment, Front 1 "
2-2h 373317 18838 3/8-24x1½ Bolt, Hex Head Ø 3/8-24 x 1½" Long 4 "
2-2i 373317 33893 3/8 Washer, Lock 3/8" ID 8 "
2-2j 373317 37304 3/8-24 Nut, Top Lock Hex 3/8-24 8 "
2-2k 373317 18834 3/8"-24x1" Bolt, Hex Head Ø 3/8-24 x 1" Long 4 "
2-2l 242316 ------ 05-046799 Hub/Brake Assembly 1 "
2-2m 242316 ------ 2708 ½-4A Pin, Yoke 2 "
2-2n 242316 ------ LL 3/32"x5/8" Pin, Cotter 2 "
2-2o 242316 ------ 2-1206-01-01 Hub, Heavy Duty 1 "
2-2p 242316 ------ DD 1-14-SHJ Nut, Slotted Hex Jam 1 "
2-2q 242316 ------ LL 1/8"x1¾" Pin, Cotter 1 "
2-2r 242316 ------ 05-005316 Washer, Tang 2 "
2-2s 242316 ------ 05-048338 Cable Assembly, Brake 2 "
2-2t 373317 18844 3/8-24x3 Bolt, Hex Head Ø 3/8-24 x 3" Long 1 "
2-3 242316 ------ 05-055785 Towbar Assembly 1 "
2-3a 242316 ------ 05-046787 Pin, Towbar 1 "
2-3b 242316 ------ GG-¾ PL Washer, Flat 2 "
2-3c 242316 ------ LL 1/8"x1¼" Pin, Cotter 2 "
2-3d 242316 ------ 05-055788 Towbar Weldment 1 "
2-4 242316 55645 AS-10102-3 Spindle Assembly 1 "
2-5 279412 909905 WT1000083 Cap, Dust - Fifth Wheel 2 "
2-6 373317 ------ ½-20 Nut, Lug 20 "
2-7 239209 6X9 TW-SS WT1000196 Tire Assembly, 600 x 9 D-Rated 4 "
2-8 268654 ------ HA1000102 Pin, 1/8" X 3" Cotter 2 "
2-9 279412 4753 WT1000091 Nut, Castellated 1" ID 2 "
2-10 372739 ST3256-4 660-4-0132-3 Washer, Thrust 2 "
2-11 239209 L-44649 WT1000251 Bearing, Outer Wheel 2 "
2-12 239209 84545 WT1000249 Hub Assembly, Wheel, with Studs & 2 "
Nuts
2-13 239209 L-68149 WT1000250 Bearing, Inner Wheel 4 "
2-14 239209 171255TB WT1000252 Seal, Hub Grease 4 "
2-15 239209 R204-84-1.500 WT1000248 Spindle, 1½ x 1-1/16" 2 "
2-16 372736 ------ GPU-10208K Weldment Kit, Frame 1 "
CD377 4-2-5
Orig
Chapter 4
10
11
12
7
13
15
14 12
17
6 18
16
5 19
20
19
21
22
4 23
3
2 24
25
1
26
27
Figure 2-3. Battery Assembly (Up to S/N 10555)
4-2-6 CD377
Orig
Chapter 4
Table 2-3. Battery Assembly (Up to S/N 10555)

Ind Number Number
3-1 372750 ------ GPU-10280 Plate, Battery Mounting 1 Up to 10555

3-2 281660 ------ GPU-10257-7 Cable, Air Intake Heater 1 "
3-3 ------ ------ ------ Cable, 6 Gauge, 12" Long (Grid 1 "
Heater Relay to Fuse)
3-4 373326 ------ GPU-10256 Bracket, Fuse Mounting 1 "
3-5 373326 1131MF T6-9011-235 Battery, Group 31C with Studs 2 "
3-6 281660 ------ GPU-10257-6 Cable, Negative, Jumper 1 "
3-7 281660 ------ GPU-10257-3 Cable, Battery, Jumper 1 "
3-8 373089 ------ LW000064 Tie-Down Weldment, Battery 1 "
3-9 242714 ------ 12911567 Bolt, J, Battery Hold Down, 5/16" 1 "
3-10 281660 ------ GPU-10257-2 Cable (Battery to Switch) 1 "
3-11 281660 ------ GPU-10257-1 Cable (Starter to Switch) 1 "
3-12 241776 191240H2 728154C1 Switch 1 "
3-13 440230 ------ 12970788 Bracket, Battery Disconnect 1 "
3-14 281660 ------ GPU-10257-4 Cable (Starter to Battery) 1 "
3-15 373317 ------ 7/8 Washer, Flat 7/8" ID 1 "
3-16 281660 ------ GPU-10257-8 Cable (Switch to Fuse) 1 "
3-17 263540 FMG-211 T6-4900-157 Holder, Fuse, 250 Amp 3 "
3-18 263540 BK/AMG-100 GPU-10225 Fuse, Air Intake Heater, 100 Amp 1 "
3-19 1181169 ------ GPU-10290 Jumper, Fuse 2 "
3-20 263540 BK/AMG-100 GPU-10225 Fuse, Alternator, 100 Amp 1 "
3-21 263540 BK/AMG-100 GPU-10225 Fuse, Control Box, 100 Amp 1 "
3-22 ------ ------ ------ Cable, Jumper, 12 Gauge 1 "
3-23 ------ ------ ------ Cable, ECM, 12 Gauge 2 "
3-24 281660 ------ GPU-10257-7 Cable, Alternator 1 "
3-25 ------ ------ ------ Cable, Control Box, 12 Gauge 1 "
3-26 252224 46530 3000053 Breaker, Circuit, 30 Amp 1 "
3-27 372196 3916301 GPU-10053 Relay, Grid Heater, 12V 1 "
CD377 4-2-7
Orig
Chapter 4
7
10
11
12
13
15
14 12
17
6 18 3
16
5
19
20
3
21 26
4
1 3 25
2 22
23
24
Figure 2-4. Battery Assembly (S/N 10555 & Up)
4-2-8 CD377
Orig
Chapter 4
Table 2-4. Battery Assembly (S/N 10555 & Up)

Ind Number Number
4-1 372750 ------ GPU-10280 Plate, Battery Mounting 1 10555 & Up

4-2 281660 ------ GPU-10257-7 Cable, Alternator 1 "
4-3 1181169 ------ GPU-10290 Jumper, Fuse 3 "
4-4 372736 ------ GPU-10256 Bracket, Fuse Mounting 1 "
4-5 373326 1131MF T6-9011-235 Battery, Group 31C with Studs 2 "
4-6 281660 ------ GPU-10257-6 Cable, Negative, Jumper 1 "
4-7 281660 ------ GPU-10257-3 Cable, Battery, Jumper 1 "
4-8 373089 ------ LW000064 Tie-Down Weldment, Battery 1 "
4-9 242714 ------ 12911567 Bolt, J, Battery Hold Down, 5/16" 1 "
4-10 281660 ------ GPU-10257-2 Cable (Battery to Switch) 1 "
4-12 241776 191240H2 728154C1 Switch 1 "
4-13 440230 ------ 12970788 Bracket, Battery Disconnect 1 "
4-15 373317 ------ 7/8 Washer, Flat, 7/8" ID 1 "
4-16 281660 ------ GPU-10257-8 Cable (Switch to Fuse) 1 "
4-17 263540 FMG-211 T6-4900-157 Holder, Fuse, 250 Amp 3 "
4-18 263540 BK/AMG-100 GPU-10225 Fuse, Air Intake Heater, 100 Amp 1 "
4-19 263540 BK/AMG-100 GPU-10225 Fuse, Alternator, 100 Amp 1 "
4-20 263540 BK/AMG-100 GPU-10225 Fuse, Control Box, 100 Amp 1 "
4-21 ------ ------ ------ Cable, Jumper, 12 Gauge 1 "
4-22 ------ ------ ------ Cable, Control Box, 12 Gauge 1 "
4-23 252224 46530 3000053 Breaker, Circuit, 30 Amp 1 "
4-24 ------ ------ ------ Cable, ECM, 12 Gauge 2 "
4-25 372196 3916301 GPU-10053 Relay, Grid Heater, 12V 1 "
4-26 281660 ------ GPU-10257-7 Cable, Air Intake Heater 1 "
CD377 4-2-9
Orig
Chapter 4
45
44
43 1
36 35
42 34 33
41 32 31
40 37 28
30 29
38 27
39 18 C1
17 25 26
2 C2
16 23 24
3 C3
K26
K27
K28 15 C4 21 22
4
K29
19 20
5
6
7 14
8 13
12
9
11
10
Figure 2-5. Control Box Assembly (Up to S/N 10533)
4-2-10 CD377
Orig
Chapter 4
Table 2-5. Control Box Assembly (Up to S/N 10533)

Ind Number Number
963191 ------ GPU-10243 Box Assembl, Control, Tier III 1 Up to 10533

5-1 963191 ------ GPU-10243-2 Box, Controller 1 "
5-2 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, S 1 "
(Starter)
5-3 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, E 1 "
(Timer)
5-4 963191 ------ 3-334-485-008 Socket, Relay Base 6 "
5-5 252224 ------ GPU-10243-7 Panel, Fuse, Buss ATC 1 "
5-6 252224 47356 3000023 Block, 6 Position, 30 Amp, 60 V 1 "
5-7 373094 2A545 6000197 Relay, EF, A (Cable 1) 1 "
5-8 373094 2A545 6000197 Relay, EF, B (Cable 2) 1 "
5-9 252224 44250 3000050 Switch, Bypass, SPST 1 "
5-10 963191 ------ GPU-10243-8 Switch, INC/DEC 1 "
5-11 296576 HD10-9-96P 3000507 Plug, T1939 1 "
5-12 963191 ------ GPU-10243-3 Plate, Controller Mounting 1 "
5-13 268860 ECU-PMTN 3000415 Timer, ECU-PMTN Programmer 1 "
5-14 242056 AVC63-12-B2 GPU-10084 Regulator, Voltage, 400HZ, AVC63- 1 "
12B2
5-15 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, A 1 "
(Alarm)
5-16 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, B 1 "
(Beacon)
5-17 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, F 1 "
(Frequency Trip)
5-18 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, V 1 "
(Voltage Trip)
5-19 296576 HD34-18-8PN 3000536 Connector, Plug, 8 Pin, C4 (Starter, 1 "
Battery, Generator-Ground)
5-20 296576 0462-203-12141 3000518 Socket, 12 Gauge 4 "
5-21 270095 HD34-18-14SN 3000508 Connector, Plug, 14 Pin, C3 (Fuel, 1 "
E-Stop, Engine Temperature, Oil
Pressure Switches, Hood Lights)
5-22 270095 0460-202-16141 3000515 Pin, 16 Gauge 13 "
CD377 4-2-11
Orig
Chapter 4
45
44
43 1
36 35
42 34 33
41 32 31
40 37 28
30 29
38 27
39 18 C1
17 25 26
2 C2
16 23 24
3 C3
K26
K27
K28 15 C4 21 22
4
K29
19 20
5
6
7 14
8 13
12
9
11
10
Figure 2-5. Control Box Assembly (Up to S/N 10533) - Con't.
4-2-12 CD377
Orig
Chapter 4
Table 2-5. Control Box Assembly (Up to S/N 10533) - Con't.

Ind Number Number
5-23 296576 HD34-18-14SN 3000508 Connector, Plug, 14 Pin, C2 1 Up to 10533

(Diagnostic, Cruise, ISC1, Key
Switches, Stop, Diag/Wif, and Wait
to Start Lights)
5-24 296576 0460-202-16141 3000515 Pin, 16 Gauge 10 "
5-25 296576 HD34-18-14SN 3000508 Connector, Plug, 14 Pin, C1 1 "
(Generator, EF Relays)
5-26 296576 0460-202-16141 3000515 Pin, 16 Gauge 12 "
5-27 296576 114020-90 3000511 Nut, Lock 4 "
5-28 296576 114021 3000512 Washer, Flat 8 "
5-29 296576 HD36-18-8SN 3000535 Connector, Receptacle, C4 1 "
5-30 296576 0460-204-12141 3000517 Pin, 12 Gauge 4 "
5-31 296576 HD36-18-14PN 3000523 Connector, Receptacle, C3 1 "
5-32 296576 0462-204-12141 3000516 Socket, 16 Gauge 13 "
5-33 296576 HD36-18-14PN 3000523 Connector, Receptacle, HD34-18- 1 "
14SN, C2
5-34 296576 0462-204-12141 3000516 Socket, 16 Gauge 10 "
5-36 296576 0462-204-12141 3000516 Socket, 16 Gauge 12 "
5-37 ------ ------ ------ Fuse, Beacon, 15 Amp 1 "
5-38 ------ ------ ------ Fuse, Fuel, 5 Amp 1 "
5-39 ------ ------ ------ Fuse, Hoodlight, 15 Amp 1 "
5-40 ------ ------ ------ Fuse, Lights, 2 Amp 1 "
5-41 ------ ------ ------ Fuse, Diagnostic, 10 Amp 1 "
5-42 ------ ------ ------ Fuse, E-Stop, 10 Amp 1 "
5-43 ------ ------ ------ Fuse, Controller, 10 Amp 1 "
5-44 ------ ------ ------ Fuse, Starter, 30 Amp 1 "
5-45 ------ ------ ------ Fuse, Alarm, 15 Amp 1 "
CD377 4-2-13
Orig
Chapter 4
44
43
42 1
35 34
41
33 32
40 31 30
39 36 27
29 28
37 26
38 17 C1
16 24 25
2 C2
15 22 23
3 C3
K26
K27
K28
14 20 21
4
K29
C4
18 19
5
6
7 13
8 12
9
11
10
Figure 2-6. Control Box Assembly (S/N 10533 & Up)
4-2-14 CD377
Orig
Chapter 4
Table 2-6. Control Box Assembly (S/N 10533 & Up)

Ind Number Number
963191 ------ GPU-10243 Box Assembly, Control, Tier III 1 10533 & Up
6-1 963191 ------ GPU-10243-1-2 Box, Controller 1 "
6-2 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, S 1 "
(Starter)
6-3 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, E 1 "
(Timer)
6-4 239337 ------ 3-334-485-008 Socket, Relay Base 6 "
6-5 963191 ------ GPU-10243-7 Panel, Fuse, Buss ATC 1 "
6-6 252224 47356 3000023 Block, 6 Position, 30 Amp, 60V 1 "
6-7 373094 2A545 6000197 Relay, EF, A (Cable 1) 1 "
6-8 373094 2A545 6000197 Relay, EF, B - Opt. (Add Cable 2) 1 As Req'd.
6-9 963191 ------ GPU-10243-8 Switch, INC/DEC 1 10533 & Up
6-10 296576 HD10-9-96P 3000507 Plug, J1939 1 "
6-11 963191 ------ GPU-10243-1-3 Plate, Controller Mounting 1 "
6-12 268860 ECU-PMTN 3000415 Timer, ECU-PMTN Programmer 1 "
6-13 242056 AVC63-12-B2 GPU-10084 Regulator, Voltage, 400HZ, 1 "
AVC63-12B2
6-14 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, A 1 "
(Alarm)
6-15 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, B 1 "
(Beacon)
6-16 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, F 1 "
(Frequency Trip)
6-17 239337 0-332-209-151 0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, V 1 "
(Voltage Trip)
6-18 296576 HD34-18-8PN 3000536 Connector, Plug, 8 Pin, C4 (Starter, 1 "
Battery, Generator Ground)
6-19 296576 0462-203-12141 3000518 Socket, 12 Gauge 4 "
6-20 296576 HD34-18-14SN 3000508 Connector, Plug, 14 Pin, C3 (Fuel, E- 1 "
Stop, Engine Temperature, Oil
Pressure Switches, Hood Lights)
6-21 296576 0460-202-16141 3000515 Pin, 16 Gauge 13 "
(Diagnostic, Cruise, ISC1, Key
Switches, Stop, Diag/Wif, and
Wait to Start Lights)
CD377 4-2-15
Orig
Chapter 4
44
43
42 1
35 34
41
33 32
40 31 30
39 36 27
29 28
37 26
38 17 C1
16 24 25
2 C2
15 22 23
3 C3
K26
K27
K28
14 20 21
4
K29
C4
18 19
5
6
7 13
8 12
9
11
10
Figure 2-6. Control Box Assembly (S/N 10533 & Up) - Con't.
4-2-16 CD377
Orig
Chapter 4
Table 2-6. Control Box Assembly (S/N 10533 & Up) - Con't.

Ind Number Number
6-23 296576 0460-202-16141 3000515 Pin, 16 Gauge 10 10533 & Up

(Generator, EF Relays)
6-25 296576 0460-202-16141 3000515 Pin, 16 Gauge 12 "
6-26 296576 114020-90 3000511 Nut, Lock 4 "
6-27 296576 114021 3000512 Washer, Flat 8 "
6-28 296576 HD36-18-8SN 3000535 Connector, Receptacle, C4 1 "
6-29 296576 0460-204-12141 3000517 Pin, 12 Gauge 4 "
6-31 296576 0462-201-16141 3000516 Socket, 16 Gauge 13 "
6-33 296576 0462-201-16141 3000516 Socket, 16 Gauge 10 "
6-35 296576 0462-201-16141 3000516 Socket, 16 Gauge 12 "
6-36 ------ ------ ------ Fuse, Beacon, 15 Amp 1 "
6-37 ------ ------ ------ Fuse, Fuel, 5 Amp 1 "
6-38 ------ ------ ------ Fuse, Hoodlight, 15 Amp 1 "
6-39 ------ ------ ------ Fuse, Lights, 2 Amp 1 "
6-40 ------ ------ ------ Fuse, Diagnostic, 10 Amp 1 "
6-41 ------ ------ ------ Fuse, E-Stop, 10 Amp 1 "
6-42 ------ ------ ------ Fuse, Controller, 10 Amp 1 "
6-43 ------ ------ ------ Fuse, Starter, 30 Amp 1 "
6-44 ------ ------ ------ Fuse, Alarm, 15 Amp 1 "
CD377 4-2-17
Orig
Chapter 4
3 8 9 10 9
2
1 4
11
2 12 9
3 13 9
14
15 9
4
5
5 16 9
6
7
6 17
7
Figure 2-7. Control Panel (Up to S/N 10533)
4-2-18 CD377
Rev 2
Chapter 4
Table 2-7. Control Panel (Up to S/N 10533)

Ind Number Number
7-1 963191 ------ GPU-10243-1 Panel, Controls 1 10533 & Up

7-2 252224 44250 3000050 Switch, SPST, Power Cable A 1 "
7-3 402641 95F4258 3000261 Switch, Contactor, 400 Hz, Cable A 1 "
7-4 402645 2GK51-73 3000049D Switch, DPST, Diagnostic 1 "
7-5 402645 2GK51-73 3000049D Switch, DPST, Master 1 "
7-6 402645 2GK51-73 3000049D Switch, DPST, Run/Idle Switch 1 "
7-7 282851 ------ LE000108 Switch, Momentary, Reset 1 "
7-8 629283 SL63013-BG-G 3000055 Light, Pilot, 28 V, Green (Cable A) 1 "
7-9 402641 95F3261 031084 3000174 Bulb, Light, 28V 6 "
7-10 629283 SL63015-BG-RED 3000287 Light, Pilot, 28 V, Red (Engine Stop) 1 "
7-11 252224 44250 3000050 Switch, SPST, Power Cable B 1 "
7-12 629283 LH392A 3000288 Light, Pilot, 28 V, Amber (Warning) 1 "
7-13 629283 LH392A 3000288 Light, Pilot, 28 V, Amber 1 "
(Water in Fuel)
7-14 402641 95F4258 3000261 Switch, Contactor, 400 Hz, Cable B 1 "
7-15 629283 SL63013-BG-G 3000055 Light, Pilot, 28 V, Green (Cable B) 1 "
7-16 629283 LH392A 3000288 Light, Pilot, 28 V, Amber (Alarm) 1 "
7-17 963191 ------ GPU-10239 Controller, 400 Hz, Deep Sea, 1 "
Model 5310
CD377 4-2-19
Rev 2
Chapter 4
3 8
2 10
1 4 11 17
2 12
3 13
14
15
4 5
5 16
18 6
7
6 9
7
Figure 2-8. Control Panel (S/N 10533 & Up)
4-2-20 CD377
Rev 2
Chapter 4
Table 2-8. Control Panel (S/N 10533 & Up)

Ind Number Number
8-1 963191 ------ GPU-10243-1-1 Panel, Controls 1 Up to 10533

8-2 252224 44250 3000050 Switch, SPST, Power Cable A 1 "
8-3 402641 95F4258 3000261 Switch, Contactor, 400 Hz, Cable A 1 "
8-4 252224 44259 3000049D Switch, DPST, Diagnostic 1 "
8-5 252224 44259 3000049D Switch, DPST, Master 1 "
8-6 252224 44259 3000049D Switch, DPST, Run/Idle Switch 1 "
8-7 282851 ------ LE000108 Switch, Momentary, Reset 1 "
8-8 963191 ECX1052-24 GPU-10243-13 Light, Pilot, 28V, Green (Cable A) 1 "
8-9 963191 ------ GPU-10239 Controller, 400 Hz, Deep Sea, 1 "
Model 5310
8-10 963191 ECX1051-24 GPU-10243-15 Light, Pilot, 28V, Red (Engine Stop) 1 "
8-11 252224 44250 3000050 Switch, SPST 1 "
8-12 963191 ECX1053-24 GPU-10243-14 Light, Pilot, 28V, Amber (Warning) 1 "
8-13 963191 ECX1053-24 GPU-10243-14 Light, Pilot, 28V, Amber (Water in Fuel) 1 "
8-14 402641 95F4258 3000261 Switch, Contactor, 400 Hz 1 "
8-15 963191 ECX1052-24 GPU-10243-13 Light, Pilot, 28V, Green 1 "
8-16 963191 ECX1053-24 GPU-10243-14 Light, Pilot, 28V, Amber (Alarm) 1 "
8-17 963191 ------ GPU-10243-4 Module, Deep Sea Expansion Relay 1 "
8-18 963191 ------ ------ Cover for Controller (Comes with 1 "
Electrical Box. Not Shown.)
CD377 4-2-21
Rev 2
Chapter 4
12
26
11
10
5
9
7
8
13
15 14
25
7
16 6
24
17
18
3
19
1
4
20
3
21
22
23
Figure 2-9. Enclosure Assembly
4-2-22 CD377
Orig
Chapter 4
Table 2-9. Enclosure Assembly

Ind Number Number
9-1 372736 ------ GPU-10208K Weldment Kit, Frame 1 Up to 10435

9-2 372750 ------ GPU-10252 Tray, Extended Height, Cable, L/H 1 "
9-3 263913 100B3X5/32 2000040 Trim-Lock 30 "
9-4 373089 ------ MPDA00105 Cover, Fuel, Left 1 "
9-5 1180572 ------ GPU-10210-19 Door, Side, Front 2 "
9-6 1180572 ------ GPU-10210-22 Box, E-Stop 1 "
9-7 1180572 ------ GPU-10210-20 Door, Side, Rear 2 "
9-8 1180572 ------ GPU-10210-24 Box, Control Panel 1 "
9-9 1180572 ------ GPU-10210-10 Frame, Rear Door 1 "
9-10 1180572 ------ GPU-10210-25 Panel, Meter 1 "
9-11 1180572 ------ GPU-10210-21 Door-Rear-opt 1 As Req'd.
9-12 1180572 ------ GPU-10210 Enclosure, Tier 3, 100,120,140 1 Up to 10435
9-13 1180572 ------ GPU-10210-35 Cover, Radiator 1 "
9-14 1180572 ------ GPU-10210-13 Panel, Right Side, Radiator Support 1 "
9-15 1180572 ------ GPU-10210-18 Panel, Top 1 "
9-16 1180572 ------ GPU-10210-17 Panel, Access 1 "
9-17 1180572 ------ GPU-10210-12 Panel, Left Side, Radiator Support 1 "
9-18 373089 ------ MPDA00052 Cover, Fuel-Right 1 "
9-19 372750 ------ GPU-10251 Tray, Extended HT, Cable, RH 1 "
9-20 372750 ------ GPU-10282 Bracket, Cable Mounting 1 "
9-21 373089 ------ GPU-10022 Spacer, Cable 1 "
9-22 269654 1/4" X 2" X 17' 2000010 Pad Rubber, Mounting 1 "
9-23 402530 733-5793 T6-4700-074 Clamp, 2 3/4" Muffler 1 "
9-24 373102 ------ 660-1-3440 Button, Locking-Red 1 "
9-25 373102 BZ102 660-1-3439 Block, Contact -NC (STOP) 1 "
9-26 230042 TL92572Y ACU-10074 Light, Yellow Strobe-opt 1 As Req'd.
CD377 4-2-23
Orig
Chapter 4
16
15
14
17
13
12
18 11
10
9
8
19
21
20
7
6
4
2
3 5
1
Figure 2-10. Engine Assembly
4-2-24 CD377
Orig
Chapter 4
Table 2-10. Engine Assembly

