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MN2037 Asp250 C3

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MN2037 Asp250 C3

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TECHNICAL MANUAL

OPERATION AND MAINTENANCE INSTRUCTIONS

TRAILER MOUNTED AIR START UNIT

(DETROIT DIESEL SERIES 60 ENGINE W/DDEC IV)

ASP250
AIR SUPERIORITY

ASP250

MAN# MN2037 NOVEMBER 1, 1999

Change 3 — October 28, 2002
TRILECTRON IND., INC.

MANUAL NO.
TECHNICAL
MANUAL

MN 2037
ASP250
TRILECTRON