Ind Number Number
10-1 372196 0130-6774-02 GPU-10259 Fan, 32" 1 10435 & Up

10-2 372196 3910129 GPU-10260 Spacer, Fan 1.5" 2 "
10-3 372196 ------ ENG-GPU-QSB 6.7-171 Engine, Cummins QSB 6.7 1 As Req'd.
171HP (GPU400-100)
372196 ------ ENG-GPU-QSB 6.7-203 Engine, Cummins QSB 6.7 1 "
203 Hp (GPU400-120)
372196 ------ ENG-GPU-QSB 6.7-240 Engine, Cummins QSB 6.7 1 "
240 Hp (GPU400-140)
10-4 372196 ------ QSB4.5-130-2 Filter, Fuel 1 10435 & Up
10-5 426744 ------ GPU-10258-3 Hose, Fuel Supply 1 "
(Filter to Pump)
10-6 426744 ------ GPU-10258-1 Hose, Fuel Return, Tier III 1 "
10-7 12MM-6MJ GPU-10253 Fitting, Straight, Supply Fuel 1 "
426744 Hose
10-8 281660 ------ GPU-10257-7 Cable, Intake (Heater to Grid 1 "
Heater Relay)
10-9 281660 ------ GPU-10257-5 Cable (Starter to Ground) 1 "
10-12 372196 ------ 3971615 Starter 1 "
10-13 372196 ------ QSB4.5-130-1 Filter, Oil 1 "
10-14 ------ ------ ------ Cable, 100 Amp (Alternator to 1 "
Fuse)
10-15 372196 4936876 4936876 Alternator 1 "
10-16 248660 360-025B 3000266 Sender, Oil Pressure, 15 PSI 1 "
10-17 240950 3220X12X8 3220X12X8 Fitting, Straight 1 "
10-18 248660 323-099B 3000014 Sender, Water Temperature 1 "
10-19 372196 ------ ENG-GPU-QSB4.5-130-3 Belt 1 "
10-20 372196 ------ ------ ECU 1 "
10-21 238715 CDP00527 CDP00527 Hose, Engine Cooling 1 "
System,
CD377 4-2-25
Orig
Chapter 4
11 3
2
1
5
10
5 9
6 8
2
7 6
Figure 2-11. Engine Installation
4-2-26 CD377
Orig
Chapter 4
Table 2-11. Engine Installation
Vendor
Fig & Tug Part
Code Part Description Qty Effective
Ind Number
Number
11-1 372196 ------ ENG-GPU-QSB 6.7-171 Engine, Cummins QSB 6.7 171 Hp 1 As Req'd.
(GPU400-100)
372196 ------ ENG-GPU-QSB 6.7-203 Engine, Cummins QSB 6.7 203 Hp 1 "
(GPU400-120)
372196 ------ ENG-GPU-QSB 6.7-240 Engine, Cummins QSB 6.7 240 Hp 1 "
(GPU400-140)
11-2 269654 RM1100-C EG1000028 Mount, Motor 2 Up to 10435
11-3* 372196 0403-6679-02 ------ Mount, Radiator/Engine, Right 1 "
11-4* 372196 0103-7300-02 ------ Bracket, Lower, Radiator 1 "
11-5 373317 ------ ------ Bolt, Hex Head, ½"--1¼" 6 "
11-6 373317 33861 ½ Washer, Flat ½" ID 12 "
11-7 373317 ------ ------ Nut, Top Lock Hex ½- 6 "
11-8* 372196 0403-6678-02 ------ Mount, Radiator/Engine, Left 1 "
11-9 373317 40694 M10-1.5x30 Bolt, Hex Head, M10-1.5 x 30mm 8 "
Long
11-10 373317 40223 M10 Washer, Flat, M10 ID 16 "
11-11 373317 ------ ------ Nut, Lock, 10mm-1.5 8 "
*Part of GPU-10212 Radiator/Charge Air Cooler
CD377 4-2-27
Orig
Chapter 4
1
2
4
12
5 11
3 9
8
6 3
7 3
10
Figure 2-12. Exhaust System (Up to S/N 10552)
4-2-28 CD377
Orig
Chapter 4
Table 2-12. Exhaust System (Up to S/N 10552)

Ind Number Number
12-1 230042 RCG400 2000196 Cap, Rain 4" 1 Up to 10552

12-2 15376 ------ GPU-10244 Bracket, Upper Exhaust 1 "
12-3 230042 R2 U400 2000205 Clamp, Muffler, 4" 4 "
12-4 262861 ------ GPU-10240 Pipe, Exhaust 1 "
12-5 239602 X007784 X005832 Clamp, Seal, 4" S/S 1 "
12-6 262861 ------ GPU-10241 Outlet, Muffler 1 "
12-7 372750 ------ GPU-10245 Bracket, Lower Exhaust 1 "
12-8 372750 ------ GPU-10247 Bracket, Muffler Outlet 1 "
12-9 240012 86562M 2000611 Muffler, 4", Type 5 1 "
12-10 262861 ------ GPU-10242 Outlet, Turbo 1 "
12-11 372750 ------ GPU-10246 Bracket, Muffler Inlet 1 "
12-12 402530 733-5793 T6-4700-074 Clamp, Band, Turbo, 2¾" 1 "
CD377 4-2-29
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Chapter 4
18
17
20
21 19
8
18
5
17
16
3
6
4 22
5
7
8 15
1 2 14
9 13
10
12
11
Figure 2-13. Fuel System
4-2-30 CD377
Orig
Chapter 4
Table 2-13. Fuel System

Ind Number Number
13-1 372736 ------ GPU-10208K Weldment Kit, Frame 1 10435 & Up

13-2 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
13-3 ------ 37264 QSB4.5-130-4 Filter/Separator, Fuel 1 "
13-4* 426744 ------ GPU-10258-2 Hose, Fuel Supply, Tier III 1 "
13-5 426744 12MM-6MJ GPU-10253 Fitting, Fuel Filter Inlet 3 "
13-6* 426744 ------ GPU-10258-3 Hose, Fuel Supply (Filter to Pump) 1 "
13-7 426744 2501-32-32 2021-32-32S Adapter, Connector, Male, 2" Tube 2 "
13-8 426744 6MS-6MP90 5000148 Adapter, Elbow, 90° 2 "
13-9 ------ ------ 5000060 Shims, Wood 4 "
13-10 254605 CGF-14-12V0 GPU-10264 Sender, Fuel Level 1 "
13-11 373317 33859 3/8 Washer, Flat, 3/8"ID 8 "
13-12 373317 15126 3/8-16x6½ Bolt, Hex Head Ø 3/8-16 x 6½" Long 4 "
13-13 242341 GA-VE-FA-26 GM3000080 Gauge, Fuel 2 "
13-14 1182549 145 5000081 Petcock, 1/4" 2 "
13-15 15376 ------ GPU-10213 Tank, Fuel, Left 1 "
13-16 426744 ------ GPU-10223 Hose, Fuel Crossover 1 "
13-17 426744 16867 SF5000078 Nipple, 3" x 3" 2 "
13-18 239848 1275G-39 5000186 Cap, 3" NPT, Female 2 "
13-19* 426744 ------ GPU-10258-1 Hose, Fuel Return, Tier III 1 "
13-20 15376 ------ GPU-10214 Tank, Fuel, Right 1 "
13-21 275689 ------ SF5000188 Plug, Pipe Square Head, 1" NPT 1 "
13-22 1181169 ------ HRN-GPU-400HZ Harness, GPU 400 HZ Tier III 1 "
*Part of GPU-10258 Hose Kit
CD377 4-2-31
Orig
Chapter 4
21
20
24
25 23
12
21
7
22
20
6 9 19
5 10
4 9
7
8
11
12 18
1 17
2 3 16
13
15
14
Figure 2-14. Fuel System (with Fuel Heater Option)
4-2-32 CD377
Orig
Chapter 4
Table 2-14. Fuel System (with Fuel Heater Option)

Ind Number Number
14-1 ------ ------ GPU-10208K Weldment Kit, Frame 1 As Req'd.

14-2 373317 ------ ------ Nut, Lock, 3/8"ID-16 4 "
14-3 ------ ------ 5000060 Shims, Wood 4 "
14-4* 426744 ------ GPU-10258-2 Hose, Fuel Supply, Tier III 1 "
14-5 372196 ------ QSB4.5-130-4 Filter, Fuel 1 "
14-6* 426744 ------ GPU-10258-3 Hose, Fuel Supply (Filter to Pump) 1 "
14-7 426744 12MM-6MJ GPU-10253 Fitting, Fuel Filter Inlet 3 "
14-8 426744 ------ G50-30034 Hose, Fuel Heater Filter 1 "
14-9 426744 4MS-8MP ------ Fitting, Straight 2 "
14-10 426744 1MB-6FP ------ Adapter 2 "
14-11 426744 2501-32-32 2021-32-32S Adapter, Connector, Male, 2" Tube 2 "
14-12 426744 6MS-6MP90 5000148 Adapter, Elbow, 90° 2 "
14-13 254605 CGF-14-12V0 GPU-10264 Sender, Fuel Level 1 "
14-14 373317 33859 3/8 Washer, Flat, 3/8"ID 8 "
14-16 242341 GA-VE-FA-26 GM3000080 Gauge, Fuel 2 "
14-17 1182549 145 5000081 Petcock, 1/4" 2 "
14-18 15376 ------ GPU-10213 Tank, Fuel, Left 1 "
14-19 426744 ------ GPU-10223 Hose, Fuel Crossover 1 "
14-20 426744 16867 SF5000078 Nipple, 3" x 3" 2 "
14-21 239848 1275G-39 5000186 Cap, 3" NPT, Female 2 "
14-22 372298 14278 G50-30026 Heater, Fuel 1 "
14-23* 426744 ------ GPU-10258-1 Hose, Fuel Return, Tier III 1 "
14-24 15376 ------ GPU-10214 Tank, Fuel, Right 1 "
14-25 275689 ------ SF5000188 Plug, Pipe Square Head, 1" NPT 1 "
*Part of GPU-10258 Hose Kit
CD377 4-2-33
Orig
Chapter 4
1 4 5
Figure 2-15. Gauge Panel
4-2-34 CD377
Orig
Chapter 4
Figure 2-15. Gauge Panel

Ind Number Number
15-1 1180572 ------ GPU-10210-25 Panel, Meter 1 10453 & Up

15-2 963191 DCVM-0-50 GM3000136 Meter, Volt, Triplet 1 "
15-3 963191 DCAM-0-1600 GM3000135 Meter, Amp, Triplet 1 "
15-4 629283 SL63013-BG-G 3000055 Light, Pilot, 28 V 1 "
15-5 373094 6VF92 3000274 Bulb, Light, 28 V 1 "
15-6 252224 44250 3000050 Switch, SPST 1 "
CD377 4-2-35
Orig
Chapter 4
2
5
4 3
1
6
18
7 17
8 19
9 16 15
10
11
12
13
14
Figure 2-16. Generator Assembly - Standard (GPU400-100)
4-2-36 CD377
Orig
Chapter 4
Figure 2-16. Generator Assembly - Standard (GPU400-100)

Ind Number Number
16-1 242056 430 PSL 1315 GPU-10180 Generator, 100 Kw, 400 Hz 1 As Req'd.
16-2 373089 ------ MPWS00167 Bracket, Rectifier 1 "
16-3 252224 47356 3000023 Block, 6 Position, 30 Amp 1 "
16-4 712577 24SW07-40C 3000284 Contactor, 400 Hz (Cable A) 1 "
16-5 373089 ------ MP6000826 Panel, Generator 1 "
16-6 402645 ------ BB200 Bushing, Male, Insulating, 2" 1 "
16-8 253741 R67G5E-30M CA3000104 Cable A, 400 Hz, 30FT, AC 1 "
253741 CTC90328-01 GPU-10055 Cable A, AC Power, 1 "
50' AC - Opt.
16-9 15376 ------ 6000208 Entrance, 2" Cable 1 "
16-10 15376 6625 6000222 Entrance, 1" Cable 1 "
16-11 1181169 ------ HRN-GPU-400HZ-111 Harness, 400 Hz, Tier III 1 "
16-12 373317 33861 ½ Washer, Flat, ½"ID 10 "
16-13 269654 RM1100-C EG1000028 Mount, Motor 2 "
16-14 373317 ------ ½-10 Nut, Top Lock Hex ½-10 6 "
16-15 402645 HKP 3000271 Holder, Fuse, Standard 2 "
16-16 1182549 ------ 3000483 Fuse, 5 AGC, 5 Amp 2 "
16-17 373317 ------ ½-10x1¼ Bolt, Hex Head Ø ½-10 x 1¼" 6 "
Long
16-18 276841 5RL501-CT 3000436 Trans., Current 400 2 "
16-19 289626 230-1001 3000464 Exciter, Winding, 40 mm 1 "
CD377 4-2-37
Orig
Chapter 4
2
5
4
3 1
6 10
7 20
8
23 22
9
19
18 17
10
11 21
12 13 16
14
15
Figure 2-17. Generator Assembly - 28V Option with One Cable (GPU400-100)
4-2-38 CD377
Orig
Chapter 4
Figure 2-17. Generator Assembly - 28V Option with One Cable (GPU400-100)

Ind Number Number
17-5 373089 ------ MP6000826 Panel, Generator Har 1 "
17-7 252224 47352 3000739 Block, 2 Position, 30 Amp (Cable ) 1 "
17-8 253741 R67G5E-30M CA3000104 Cable A, 400 Hz, 30 Ft, AC 1 "
253741 CTC90328-01 GPU-10055 Cable A, AC Power, 50' AC - Opt. 1 "
17-9 15376 ------ 6000208 Entrance, 2" Cable 1 "
17-10 15376 6625 6000222 Entrance, 1" Cable 2 "
17-11 1181169 ------ HRN-GPU-400HZ-111 Harness, 400 Hz, Tier 3 1 "
17-12 373317 ------ ½-10x1¼ Bolt, Hex Head Ø ½-10 x 1¼" Long 6 "
17-13 373317 33861 ½ Washer, Flat, ½" ID 10 "
17-15 373317 ------ ½-10 Nut, Top Lock Hex ½-10 6 "
17-16 372750 ------ GPU-10288 Panel, Generator, Side (28V) 1 "
17-17 402645 HKP 3000271 Fuse Holder, Standard 2 "
17-18 1182549 ------ 3000483 Fuse, 5 AGC, 5 Amp 2 "
17-19 402645 26-810-2DA 3000002 Circuit Breaker, 100 Amp 1 "
17-21 1181169 ------ GPU-10290 Jumper, 28 V, Circuit Breaker 3 "
17-22 ------ ------ ------ Cable, Transformer, 6 Gauge 3 "
CD377 4-2-39
Orig
Chapter 4
2
22
4 3
1
6
20
5 19
7
21
23
18
16 17
8
22
9 10
12 15
11 13
14
Figure 2-18. Generator Assembly - Two Cables (GPU400-100)
4-2-40 CD377
Orig
Chapter 4
Figure 2-18. Generator Assembly - Two Cables (GPU400-100)

Ind Number Number
18-3 252224 47356 3000023 Block, 6 Position, 30Amp 1 "
253741 CTC90328-01 GPU-10055 Cable A, AC Power, 50' - Opt. 1 "
18-8 223505 6625 6000222 Entrance, 1" Cable 1 "
18-9 1181169 ------ HRN-GPU-400-111 Harness, 400 Hz, Tier III 1 "
18-10 15376 ------ 6000208 Eentrance, 2" Cable 2 "
18-11 253741 R67G5E-30M CA3000104 Cable B, 400 Hz, 30 Ft, AC 1 "
253741 CTC90328-01 GPU-10055 Cable B, AC Power, 50' - Opt. 1 "
18-12 373317 33861 ½ Washer, Flat, ½"ID 10 "
18-14 373317 ------ ½-10 Nut, Lock ½-10 6 "
18-16 402645 HKP 3000271 Fuseholder, Standard 2 "
18-17 ------ 782-2056 3000483 Fuse, 5 AGC, 5 Amp 2 "
18-18 402530 24SW07-40C 3000284 Contactor, 400 Hz (Cable B) 1 "
18-21 1181169 ------ GPU-10289 Jumper, Contactor, 400 Hz 3 "
CD377 4-2-41
Orig
Chapter 4
5
24 3 1
6 22
7 4
8
23
27 21 25
18 19
20
9
10
11
17
12
13 26
14
15 16
Figure 2-19. Generator Assembly - Two Cables with 28V Option (GPU400-100)
4-2-42 CD377
Orig
Chapter 4
Figure 2-19. Generator Assembly - Two Cables with 28V Option (GPU400-100)

Ind Number Number
19-1 242056 430 PSL 1315 GPU-10180 Generator, 100 Kw, 400Hz 1 As Req'd.
19-4 373317 ------ ------ Bolt, Hex Head Ø ½-10 x 1¼" "
Long 6
(Contactor - Cable A)
19-9 15376 6625 6000222 Entrance, 1" Cable 1 "
19-11 15376 ------ 6000208 Entrance, 2" Cable 2 "
19-13 373317 33861 ½ Washer, Flat, ½" ID 10 "
19-15 373317 ------ ½-10 Nut, Lock ½-10 6 "
(Contactor - Cable B)
19-17 372750 ------ GPU-10288 Panel, Generator, Side 28 V - Opt. 1 "
19-19 402530 782-2056 3000483 Fuse, 5 AGC, 5 Amp 2 "
19-20 402645 26-810-2DA-HB 3000002 Circuit Breaker, 100 Amp 1 "
19-27 289626 ------ 3000464 Exciter, Winding, 40 mm 1 "
CD377 4-2-43
Orig
Chapter 4
2
22
4 3
1
20
5 19
6 21
7 23
18
16 17
8
22
9 10
12 15
11
13
14
Figure 2-20. Generator Assembly - Standard (GPU400-120/140)
4-2-44 CD377
Orig
Chapter 4
Figure 2-20. Generator Assembly - Standard (GPU400-120/140)

Ind Number Number
20-1 242056 ------ 4000004 Generator, 400 Hz, 100 Kw 1 As Req'd.

20-7 253741 R67G5E-30M CA3000104 Cable A, 400 Hz, 30 Ft, Ac 1 "
253741 CTC90328-01 GPU-10055 Cable A, Ac Power, 50' - Opt. 1 "
20-8 15376 6625 6000222 Entrance, 1" Cable 1 "
20-10 15376 ------ 6000208 Entrance, 2" Cable 2 "
20-11 253741 R67G5E-30M CA3000104 Cable B, 400 Hz, 30 Ft, Ac 1 "
20-12 373317 33861 ½ Washer, Flat, ½" ID 10 "
20-14 373317 ------ ½-10 Nut, Lock ½-10 6 "
20-17 402530 782-2056 3000483 Fuse, 5 AGC, 5 Amp 2 "
20-20 276841 5RL-501-CT 3000436 Trans., Current 400 2 "
CD377 4-2-45
Orig
Chapter 4
5
24 3 1
6 22
7 4
8
23
27 21 25
18 19
20
9
10
11
17
12
13 26
14
15 16
Figure 2-21. Generator Assembly - 28V Option (GPU400-120/140)
4-2-46 CD377
Orig
Chapter 4
Figure 2-21. Generator Assembly - 28V Option (GPU400-120/140)

Ind Number Number
21-1 242056 ------ 4000004 Generator, 400 Hz, 100 Kw 1 As Req'd.

21-9 15376 6625 6000222 Entrance, 1" Cable 1 "
21-11 15376 ------ 6000208 Entrance, 2" Cable 2 "
21-13 373317 33861 ½ Washer, Flat, ½" ID 10 "
21-15 373317 ------ ½-10 Nut, Lock ½-10 6 "
21-17 372750 ------ GPU-10288 Panel, Generator, Side (28 V Opt) 1 "
21-19 402530 782-2056 3000483 Fuse, 5 AGC, 5 Amp 2 "
21-20 402645 ------ 3000002 Circuit Breaker, 100 Amp 1 "
21-22 276841 5RL-501-CT 3000436 Trans., Current 400 2 "
CD377 4-2-47
Orig
Chapter 4
16
15
14
13
17
18
12
11
3
10
12
9
1
7
6
5
2
Figure 2-22. Radiator Assembly
4-2-48 CD377
Orig
Chapter 4
Figure 2-22. Radiator Assembly

Ind Number Number
22-1 372196 0130-7456 ------ Radiator (Fan Cowl) 1 10435 & Up

22-2 372196 0402-0728-02 ------ Isolator, Vibration 3 "
22-3 372196 0130-7300-02 ------ Bracket, Radiator, Bottom 1 "
22-4 372196 0403-6678-02 ------ Mount, Engine, Left 1 "
22-5 372196 0403-6679-02 ------ Mount, Engine, Right 1 "
22-6 372196 0130-7294-02 ------ Guard, Belt 1 "
22-7 372196 0130-7311-02 ------ Guard, Radiator, Left 1 "
22-8 372196 0130-7328-02 ------ Guard, Radiator, Alternator 1 "
22-9 372196 0130-7312-02 ------ Guard, Radiator, Right 1 "
22-10 372196 0130-7377-02 ------ Bracket, Radiator 1 "
22-11 372196 0130-7299-02 ------ Bracket, Radiator, Top 1 "
22-12 372196 0130-7455SM ------ Bracket, Radiator, Sides 2 "
22-13 372196 0505-2397 ------ Bushing, Reducer 1 "
22-14 372196 0130-7455 ------ Radiator 1 "
22-15 372196 0130-7370 ------ Tank, Coolant 1 "
22-16 372196 0130-7688 ------ Cap, Coolant 1 "
22-17 372196 0130-7689 ------ Cap, Pressure (Radiator) 1 "
22-18 372196 0130-7453 ------ Radiator (Charge Air) 1 "
CD377 4-2-49
Orig
Chapter 4
7
14 13
12
15 11
10
1 9 7
8
4
2
3 4
5
6
4-2-50 CD377
Orig
Chapter 4

Ind Number Number
23-1 372196 0130-7320-01 GPU-10212 Radiator/Charge Air Cooler 1 10435 & Up

23-2 372196 0518-0773 ------ Clamp, Hose, Loop 1 "
23-3 372196 0503-2862 ------ Hose, Radiator 1 "
23-4 372196 0503-2876-14 ------ Clamp, Hose, T-Bolt 3 "
23-5 372196 0130-7288 ------ Tube, Air 1 "
23-6 372196 0502-1293 ------ Connector, Turbo, Tube 1 "
23-7 372196 0503-1872-03 GPU-10207-15 Clamp, Hose, T-Bolt 3 "
23-8 372196 0502-1617 ------ Connector, Tube 1 "
23-9 372196 0503-2876 ------ Clamp, Hose, T-Bolt 1 "
23-10 372196 0503-2861 ------ Hose, Radiator 1 "
23-11 372196 4928568 GPU-10250 Sensor, Coolant Level 1 "
23-12 372196 ------ 208007-4-4S Tee, Cross 1 "
23-13 372196 ------ 4738-4-4B Fitting, Hose, ¼" MNPT 1 "
23-14 372196 0130-7370 ------ Tank, Coolant 1 "
23-15 372196 ------ ------ Hose, ¼" ID (Coolant Tank to 1 "
Radiator)
CD377 4-2-51
Orig
Chapter 4
21
24
25
22
18
17 23
22
19
21
15
20
14
13
12
11
10
1 9
2 8
3
4
5 6
7
Figure 2-24. Rectifier Assembly
4-2-52 CD377
Orig
Chapter 4
Figure 2-24. Rectifier Assembly

Ind Number Number
24-1 15376 ------ GPU-10281 Plate, Rectifier Mounting 1 10435 & Up

24-2 15376 ------ MPDA00090 Bracket, Magnum Relay 1 "
24-3 712103 29.511.12.900 3000024 Relay, Series 29 500 1 "
24-4 402645 433U040X5C 3000031D Capacitor, 43,000 MFD 1 "
24-5 402641 2113VR12A 6000109 Bracket, Capacitor 1 "
24-6 373089 ------ MPDA00097 Spacer, Ø 7/8" 2 "
24-7 373317 37264 3/8-16 Nut, Lock 3/8-16 2 "
24-8 373317 15115 ------ Bolt, Hex Head Ø 3/8"-16 x 3" Long 2 "
24-9 21557 ------ MP3000033 Pad, Contactor Lug 1 "
24-10 373317 33859 3/8 Washer, Flat, 3/8"ID 2 "
24-12 373317 37341 3/8-16 Nut, Flange Lock Hex 3/8-16 7 "
24-13 373089 ------ 3000328 Bus Bar, Copper 1/4 1 "
24-14 634120 R65G3E-30M CA3000467 Cable, 4/0 Non-Sensing, 30 Ft 1 "
634120 R65G3E-50M CA3000472 Cable, 4/0 Non-Sensing, 50 Ft - Opt. 1 As Req'd.
634120 R65QB130M GPU-10199 Cable, Kit, Breakway, 30 Ft - Opt. 1 "
24-15* 1181169 ------ GPU-10278-3 Cable, Negative, 28 V Rectifier 1 10435 & Up
24-16* 1181169 ------ GPU-10278-2 Cable, Positive, 28 V Rectifier 1 "
24-17 402641 PFE5K1R60 3000034 Resistor, 1.6 OHM 1 "
24-18 933325 6BU600F04 GPU-10152 Rectifier Unit, 28 V 1 "
24-19* 1181169 ------ GPU-10278-1 Cable, Jumper, 28 V Rectifier 6 "
24-20 1180420 ------ 3000105 Transformer, 400 Hz 1 "
24-21 656221 2923 3000027 Capacitor, 2.3 MFD 12 "
24-22 524161 ------ 3000030 Diode, Negative 6 "
24-23 643893 WB-600-50NB 3000037 Shunt 1 "
24-24 524161 ------ 3000028 Diode, Positive 6 "
24-25 252224 S-7-199 6000118 Clamp, Rectifier Diode ½" 12 "
*Part of GPU-10278 28 V Recitifier Cable Kit
CD377 4-2-53
Orig
Chapter 4
8
7
5
4
3 6
Figure 2-25. Exhaust System (S/N 10552 & Up)
4-2-54 CD377
Orig
Chapter 4
Figure 2-25. Exhaust System (S/N 10552 & Up)

Ind Number Number
25-1 262861 ------ GPU-10301 Tube, Lower, Exhaust 1 10552 & Up

25-2 15376 ------ GPU-10244 Bracket, Upper Exhaust 1 "
25-3 230042 R2 U400 2000205 Clamp, Muffler, 4" 3 "
25-4 372750 ------ GPU-10247 Bracket, Muffler Outlet 1 "
25-5 240012 86562M 2000611 Muffler, 4", Type 5 1 "
25-6 262861 ------ GPU-10242 Outlet, Turbo 1 "
25-7 372750 ------ GPU-10246 Bracket, Muffler Inlet 1 "
25-8 402530 733-5793 T6-4700-074 Clamp, Band, Turbo, 2¾" 1 "
CD377 4-2-55
Orig
Chapter 4
4-2-56 CD377
Orig
Chapter 4
Davco Model GPU-400-100/120/140 Section 3
SECTION 3:
NUMERICAL INDEX
TUG Part Number Description Fig & Ind#
——— Adapter 14-10

——— Bracket, Lower, Radiator 11-4
——— Bracket, Radiator 22-10
——— Bracket, Radiator, Bottom 22-3
——— Bracket, Radiator, Sides 22-12
——— Bracket, Radiator, Top 22-11
——— Bushing, Reducer 22-13
——— Cable, 6 Gauge, 12" Long (Grid Heater Relay to Fuse) 3-3
——— Cable, 100 Amp (Alternator to Fuse) 10-14
——— Cable, Control Box, 12 Gauge 3-25
——— Cable, ECM, 12 Gauge 3-23
——— Cable, Jumper, 12 Gauge 3-22
——— Cable, Transformer, 6 Gauge 17-22
——— Cap, Coolant 22-16
——— Cap, Pressure (Radiator) 22-17
——— Clamp, Hose, Loop 23-2
——— Clamp, Hose, IDEAL 5056 1-2
——— Clamp, Hose, T-Bolt 23-4
——— Connector, Turbo, Tube 23-6
——— Connector, Tube 23-8
——— Cover for Controller (Comes with Electrical Box) 7-18
——— ECU 10-20
——— Fitting, Straight 14-9
——— Fuse, Alarm, 15 Amp 5-45
——— Fuse, Beacon, 15 Amp 5-37
——— Fuse, Controller, 10 Amp 5-43
——— Fuse, Diagnostic, 10 Amp 5-41
——— Fuse, E-Stop, 10 Amp 5-42
CD386 4-3-1
Rev 2
Chapter 4
Section 3 Davco Model GPU-400-100/120/140
——— Fuse, Fuel, 5 Amp 5-38

——— Fuse, Hoodlight, 15 Amp 5-39
——— Fuse, Lights, 2 Amp 5-40
——— Fuse, Starter, 30 Amp 5-44
——— Guard, Belt 22-6
——— Guard, Radiator, Alternator 22-8
——— Guard, Radiator, Left 22-7
——— Guard, Radiator, Right 22-9
——— Hose, ¼” ID (Coolant Tank to Radiator) 23-15
——— Hose, Radiator 23-3
——— Isolator, Vibration 22-2
——— Mount, Engine, Left 22-4
——— Mount, Engine, Right 22-5
——— Mount, Radiator/Engine, Left 11-8
——— Mount, Radiator/Engine, Right 11-3
——— Radiator 22-14
——— Radiator (Charge Air) 22-18
——— Radiator (Fan Cowl) 22-1
——— Tank, Coolant 22-15
——— Tube, Air 23-5
——— Turbo, Air Intake 1-1
0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, A (Alarm) 5-15
0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, B (Beacon) 5-16
0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, E (Timer) 5-3
0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, F (Frequency Trip) 5-17
0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, S (Starter) 5-2
0-332-204-151 Relay, SPDT, 12V, 20-30 Amp, V (Voltage Trip) 5-18
05-005316 Washer, Tang 2-2r
05-046787 Pin, Towbar 2-3a
05-046799 Hub/Brake Assembly 2-2l
05-048332 Cable Assembly, Lever 2-2c
05-048336 Roller 2-2f
05-048338 Cable Assembly, Brake 2-2s
4-3-2 CD386
Rev 2
Chapter 4
05-051009 Latch, Pedal 2-2a

05-052768 Axle Weldment, Front 2-2g
05-052783 Axle Assembly, Front (2 Piece Axle) 2-2
05-055785 Towbar Assembly 2-3
05-055788 Towbar Weldment 2-3d
½ Washer, Flat ½” ID 11-6
½ Washer, Flat, ½”ID 16-12
½ Washer, Flat, ½” ID 17-13
½-10 Nut, Top Lock Hex ½-10 11-7
½-10 Nut, Top Lock Hex ½-10 16-14
½-10 Nut, Top Lock Hex ½-10 17-15
½-10 Nut, Lock ½-10 18-14
½-10 Nut, Lock ½-10 19-15
½-10 Nut, Lock ½-10 20-14
½-10 Nut, Lock ½-10 21-15
½-10 x 1¼ Bolt, Hex Head, ½”-10 x 1¼” 11-5
½-10 x 1¼ Bolt, Hex Head Ø ½-10 x 1¼” Long 16-17
½-20 Nut, Lug 2-6
3/8 Washer, Lock 3/8" ID 2-2i
3/8 Washer, Flat, 3/8"ID 13-11
3/8-16 Nut, Top Lock Hex 3/8-16 13-2
3/8-16 Nut, Lock 3/8-16 24-7
3/8"-16 Nut, Lock, 3/8"ID-16 14-2
3/8-16 Nut, Flange Lock Hex 3/8-16 24-12
3/8-24 Nut, Top Lock Hex 3/8-24 2-2j
3/8-16 x 3 Bolt, Hex Head Ø 3/8"-16 x 3" Long 24-8
3/8-16x3½ Bolt, Hex Head Ø 3/8-16 x 3½” Long 24-11
3/8"-24x1" Bolt, Hex Head Ø 3/8-24 x 1" Long 2-2k
3/8-24x1½ Bolt, Hex Head Ø 3/8-24 x 1½” Long 2-2h
3/8-24x3 Bolt, Hex Head Ø 3/8-24 x 3" Long 2-2t
3/8-24x3¼ Bolt, Hex Head Ø 3/8-24 x 3¼” Long 2-2d
7/8 Washer, Flat 7/8" ID 3-15
CD386 4-3-3
Rev 2
Chapter 4
7/8 Washer, Flat, 7/8" ID 4-15

10mm-1.5 Nut, Lock, 10mm-1.5 11-11
12911567 Bolt, J, Battery Hold Down, 5/16" 3-9
12912045 Hose, Turbo, Ø 4" x 4" Long 1-3
12970788 Bracket, Battery Disconnect 3-13
2000010 Pad Rubber, Mounting 9-22
2000040 Trim-Lock 9-3
2000119 Hose, Hump, 5" x 4" 1-5
2000196 Cap, Rain 4" 12-1
2000205 Clamp, Muffler, 4" 12-3
2000205 Clamp, Muffler, 4" 25-3
2000611 Muffler, 4", Type 5 12-9
2000611 Muffler, 4", Type 5 25-5
2021-32-32S Adapter, Connector, Male, 2" Tube 13-7
208007-4-4S Tee, Cross 23-12
2-1206-01-01 Hub, Heavy Duty 2-2o
2708 ½-4A Pin, Yoke 2-2m
3000002 Circuit Breaker, 100 Amp 17-19
3000014 Sender, Water Temperature 10-18
3000023 Block, 6 Position, 30 Amp, 60 V 5-6
3000023 Block, 6 Position, 30 Amp, 60V 6-6
3000023 Block, 6 Position, 30 Amp 16-3
3000023 Block, 6 Position, 30Amp 18-3
3000024 Relay, Series 29 500 24-3
3000027 Capacitor, 2.3 MFD 24-21
3000028 Diode, Positive 24-24
3000030 Diode, Negative 24-22
3000031D Capacitor, 43,000 MFD 24-4
3000034 Resistor, 1.6 OHM 24-17
3000037 Shunt 24-23
3000049D Switch, DPST, Diagnostic 7-4
3000049D Switch, DPST, Master 7-5
3000049D Switch, DPST, Run/Idle Switch 7-6
4-3-4 CD386
Rev 2
Chapter 4

3000050 Switch, Bypass, SPST 5-9
3000050 Switch, SPST, Power Cable A 7-2
3000050 Switch, SPST 7-11
3000050 Switch, SPST, Power Cable B 8-11
3000053 Breaker, Circuit, 30 Amp 3-26
3000055 Light, Pilot, 28 V, Green (Cable A) 8-8
3000055 Light, Pilot, 28 V, Green (Cable B) 8-15
3000055 Light, Pilot, 28 V 15-4
3000105 Transformer, 400 Hz 24-20
3000174 Bulb, Light, 28V 8-9
3000261 Switch, Contactor, 400 Hz, Cable A 7-3
3000261 Switch, Contactor, 400 Hz 7-14
3000261 Switch, Contactor, 400 Hz, Cable B 8-14
3000266 Sender, Oil Pressure, 15 PSI 10-16
3000271 Holder, Fuse, Standard 16-15
3000271 Fuse Holder, Standard 17-17
3000271 Fuseholder, Standard 18-16
3000274 Bulb, Light, 28 V 15-5
3000284 Contactor, 400 Hz (Cable A) 16-4
3000284 Contactor, 400 Hz (Cable B) 18-18
3000287 Light, Pilot, 28 V, Red (Engine Stop) 8-10
3000288 Light, Pilot, 28 V, Amber (Warning) 8-12
3000288 Light, Pilot, 28 V, Amber (Water in Fuel) 8-13
3000288 Light, Pilot, 28 V, Amber (Alarm) 8-16
3000328 Bus Bar, Copper 1/4 24-13
3000415 Timer, ECU-PMTN Programmer 5-13
3000436 Trans., Current 400 16-18
3000436 Trans., Current 400 17-20
CD386 4-3-5
Rev 2
Chapter 4
3000436 Trans., Current 400 18-20

3000436 Trans., Current 400 19-22
3000436 Trans., Current 400 20-20
3000436 Trans., Current 400 21-22
3000464 Exciter, Winding, 40 mm 16-19
3000483 Fuse, 5 AGC, 5 Amp 16-16
3000483 Fuse, 5 AGC, 5 Amp 17-18
3000483 Fuse, 5 AGC, 5 Amp 18-17
3000483 Fuse, 5 AGC, 5 Amp 19-19
3000483 Fuse, 5 AGC, 5 Amp 20-17
3000483 Fuse, 5 AGC, 5 Amp 21-19
3000507 Plug, T1939 5-11
3000507 Plug, J1939 6-10
3000508 Connector, Plug, 14 Pin, C3 (Fuel, E-Stop, Engine Temperature,
Oil Pressure Switches, Hood Lights) 5-21
3000508 Connector, Plug, 14 Pin, C2 (Diagnostic, Cruise, ISC1, Key
Switches, Stop, Diag/Wif, and Wait to Start Lights) 5-23
3000508 Connector, Plug, 14 Pin, C1 (Generator, EF Relays) 5-25
3000511 Nut, Lock 5-27
3000511 Nut, Lock 6-26
3000512 Washer, Flat 5-28
3000515 Pin, 16 Gauge 5-22
3000515 Pin, 16 Gauge 5-24
3000515 Pin, 16 Gauge 5-26
3000515 Pin, 16 Gauge 6-21
3000515 Pin, 16 Gauge 6-23
3000515 Pin, 16 Gauge 6-25
3000516 Socket, 16 Gauge 5-32
3000516 Socket, 16 Gauge 5-34
3000516 Socket, 16 Gauge 5-36
3000516 Socket, 16 Gauge 6-31
3000516 Socket, 16 Gauge 6-33
3000516 Socket, 16 Gauge 6-35
3000517 Pin, 12 Gauge 5-30
4-3-6 CD386
Rev 2
Chapter 4
3000517 Pin, 12 Gauge 6-29

3000518 Socket, 12 Gauge 5-20
3000518 Socket, 12 Gauge 6-19
3000523 Connector, Receptacle, C3 5-31
3000523 Connector, Receptacle, HD34-18-14SN, C2 5-33
3000536 Connector, Plug, 8 Pin, C4 (Starter, Battery, Generator-Ground) 5-19
3000536 Connector, Plug, 8 Pin, C4 (Starter, Battery, Generator Ground) 6-18
3000739 Block, 2 Position, 30 Amp (Cable ) 17-7
3000739 Block, 2 Position, 30 Amp (Contactor - Cable A) 19-7
3000739 Block, 2 Position, 30 Amp (Contactor - Cable B) 19-16
3220X12X8 Fitting, Straight 10-17
3-334-485-008 Socket, Relay Base 5-4
3971615 Starter 10-12
4000004 Generator, 400 Hz, 100 Kw 20-1
4000004 Generator, 400 Hz, 100 Kw 21-1
4738-4-4B Fitting, Hose, ¼” MNPT 23-13
4936876 Alternator 10-15
5000060 Shims, Wood 13-9
5000060 Shims, Wood 14-3
5000081 Petcock, 1/4" 13-14
5000081 Petcock, 1/4" 14-17
5000148 Adapter, Elbow, 90° 13-8
5000148 Adapter, Elbow, 90° 14-12
5000186 Cap, 3" NPT, Female 13-18
5000186 Cap, 3" NPT, Female 14-21
6000109 Bracket, Capacitor 24-5
6000118 Clamp, Rectifier Diode ½” 24-25
6000197 Relay, EF, A (Cable 1) 5-7
6000197 Relay, EF, B (Cable 2) 5-8
6000197 Relay, EF, A (Cable 1) 6-7
6000197 Relay, EF, B - Opt. (Add Cable 2) 6-8
CD386 4-3-7
Rev 2
Chapter 4
6000208 Entrance, 2" Cable 16-9

6000208 Eentrance, 2" Cable 18-10
660-1-3439 Block, Contact -NC (STOP) 9-25
660-1-3440 Button, Locking-Red 9-24
660-4-0132-3 Washer, Thrust 2-10
728154C1 Switch 3-12
728154C1 Switch 4-12
90-034050-8 Nut, Self-Locking, 3/8-24 2-2e
ACU-10074 Light, Yellow Strobe-opt 9-26
AS-10102 Assembly, 5th Wheel 2-1
AS-10102-3 Spindle Assembly 2-4
BB200 Bushing, Male, Insulating, 2" 16-6
CA3000104 Cable A, 400 Hz, 30FT, AC 16-8
CA3000104 Cable A, 400 Hz, 30 Ft, AC 17-8
CA3000104 Cable A, 400 Hz, 30 Ft, AC 18-7
CA3000104 Cable B, 400 Hz, 30 Ft, AC 18-11
CA3000104 Cable A, 400 Hz, 30 Ft, AC 19-8
CA3000104 Cable B, 400 Hz, 30 Ft, AC 19-12
CA3000104 Cable A, 400 Hz, 30 Ft, Ac 20-7
CA3000104 Cable B, 400 Hz, 30 Ft, Ac 20-11
CA3000104 Cable A, 400 Hz, 30 Ft, AC 21-8
CA3000104 Cable B, 400 Hz, 30 Ft, AC 21-12
CA3000467 Cable, 4/0 Non-Sensing, 30 Ft 24-14
CA3000472 Cable, 4/0 Non-Sensing, 50 Ft - Opt. 24-14
CDP00527 Hose, Engine Cooling System, ¾” x 5' Long 10-21
DD 1-14-SHJ Nut, Slotted Hex Jam 2-2p
EG1000028 Mount, Motor 11-2
4-3-8 CD386
Rev 2
Chapter 4

ENG-GPU-QSB 6.7-171 Engine, Cummins QSB 6.7 171HP (GPU400-100) 10-3
ENG-GPU-QSB 6.7-171 Engine, Cummins QSB 6.7 171 Hp (GPU400-100) 11-1
ENG-GPU-QSB 6.7-203 Engine, Cummins QSB 6.7 203 Hp (GPU400-120) 10.3
ENG-GPU-QSB4.5-130-3 Belt 10-19
G50-30026 Heater, Fuel 14-22
G50-30034 Hose, Fuel Heater Filter 14-8
GG-¾ PL Washer, Flat 2-3b
GM3000080 Gauge, Fuel 13-13
GM3000135 Meter, Amp, Triplet 15-3
GM3000136 Meter, Volt, Triplet 15-2
GPU-10022 Spacer, Cable 9-21
GPU-10053 Relay, Grid Heater, 12V 3-27
GPU-10055 Cable A, AC Power, 50' AC - Opt. 16-8
GPU-10055 Cable A, AC Power, 50' - Opt. 18-7
GPU-10055 Cable B, AC Power, 50' - Opt. 18-11
GPU-10055 Cable A, Ac Power, 50' - Opt. 20-7
GPU-10084 Regulator, Voltage, 400HZ, AVC63-12B2 5-14
GPU-10089 Clamp, Air Filter, GPU 400/100 1-7
GPU-10152 Rectifier Unit, 28 V 24-18
GPU-10180 Generator, 100 Kw, 400 Hz 16-1
GPU-10180 Generator, 100 Kw, 400Hz 19-1
GPU-10199 Cable, Kit, Breakway, 30 Ft - Opt. 24-14
GPU-10207-15 Clamp, Hose, T-Bolt 23-7
GPU-10208K Weldment Kit, Frame 2-16
GPU-10210 Enclosure, Tier 3, 100,120,140 9-12
CD386 4-3-9
Rev 2
Chapter 4
GPU-10210-10 Frame, Rear Door 9-9

GPU-10210-12 Panel, Left Side, Radiator Support 9-17
GPU-10210-13 Panel, Right Side, Radiator Support 9-14
GPU-10210-17 Panel, Access 9-16
GPU-10210-18 Panel, Top 9-15
GPU-10210-19 Door, Side, Front 9-5
GPU-10210-20 Door, Side, Rear 9-7
GPU-10210-21 Door-Rear-opt 9-11
GPU-10210-22 Box, E-Stop 9-6
GPU-10210-24 Box, Control Panel 9-8
GPU-10210-25 Panel, Meter 9-10
GPU-10210-35 Cover, Radiator 9-13
GPU-10212 Radiator/Charge Air Cooler 23-1
GPU-10213 Tank, Fuel, Left 13-15
GPU-10214 Tank, Fuel, Right 13-20
GPU-10223 Hose, Fuel Crossover 13-16
GPU-10225 Fuse, Air Intake Heater, 100 Amp 3-18
GPU-10225 Fuse, Alternator, 100 Amp 3-20
GPU-10225 Fuse, Control Box, 100 Amp 3-21
GPU-10239 Controller, 400 Hz, Deep Sea, Model 5310 7-17
GPU-10240 Pipe, Exhaust 12-4
GPU-10241 Outlet, Muffler 12-6
GPU-10242 Outlet, Turbo 12-10
GPU-10243 Box Assembl, Control, Tier III 5-
GPU-10243 Box Assembly, Control, Tier III 6-
GPU-10243-1 Panel, Controls 8-1
GPU-10243-1-1 Panel, Controls 7-1
GPU-10243-1-2 Box, Controller 6-1
GPU-10243-2 Box, Controller 5-1
GPU-10243-3 Plate, Controller Mounting 5-12
GPU-10243-4 Module, Deep Sea Expansion Relay 8-17
GPU-10243-7 Panel, Fuse, Buss ATC 5-5
GPU-10243-8 Switch, INC/DEC 5-10
GPU-10243-13 Light, Pilot, 28V, Green (Cable A) 7-8
4-3-10 CD386
Rev 2
Chapter 4
GPU-10243-13 Light, Pilot, 28V, Green 7-15

GPU-10243-1-3 Plate, Controller Mounting 6-11
GPU-10243-14 Light, Pilot, 28V, Amber (Warning) 7-12
GPU-10243-14 Light, Pilot, 28V, Amber (Water in Fuel) 7-13
GPU-10243-14 Light, Pilot, 28V, Amber (Alarm) 7-16
GPU-10243-15 Light, Pilot, 28V, Red (Engine Stop) 7-10
GPU-10244 Bracket, Upper Exhaust 12-2
GPU-10245 Bracket, Lower Exhaust 12-7
GPU-10246 Bracket, Muffler Inlet 12-11
GPU-10247 Bracket, Muffler Outlet 12-8
GPU-10248 Cleaner Assembly, Air 1-8
GPU-10248-1 Element, Air Cleaner 1-9
GPU-10250 Sensor, Coolant Level 23-11
GPU-10251 Tray, Extended HT, Cable, RH 9-19
GPU-10252 Tray, Extended Height, Cable, L/H 9-2
GPU-10253 Fitting, Straight, Supply Fuel Hose 10-7
GPU-10253 Fitting, Fuel Filter Inlet 13-5
GPU-10256 Bracket, Fuse Mounting 3-4
GPU-10257-1 Cable (Starter to Switch) 3-11
GPU-10257-2 Cable (Battery to Switch) 3-10
GPU-10257-3 Cable, Battery, Jumper 3-7
GPU-10257-4 Cable (Starter to Battery) 3-14
GPU-10257-5 Cable (Starter to Ground) 10-9
GPU-10257-6 Cable, Negative, Jumper 3-6
GPU-10257-7 Cable, Air Intake Heater 3-2
GPU-10257-7 Cable, Alternator 3-24
GPU-10257-7 Cable, Intake (Heater to Grid Heater Relay) 10-8
GPU-10257-8 Cable (Switch to Fuse) 3-16
GPU-10258-1 Hose, Fuel Return, Tier III 10-6
CD386 4-3-11
Rev 2
Chapter 4

GPU-10258-2 Hose, Fuel Supply, Tier III 13-4
GPU-10258-3 Hose, Fuel Supply (Filter to Pump) 10-5
GPU-10259 Fan, 32" 10-1
GPU-10260 Spacer, Fan 1.5" 10-2
GPU-10261 Tube, Intake 1-4
GPU-10264 Sender, Fuel Level 13-10
GPU-10278-1 Cable, Jumper, 28 V Rectifier 24-19
GPU-10278-2 Cable, Positive, 28 V Rectifier 24-16
GPU-10278-3 Cable, Negative, 28 V Rectifier 24-15
GPU-10280 Plate, Battery Mount 1-10
GPU-10280 Plate, Battery Mounting 3-1
GPU-10281 Plate, Rectifier Mounting 24-1
GPU-10282 Bracket, Cable Mounting 9-20
GPU-10288 Panel, Generator, Side (28V) 17-16
GPU-10288 Panel, Generator, Side 28 V - Opt. 19-17
GPU-10288 Panel, Generator, Side (28 V Opt) 21-17
GPU-10289 Jumper, Contactor, 400 Hz 18-21
GPU-10290 Jumper, Fuse 3-19
GPU-10290 Jumper, 28 V, Circuit Breaker 17-21
GPU-10301 Tube, Lower, Exhaust 25-1
HA1000102 Pin, 1/8" X 3" Cotter 2-8
HRN-GPU-400-111 Harness, 400 Hz, Tier III 18-9
HRN-GPU-400HZ Harness, GPU 400 HZ Tier III 13-22
HRN-GPU-400HZ-111 Harness, 400 Hz, Tier III 16-11
HRN-GPU-400HZ-111 Harness, 400 Hz, Tier 3 17-11
LC-063F-7 Spring, Comp. 2-2b
LE000108 Switch, Momentary, Reset 7-7
LL 1/8"x1¼” Pin, Cotter 2-3c
4-3-12 CD386
Rev 2
Chapter 4
LL 1/8"x1¾” Pin, Cotter 2-2q

LL 3/32"x5/8" Pin, Cotter 2-2n
LW000064 Tie-Down Weldment, Battery 3-8
M10 Washer, Flat, M10 ID 11-10
M10-1.5x30 Bolt, Hex Head, M10-1.5 x 30mm Long 11-9
MP3000033 Pad, Contactor Lug 24-9
MP6000826 Panel, Generator 16-5
MP6000826 Panel, Generator Har 17-5
MPDA00052 Cover, Fuel-Right 9-18
MPDA00090 Bracket, Magnum Relay 24-2
MPDA00097 Spacer, Ø 7/8" 24-6
MPDA00105 Cover, Fuel, Left 9-4
MPWS00167 Bracket, Rectifier 16-2
QSB4.5-130-1 Filter, Oil 10-13
QSB4.5-130-2 Filter, Fuel 10-4
QSB4.5-130-4 Filter/Separator, Fuel 13-3
SF5000078 Nipple, 3" x 3" 13-17
SF5000078 Nipple, 3" x 3" 14-20
SF5000188 Plug, Pipe Square Head, 1" NPT 13-21
T6-4700-074 Clamp, 2 3/4" Muffler 9-23
T6-4700-074 Clamp, Band, Turbo, 2¾” 12-12
T6-4900-157 Holder, Fuse, 250 Amp 3-17
T6-4900-157 Holder, Fuse, 250 Amp 4-17
T6-9011-235 Battery, Group 31C with Studs 3-5
WT1000083 Cap, Dust - Fifth Wheel 2-5
WT1000091 Nut, Castellated 1" ID 2-9
WT1000196 Tire Assembly, 600 x 9 D-Rated 2-7
WT1000248 Spindle, 1½ x 1-1/16" 2-15
WT1000249 Hub Assembly, Wheel, with Studs & Nuts 2-12
WT1000250 Bearing, Inner Wheel 2-13
WT1000251 Bearing, Outer Wheel 2-11
CD386 4-3-13
Rev 2
Chapter 4
WT1000252 Seal, Hub Grease 2-14

X005832 Clamp, Seal, 4" S/S 12-5
4-3-14 CD386
Rev 2
Chapter 4
SECTION 4:
ALPHABETICAL INDEX
——— Adapter 14-10

5000148 Adapter, Elbow, 90° 13-8
5000148 Adapter, Elbow, 90° 14-12
4936876 Alternator 10-15
AS-10102 Assembly, 5th Wheel 2-1
05-052783 Axle Assembly, Front (2 Piece Axle) 2-2
05-052768 Axle Weldment, Front 2-2g
WT1000250 Bearing, Inner Wheel 2-13
WT1000251 Bearing, Outer Wheel 2-11
ENG-GPU-QSB4.5-130-3 Belt 10-19
3000739 Block, 2 Position, 30 Amp (Cable ) 17-7
3000023 Block, 6 Position, 30 Amp, 60 V 5-6
3000023 Block, 6 Position, 30 Amp, 60V 6-6
3000023 Block, 6 Position, 30Amp 18-3
660-1-3439 Block, Contact -NC (STOP) 9-25
½-10 x 1¼ Bolt, Hex Head, ½”-10 x 1¼” 11-5
3/8-16 x 3 Bolt, Hex Head Ø 3/8"-16 x 3" Long 24-8
CD386 4-4-1
Rev 2
Chapter 4

3/8"-24x1" Bolt, Hex Head Ø 3/8-24 x 1" Long 2-2k
3/8-24x1½ Bolt, Hex Head Ø 3/8-24 x 1½” Long 2-2h
3/8-24x3 Bolt, Hex Head Ø 3/8-24 x 3" Long 2-2t
3/8-24x3¼ Bolt, Hex Head Ø 3/8-24 x 3¼” Long 2-2d
M10-1.5x30 Bolt, Hex Head, M10-1.5 x 30mm Long 11-9
GPU-10243 Box Assembl, Control, Tier III 5-
GPU-10243 Box Assembly, Control, Tier III 6-
GPU-10210-24 Box, Control Panel 9-8
GPU-10243-1-2 Box, Controller 6-1
GPU-10243-2 Box, Controller 5-1
GPU-10210-22 Box, E-Stop 9-6
GPU-10282 Bracket, Cable Mounting 9-20
6000109 Bracket, Capacitor 24-5
GPU-10245 Bracket, Lower Exhaust 12-7
——— Bracket, Lower, Radiator 11-4
MPDA00090 Bracket, Magnum Relay 24-2
——— Bracket, Radiator 22-10
——— Bracket, Radiator, Bottom 22-3
——— Bracket, Radiator, Sides 22-12
——— Bracket, Radiator, Top 22-11
3000274 Bulb, Light, 28 V 15-5
3000174 Bulb, Light, 28V 8-9
4-4-2 CD386
Rev 2
Chapter 4
3000328 Bus Bar, Copper 1/4 24-13

——— Bushing, Reducer 22-13
660-1-3440 Button, Locking-Red 9-24
GPU-10257-5 Cable (Starter to Ground) 10-9
CA3000104 Cable A, 400 Hz, 30 Ft, AC 17-8
CA3000104 Cable A, 400 Hz, 30 Ft, AC 18-7
CA3000104 Cable A, 400 Hz, 30 Ft, AC 19-8
CA3000104 Cable A, 400 Hz, 30 Ft, Ac 20-7
CA3000104 Cable A, 400 Hz, 30 Ft, AC 21-8
CA3000104 Cable A, 400 Hz, 30FT, AC 16-8
GPU-10055 Cable A, Ac Power, 50' - Opt. 20-7
05-048338 Cable Assembly, Brake 2-2s
05-048332 Cable Assembly, Lever 2-2c
CA3000104 Cable B, 400 Hz, 30 Ft, AC 18-11
CA3000104 Cable B, 400 Hz, 30 Ft, AC 19-12
CA3000104 Cable B, 400 Hz, 30 Ft, Ac 20-11
CA3000104 Cable B, 400 Hz, 30 Ft, AC 21-12
——— Cable, 100 Amp (Alternator to Fuse) 10-14
CA3000467 Cable, 4/0 Non-Sensing, 30 Ft 24-14
CA3000472 Cable, 4/0 Non-Sensing, 50 Ft - Opt. 24-14
CD386 4-4-3
Rev 2
Chapter 4
——— Cable, 6 Gauge, 12" Long (Grid Heater Relay to Fuse) 3-3
GPU-10257-7 Cable, Intake (Heater to Grid Heater Relay) 10-8
GPU-10278-1 Cable, Jumper, 28 V Rectifier 24-19
GPU-10199 Cable, Kit, Breakway, 30 Ft - Opt. 24-14
GPU-10278-3 Cable, Negative, 28 V Rectifier 24-15
GPU-10278-2 Cable, Positive, 28 V Rectifier 24-16
5000186 Cap, 3" NPT, Female 14-21
5000186 Cap, 3" NPT, Female 13-18
——— Cap, Coolant 22-16
WT1000083 Cap, Dust - Fifth Wheel 2-5
——— Cap, Pressure (Radiator) 22-17
2000196 Cap, Rain 4" 12-1
3000027 Capacitor, 2.3 MFD 24-21
3000031D Capacitor, 43,000 MFD 24-4
T6-4700-074 Clamp, 2 3/4" Muffler 9-23
GPU-10089 Clamp, Air Filter, GPU 400/100 1-7
——— Clamp, Hose, Loop 23-2
GPU-10207-15 Clamp, Hose, T-Bolt 23-7
2000205 Clamp, Muffler, 4" 12-3
4-4-4 CD386
Rev 2
Chapter 4
2000205 Clamp, Muffler, 4" 25-3

6000118 Clamp, Rectifier Diode ½” 24-25
X005832 Clamp, Seal, 4" S/S 12-5
GPU-10248 Cleaner Assembly, Air 1-8
3000536 Connector, Plug, 8 Pin, C4 (Starter, Battery, Generator Ground) 6-18
3000536 Connector, Plug, 8 Pin, C4 (Starter, Battery, Generator-Ground) 5-19
3000523 Connector, Receptacle, HD34-18-14SN, C2 5-33
——— Connector, Tube 23-8
——— Connector, Turbo, Tube 23-6
——— Cover for Controller (Comes with Electrical Box) 7-18
MPDA00105 Cover, Fuel, Left 9-4
MPDA00052 Cover, Fuel-Right 9-18
GPU-10210-35 Cover, Radiator 9-13
3000030 Diode, Negative 24-22
3000028 Diode, Positive 24-24
GPU-10210-19 Door, Side, Front 9-5
GPU-10210-20 Door, Side, Rear 9-7
CD386 4-4-5
Rev 2
Chapter 4
GPU-10210-21 Door-Rear-opt 9-11

——— ECU 10-20
6000208 Eentrance, 2" Cable 18-10
GPU-10248-1 Element, Air Cleaner 1-9
GPU-10210 Enclosure, Tier 3, 100,120,140 9-12
ENG-GPU-QSB 6.7-171 Engine, Cummins QSB 6.7 171HP (GPU400-100) 10-3
ENG-GPU-QSB 6.7-203 Engine, Cummins QSB 6.7 203 Hp (GPU400-120) 10.3
GPU-10259 Fan, 32" 10-1
QSB4.5-130-1 Filter, Oil 10-13
QSB4.5-130-4 Filter/Separator, Fuel 13-3
4738-4-4B Fitting, Hose, ¼” MNPT 23-13
——— Fitting, Straight 14-9
3220X12X8 Fitting, Straight 10-17
GPU-10253 Fitting, Straight, Supply Fuel Hose 10-7
GPU-10210-10 Frame, Rear Door 9-9
3000271 Fuse Holder, Standard 17-17
3000483 Fuse, 5 AGC, 5 Amp 16-16
3000483 Fuse, 5 AGC, 5 Amp 17-18
3000483 Fuse, 5 AGC, 5 Amp 18-17
4-4-6 CD386
Rev 2
Chapter 4
3000483 Fuse, 5 AGC, 5 Amp 19-19

3000483 Fuse, 5 AGC, 5 Amp 20-17
3000483 Fuse, 5 AGC, 5 Amp 21-19
GPU-10180 Generator, 100 Kw, 400Hz 19-1
4000004 Generator, 400 Hz, 100 Kw 20-1
4000004 Generator, 400 Hz, 100 Kw 21-1
——— Guard, Belt 22-6
——— Guard, Radiator, Alternator 22-8
——— Guard, Radiator, Left 22-7
——— Guard, Radiator, Right 22-9
HRN-GPU-400HZ-111 Harness, 400 Hz, Tier 3 17-11
CD386 4-4-7
Rev 2
Chapter 4
HRN-GPU-400-111 Harness, 400 Hz, Tier III 18-9

HRN-GPU-400HZ Harness, GPU 400 HZ Tier III 13-22
G50-30026 Heater, Fuel 14-22
T6-4900-157 Holder, Fuse, 250 Amp 3-17
T6-4900-157 Holder, Fuse, 250 Amp 4-17
3000271 Holder, Fuse, Standard 16-15
——— Hose, ¼” ID (Coolant Tank to Radiator) 23-15
CDP00527 Hose, Engine Cooling System, ¾” x 5' Long 10-21
G50-30034 Hose, Fuel Heater Filter 14-8
2000119 Hose, Hump, 5" x 4" 1-5
12912045 Hose, Turbo, Ø 4" x 4" Long 1-3
WT1000249 Hub Assembly, Wheel, with Studs & Nuts 2-12
2-1206-01-01 Hub, Heavy Duty 2-2o
05-046799 Hub/Brake Assembly 2-2l
——— Isolator, Vibration 22-2
05-051009 Latch, Pedal 2-2a
3000055 Light, Pilot, 28 V 15-4
3000288 Light, Pilot, 28 V, Amber (Alarm) 8-16
3000288 Light, Pilot, 28 V, Amber (Warning) 8-12
4-4-8 CD386
Rev 2
Chapter 4
3000288 Light, Pilot, 28 V, Amber (Water in Fuel) 8-13

3000055 Light, Pilot, 28 V, Green (Cable A) 8-8
3000055 Light, Pilot, 28 V, Green (Cable B) 8-15
3000287 Light, Pilot, 28 V, Red (Engine Stop) 8-10
GPU-10243-14 Light, Pilot, 28V, Amber (Alarm) 7-16
GPU-10243-14 Light, Pilot, 28V, Amber (Warning) 7-12
GPU-10243-14 Light, Pilot, 28V, Amber (Water in Fuel) 7-13
GPU-10243-13 Light, Pilot, 28V, Green 7-15
GPU-10243-13 Light, Pilot, 28V, Green (Cable A) 7-8
GPU-10243-15 Light, Pilot, 28V, Red (Engine Stop) 7-10
ACU-10074 Light, Yellow Strobe-opt 9-26
GM3000135 Meter, Amp, Triplet 15-3
GM3000136 Meter, Volt, Triplet 15-2
GPU-10243-4 Module, Deep Sea Expansion Relay 8-17
——— Mount, Engine, Left 22-4
——— Mount, Engine, Right 22-5
——— Mount, Radiator/Engine, Left 11-8
——— Mount, Radiator/Engine, Right 11-3
2000611 Muffler, 4", Type 5 12-9
2000611 Muffler, 4", Type 5 25-5
SF5000078 Nipple, 3" x 3" 13-17
SF5000078 Nipple, 3" x 3" 14-20
DD 1-14-SHJ Nut, Slotted Hex Jam 2-2p
WT1000091 Nut, Castellated 1" ID 2-9
3/8-16 Nut, Flange Lock Hex 3/8-16 24-12
3000511 Nut, Lock 5-27
3000511 Nut, Lock 6-26
½-10 Nut, Lock ½-10 18-14
½-10 Nut, Lock ½-10 19-15
½-10 Nut, Lock ½-10 20-14
½-10 Nut, Lock ½-10 21-15
3/8-16 Nut, Lock 3/8-16 24-7
10mm-1.5 Nut, Lock, 10mm-1.5 11-11
3/8"-16 Nut, Lock, 3/8"ID-16 14-2
½-20 Nut, Lug 2-6
90-034050-8 Nut, Self-Locking, 3/8-24 2-2e
½-10 Nut, Top Lock Hex ½-10 11-7
CD386 4-4-9
Rev 2
Chapter 4
½-10 Nut, Top Lock Hex ½-10 16-14

½-10 Nut, Top Lock Hex ½-10 17-15
3/8-16 Nut, Top Lock Hex 3/8-16 13-2
3/8-24 Nut, Top Lock Hex 3/8-24 2-2j
GPU-10241 Outlet, Muffler 12-6
2000010 Pad Rubber, Mounting 9-22
MP3000033 Pad, Contactor Lug 24-9
GPU-10210-17 Panel, Access 9-16
GPU-10243-1 Panel, Controls 8-1
GPU-10243-1-1 Panel, Controls 7-1
MP6000826 Panel, Generator Har 17-5
GPU-10288 Panel, Generator, Side (28 V Opt) 21-17
GPU-10288 Panel, Generator, Side (28V) 17-16
GPU-10288 Panel, Generator, Side 28 V - Opt. 19-17
GPU-10210-12 Panel, Left Side, Radiator Support 9-17
GPU-10210-13 Panel, Right Side, Radiator Support 9-14
GPU-10210-18 Panel, Top 9-15
5000081 Petcock, 1/4" 13-14
5000081 Petcock, 1/4" 14-17
HA1000102 Pin, 1/8" X 3" Cotter 2-8
3000517 Pin, 12 Gauge 5-30
3000517 Pin, 12 Gauge 6-29
3000515 Pin, 16 Gauge 5-22
3000515 Pin, 16 Gauge 5-24
3000515 Pin, 16 Gauge 5-26
3000515 Pin, 16 Gauge 6-21
3000515 Pin, 16 Gauge 6-23
3000515 Pin, 16 Gauge 6-25
LL 1/8"x1¼” Pin, Cotter 2-3c
LL 1/8"x1¾” Pin, Cotter 2-2q
LL 3/32"x5/8" Pin, Cotter 2-2n
05-046787 Pin, Towbar 2-3a
2708 ½-4A Pin, Yoke 2-2m
GPU-10240 Pipe, Exhaust 12-4
4-4-10 CD386
Rev 2
Chapter 4
GPU-10280 Plate, Battery Mount 1-10

GPU-10243-3 Plate, Controller Mounting 5-12
GPU-10243-1-3 Plate, Controller Mounting 6-11
GPU-10281 Plate, Rectifier Mounting 24-1
3000507 Plug, J1939 6-10
3000507 Plug, T1939 5-11
——— Radiator 22-14
——— Radiator (Charge Air) 22-18
——— Radiator (Fan Cowl) 22-1
GPU-10212 Radiator/Charge Air Cooler 23-1
GPU-10152 Rectifier Unit, 28 V 24-18
6000197 Relay, EF, A (Cable 1) 5-7
6000197 Relay, EF, A (Cable 1) 6-7
6000197 Relay, EF, B - Opt. (Add Cable 2) 6-8
6000197 Relay, EF, B (Cable 2) 5-8
3000024 Relay, Series 29 500 24-3
3000034 Resistor, 1.6 OHM 24-17
05-048336 Roller 2-2f
WT1000252 Seal, Hub Grease 2-14
3000266 Sender, Oil Pressure, 15 PSI 10-16
3000014 Sender, Water Temperature 10-18
GPU-10250 Sensor, Coolant Level 23-11
5000060 Shims, Wood 13-9
CD386 4-4-11
Rev 2
Chapter 4
5000060 Shims, Wood 14-3

3000037 Shunt 24-23
3000518 Socket, 12 Gauge 5-20
3000518 Socket, 12 Gauge 6-19
3000516 Socket, 16 Gauge 5-32
3000516 Socket, 16 Gauge 5-34
3000516 Socket, 16 Gauge 5-36
3000516 Socket, 16 Gauge 6-31
3000516 Socket, 16 Gauge 6-33
3000516 Socket, 16 Gauge 6-35
GPU-10022 Spacer, Cable 9-21
GPU-10260 Spacer, Fan 1.5" 10-2
MPDA00097 Spacer, Ø 7/8" 24-6
AS-10102-3 Spindle Assembly 2-4
WT1000248 Spindle, 1½ x 1-1/16" 2-15
LC-063F-7 Spring, Comp. 2-2b
3971615 Starter 10-12
728154C1 Switch 3-12
728154C1 Switch 4-12
3000050 Switch, Bypass, SPST 5-9
3000261 Switch, Contactor, 400 Hz 7-14
3000261 Switch, Contactor, 400 Hz, Cable B 8-14
3000050 Switch, SPST, Power Cable B 8-11
4-4-12 CD386
Rev 2
Chapter 4

208007-4-4S Tee, Cross 23-12
WT1000196 Tire Assembly, 600 x 9 D-Rated 2-7
05-055785 Towbar Assembly 2-3
05-055788 Towbar Weldment 2-3d
3000436 Trans., Current 400 16-18
3000436 Trans., Current 400 17-20
3000436 Trans., Current 400 18-20
3000436 Trans., Current 400 19-22
3000436 Trans., Current 400 20-20
3000436 Trans., Current 400 21-22
3000105 Transformer, 400 Hz 24-20
GPU-10252 Tray, Extended Height, Cable, L/H 9-2
GPU-10251 Tray, Extended HT, Cable, RH 9-19
2000040 Trim-Lock 9-3
——— Tube, Air 23-5
GPU-10261 Tube, Intake 1-4
GPU-10301 Tube, Lower, Exhaust 25-1
——— Turbo, Air Intake 1-1
GG-¾ PL Washer, Flat 2-3b
½ Washer, Flat ½” ID 11-6
7/8 Washer, Flat 7/8" ID 3-15
7/8 Washer, Flat, 7/8" ID 4-15
M10 Washer, Flat, M10 ID 11-10
3/8 Washer, Lock 3/8" ID 2-2i
05-005316 Washer, Tang 2-2r
660-4-0132-3 Washer, Thrust 2-10
CD386 4-4-13
Rev 2
Chapter 4

4-4-14 CD386
Rev 2
Chapter 5
Davco Model GPU400-100/120/140 Contents
CHAPTER 5: APPENDICES
TABLE OF CONTENTS
SECTION 1: PERIODIC MAINTENANCE CHECKLIST .......................................................... 5-1-1

SECTION 2: ADDITIONAL INFORMATION & VENDOR PUBLICATIONS ............................. 5-2-1
A. Description ........................................................................................................... 5-2-1
CD377 5-TOC-i
Orig
Chapter 5
Contents Davco Model GPU400-100/120/140
5-TOC-ii CD377
Orig
Chapter 5
SECTION 1: PERIODIC MAINTENANCE CHECKLIST
Davco Model GPU400-60

Serial Number: Date Manufactured:
Date: ID Number:
Service Requirement in Hours Daily 50 125 250 375 500 625 750 875 1000 2000 3000
Inspect Lubrication System for Leaks
Check Oil Level
Inspect Engine Cooling System for Leaks
Check Coolant Level; Add as Required
Inspect Air Intake System for Leaks & Air Restrictions
Inspect Exhaust System for Leaks, Restrictions, & Corrosion
Inspect Clamps for Tightness
Inspect Oil Line to Turbocharger for Leaks/Chafing
Inspect Turbocharger for Excessive Noise
Inspect Battery; Ensure Electrolyte Level Covers Plates
Inspect Battery Hold-Down
Inspect Battery Terminals for Security/Corrosion
Inspect Unit for Any Loose/Missing Hardware
Perform Initial Oil Change (Every 250 Hrs Afterward)
Inspect Radiator Core for Cleanliness
Inspect Air Intake System for Corrosion
Inspect Muffler for Security
Check Battery's State of Charge
Inspect/Lubricate Doors and Hinges for Defects
Inspect Drawbar for Cracks, Corrosion, & Excessive Wear
Inspect Drawbar Latch for Proper Operation
Inspect Axles for Security
Inspect Tires for Wear
Inspect Wheel Bearings for Looseness
Change Oil and Filter
Change Air Filter Element
Change (2) Fuel Filters (Engine-Mounted and Frame)
Repack Wheel Bearings
Change AntiFreeze Solution
5-1-1
CD377 Orig
Chapter 5
5-1-2
Orig CD377
Chapter 5
SECTION 2: ADDITIONAL INFORMATION & VENDOR PUBLICATIONS
A. DESCRIPTION
The following pages/booklets contain additional information relevant to the operation and service of
the GPU400-100/120/140.
CD377 5-2-1
Orig
Chapter 5
5-2-2 CD377
Orig
AEB15.43
Table 5 – Fault Codes for Quantum Industrial Engines
48 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
(LAMP) FMI FMI Number (**)
111 S254 629 Engine Control Module – Critical internal

failure X X X X X X X X 3 3 3
(Red) 12 12
112 S020 635 Engine Timing Actuator is not
responding to ECM commands X X 2 2 2
(Red) 7 7
113 S020 635 Engine Timing Actuator Circuit - shorted
high X X X 2 2 2
(Yellow) 3 3
114 S020 635 Engine Timing Actuator Circuit - shorted
low X
(Yellow) 4 4
P190 190 Engine Speed/Position Sensor Circuit -
115 lost both of two signals from the
2 2 X X X X X X X X 2 2 2
(Red) magnetic pickup sensor
116 P156 156 Fuel Timing Pressure Sensor Circuit -

shorted high X X X X 2 2 2
(Red) 3 3
117 P156 156 Fuel Timing Pressure Sensor Circuit -
shorted low X X X X 2 2 2
(Red) 4 4
118 P135 135 Fuel Pump Delivery Pressure Sensor
Circuit - shorted high X X X X 3 3 3
(Yellow) 3 3
119 P135 135 Fuel Pump Delivery Pressure Sensor
Circuit - shorted low X X X X 3 3 3
(Yellow) 4 4
P190 190 Engine Speed/Position Sensor Circuit -
121 lost one of two signals from the
10 10 X X X X X X X 2 2 2
(Yellow) magnetic pickup sensor
122 P102 102 Intake Manifold Pressure Sensor #1

Circuit - shorted high X X X X X X X X 2 2 2
(Yellow) 3 3
123 P102 102 Intake Manifold Pressure Sensor #1
Circuit - shorted low X X X X X X X X 2 2 2
(Yellow) 4 4
124* 102 High Intake Manifold Pressure Left Bank
X 3 3 3
(Yellow) 16
125* 102 Low Intake Manifold Pressure Left Bank
X 3 3 3
(None) 18
126* 1129 High Intake Manifold Pressure Right
Bank X 3 3 3
(Yellow) 16
127* 1129 Low Intake Manifold Pressure Right
Bank X 3 3 3
(None) 18
128* 1129 Right Bank Intake Manifold Pressure
Sensor Circuit Failed High X 3 3 3
(None) 3
(*) Denotes Cense Fault codes
(**) HHP QSK45/60/78 Fault Severity Levels:

Level 1: Stop Engine Now Level 3: Repair at Next PM
Level 2: Repair Engine Same Day Level 4: Information Only
AEB15.43
49 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
129* 1129 Right Bank Intake Manifold Pressure

Sensor Circuit Failed Low X 3 3 3
(None) 4
131 P091 091 Accelerator Pedal Position Sensor
(Red) 3 3
(Red) 4 4
133 P029 974 Remote Accelerator Pedal Position
Sensor Circuit - shorted high X X X X X X
(Red) 3 3
Sensor Circuit - shorted high X X 2 2 2
(Red) 3 3
Sensor Circuit - shorted low X X X X X X
(Red) 4 4
Sensor Circuit - shorted low X X 2 2 2
(Red) 4 4
135 P100 100 Engine Oil Pressure Sensor Circuit -
shorted high X X X X X X X X 2 2 2
(Yellow) 3 3
136* 1208 Pre Filter Oil Pressure Sensor Circuit
Failed High X 3 3 3
(None) 3
137* 1208 Pre Filter Oil Pressure Sensor Circuit
Failed Low X 3 3 3
(None) 4
shorted low X X X X X X X X 2 2 2
(Yellow) 4 4
143 P100 100 Engine Oil Pressure Low – Warning
X X X X X X
(Yellow) 1 18
143 P100 100 Engine Oil Pressure Low – Warning
X X 1 1 1
(White) 1 1
144 P110 110 Engine Coolant Temperature Sensor
(Yellow) 3 3
145 P110 110 Engine Coolant Temperature Sensor
(Yellow) 4 4
146 P110 110 Engine Coolant Temperature High –
Warning X X X
(Yellow) 0 16
Circuit - low frequency X X X X X X X X 2 2 2
(Red) 8 8
Circuit - high frequency X X X X X X X X 2 2 2
(Red) 8 8

AEB15.43
50 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level

Critical X X X X X X
(Red) 0 0
Critical X X 1 1 1
(White) 0 0
153 P105 105 Intake Manifold Temperature Sensor #1
(Yellow) 3 3
154 P105 105 Intake Manifold Temperature Sensor #1
(Yellow) 4 4
155 P105 105 Intake Manifold Temperature #1 High -
Critical X X X X X X
(Red) 0 0
155 P105 105 Intake Manifold Temperature #1 High –
Critical X X 1 1 1
(White) 0 0
156* 1131 Left Bank Rear Intake Manifold Temp
Sensor Circuit Failed High 2 2 2
(Yellow) 3
157* 1131 Left Bank Rear Intake Manifold Temp
Sensor Circuit Failed Low 2 2 2
(Yellow) 4
158* 1131 High Intake Manifold Temp - Left Bank
Rear 1 1 1
(White) 0
159* 1132 Right Bank Front Intake Manifold
Temperature Sensor Circuit Failed High 2 2 2
(Yellow) 3
161* 1132 Right Bank Front Intake Manifold
Temperature Sensor Circuit Failed Low 2 2 2
(Yellow) 4
162* 1132 High Intake Manifold Temperature -
Right Bank Front 1 1 1
(White) 0
163* 1133 Right Bank Rear Intake Manifold
Temperature Sensor Circuit Failed High 2 2 2
(Yellow) 3
164* 1133 Right Bank Rear Intake Manifold
Temperature Sensor Circuit Failed Low 2 2 2
(Yellow) 4
165* 1133 High Intake Manifold Temperature -
Right Bank Rear 1 1 1
(White) 0
166 S024 733 Rack Position Sensor #1 Circuit -
shorted high X
(Yellow) 3 3
172 S023 638 Rack Actuator Position #1 Circuit -
grounded circuit X
(Red) 6 6
173 S023 638 Rack Actuator - mechanically stuck open
X
(Yellow) 7 7

AEB15.43
51 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
184 S233 609 Engine Control Module Identification

Input State Error X X X X
(Yellow) 2 2
185 S231 639 Engine Control Module Network
Communication Error X
(Yellow) 2 2
187 S232 620 Sensor Supply Voltage #2 Circuit -
shorted low X X
(Yellow) 4 4
211 S216 1484 Additional OEM/Vehicle Diagnostic
Codes have been logged. Check other X X
(None) 11 31 ECM's for DTC's.
211* 613 OEM Component Failure
X 3 3 3
(None) 14
212 P175 175 Engine Oil Temperature Sensor Circuit -
shorted high X X X
(Yellow) 3 3
212* 175 Engine Oil Temperature Sensor Circuit -
shorted high 2 2 2
(Yellow) 3
213 P175 175 Engine Oil Temperature Sensor Circuit -
shorted low X X X
(Yellow) 4 4
213* 175 Engine Oil Temperature Sensor Circuit -
shorted low 2 2 2
(Yellow) 4
214 P175 175 Engine Oil Temperature High - Critical
X X
(Red) 0 0
214* 175 Engine Oil Temperature High – Critical
1 1 1
(White) 0
219 P17 1380 Low Oil Level in the Centinel makeup oil
tank X X
Maint. 1 17
219 P17 1380 Low Oil Level in the Centinel makeup oil
tank X X 2 2 2
(White) 1 1
221 P108 108 Ambient Air Pressure Sensor Circuit –
shorted high X X X X X X X 2 2 2
(Yellow) 3 3
222 P108 108 Ambient Air Pressure Sensor Circuit –
shorted low X X X X X X X 2 2 2
(Yellow) 4 4
223 S085 1265 Engine Oil Burn Valve Solenoid Circuit –
(Yellow) 4 4
225 S086 1266 Engine Oil Replacement Valve Solenoid
Circuit - shorted low X X 2 2 2
(Yellow) 4 4
shorted high X X
(Yellow) 3 3

AEB15.43
52 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
231 P109 109 Engine Coolant Pressure Sensor Circuit

- shorted high X X X 2 2 2
(Yellow) 3 3
232 P109 109 Engine Coolant Pressure Sensor Circuit
- shorted low X X X 2 2 2
(Yellow) 4 4
233 P109 109 Engine Coolant Pressure Low – Warning
X
(Yellow) 1 18
233 P109 109 Engine Coolant Pressure Low – Warning
X X 1 1 1
(White) 1 1
234 P190 190 Engine Speed High – Critical
X X X X X X X X 3 3 3
(Red) 0 0
235 P111 111 Engine Coolant Level Low - Critical
X X X X X X
(Red) 1 1
235 P111 111 Engine Coolant Level Low – Critical
X X 1 1 1
(White) 1 1
237 S030 644 External Speed Input (Multiple Unit
Sychronization) - data incorrect X X X 2 2 2
(Yellow) 2 2
241 P084 084 Vehicle Speed Sensor Circuit - data
incorrect X X X X X
(Yellow) 2 2
242 P084 084 Vehicle Speed Sensor Circuit -
tampering has been detected X X X X X
(Yellow) 10 10
243 P121 513 Engine Brake Driver #1 Circuit - shorted
low X X X
(Yellow) 4 4
245 S033 647 Fan Clutch Circuit - shorted low
X X X X X
(Yellow) 4 4
252 P098 098 Engine Oil Level #1 Sensor Circuit - data
incorrect 2 2 2
(Yellow) 2 2
253 P098 098 Engine Oil Level #1 Low – Critical
1 1 1
(White) 1 1
254 S017 632 Fuel Shutoff Valve Circuit - shorted low
X X X
(Red) 4 4
254 S017 632 Fuel Shutoff Valve Circuit - shorted low
X X 2 2 2
(None) 4 4
255 S017 632 Fuel Shutoff Valve Circuit - shorted high
X X
(Yellow) 3 3
259 S017 632 Fuel Shutoff Valve - stuck open
X X X X 2 2 2
(Red) 7 7

AEB15.43
53 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
261 P174 174 Fuel Temperature High – Warning

X
(Yellow) 0 16
261 P174 174 Fuel Temperature High – Warning
X X 1 1 1
(White) 0 0
263 P174 174 Fuel Temperature Sensor Circuit -
shorted high X X X X 2 2 2
(Yellow) 3 3
264 P174 174 Fuel Temperature Sensor Circuit - data
out-of-range X
(Yellow) 11 11
265 P174 174 Fuel Temperature Sensor Circuit -
(Yellow) 4 4
268 P094 94 Fuel Pressure Sensor Circuit - data
incorrect X X
(Yellow) 2 2
271 S126 1347 High Fuel Pressure Solenoid Valve #1
Circuit - shorted low X X
(Yellow) 4 4
Circuit - shorted high X X
(Yellow) 3 3
Circuit - shorted low X X
(Yellow) 4 4
(Yellow) 3 3
275 S126 1347 Fuel Pumping Element #1 (Front) -
mechanically stuck X X
(Yellow) 7 7
276 S018 633 Fuel Injection Control Valve Circuit -
shorted high X X
(Yellow) 3 3
277 S018 633 Fuel Injection Control Valve -
(Yellow) 7 7
278 P073 1075 Fuel Priming Pump Control Circuit -
shorted high/low X X X
(Yellow) 11 11
279 S018 633 Fuel Injection Control Valve Circuit -
shorted low X X
(Yellow) 4 4
281 S126 1347 High Fuel Pressure Solenoid Valve #1 -
(Yellow) 7 7
282 S127 1348 High Fuel Pressure Solenoid Valve #2 -
(Yellow) 7 7
283 S221 1043 Engine Speed/Position Sensor #1
(Crankshaft) Supply Voltage Circuit - X X X
(Yellow) 3 3 shorted high

AEB15.43
54 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level

(Crankshaft) Supply Voltage Circuit - X X X X
(Yellow) 4 4 shorted low
285 S231 639 SAE J1939 Multiplexing PGN Timeout
Error X X X X X
(Yellow) 9 9
286 S231 639 SAE J1939 Multiplexing Configuration
Error X X X X X
(Yellow) 13 13
287 P091 91 SAE J1939 Multiplexing Accelerator
Pedal Sensor System Error X X X X X
(Red) 2 19
288 P029 974 SAE J1939 Multiplexing Remote Throttle
Data Error X X X X X
(Red) 2 19
292 P223 1083 Auxiliary Temperature Sensor Input # 1
Engine Protection - Critical X X 3 3 3
(White) 14 14
293 S441 441 Auxiliary Temperature Sensor Input # 1
Circuit – shorted high
(Yellow) 3 3
Circuit – shorted high X X 3 3 3
(Yellow) 3 3
Circuit – shorted high X X
(Yellow) 3 3
Circuit – shorted low
(Yellow) 4 4
Circuit – shorted low X X 3 3 3
(Yellow) 4 4
Circuit – shorted low X X
(Yellow) 4 4
295 P108 108 Ambient Air Pressure Sensor Circuit -
data incorrect X X
(Yellow) 2 2
296 P223 1387 Auxiliary Pressure Sensor Input # 2
Engine Protection - Critical X X X
(Red) 14 14
Engine Protection - Critical X X 3 3 3
(White) 14 14
Circuit – shorted high X X X
(Yellow) 3 3
Circuit – shorted high X X X X 3 3 3
(Yellow) 3 3
Circuit – shorted low X X X
(Yellow) 4 4

AEB15.43
55 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level

Circuit – shorted low X X X X 3 3 3
(Yellow) 4 4
299 S117 1384 Engine Shutdown Commanded by
J1939 X X 3 3 3
(None) 14 31
299 S117 1384 Engine Shutdown Commanded by
J1939 X X
(Yellow) 11 31
311 S001 651 Injector Solenoid Valve Cylinder #1
Circuit – grounded circuit X X
(Yellow) 6 6
(Yellow) 6 6
(Yellow) 6 6
Circuit - grounded circuit X X
(Yellow) 6 6
(Yellow) 6 6
316 S078 931 Fuel Supply Pump Actuator Circuit -
shorted high X X 3 3 3
(Yellow) 3 3
318 S078 931 Fuel Supply Pump Actuator –
mechanically stuck X X 2 2 2
(Yellow) 7 7
319 P251 251 Real Time Clock - Power Interrupt
X X X X X
Maint. 2 2
Circuit - grounded circuit X
(Yellow) 6 6
Circuit - open circuit X
(Yellow) 5 5
Circuit – open circuit X
(Yellow) 5 5
(Yellow) 5 5
(Yellow) 5 5
328 S152 1348 Fuel Pumping Element #2 (Rear) -
(Yellow) 7 7
329 S233 1077 Fuel System Leakage error
X X
(Yellow) 14 14

AEB15.43
56 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level

(Yellow) 5 5
(Yellow) 5 5
341 S253 630 Engine Control Module – data lost
X X
(Yellow) 2 2
342 S253 630 Engine Control Module – out of
calibration X
(Red) 13 13
343 S254 629 Engine Control Module - Warning
internal hardware failure X X X X X 4 4 4
(Yellow) 12 12
346 S253 630 Engine Control Module - Warning
Software error X X X X X 4 4 4
(Yellow) 12 12
349 P191 191 Transmission Output Shaft (Tailshaft)
Speed High – Warning X X X X X
(Yellow) 0 16
Speed High – Warning X X 2 2 2
(Yellow) 0 0
shorted low X X X X X
(Yellow) 4 4
361 S251 1076 Fuel Pump Control Module, Fuel Control
Valve Circuit - shorted high X
(Red) 3 3
Valve Circuit - shorted low X
(Yellow) 4 4
Valve - mechanically stuck X
(Yellow) 7 7
364 S233 1077 Fuel Pump Control Module, CAN

Communication Error - abnormal update X
(Yellow) 9 9 rate
365 S233 1077 Fuel Pump Control Module, Supply
Voltage Circuit - shorted low X
(Yellow) 4 4
366 S233 1077 Fuel Pump Control Module, Supply
Voltage Circuit - data incorrect X
(Yellow) 2 2
367 P190 1078 Fuel Pump Control Module, Increment
Angle Time Sensor Error X
(Yellow) 11 11
368 S254 1078 Fuel Pump Control Module, Timing Error
X
(Yellow) 8 8

AEB15.43
57 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
369 P190 1078 Fuel Pump Control Module, Engine

Synchronization Error X
(Yellow) 2 2
372 S233 1077 Fuel Pump Control Module, Idle
Validation Error X
(Yellow) 11 11
373 S233 1077 Fuel Pump Control Module, Fuel Shutoff
Error X
(Red) 3 3
374 S233 1077 Fuel Pump Control Module, Self-Test
Error X
(Yellow) 12 12
375 S254 629 Fuel Pump Control Module, Electronic

Calibration Code Error X
(Yellow) 2 2
376 S233 1077 Fuel Pump Control Module, Fueling or
Engine Speed Mismatch X
(Yellow) 13 13
377 S233 1077 Fuel Pump Control Module, Stuck Relay
Error X
(Yellow) 7 7
378 S018 633 Fueling Actuator #1 Circuit - open circuit
X
(Yellow) 5 5
379 S018 633 Fueling Actuator #1 Circuit - grounded
circuit X
(Yellow) 6 6
381 S237 626 Intake Air Heater (Relay Enable) #1
Circuit - data incorrect X X X
(Yellow) 11 11
382 S237 626 Intake Air Heater (Relay Enable) #2
Circuit - data incorrect X X X
(Yellow) 11 11
384 S237 626 Start Assist Device Control Circuit Error
(Ether Injection) X X 3 3 3
(Yellow) 11 11
385 S232 620 OEM Sensor Supply Voltage Circuit -
shorted high X X X
(Yellow) 3 3
shorted high X X X X X
(Yellow) 3 3
387 S221 1043 Accelerator Pedal Position Sensor
Supply Voltage Circuit - shorted high X X X X X
(Yellow) 3 3
389 S033 647 Fan Clutch Circuit Error
X X X
(Yellow) 11 11
391 S017 632 Fuel Shutoff Valve Supply Voltage error
X
(Yellow) 11 11
394 S020 635 Timing Actuator #1 Circuit - open circuit
X
(Yellow) 5 5

AEB15.43
58 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
395 S020 635 Timing Actuator #1 Circuit - grounded

circuit X
(Yellow) 6 6
396 S083 1244 Fueling Actuator #2 Circuit - open circuit
X
(Yellow) 5 5
397 S083 1244 Fueling Actuator #2 Circuit - grounded
circuit X
(Yellow) 6 6
398 S084 1245 Timing Actuator #2 Circuit - open circuit
X
(Yellow) 5 5
399 S084 1245 Timing Actuator #2 Circuit - grounded
circuit X
(Yellow) 6 6
414* S250 608 Data Communication error over the
J1587 data link Circuit X
(Yellow) 9 9
415 P100 100 Engine Oil Pressure Low – Critical
X X X X X X
(Red) 1 1
415 P100 100 Engine Oil Pressure Low – Critical
X X 1 1 1
Level1 1 1
418 P097 097 Water in Fuel Indicator High –
Maintenance
WIF / 0 15 X X X X X X
Maint.
419 1319 Intake Manifold Boost Pressure
Imbalance X
(Yellow) 2
422 P111 111 Engine Coolant Level Sensor Circuit -
data incorrect X X X X X X X X 2 2 2
(Yellow) 2 2
423 P156 156 Fuel Timing Pressure or Timing Actuator
Stuck X X X 2 2 2
(Yellow) 2 2
426 S231 639 SAE J1939 datalink - cannot transmit
X X
(None) 2 2
426 S231 639 SAE J1939 datalink - cannot transmit
X X 3 3 3
(Yellow) 2 2
426* 639 SAE J1939 datalink - cannot transmit
3 3 3
(None) 2
427 S231 639 SAE J1939 not fast enough
X X 4 4 4
(None) 9
428 P097 97 Water in Fuel Sensor Circuit - shorted
high X X X
(Yellow) 3 3

AEB15.43
59 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
429 P097 097 Water in Fuel Sensor Circuit - shorted

low X X X X X X
(Yellow) 4 4
431 S230 558 Accelerator Pedal Idle Validation Circuit
- data incorrect X X X X X X
(Yellow) 2 2
431 P091 91 Accelerator Pedal Idle Validation Circuit
- data incorrect X X 3 3 3
(Yellow) 2 2
- out of calibration X X X X X X
(Red) 13 13
- out of calibration X X 3 3 3
(Red) 13 13
433 P102 102 Intake Manifold Pressure Sensor Circuit
- data incorrect X X X X X
(Yellow) 2 2
434 S251 627 Power Lost without Ignition Off
X X X X X
(Yellow) 2 2
data incorrect X X
(Yellow) 2 2
441 P168 168 Battery #1 Voltage Low - Warning
X X X X X X
(Yellow) 1 18
441 P168 168 Battery #1 Voltage Low - Warning
X X 3 3 3
(None) 1 1
442 P168 168 Battery #1 Voltage High - Warning
X X X X X X
(Yellow) 0 16
442 P168 168 Battery #1 Voltage High – Warning
X X 2 2 2
(Yellow) 0 0
443 S221 1043 Accelerator Pedal Position Sensor
Supply Voltage Circuit - shorted low X X X X X
(Yellow) 4 4
444 S232 620 OEM Sensor Supply Voltage Low -
Warning X X X
(Yellow) 1 18
446* N/A GSP Communication Failure
X 4 4 4
(None)
447* N/A RPC Number Not Supported
X 4 4 4
(None)
448* N/A RPC Argument Mismatch
X 4 4 4
(None)
449 P094 094 Fuel Pressure High - Warning
X X X
(Yellow) 0 16

AEB15.43
60 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
451 P157 157 Injector Metering Rail #1 Pressure

Sensor Circuit - shorted high X X X
(Yellow) 3 3
Sensor Circuit - shorted high X X 2 2 2
(Red) 3 3
Sensor Circuit - shorted low X X X
(Yellow) 4 4
Sensor Circuit - shorted low X X 2 2 2
(Red) 4 4
455 S018 633 Fuel Control Valve Circuit - shorted high
X X 2 2 2
(Red) 3 3
466 S032 1188 Turbocharger #1 Wastegate Control
Circuit - shorted low X
(Yellow) 4 4
467 S020 635 Timing Rail Actuator Circuit - data
incorrect X X 2 2 2
(Yellow) 2 2
468 S018 633 Fuel Rail Actuator Circuit - data incorrect
X X 2 2 2
(Yellow) 2 2
471 P098 98 Engine Oil Level Low – Maintenance
1 1 1
Maint. 1 1
472 P017 1380 Engine Oil Level #2 Low – Maintenance
3 3 3
Maint. 2 2
473 P017 1380 Engine Oil Level #2 Low – Warning
2 2 2
(Yellow) 2 2
479* 1318 Exhaust Port Temperature Bank
Imbalance X
(None) 9
482 P094 094 Fuel Pressure Low - Warning
X
(Yellow) 1 18
Sensor Circuit - shorted high X
(Yellow) 3 3
Sensor Circuit - shorted low X
(Yellow) 4 4
485 P129 1349 Injector Metering Rail #2 Pressure High -
Warning X
(Yellow) 0 16
486 P129 1349 Injector Metering Rail #2 Pressure Low -
Warning X
(Yellow) 1 18
487 S237 626 Start Assist Device - Canister Empty
(Ether Injection) X X 3 3 3
(None) 1 1

AEB15.43
61 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
488 P105 105 Intake Manifold Temperature High –

Warningl X X X
(Yellow) 0 16
Speed Low – Warning X X X X X
(Yellow) 1 18
489 P191 191 Transmission Output Shaft (Aux Gov)
Speed Low – Warning X X 2 2 2
(Yellow) 1 1
S018 1076 Fuel Pump Calibration Trim Circuit Error
493 X X
13 13
(Camshaft) Supply Voltage X
(Yellow) 11 11
497 S114 1377 Multiple Unit Synchronization Switch
Circuit - data incorrect X X X X X 2 2 2
(Yellow) 2 2
514 S018 633 Fuel Control Valve - mechanically stuck
X
X 2 2 2
(Red) 7 7 X
515 P091 091 Accelerator Pedal Frequency Position

Sensor Supply Circuit - shorted high X X X
(Yellow) 3 3
516 P091 091 Accelerator Pedal Frequency Position
Sensor Supply Circuit - shorted low X X X
(Yellow) 4 4
517 S251 1076 Fuel Metering Solenoid - bad device
X
(Yellow) 12 12
524 P113 113 OEM Alternate Droop Switch Validation
- data incorrect X X X X
(Yellow) 2 2
P154 702 Auxiliary Input/Output #2 Circuit -
527 shorted high X X X X X X
(Yellow) 3 3
S040 702 Auxiliary Input/Output #2 Circuit -
527 shorted high X X 2 2 2
(Yellow) 3 3
528 P093 093 OEM Alternate torque validation switch -
data incorrect X X X X X X
(Yellow) 2 2
529 S051 703 Auxiliary Input/Output #3 Circuit -
shorted high X X X X X X X X 2 2 2
(Yellow) 3 3
539 S018 633 Injector Control Valve Electronic Filter
(Transorb) Error X X
(Yellow) 11 11
546 P094 94 Fuel Delivery Pressure Sensor Circuit -
shorted high X
(Yellow) 3 3
547 P094 94 Fuel Delivery Pressure Sensor Circuit-
shorted low X
(Yellow) 4 4

AEB15.43
62 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level

- shorted low X X X X X X
(Yellow) 4 4
- shorted low X X 2 2 2
(Red) 4 4
warning level X
(Yellow) 0 16
warning level X X 2 2 2
(Red) 0 0
554 P157 157 Fuel Pressure Sensor Error
X X 2 2 2
(Yellow) 2 2
555 P022 1264 Engine Blowby - Warning Level
X
(Yellow) 0 16
555 P022 1264 Engine Blowby - Warning Level
X X 1 1 1
(White) 0 0
581 P015 1381 Fuel Supply Pump Inlet Pressure Sensor
(Yellow) 3 3
582 P015 1381 Fuel Supply Pump Inlet Pressure Sensor
Circuit – shorted low X X
(Yellow) 4 4
583 P015 1381 Fuel Supply Pump Inlet Pressure Low -
warning level X X
(Yellow) 1 18
595 P103 103 Turbocharger #1 Speed High - warning
level X
(Yellow) 0 16
596 P167 167 Electrical Charging System Voltage High
- warning level X X
(Yellow) 0 16
597 P167 167 Electrical Charging System Voltage Low
- Warning Level X X
(Yellow) 1 18
598 P167 167 Electrical Charging System Voltage Low
- Critical Level X X
(Red) 1 1
599 S025 640 OEM Commanded Dual Output
Shutdown X X X
(Red) 14 14
611 S151 1383 Engine Hot Shutdown
X X X X X
(None) 11 31
611 S151 1383 Engine Hot Shutdown
X X X 3 3 3
(None) 14 31
612* 99 High Lubricating Oil Filter Restriction
X 2 2 2
(Red) 1

AEB15.43
63 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
616* 1173 High Turbo Compressor Inlet Temp RB

3 3 3
(None) 16
617* 1172 High Turbo Compressor Inlet Temp LB
X
(None) 0
621* 1137 Low #1 LB Cylinder Power
X 2 2 2
(Yellow) 18
X 2 2 2
(Yellow) 18
X 2 2 2
(Yellow) 18
X 2 2 2
(Yellow) 18
X 2 2 2
(Yellow) 18
X 2 2 2
(Yellow) 18
2 2
(Yellow) 18
2 2
(Yellow) 18
1143 Low #1 RB Cylinder Power
(45)
631*
1145 2 2 2
(Yellow) (60)
18
631* 1329 Low #1 RB Cylinder Power
X
(Yellow) 1
(45)
632*
1146 2 2 2
(Yellow) (60)
18
X
(Yellow) 1
(45)
633*
1147 2 2 2
(Yellow) (60)
18

AEB15.43
64 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level

X
(Yellow) 1
(45)
634*
1148 2 2 2
(Yellow) (60)
18
X
(Yellow) 1
(45)
635*
1149 2 2 2
(Yellow) (60)
18
X
(Yellow) 1
(45)
636*
1150 2 2 2
(Yellow) (60)
18
X
(Yellow) 1
2 2
(Yellow) 18
2 2
(Yellow) 18
641* 1137 High #1 LB Cylinder Exhaust
Temperature X 2 2 2
(Red) 0
Temperature X 2 2 2
(Red) 0
Temperature X 2 2 2
(Red) 0
Temperature X 2 2 2
(Red) 0
Temperature X 2 2 2
(Red) 0
Temperature X 2 2 2
(Red) 0

AEB15.43
65 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level

Temperature 2 2
(Red) 0
Temperature 2 2
(Red) 0
649 S115 1378 Change Lubricating Oil and Filter
X X 3 3 3
(None) 0 0
1143 High #1 RB Cylinder Exhaust
(30,45) Temperature
651*
1145 X 2 2 2
(Red) (60)
0
(30,45) Temperature
652*
1146 X 2 2 2
(Red) (60)
0
(30,45) Temperature
653*
1147 X 2 2 2
(Red) (60)
0
(30,45) Temperature
654*
1148 X 2 2 2
(Red) (60)
0
(30,45) Temperature
655*
1149 X 2 2 2
(Red) (60)
0
(30,45) Temperature
656*
1149 X 2 2 2
(Red) (60)
0
657* 1150 High #7 RB Cylinder Exhaust
Temperature 2 2
(Red) 0
Temperature 2 2
(Red) 0
659* Change fuel filter
X 4 4 4
(None)

AEB15.43
66 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
661* 1137 High #1 LB Cylinder Power

2 2 2
(Yellow) 16
X
(Yellow) 0
2 2 2
(Yellow) 16
X
(Yellow) 0
2 2 2
(Yellow) 16
X
(Yellow) 0
2 2 2
(Yellow) 16
X
(Yellow) 0
2 2 2
(Yellow) 16
X
(Yellow) 0
2 2 2
(Yellow) 16
X
(Yellow) 0
2 2
(Yellow) 16
2 2
(Yellow) 16
669* Change coolant filter
X 4 4 4
(None)
671* 1137 Cyl #1 LB Exhaust Temp Sens Failed
Low X 4 4 4
(None) 4
Low X 4 4 4
(None) 4
Low X 4 4 4
(None) 4

AEB15.43
67 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level

Low X 4 4 4
(None) 4
Low X 4 4 4
(None) 4
Low X 4 4 4
(None) 4
Low 4 4
(None) 4
Low 4 4
(None) 4
679* Change Coolant
X X 4 4
(None)
691* 1172 LBF Turbo Comp Inlet Temp Sens
Failed High X
(None) 3
692* 1172 LBR Turbo Comp Inlet Temp Sens
Failed Low X
(None) 4
694* 1173 RBF Turbo Comp Inlet Temp Sens
Failed High 3 3 3
(None) 3
695* 1174 RBR Turbo Comp Inlet Temp Sens
Failed Low 3 3 3
(None) 4
1143 High #1 RB Cylinder Power
(45)
711*
1145 2 2 2
(Yellow) (60
16
711* 1329 High #1 RB Cylinder Power
X
(Yellow) 0
(45)
712*
1146 2 2 2
(Yellow) (60)
16
X
(Yellow) 0
(45)
713*
1147 2 2 2
(Yellow) (60)
16

AEB15.43
68 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level

X
(Yellow) 0
(45)
714*
1148 2 2 2
(Yellow) (60)
16
X
(Yellow) 0
(45)
715*
1148 2 2 2
(Yellow) (60)
16
X
(Yellow) 0
(45)
716*
1149 2 2 2
(Yellow) (60)
16
X
(Yellow) 0
2 2
(Yellow) 0
2 2
(Yellow) 0
719 P022 1264 Crankcase Blowby Pressure Sensor
Circuit - shorted high X X X 2 2 2
(Yellow) 3 3
1143 Cyl #1 RB Exhaust Temp Sens Failed
(30,45) Low
721*
1145 X 4 4 4
(None) (60)
4
(30,45) Low
722*
1146 X 4 4 4
(None) (60)
4

AEB15.43
69 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level

(30,45) Low
723*
1147 X 4 4 4
(None) (60)
4
(30,45) Low
724*
1148 X 4 4 4
(None) (60)
4
(30,45) Low
725*
1149 X 4 4 4
(None) (60)
4
(30,45) Low
726*
1150 X 4 4 4
(None) (60)
4
727* 1151 Cyl #7 RB Exhaust Temp Sens Failed
Low 4 4
(None) 4
728* 1152 Cyl #8 RB Exhaust Temp Sens Failed
Low 4 4
(None) 4
729 P022 1264 Crankcase Blowby Pressure Sensor
Circuit - shorted low X X X 2 2 2
(Yellow) 4 4
747* Trend Data Memory Nearly Full
X 4 4 4
(None)
748* Trend Data Memory Full
X 3 3 3
(None)
749* Fault Log Snapshot Data Nearly Full
X 4 4 4
(None)
753 S064 723 Engine Speed/Position #2 - Cam sync
error X X X 3 3 3
(None) 2 2
754* Fault Log Snapshot Data Full
X 3 3 3
(None)
Malfunction X
(Yellow) 7 7

AEB15.43
70 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
756* Change Lubricating Oil Filters

X 4 4 4
(None)
757* Catastrophic Power Loss - ECM Data
Lost X 4 4 4
(None)
Malfunction X
(Yellow) 7 7
768 S009 923 Output Device Driver (VGT or
Transmission shift PWM signal) X X X
(Yellow) 11 11
777 P173 1180 Turbocharger #1 Turbine Inlet
Temperature High - warning level X 2 2 2
(Yellow) 0 0
779 S051 703 Auxiliary Equipment Sensor Input # 3
(OEM Switch) X X X
(Yellow) 11 11
Rapid Rise in Intake Manifold
783 1 1
Temperature LBF
951 P166 166 Cylinder Power Imbalance between
cylinders X X
(None) 2 2
1000* Vehicle Controller initiated fault log
X
(None)
Temperature 2
0 0
Temperature 2
0 0
1153 Exhaust Gas Temperature Sensor
2146* Circuit Failed Low Cyl # 9 RB 4
4 4
1154 Exhaust Gas Temperature Sensor
2147* Circuit Failed Low Cyl # 9 LB 4
4 4
1340 High Power – Cylinder # 9 Left Bank
2148* 2
0 16
1341 High Power – Cylinder # 9 Right Bank
2149* 2
16
1340 Low Power – Cylinder # 9 Left Bank
2151* 2
18
1341 Low Power – Cylinder # 9 Right Bank
2152* 2
18
2154* 611 Post-Filter Oil Pressure Sensor Circuit-
Shorted high X 3 3 3
(None) 3

AEB15.43
71 of 72
QSK45
QSK60
QSK78
SID(S)
FAULT
CODE PID(P) SPN
QSM11
QSK19
QSK23
QSX15
QST30
DESCRIPTION
QSL9
QSB
QSC
HHP Level
2155* 611 Post-Filter Oil Pressure Sensor Circuit-

Shorted Low X 3 3 3
(None) 4
1131 Rapid Rise in Intake Manifold
2157* Temperature LBR 1 1
10
2158* Temperature RBF 1 1
10
2159* Temperature RBR 1 1
10
2194* P223 1387 Auxiliary Equipment Sensor Input # 2
(OEM Pressure Sensor) Engine X X X
(Yellow) 11 11 Protection – Warning
2195* S051 703 Auxiliary Equipment Sensor Input # 3
(OEM Switch) Engine Protection - X X X
(Red) 14 14 Critical
Left Bank Middle High Intake Manifold
2241* 2
Temperature - EP
Left Bank Middle Intake Manifold Temp
2242* 2
Sensor Circuit Failed High
Left Bank Middle Intake Manifold Temp
2243* 2
Sensor Circuit Failed Low
2244* 2
Temperature LBM
Right Bank Middle High Intake Manifold
2245* 2
Temperature - EP
Right Bank Middle Intake Manifold Temp
2246* 2
Sensor Circuit Failed High
Right Bank Middle Intake Manifold Temp
2247* 2
Sensor Circuit Failed Low
2248* 2
Temperature RBM
2251* Front Intercooler Boost Pressure High 2
2252* Front Intercooler Boost Pressure Low 2
Front Intercooler Boost Pressure Out of
2253* 2
Range High
Front Intercooler Boost Pressure Out of
2254* 2
Range Low
2255* Rear Intercooler Boost Pressure High 2
2256* Rear Intercooler Boost Pressure Low 2
Rear Intercooler Boost Pressure Out of
2257* 2
Range High
Rear Intercooler Boost Pressure Out of
2258* 2
Range Low

AEB15.43
72 of 72
Change Log
Date Description Pages/Sections Editor

Sept. 1,2009 Corrected Cense Fault Lamp Pin out Page 9 Jeff Martin
March 23, Acknowledged release of new QSK23 calibration Page 34 H. Abbas
2009 software phase
Nov2007 PGN References added/modified Pg. 30, 33, 34 H. Abbas
June 2005 Revised Requirements and Recommendations Page 1, 31 M. Cowherd
and J1939 messages
May 2004 Added Requirements and Recommendations C. Hobbs
May 2004 Added Fault Lamp Changes, added clarity to Fault Sections I & IV D. Dow
Flashout information and added HHP Fault Severity
information to Table 5.
Feb. 2004 Reformatted for clarity. Corrected errors in text and All Sections. D. Pietsch
fault code tables.
GENERATOR
280–430 Frame
Installation, Operation,
and Maintenance Manual
Marathon Electric Mfg. Corp.

A REGAL-BELOIT COMPANY
P.O. Box 8003
Wausau, WI 54402-8003
Phone: (715) 675 3359
Fax: (715) 675 8026
www.marathonelectric.com
CONTENTS When in doubt, ask. Questions are much easier to handle
Safety 2 than mistakes caused by a misunderstanding of the
Receiving and Storage 2 information presented in this manual.
Principles of Operation 3-4
Installation 4-6
Wiring Connections 6-9 RECEIVING AND STORAGE
Operation 9 - 10
Maintenance 11 - 12 RECEIVING AND STORAGE
Testing 12 - 13
Service 13 - 15 Upon receipt of the generator, it is recommended that it be
Troubleshooting 15 - 18 carefully examined for possible shipping damage. The
Specifications 19 generator was given to the freight carrier in good condition;
Parts List & Recommended Spare Parts 20 - 22 thus, the carrier is responsible for the product from the
factory dock to the destination. Any damage should be noted
on the freight bill before accepting the shipment. Any claims
for damage must be promptly filed with the delivering carrier.
SAFETY
PLEASE REMEMBER SAFETY FIRST. If you are not sure of UNPACKING AND HANDLING
the instructions or procedures contained herein, seek
qualified help before continuing. Carefully read all instruction tags shipped with the unit. When
lifting, attach an overhead crane to the lifting lug(s) on the
This service manual emphasizes the safety precautions generator frame. Apply lifting forces in a vertical direction.
necessary during the installation, operation, and When transporting single bearing generators, the generator’s
maintenance of your MagnaPLUS® generator. Each section of rotor must be adequately supported to prevent damage.
this manual has caution and warning messages. These
messages are for your safety, and the safety of the equipment
involved. If any of these cautions or warnings are not
readily understood, seek clarification from qualified
personnel before proceeding.
THE LIFTING LUG(S) ON THE GENERATOR ARE
Before any service work is done, disconnect all power DESIGNED TO SUPPORT THE GENERATOR ONLY.
sources and lock out all controls to prevent an unexpected DO NOT LIFT A COMPLETE GENERATOR AND
start up of the generator set driver. Proper grounding DRIVER ASSEMBLY BY MEANS OF LIFTING LUG(S)
(earthing) of the generator frame and distribution system in ON THE GENERATOR. PERSONAL INJURY OR
compliance with local and national electrical codes and EQUIPMENT DAMAGE MAY RESULT.
specific site requirements must be provided. These safety
precautions are necessary to prevent potential serious
personal injury, or even death.
STORAGE
The hazards associated with lifting or moving your
MagnaPLUS® generator are pointed out in the installation and In the event that the generator is not immediately installed on
maintenance sections. Incorrect lifting or moving can result in its prime mover, it is recommended that the unit be stored
personal injury or damage to the unit. indoors in a clean, dry area which is not subject to rapid
changes in temperature and humidity. If the generator is
Prior to start up of the unit ensure that all generator leads are stored for a long period of time, the generator should be
properly connected to the generator link board located inside tested, cleaned and dried as required before being put into
the connection box. Always assume that there will be voltage service. See the maintenance section of this manual for
present at the generator terminals whenever the generator's further information. If the unit has been stored in an area
shaft is rotating, and proceed accordingly. Residual voltage is where it has been subject to vibration, it is recommended that
present at the generator terminals and at the automatic the bearing(s) be inspected and replaced as necessary.
voltage regulator panel connections even with the regulator
fuse removed. Caution must be exercised, or serious injury or
death can result.
This manual is not intended to be a substitute for properly

trained personnel. Installation and repairs should only be
attempted by qualified, trained people. The cautions and
warnings point out known conditions and situations that are
potentially hazardous. Each installation may well create its
own set of hazards.
2
PRINCIPLES OF OPERATION
FIGURE 1 -- MagnaPLUS® Circuit Diagram
FIGURE 2 -- Typical MagnaPLUS® Layout Diagram
3
PRINCIPLE OF OPERATION generator KW in motor starting capability. For specific data
contact Marathon Electric.
MagnaPLUS® generators are brushless, self excited,
externally voltage regulated, synchronous AC generator. The
PARALLEL OPERATION
generator is made up of six major components: main stator
(armature), main rotor (field), exciter stator (field), exciter
All MagnaPlus® generators are built with 2/3 pitch main
rotor (armature), rectifier assembly, and voltage regulator. In
stator windings and full amortisseur (damper) windings.
understanding the above terminology, note the following:
These features make the MagnaPlus® generators suitable for
stators are stationary, rotors rotate, a field is a DC electrical
parallel operation when equipped with the proper voltage
input, and an armature is an AC electrical output. These
regulators and voltage regulator accessories. Consult with the
system components are electrically interconnected as shown
factory for further information relative to parallel operations.
in Figure 1 and physically located as shown in Figure 2.
The generator’s exciter consists of a stationary field and a

NONLINEAR LOADING
rotating armature. The stationary field (exciter stator) is
designed to be the primary source of the generator’s residual
Solid state electronic control devices (variable frequency
magnetism. This residual magnetism allows the exciter rotor
drives, precision motor controls, battery chargers, etc.) utilize
(armature) to produce AC voltage even when the exciter
electronic switching circuits (thyristors, SCRs, Diodes, etc.).
stator (field) is not powered. This AC voltage is rectified to DC
These switching circuits introduce high frequency harmonics
by the rotating rectifier assembly and fed directly to the main
which distort the normal wave form of the generator. This
rotor (field). As the generator shaft continues to rotate, the
creates additional heat in the generator windings and may
main rotor (field) induces a voltage into the generator's main
cause the generator to over-heat. Problems which can occur
stator (armature). At rated speed, the main stator’s voltage
are not limited to the generator. Poor wave shape may
produced by the residual magnetism of the exciter allows the
adversely effect various loads connected to the generator.
automatic voltage regulator to function. The regulator
Consult Marathon Electric for further information relative to
provides voltage to the exciter field resulting in a build-up of
nonlinear loads.
generator terminal voltage. This system of using residual
magnetism eliminates the need for a special field flashing
circuit in the regulator. After the generator has established the
initial residual voltage, the regulator provides a controlled DC
field voltage to the exciter stator resulting in a controlled
INSTALLATION
generator terminal voltage.
PREPARATION FOR USE
Although the generator has been carefully inspected and
Voltage Regulation tested in operation prior to shipment from the factory, it is
recommended that the generator be thoroughly inspected.
In the standard configuration (shunt excited), the automatic
Check all bolts for tightness and examine the insulation on
voltage regulator receives both its input power and voltage
lead wires for chafing prior to proceeding with installation.
sensing from the generator's output terminals (See Figure 1).
Remove all shipping tapes, bags, skids and rotor support
With the optional PMG configuration, the regulator receives
blocking. For two bearing units, rotate the shaft by hand to
input power from the PMG. The regulator automatically
ensure that it rotates smoothly without binding.
monitors the generator's output voltage against an internal
reference set point and provides the necessary DC output
voltage to the exciter field required to maintain constant
generator terminal voltage. The generator's terminal voltage
is changed by adjusting the regulator's reference set point.
Consult the regulator manual for specific adjustment and
operating instructions.
MOTOR STARTING
When a motor is started, a large surge of current is drawn by
the motor. This starting current is equivalent to the motors
locked rotor or stall current and is 5 to 10 times normal full
load current. When the generator supplies this in-rush of
starting current, the generator voltage dips temporarily. If the
motor is too large for the generator, the generator’s voltage
dips greater than 30 percent. This may result in the motor
starter de-energizing or the motor stalling. MagnaPlus®
generators generally supply .3 to .4 horsepower per
4
GENERATOR MOUNTING
Two Bearing Generators -- Direct Drive
DISABLE AND LOCKOUT ANY ENGINE CRANKING Two bearing generators are provided with a keyed shaft
DEVICES BEFORE ATTEMPTING TO INSTALL OR extension. For direct drive generators, the assembler
SERVICE THE GENERATOR. FOR ELECTRIC START furnishes a flexible coupling which is installed between the
SETS, DISCONNECT THE CRANKING BATTERY. FOR driver and the generator's shaft. Aligning the generator and its
AIR START, DISCONNECT THE AIR SUPPLY. FOR driver as accurately as possible will reduce vibration, increase
MOTOR GENERATOR SETS, OPEN THE POWER bearing life, and ensure minimum coupling wear. It may be
SUPPLY TO THE DRIVE MOTOR. FAILURE TO necessary to shim the generator feet for proper
COMPLY WITH THESE SAFETY PROCEDURES support and alignment. Secure the feet of the generator with
COULD RESULT IN SEVERE PERSONAL INJURY OR grade 5 or greater bolts through the holes provided in the
EQUIPMENT DAMAGE. mounting feet. Consult the coupling manufacturer's
instructions for alignment specifications and procedures.
NEVER "BAR OVER" THE ENGINE GENERATOR SET
USING THE GENERATOR'S FAN. THE FAN IS NOT
DESIGNED FOR THIS PURPOSE. BARRING OVER GENERATOR MOUNTING
THE SET WITH THE FAN COULD DAMAGE THE FAN Two Bearing Units -- Belt Driven
AND RESULT IN PERSONAL INJURY OR
EQUIPMENT DAMAGE. Two bearing MagnaPLUS® generators can be belt driven
provided belts are sized and applied correctly. Please refer to
your supplier of belts and sheaves for correct sizing and
tensioning specifications. A bearing life calculation should be
GENERATOR MOUNTING performed. Marathon Electric recommends a minimum B-10
Single Bearing Units. life of 40,000 hours. If cog type belts are used, a vibration may
be introduced which could lead to premature failure of the
Single bearing units are provided with an SAE flywheel bearings.
housing adapter flange and flexible drive discs. Coupling the
generator's shaft to the engine flywheel is accomplished with
special steel drive discs bolted to the shaft. In addition to the HYDRAULIC DRIVE WITH SHAFT SPLINE
drive discs, there may be a hub spacer, spacer discs, or a Two Bearing Units
combination of hub spacer and spacer discs inserted
between the drive discs and the shaft to achieve the proper All 280 PDL MagnaPLUS® two bearing hydraulic drive
shaft extension ("G" dimension per SAE J620c). Holes are generators are equipped with a Zerk grease fitting mounted in
provided in the periphery of the coupling discs which the drive end of the shaft. Prior to assembly to the hydraulic
correspond to tapped holes in the prime mover's flywheel. drive motor, lightly coat the hydraulic drive motor shaft, and/or
The outside diameter of the drive discs fit in a rabbet in the grease the generator spline per the greasing instructions in
flywheel so that concentricity is assured. the MAINTENANCE section, page 12. DO NOT assemble
the generator to the hydraulic drive motor with the spline
Grade 8 place bolts and hardened washers are recommended dry.
to mount the drive discs to the flywheel. DO NOT USE SPLIT
TYPE LOCK WASHERS. Split lock washers when biting into
the drive disc cause stress risers which may result in the disc END PLAY TESTING
fracturing.
Refer to the engine manual for recommended end play
The SAE flywheel housing adapter ring and the engine specifications and measurement procedures. If end play is
flywheel housing are designed to match each other with no not to specification, it is an indication that the generator shaft
further alignment necessary. Use grade 5 or greater is not moving freely in the assembly, and normal life of the
mounting bolts. MagnaPLUS® generator frames are thrust bearing could be impaired. Probable causes of this
constructed with two or three bolt holes per foot. The feet problem are:
should be shimmed where necessary to obtain solid contract
with the sub-base. With the frame securely bolted to the 1. Improper seating of drive discs in the flywheel resulting in
engine flywheel housing, there is no side thrust or pull on the misalignment.
generator frame, thus no real need to secure the feet with
more than one bolt per foot. 2. Improper mating of generator frame to engine flywheel
housing resulting in misalignment.
3. Improper "G" dimension per SAE J620c on either the

engine or generator.
5
TORSIONAL VIBRATION The generator conduit box construction allows cable entry
from multiple sides. A hole saw or other appropriate tool may
Torsional vibrations are generated in all rotating shaft be used to provide for conduit entrance. Protect the interior of
systems. In some cases, the amplitude of these vibrations at the generator from shavings when drilling or sawing. An
critical speeds may cause damage to either the generator, its approved connector must be used in conjunction with the
driver, or both. It is therefore necessary to examine the conduit. To minimize the transmission of vibration, it is
torsional vibration effect on the entire rotating system. IT IS essential that flexible conduit be used for all electrical
THE RESPONSIBILITY OF THE GENERATOR SET ASSEM- entrance to the generator conduit box.
BLER TO ASSURE THE TORSIONAL COMPATIBILITY OF
THE GENERATOR AND ITS DRIVER. Drawings showing All MagnaPLUS® generators are equipped with link boards
pertinent dimensions and weights of the rotating assembly (terminal strips) for both internal and external connections. All
will be supplied by Marathon Electric upon request. connections made to the studs of the link board should be
made with high quality ring terminals. Ring terminal sizes are:
6 mm (280 Series Frames) and 10 mm (360 and 430 Series
ENVIRONMENTAL CONSIDERATIONS Frames). Torque link board connections to the
following specifications: 280 frame -- 5.4 NM (4 Ft Lb); 360 &
The MagnaPLUS® generator is designed for heavy duty 430 frame -- 27 NM (20 Ft Lb).
industrial applications; however, dirt, moisture, heat and
vibration are enemies of rotating electrical machinery. Refer to the connection diagram supplied with the generator
Excessive exposure to the elements may shorten generator and / or the proper diagrams shown in this manual. Install all
life. The temperature of the cooling air entering the intake inter component and external wiring in accordance with
openings of the generator should not exceed the ambient national and local electrical codes. The neutral in the
temperature shown on the generator’s nameplate. Generators following connection diagrams shown below may be either
intended for outdoor application should be protected with grounded (earthed) or left above ground potential (floating).
housings having adequate ventilation. Although the standard See national and local codes and / or the system distribution
insulation systems are moisture and humidity resistant, space wiring schematic diagram for the proper connection of the
heaters are recommended for extreme conditions. If the neutral.
generator is to be installed in an area where blowing sand
and dust are present, the enclosure should be fitted with The following connection diagrams are shown for twelve
filters. Filters reduce erosion on the generator's insulation by lead generators. Ten lead generators have the same
blocking high velocity abrasive particles generated by the flow terminal designations except for leads T10, T11, and T12.
of cooling air through the generator. Consult the factory for These three leads are internally connected inside the
appropriate filters and generator deratings required. generator and brought out as a single lead (T0). Ten lead
generators can only be connected in a wye configuration.
WIRING CONNECTIONS
Wiring of the generator and accessories should be
done in accordance with good electrical practices.
Follow government, industry and association
standards.
HIGH (SERIES) WYE CONNECTION

L1
T1
VOLTAGE (HIGH WYE)

T4
Hz L-L L-Lo
12 Lead 60 380 219
T7 416 240
L-L
440 254
T12 T10 460 266
480 277
T9
T6 T11 50 380 219
T8 400 231
T3 T5 415 240
T2
L3 L - L0 L2 440 254
6
LOW (PARALLEL) WYE CONNECTION
L1
T7 T1
VOLTAGE (LOW WYE)
Hz L-L L-L0
12 Lead 60 190 110
208 120
L-L
T10 T4
220 127
T12 T5 230 133
240 139
T6 T11 50 190 110
T9 T2
200 115
L3 L2
208 120
T3 T8 220 127
L - L0
HIGH (SERIES) DELTA CONNECTION
L1
T12 T1
VOLTAGE (HIGH DELTA)
L-L0 Hz L-L L-L0
60 240 120
T9 T4 277 139
L-L L0
T6 T7 50 200 100
220 110
L-L0 240 120
T3 T10
L3 T11 T8 T5 T2 L2
LOW (PARALLEL) DELTA CONNECTION
L1
12 Lead
T12
T1 VOLTAGE (LOW DELTA)
T6 T
7 Hz L-L
L-L 60 110
T9 120
T4
T3 50 100
T10
110
T5 T2
L3 T11 T8 L2
L-L
7
DOUBLE DELTA -- SINGLE PHASE CONNECTION
VOLTAGE (DOUBLE DELTA)

T3 T5 T9 T11 Hz L-L L-LO
60 200 100
220 110
240 120
T6 T12 T8 50 220 110
T2 L0 Note: Single phase KW/KVA ratings are
approximately equal to 50% of the
L2 T1 T4 T7 T10 L1 generator’s three phase ratings.
L - L0 L - L0
L-L
LOW ZIG ZAG -- SINGLE PHASE (PARALLEL) CONNECTION
VOLTAGE (LOW ZIGZAG)

T6 T2
Hz L-L L-LO
T12 T8 12 Lead 60 200 100
220 110
T3 T5 240 120
T11 50 220 110
T9
T4 T1 L1
L2 L0 Note: Single phase KW/KVA ratings are
T10 T7
approximately equal to 50% of the
L - L0 L - L0 generator’s three phase ratings.
L-L
HIGH ZIG ZAG -- SINGLE PHASE (SERIES) CONNECTION
T12 T1
VOLTAGE (HIGH ZIGZAG)
Hz L-L L-L0
12 Lead
60 480 240
T9 T4
T6 T7
T10
T3 T11 T8 T5 T2 Note: Single phase KW/KVA ratings are
L0 L1 approximately equal to 50% of the
L2 L - L0 L - L0 generator’s three phase ratings.
L-L
8
DEDICATED SINGLE PHASE CONNECTION
HIGH VOLTAGE - SERIES CONNECTED
VOLTAGE (DEDICATED)
Hz L-L L-N
60 240 120
220 110
50 220 110
200 100
SINGLE PHASE CONNECTION - SINGLE VOLTAGE PARALLEL
VOLTAGE
L-L
60 HZ 120
50 HZ 110
Note: For 120 volt only service. Use an

AVC63-4A or a VR63-4C voltage regulator to
replace the standard SE350 regulator.
9
OPERATION START-UP
The following procedure should be followed when starting the
PRE-START INSPECTION generator set for the first time.
Before starting the generator for the first time, the following 1. The generator output must be disconnected from the
inspection checks are recommended: load. Be sure that the main circuit breaker or fused
disconnect is in the open position.
1. A visual inspection should be made for any loose parts,
bad connections, or foreign materials. 2. Open the input power to the automatic voltage
regulator. Remove the fuse or disconnect and insulate
2. Bar the set over by hand for at least 2 revolutions to be one of the regulator input power leads. (See separate
sure that there is no interference and that the set turns regulator manual)
freely. If the set does not turn freely, check for clearance
in the generator and exciter air gap. 3. Verify that all prime mover start-up procedures have
been followed.
3. Check all wiring against the proper connection diagrams,
and ensure that all connections and terminations are 4. If the unit is provided with space heaters, ensure that
tight and properly insulated. they are de energized. In some installations, a set of
auxiliary contacts on the main circuit breaker or transfer
4. Verify that all equipment is properly grounded (earthed). switch will automatically open the space heater circuit
when the generator is connected to the load.
5. Start the prime mover, and adjust it for proper speed. See
generator nameplate.
MAGNAPLUS® GENERATORS MAY HAVE VOLTAGE
PRESENT AT THE LEAD TERMINALS WHEN THE 6. The purpose of this initial test with the regulator out of the
SHAFT IS ROTATING. DO NOT PERMIT OPERATION circuit is to detect any wiring mistakes without exposing
OF THE GENERATOR UNTIL ALL LEADS HAVE the unit to undue risk. Check all line to line and line to
BEEN CONNECTED AND INSULATED. FAILURE TO neutral voltages for balanced voltage. If voltages are
DO THIS MAY RESULT IN PERSONAL INJURY OR balanced, shut down the set and reconnect the
EQUIPMENT DAMAGE. regulator. If voltages are unbalanced, shut down the
equipment and check for improper wiring. If the
problem persists, consult the factory.
5. Clear the surrounding area of any materials that could be
drawn into the generator. With the regulator de energized, the residual voltage
should be 10 - 25% of rated value. It is recommended
6. Check all fasteners for tightness. that this residual voltage and driver RPM be recorded for
use as a future troubleshooting benchmark.
7. Check all access plates, covers, screens and guards. If
they have been removed for assembly or inspection,
reinstall and check for security.
8. Review all prime mover prestart up instructions, and THE FOLLOWING TEST MUST BE CONDUCTED BY
ensure that all recommended steps and procedures have QUALIFIED ELECTRICAL PERSONNEL. LETHAL
been followed. VOLTAGE MAY BE PRESENT AT BOTH THE
GENERATOR AND VOLTAGE REGULATOR
9. Remove any masking materials affixed during painting. TERMINALS DURING THIS PROCEDURE. CAUTION
Inspect the generator, prime mover, and any accessory MUST BE EXERCISED NOT TO COME INTO
equipment to ensure that nameplates, and all safety PERSONAL CONTACT WITH LIVE TERMINALS,
warning / caution signs and decals provided with the LINKS, OR STUDS. SERIOUS INJURY OR DEATH
equipment are in place and clearly visible. COULD RESULT.
Note: It is strongly recommended that the authority

having jurisdiction over the installation site be 7. Start the set and adjust the terminal voltage to the
consulted to determine if any additional warning or desired value by means of the regulator voltage
caution notices, or additional safety devices are adjustment. If the regulator is equipped with a stability
required by local codes / standards. Any such adjustment, follow the instructions in the regulator
required notices or devices should be installed prior manual to adjust the stability. Again, check all line to line
to initial startup. and line to neutral voltages for balance. It is
10
recommended practice to record the no load excitation rather one that should be conducted by an authorized
(DC voltage to the exciter stator), generator terminal service center equipped with the appropriate apparatus
voltage, and driver speed as a benchmark for future and solvents necessary to properly clean and dry the
troubleshooting. generator.
8. Close the main circuit breaker to the load.
9. Monitor the generator output current to verify that it is at

or below nameplate value.
THE FOLLOWING TEST MUST BE CONDUCTED BY
10. Check generator speed (frequency) under load. Adjust as QUALIFIED ELECTRICAL PERSONNEL. LETHAL
necessary. (Refer to prime mover or governor manuals) VOLTAGE MAY BE PRESENT AT BOTH THE
TERMINALS DURING THIS PROCEDURE. CAUTION
SHUTDOWN PROCEDURE MUST BE EXERCISED NOT TO COME INTO
PERSONAL CONTACT WITH LIVE TERMINALS,
There are no specific instructions for shutting down the LINKS, OR STUDS. SERIOUS INJURY OR DEATH
generator; however, several good practices should be COULD RESULT.
observed to prolong equipment life.
1. It is advisable to disconnect all loads (open main circuit 4. Every 2,000 operating hours or in conjunction with
breaker or disconnect) prior to shutdown. This is scheduled engine maintenance, check the DC no load
especially important if loads can be damaged by low excitation voltage per item #7 in the startup procedure.
voltage or low frequency conditions during generator Compare this voltage with the value recorded during
"coast down". initial startup. If this value of no load excitation voltage is
markedly higher than the bench mark reading, it is an
2. Isolate all conditions that could apply voltage to the indication of problems in either the exciter, main field, or
generator terminals while the generator is at rest. Failure the rotating rectifier assembly. Ensure that RPM is the
to comply could result in personnel injury or equipment same as initial test.
damage.
5. Monitor and record insulation resistance with a 500 volt
3. If the unit is equipped with space heaters, verify that the mega-ohm meter. The minimum acceptable reading is 2
heater circuit is energized. mega-ohms. If the reading drops below the minimum, the
generator should be cleaned and dried at an authorized
service shop. Consult Marathon Electric for more
information.
MAINTENANCE
The following maintenance procedures should be followed to DRYING WINDINGS
ensure long equipment life and satisfactory performance.
Maintenance intervals will depend upon operating conditions. Generators in service may inadvertently have their windings
exposed to splashing or sprayed water. Units that have been
1. Routinely check intake and exhaust air screens to ensure in transit or storage for long periods of time may be
that they are clean and free of debris. Clogged intake air subjected to extreme temperature and moisture changes
screens will reduce cooling air flow and result in higher causing excessive condensation. Regardless of the source of
operating temperatures. This will reduce generator life moisture, wet windings should be thoroughly dried out before
and may result in generator damage. operating the unit. If this precaution is not taken,
serious damage to the generator can result. The following
2. All MagnaPLUS® generators are equipped with double procedures may be utilized in drying the generator’s
shielded ball bearings lubricated for the life of the windings. The method selected will be influenced by winding
bearing. Every 1,000 hours check the bearing(s) for wetness and situation limitations.
smooth, quiet operation. For continuous duty generators,
recommended practice is to replace the bearing during Space Heaters
major overhauls of the engine. An electric heater may have been supplied with the
generator. When energized from a power source other than
3. Periodically inspect the unit for any buildup of the generator, the heater will gradually dry the generator. This
contamination (dirt, oil, etc.) on the windings. If the process can be accelerated by enclosing the unit with a
wound components have become coated with heavy covering and inserting additional heating units. A hole should
concentrations of oil and grime, the unit should be be left at the top of the covering to permit the escape of
disassembled and thoroughly cleaned. This operation is moisture. Care should be taken not to overheat various
not one that can be accomplished effectively on site, but accessory equipment mounted with the generator.
11
Forced Air that the generator’s air gaps (main rotor and exciter) are free
Another method to dry the generator is to run the set with no from obstructions. If possible, rotate the generator manually
excitation (see startup procedure item #2). The natural flow of to ensure free rotation. Never “bar over” the engine generator
ambient air through the generator will tend to dry the set using the generator fan.
windings. This method can be accelerated by adding a source
of heat at the air intake to the generator. Heat at point of entry
should not exceed 80 C (180° F).
THE FOLLOWING TEST MUST BE CONDUCTED BY

HYDRAULIC DRIVE GENERATORS, QUALIFIED ELECTRICAL PERSONNEL. LETHAL
SHAFT SPLINE LUBRICATION VOLTAGE MAY BE PRESENT AT BOTH THE
The shaft spline should be greased prior to initial assembly to TERMINALS DURING THIS PROCEDURE. CAUTION
the driver, and every three (3) months to reduce maintenance, MUST BE EXERCISED NOT TO COME INTO
and prolong the life of the spline coupling per the following PERSONAL CONTACT WITH LIVE TERMINALS,
procedure: LINKS, OR STUDS. SERIOUS INJURY OR DEATH
COULD RESULT.
1. Material: Molybdenum Disulfide - sometimes referred to
as “Molly Grease.”
2. Turn the rotor assembly so that the Zerk fitting is in line CONSTANT EXCITATION TEST
with the access hole in the top of the drive end bearing (12V BATTERY TEST)
bracket as illustrated in Figure 3.
The generator “no load” voltage is dependent on exciter input
3. Using a hand held grease gun with a solid coupling, voltage and generator speed. With the generator operating at
apply a small amount of grease into the fitting. DO NOT rated speed and 12 volts dc applied to the exciter field, the
OVER GREASE. Limit the amount of grease to one (1) generators terminal voltage will be near rated value.
trigger pull of the grease gun.
1. Shutdown the generator set and connect a voltmeter on
the generator terminals.
Shaft Mounted 2. Disconnect the regulator’s F+ (F1) and F- (F2) leads and
Zerk Fitting connect them to a 12V battery. Caution should be taken
to ensure that the battery is not exposed to any
potential arcing.
Grease Gun
Access Hole
3. With no load on the generator (main breaker open) run
the generator at rated speed. Measure the generator’s
terminal voltage and compare this value with values
recorded during installation.
If voltage readings are normal, the main generator and

excitation are operating properly. Troubleshooting should
continue with the regulator. If readings are not normal the
problem is in the generator. Continue testing diodes, surge
suppressor, and windings.
Figure 3--Drive End Bearing Bracket Continuity / Resistance Test

The generator has four components which can be checked
using an ohm meter: exciter stator, exciter rotor, main stator
and main rotor. Each of these components are comprised of
TESTING various windings which form a complete electrical path of
relatively low resistance. Using an ohm meter measure the
Visual Inspection loop resistance of each component. Compare these
measured values with the values listed in the specification
Remove covers and look for any obvious problems: burnt section of this manual. Note that very small resistance values
windings, loose connections, broken wires, frayed insulation, require precision equipment to make accurate
cracked brackets, missing hardware, etc. Check for foreign measurements; however, a standard ohm meter will provide a
objects which may have been drawn into the generator. Verify good indication of winding continuity.
12
Insulation Test When the positive test probe is connected to the diode's
anode and the negative test probe is connected to the diode's
Insulation resistance is a measure of the integrity of the cathode (forward biased), the diode will switch on and
insulating materials that separate the electrical windings from conduct electricity (Figure 4). This is observed by a low
the generator’s steel core. This resistance can degrade over resistance reading when using an ohm meter or the lighting
time or be degraded by contaminants: dust, dirt, oil, grease, of the bulb when using a battery light continuity tester.
and especially moisture. Most winding failures are due to a Reversing the test leads (reverse biased) will result in the
breakdown in the insulation system. In many cases, low diode switching off and no electricity will be conducted. The
insulation resistance is caused by moisture collected when results of these tests should indicate one of three conditions:
the generator is shutdown
1. Good diode: Will have a much greater resistance in one
Insulation resistance is measured with a megger (mega-ohm direction than the other. Typical reverse biased resistance
meter). A megger measures insulation resistance by placing will be 30,000 ohms or greater, while forward biased
500 volts between the winding and the frame of the resistance will be less than 10 ohms. The battery light
generator. Caution must be taken to remove all electronic tester will have the light "on" in one direction and "off" in
devices (regulators, diodes, surge protectors, capacitors, the other.
protective relays, etc.) from the winding circuit before
checking the insulation. Winding insulation can be checked on 2. Shorted condition: Ohmmeter reading will be zero, or
the main stator, main rotor, exciter stator, and exciter rotor. very low in both directions. The continuity tester will have
Minimum resistance is 2 mega-ohms. If the winding the light "on" in both directions.
resistance is low it must be dried (see maintenance section)
or repaired. 3. Open condition: Ohmmeter will have a maximum
(infinity) reading in both directions. Continuity tester light
will be off in both directions.
DIODE TESTING
Diode failure after a 25 hour "run in" period is generally
If the generator is close coupled to an engine, it may be traceable to external causes such as a lightning strike,
necessary to "bar over" the engine in order to gain access to reverse current, line voltage spikes, etc. All 6 diodes are
a given area of the rectifier assembly. NEVER use the essentially in the same circuit. When a diode is stressed to
generator's fan as a fulcrum to accomplish this. Use the failure, there is no easy method to determine remaining life in
engine manufacturer's recommended practice to manually the other diodes. To avoid possible continued failures, it is
turn over the engine. To prevent possible injury to personnel, recommended that the entire rectifier assembly be replaced
and damage to the equipment, ensure that the engine rather than replacing individual diodes.
cannot start during this procedure.
Remove the two main rotor leads and the three exciter rotor
leads from the rectifier assembly (Figure 5). The rectifier SERVICE
assembly is now electrically isolated from the generator. The
diodes remain mounted and the diode leads remain
connected to the terminal posts. Using an ohmmeter or a GENERAL
battery light continuity tester, place one test probe on the
diode lead terminal post. In succession, touch the other test The service procedures given in this section are those which
probe to the lead screw hole in each heat sink. Reverse the can reasonably be conducted on-site with a minimum
probes and repeat the procedure. You have now tested the number of special tools and equipment. All service
three diodes connected to this terminal post in both the procedures should be conducted by qualified maintenance
forward and reverse direction. Repeat the procedure using personnel. Replacement parts may be ordered through an
the other diode terminal post. authorized service center or directly from the factory.
Forward Reverse FIELD FLASHING

Terminal End Restoring Residual Magnetism
(not applicable on PMG equipped generators)
Anode Cathode
(+) (-)
To restore residual magnetism to the generator, connect a 12
volt battery to the exciter field while the generator using the
following procedure:
Stud End
Cathode Anode
1. Shutdown the generator set. Remove the exciter field
(-) (+) leads F+ and F from the regulator.
FIGURE 4: DIODE POLARITY
13
Reassembly note: Before the bearing bracket is seated
against the frame, a threaded rod may be used to help align
Failure to remove the exciter field leads from the the inner bearing cap with the bearing bracket.
automatic voltage regulator during flashing
procedures may destroy the regulator.
BEARING REPLACEMENT
2. Connect the F+ and F- leads to the battery’s
corresponding positive and negative terminals. This Using a bearing puller, remove the existing bearing. It is
should be done using an appropriate length of lead wire strongly recommended that the bearing be replaced any time
to separate the battery from the point of connection the it is removed from the shaft. ALWAYS install the same
(batteries may explode when exposed to an electric arc). type and size bearing that was supplied as original
After 3 to 5 seconds, remove the F- lead. An inductive arc equipment. Order by part number from the parts list, and
should result. If no arc is drawn, repeat the procedure. include the unit serial number and part number when
ordering. Heat the bearing to a maximum of 100°C (212°F) in
3. Reconnect the F+ and F- leads to the regulator. Restart an oven. Apply a thin coat of clean lubricating oil to the press
the generator and verify that terminal voltage is fit area of the rotor shaft. Using suitable heat resistant gloves,
developed. If terminal voltage does not develop, repeat install the bearing over the end of the shaft until it seats
the field flashing procedure and / or consult the trouble against the shaft shoulder. The bearing should slide on the
shooting section. shaft and be seated without excessive force. Should the
bearing bind on the shaft prior to being seated against the
shoulder, a piece of tubing slightly larger than the press fit
BEARING REMOVAL area can be used to drive the bearing to its final position.
Using light taps with a soft mallet, apply pressure to the inner
Prior to performing this operation, it is suggested that the race only.
alternator's shaft be rotated until two of the main rotor poles
are in a vertical position. Once the bearing bracket is backed
out, the rotor will drop on the main stator core. Having the RECTIFIER ASSEMBLY REMOVAL
rotor in this position will limit the amount of rotor drop to that
of the air gap. Visually inspect the bearing bore for damage or The rectifier assembly cannot be removed until the opposite
wear. If worn or damaged, replace prior to reassemble. drive end bearing bracket and bearing have been removed
(see bearing removal procedure). Remove the three exciter
Opposite Drive End Bearing Bracket Removal. rotor leads from the heat sinks and the two main rotor leads
Prior to proceeding with bracket removal, disconnect exciter from the main rotor posts (see Figures 5). Remove the screws
field leads F+ and F- from the automatic voltage regulator and securing the rectifier assembly and pull the assembly free
ensure that they are free to move when the bearing bracket is from the shaft.
removed. Remove the bearing bracket retaining bolts. Using a
pair of screw drivers, wedge the bracket off the frame. After
approximately 1/8 inch, the bracket will clear the locating DIODE REPLACEMENT
register on the frame and will drop until the rotor is resting on
the main stator core. Continue to pull the bracket free from the Prior to installing a replacement diode on the heat sink, apply
bearing. Visually inspect the bearing bore and o-ring (if a thin film of conductive heat sink compound around the base
equipped) for damage or wear. If worn or damaged, repair or of the diode (do not coat the threads). When installing a diode
replace prior to reassembly. on the heat sink, care should be taken not to over torque the
retaining nut which could cause damage to the device. Torque
Drive End Bearing Bracket Removal, to 28 pound inches. If not damaged, the existing diode lead
Two Bearing Units. wire may be unsoldered from the failed diode, and resoldered
Remove any drive arrangement from the generator shaft on the replacement.
extension. Remove the bearing lock ring retaining screws.
There is no o-ring in the drive end bearing bracket. The shaft
extension must be supported before proceeding further. A
hoist and sling, jack, or some other means of support with a
capacity of 2 tons should be used.
Remove the bearing bracket retaining cap screws. Using a flat

bladed screw driver or chisel, pry the bracket back from the
frame. After approximately 1/8 inch, the bracket will clear the
locating register on the frame. Lower the shaft extension until
the rotor is resting on the main stator core. Continue to pull
the bracket free from the bearing. Visually inspect the
bearing bore for damage or wear. If worn or damaged, sleeve
or replace prior to reassembly.
14
430 FRAME 280 / 360 FRAME
A - Exciter Rotor Lead, B - Main Rotor Lead, C - Red (+) Suppressor Lead, D - Black (-) Suppressor Lead
FIGURE 5: ROTATING RECTIFIER ASSEMBLY
RETURNED GOODS
TROUBLESHOOTING
Contact Marathon Electric Manufacturing Corporation for
This section is intended to suggest a systematic approach to
authorization before returning any product. We can not be
locating and correcting generator malfunctions. The section is
responsible for any items returned without authorization.
arranged according to the symptoms of the problem. The
steps have been arranged in an attempt to do the easy
checks first and prevent further damage when
troubleshooting a disabled machine.
Single bearing generators must have their rotor
The first step of troubleshooting is to gather as much
assembly properly secured to prevent damage during
information as is possible from operating personnel and
transit to the factory, or to an authorized service cen-
individuals present during the failure. Typical information
ter.
includes: how long the unit had been operating; what loads
were on line; weather conditions; protective equipment that
did or did not function. In addition, information as to the
operating condition of the generator's prime mover is vital.
Has the prime mover been maintaining constant speed? If
not, have there been extended periods of under speed
operation? Has the prime mover experienced an over-speed
condition? If yes, what was the maximum speed, and how
long did the unit operate at that elevated speed?
The generator speed should be maintained at rated

nameplate value during all operating tests. The frequency of
the generator depends upon rotational speed. Most
regulators used with MagnaPLUS® generators have built in
under frequency protection such that if the speed is reduced
more than 5%, the voltage will drop off rather rapidly with
further reductions in speed.
15
WARNING
HIGH VOLTAGES MAY BE PRESENT AT THE GENERATOR’S TERMINALS WHEN THE UNIT IS RUNNING. SOME
ACCESSORY EQUIPMENT SUCH AS SPACE HEATERS MAY BE ENERGIZED FROM AN OUTSIDE POWER SOURCE
WHEN THE UNIT IS AT REST. TOOLS, EQUIPMENT, CLOTHING AND YOUR BODY MUST BE KEPT CLEAR OF
ROTATING PARTS AND ELECTRICAL CONNECTIONS. SPECIAL PRECAUTIONS MUST BE TAKEN DURING
TROUBLESHOOTING SINCE PROTECTIVE COVERS AND SAFETY DEVICES MAY BE REMOVED OR DISABLED TO
GAIN ACCESS AND PERFORM TESTS. BE CAREFUL. SERIOUS PERSONAL INJURY OR DEATH CAN RESULT FROM
THESE HAZARDS. CONSULT QUALIFIED PERSONNEL WITH ANY QUESTIONS.
GENERATOR PRODUCES NO VOLTAGE

CAUSE CHECK AND REMEDY
Voltmeter off or defective Check voltage with a separate meter at the generator terminals.
Incorrect or defective connections Verify generator connections. See drawings supplied with the generator or lead
connection diagrams in this manual. Inspect all wiring for loose connections, open
circuits, grounds, and short circuits.
Loss of residual Flash the field. Refer to field flashing in the service section. If the generator is equipped
with a PMG, field flashing is not necessary -- check regulator fuse and input power
from the PMG.
Defective diodes, suppressor, or windings Test the generator using the 12 volt battery test as specified in the testing section. If
the results indicate generator problems, perform insulation, continuity, and diode tests
as specified in the testing section.
Regulator protection operating Adjust regulator. Consult regulator manual.
Regulator inoperative Adjust or replace regulator. Consult regulator manual.
GENERATOR PRODUCES LOW VOLTAGE, NO LOAD

Underspeed operation Check speed using a tachometer or frequency meter.
Voltmeter off or defective Check voltage with a separate meter at the generator terminals.
Incorrect or defective connections Verify generator connections. See drawings supplied with the generator or lead
connection diagrams in this manual. Inspect all wiring for grounds, open circuits and
short circuits.
Loss of regulator power Check regulator fuse and input power. Input power is produced by the generator’s
residual voltage or from an optional PMG.
Regulator adjustment Adjust regulator settings. Consult regulator manual.
Regulator incorrectly connected Review the generator connection diagram or reference the regulator manual.
Regulator inoperative Adjust or replace regulator. Consult regulator manual.
16
GENERATOR PRODUCES LOW VOLTAGE WHEN LOAD APPLIED
Excessive load Reduce load. The load on each leg should be evenly balanced, and rated current
should not be exceeded on any leg.
Large motor starting or low Motor starting currents are too large for the generator. When starting multiple motors,
load power factor sequence the motors and start the largest motors first. Reduce lagging power factor
load.
Driver speed droop or belt slip Check driver. If belt driven, check belt tension. Check under frequency setting on
regulator. Under frequency voltage roll-off may be activated.
Reactive droop If the generator is equipped for parallel operation, some droop is normal as reactive
load increases. When operating as a single unit, the parallel CT can be shorted to
eliminate this effect. Refer to Regulator manual.
Line drop If voltage is proper at generator terminals but low at load terminals, increase external
wire size.
GENERATOR PRODUCES FLUCTUATING VOLTAGE

Fluctuating engine speed Check engine and governor systems for malfunctions. Check load for fluctuation.
Regulator stability Adjust Regulator stability. Refer to Regulator manual.
Regulator external rheostat Replace defective or worn rheostat. Use shielded cable to minimize electrical noise.
Defective rectifier assembly Check assembly for loose connections. Test the diodes as specified in the test section.
Loose terminal or load connections Improve connections both mechanically and electrically.
Defective regulator Replace regulator.
GENERATOR PRODUCES HIGH VOLTAGE

Faulty metering Check voltage with separate meter at generator terminals.
Incorrect connections Verify generator connections. Refer to drawings supplied with the generator or
connection diagrams in this manual.
Regulator adjustments Adjust regulator. Consult regulator manual.
Leading power factor Check the power factor of the load. If power factor is leading, change load
configuration. Excessive leading power factor (capacitors) can cause voltage to climb
out of control.
Incorrect regulator connection Verify regulator voltage sensing is connected correctly. Consult regulator manual.
Defective regulator Replace regulator.
17
GENERATOR BUILDS VOLTAGE FROM STARTUP,
THEN GOES TO LOW (RESIDUAL) VOLTAGE
Regulator protective circuit operating Check indicators on regulator. Correct problems and adjust regulator as is required.
Refer to regulator manual.
GENERATOR IS OVERHEATING
Generator is overloaded Reduce load. Check with ammeter and compare with nameplate rating.
Clogged ventilating screens Clean air passages.
High room temperature or altitude Improve ventilation or reduce load.
Insufficient circulation of cooling air Generator location and enclosure design must provide adequate air flow and
minimize recirculation of hot air.
Unbalanced load The load on each leg should be as evenly balanced as possible and should not exceed
rated current on any one leg.
GENERATOR PRODUCES MECHANICAL NOISE

Defective bearing Replace bearing.
Loose or misaligned coupling Tighten, realign, or replace coupling.
Belt slap or loose guards Check belt tensioning. Check belt guard fasteners.
EQUIPMENT RUNS NORMALLY ON UTILITY POWER,

BUT WILL NOT RUN ON GENERATOR SET
Distorted voltage waveform Analyze load. Excessive SCR (thyristor) loading will cause distortion. Some equipment
may be sensitive to distorted waveforms. Refer to Marathon Electric..
Improper generator voltage or frequency Check name plates of devices comprising the load. Compare required voltage and
frequency with that of the generator. Adjust driver speed and/or generator voltage as
necessary to match generator output to load requirements.
Compare required voltage, frequency, and KVA with generator nameplate to ensure adequate generator capacity. If in
doubt, consult Marathon Electric for information regarding generator capacity.
18
SPECIFICATIONS
EXCITER RESISTANCE
MODEL / FRAME SIZE
STATOR ROTOR
281, 282, 283, 284, 285, 286, 287 18.0 .120
361, 362, 363 -- three phase 23.5 .120
361, 362, 363 -- dedicated single phase 23.0 .135
431, 432, 433 -- three phase 18.5 .120
431, 432 -- dedicated single phase 18.0 .105
EXCITER FIELD DEDICATED EXCITER FIELD

MODEL GENERATOR RESISTANCE NO LOAD VOLTS SINGLE GENERATOR RESISTANCE NO LOAD VOLTS
STATOR* ROTOR 480 V / 60 HZ PHASE STATOR ROTOR 480 V / 60 HZ
281PSL1500 4.20 .400 11.0 281PSL1500 4.20 .400 11.0
281PSL1501 4.15 .400 11.0 281CSL1513 0.47 0.72 4.3
281CSL1502 0.47 0.72 6.40 281PSL1511 1.420 .381 8.3
281PSL1502 3.20 .439 9.0 281PSL1512 1.106 .395 8.1
282PSL1703 1.07 0.34 14.70 281PSL1513 .632 .430 8.7
282CSL1504 1.24 0.80 6.20 282CSL1515 0.21 0.82 6.2
282PSL1704 1.07 0.34 14.70 282PSL1714 0.19 0.35 13.0
282CSL1505 0.87 0.90 5.80 282PSL1715 0.19 0.35 13.0
282PSL1705 0.74 0.37 14.35 282PSL1716 0.11 0.36 12.4
283CSL1506 0.54 1.00 8.20 283CSL1517 0.08 1.14 12.7
283PSL1706 0.45 0.40 12.95 283PSL1717 0.5 0.41 11.8
283CSL1507 0.44 1.18 9.20 283PSL1718 0.07 0.46 10.1
283PSL1707 0.39 0.46 11.20 284CSL1518 0.06 1.41 12.5
284CSL1508 0.29 1.36 10.00 284CSL1550 0.05 1.48 16
284PSL1708 0.27 0.52 14.18 284PSL1750 0.05 0.55 11.1
284CSL1542 0.27 1.36 8.30 285PSL1711 0.04 0.58 11.0
284PSL1742 0.22 0.54 14.00 286PSL1712 0.03 0.71 9.7
285PSL1700 0.20 0.58 11.90 287PSL1713 0.02 0.78 12.3
286PSL1701 0.14 0.72 10.68 361PSL1611 .070 .750 17.5
287PSL1702 0.12 0.79 10.9 361PSL1612 .043 .857 16.1
361CSL1600 .381 .750 11.8 361CSL1613 .037 .926 13.6
361CSL1601 .264 .810 12.5 362CSL1615 .019 1.20 17.0
361CSL1602 .181 .990 14.1 363CSL1617 .012 1.35 23.0
362CSL1604 .138 1.05 12.2 431PSL6222 .025 .516 9.9
362CSL1606 .098 1.20 10.8 431PSL6224 .013 .615 13.8
363CSL1607 .069 1.37 12.2 431PSL6226 .009 .643 15.1
431CSL6202 .021 .811 15.1 432PSL6228 .007 .852 11.2
431CSL6204 .048 .637 13.6
431CSL6206 .037 .679 13.82
431CSL6208 .013 .715 12.20
432PSL6210 .021 .811 15.1
432PSL6212 .023 .866 14.1
433PSL6216 .012 1.067 16.2
433PSL6220 .012 .974 15.6
* Stator resistance measured line to line in a high wye

connection.
19
PARTS LIST – SINGLE BEARING
Typical Generator Cross Section
8 9 10 11 12 13 14 15
16
7
17
5
18
20 19
Reference Part Name Reference Part Name

Number Number
1 End Bracket (under end cover 360 & 430 frames) 11 Main Stator
2 Bearing 12 Main Rotor
3 O-ring (280 and 360 frame only) 13 Rotor Integral Keyway
4 Rectifier Assembly 14 Fan
5 Air Intake Cover 15 Mounting Adapter (SAE)
6 Exciter Rotor 16 Shaft
7 Exciter Stator 17 Drive Hub
8 Link Board (terminal block) 18 Drive Disk (SAE)
9 Conduit Box 19 Exhaust Screen (drip cover not shown)
10 Generator Frame 20 Mounting Base
Note: Illustration above is a 360 frame MagnaPLUS®. Other Frame sizes are typical. Optional PMG not shown. The generator
model and serial numbers are required when ordering parts.
20
PARTS LIST – DUAL BEARING
Typical Generator Cross Section
8 9 10 11 12 13 14 15
16
7
17
5
18
20 19
Reference Part Name Reference Part Name

Number Number
1 End Bracket (under end cover 360 & 430 frames) 11 Main Stator
2 Bearing (nondrive end) 12 Main Rotor
3 O-ring (280 and 360 frame only) 13 Rotor Integral Keyway
4 Rectifier Assembly 14 Fan
5 Air Intake Cover 15 End Bracket (drive end)
6 Exciter Rotor 16 Bearing (drive end)
7 Exciter Stator 17 Shaft
8 Link Board (terminal block) 18 Key
9 Conduit Box 19 Exhaust Screen (drip cover not shown)
10 Generator Frame 20 Mounting Base
Note: Illustration above is a 360 frame MagnaPLUS®. Other Frame sizes are typical. Optional PMG not shown. The generator
model and serial numbers are required when ordering parts.
21
PARTS LIST – PMG GENERATORS
3 10
11
12 Typical 280 and 360 Frame Add-On PMG
5 6 Item Description Qty

1 PMG Stator Assembly 1
1 2 PMG Rotor Assembly 1
3 Stator Adaptor 1
2
LEADS TO 4 Shaft, PMG rotor 1
CONDUIT BOX 5 Screw, Hex Hd Flg Lock 1/4 - 20 4
7 8 6 Washer, Belleville - 1/4 4
7 Hex Hd Cap Screw, 1/2 - 13 x 4" 1
8 Washer, Belleville - 1/2 4
4 9 Roll Pin 0.25 x .88 1
10 Drip Cover - PMG Add-on 1
11 Screw, Hex Hd Flg Lock 1/4-20 4
9
12 Pushpin 4
13 14 15
Typical 430 Frame Add-On PMG

3 11
Item Description Qty
5 6
1 PMG Stator Assembly 1
2 PMG Rotor Assembly 1
1 3 Stator Adaptor 1
4 Shaft, PMG rotor 1
LEADS TO
2 CONDUIT BOX 5 Screw, Hex Hd Flg Lock 1/4 - 20 4
6 Washer, Belleville, 1/4 4
7 Hex Hd Cap Screw, 1/2 - 13 x 4" 1
7 8 8 Washer, Belleville, 1/2 1
9 Roll Pin 0.25 x .88 1
4 10 Air Intake - PMG Add-on 1
11 Screw, Hex Hd Flg Lock 1/4 - 20 4
9 12 PMG Cover 1
13 Hex Hd Cap Screw, 3/8 - 16 6
14 Washer, flat - 3/8 6
12
15 Washer, split lock - 3/8 6
10
22
23
Marathon Electric Mfg. Corp.
P.O. Box 8003
Wausau, WI 54402-8003 USA
Phone: 715.675.3359
Fax: 715.675.8026
www.marathonelectric.com
Printed in USA
SB504 05/06
5481J/10K/5-06/ML/BH
400 HERTZ SUPPLEMENT TO:
SER IOM Manual SB505 (360 Frame)

MagnaPLUS IOM Manual SB504 (430 Frames)
General Information. Marathon Electric Manufacturing Corporation's 400 Hertz line of AC

generators are synchronous, brushless, AC generators employing a 24 pole main revolving field
to produce 400 Hertz at 2000 RPM. The main stator (armature windings) are two circuit 10 lead
designs, internally connected in a Wye connection. Design output voltages are 208Y/120 volts
(Low Wye connection), and 416Y/240 volts (High Wye connection).
Applicable Service Manuals.
400 Hertz, 360 frame, generators such as catalog models 360SSL1311A, 360SSL1312A, and
360SSL1313A are essentially Marathon's type SER generators, and Service Manual SB505
(Old 3600S) applies to these generators with the few exceptions covered in this Supplement.
400 Hertz, 430 frame, generators such as catalog models 430PSL1314A , 3430PSL1312A, and
430PSL1313A are essentially Marathon's type MagnaPLUS generators, and Service Manuals
SB504 and GPN005 apply to these generators with the few exceptions covered in this
Supplement.
Operating Speed. Synchronous speed for 400 Hertz operation is 2000 RPM. All startup,
operating and running trouble shooting procedures contained in the above referenced service
manuals should be conducted at 2000 RPM. Substitute 400 Hertz, 2000 RPM for 60 Hertz,
1800 RPM, or 50 Hertz, 1500 RPM wherever these two frequencies and speeds are indicated.
Connection Diagrams. The external generator connections applicable to these generators,

regardless of frame size, are on Page 2 of this Supplement.
Automatic Voltage Regulator. The standard automatic voltage regulator furnished by

Marathon for use with our 400 Hertz generators is Basler Electric Company Model AVC63-
12B2. For parallel operation, a paralleling current transformer will be required. The connection
diagrams on Page 3 of this Supplement are typical for hook-up of the generators with the
standard Model AVC63-12B2. Should your specific unit be equipped with additional
accessories, or with an automatic voltage regulator other than the AVC63-12B2, please consult
the factory, or your supplier for the appropriate diagrams.
Technical Data. Typical technical data such as winding resistances, excitation requirements
and limited general data are contained on Page 4 of this Supplement. For rewind data, or more
in depth technical data, please consult the factory or specific generator Typical Submittal Data
Sheet.
G:\Marketing_Generators\Product Application Data - Small Generators\Lima SER - 400Hz\SB515.doc 3/1/13

Electrical Connection Diagrams
High WYE
Voltage
HZ
L-L L–N
400 416 240
Low WYE
Voltage
HZ
L-L L–N
400 208 120
400 200 115

AVR Connection Diagrams
10 Lead High (Series) WYE (Star) Connection – Ref. 14000-1196
10 Lead Low (Parallel) WYE (Star) Connection – Ref. 14000-1196

Specifications
Exciter Field Resistance Values - Ω - Nominal Cold (25°C)

Model No Load Main Main Exciter Exciter
Volts (1) Stator (2) Rotor Stator Rotor
360SSL1311 20.2 0.063 1.500 28.5 0.240
360SSL1312 23.9 0.027 2.290 28.5 0.240
360SSL1313 24.0 0.027 2.290 28.5 0.240
430PSL1314 28.5 0.015 1.250 28.5 0.110
430PSL1315 28.5 0.015 1.255 28.5 0.110
430PSL1316 28.5 0.015 1.260 28.5 0.110
432PSL1821 30.0 0.031 1.755 27.8 0.113
Notes:
1. See generator nameplate for rated full load exciter voltage
2. Main stator resistance values shown are for Low WYE (208Y) voltage connection.
For High WYE (416Y) voltage connection, multiply by 4
Phase Sequence: ABC with CCW rotation when viewed from opposite drive end.
Cooling Air Volume: 360 frame : 400 cfm 430 frame : 1200 cfm
Insulation Resistance: >1.5 Megohms
High Potential Tests:

Main Stator: 2000 volts
Main Rotor: 1500 volts
Exciter Stator: 1500 volts
Exciter Rotor: 1500 volts
Overspeed Limit: 2500 rpm

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DAVCO MODEL

NOTE: The information contained in this publication is intended

NOTE: The information contained in this document is intended to be

City: State: Zip Code:

Date of original publication: July 2009

Revision Number Date Brief Description

1 May 5, 2010 Rev. Operation Section; New Warranty

2 June, 5, 2013 Changes Chapter 4

LIST OF EFFECTIVE PAGES

INTRO- 1 Rev 1 1-1- 8 Orig

SAFETY- 1 Orig 1-4- 1 Orig

2-1- 7 Orig 4-1- 6 Orig

MANUAL TABLE OF CONTENTS

Record of Revisions ............................................................................................................... INTRO-iii

SAFETY ............................................................................................................................... SAFETY-I

CHAPTER 1: GENERAL INFORMATION AND

SECTION 2: TROUBLESHOOTING ........................................................................................ 2-2-1

SECTION 1: OVERHAUL DATA ............................................................................................... 3-1-1

CHAPTER 4: ILLUSTRATED PARTS LIST

SECTION 1: DESCRIPTION ..................................................................................................... 4-1-1

SECTION 2: ILLUSTRATED PARTS LIST ............................................................................... 4-2-1

SECTION 3: NUMERICAL INDEX ............................................................................................ 4-3-1

SECTION 4: ALPHABETICAL INDEX ....................................................................................... 4-4-1

SECTION 1: PERIODIC MAINTENANCE CHECKLIST .......................................................... 5-1-1

SECTION 2: ADDITIONAL INFORMATION & VENDOR PUBLICATIONS ............................. 5-2-1

This manual is copyrighted as an unpublished work.

This manual contains the confidential and proprietary information of TUG.

© Copyright 2010 by TUG. All rights reserved.

815 ALLGOOD RD.

If applicable, enter your company identification number

TUG Technologies Corporation

TUG Technologies Corporation

The primary goal of warranty adjustment is to satisfy our customers.

This Warranty Policy and Procedures Manual includes the warranties

Tug Technologies is responsible for handling warranty and policy

WARRANTY POLICY & COVERAGE

SERVICE RECALLS OR OWNER NOTIFICATION PROGRAMS

Total or partial warranty cancellation is registered in TUG TECHNOLOGIES records.

WARRANTY POLICY & COVERAGE

Warranty Claim Process

Contact TUG Technologies by:

To expedite the claim process please provide the following information:

AIRCRAFT GROUND SUPPORT EQUIPMENT

General Warranty Terms & Conditions

The warranty is automatically void by Tug Technologies in the following cases:

GPU Warranty Labor Flat Rate Guide

Brakes Front Axle

R&R Turn Signal Light 0.3 0.3 0.3 0.3 0.3

GPU Warranty Labor Flat Rate Guide

HOW TO USE THIS MANUAL

SAFETY NOTES THAT MUST BE FOLLOWED TO AVOID SERIOUS

SAFETY NOTES THAT NEED TO BE FOLLOWED TO PREVENT

Note Relevent information for the reader that is not hazard-related.

5. When operating in an enclosed area, pipe the exhaust fumes outside.

6. Follow the manufacturer’s recommendations to properly maintain equipment.

8. In case of accident, shut down the unit immediately.

WARNING: DO NOT ENGAGE EMERGENCY STOP FOR NORMAL

WARNING: NEVER SMOKE OR ALLOW AN OPEN FLAME WITHIN

WARNING: TO PREVENT SPARKING BETWEEN FILLER NOZZLE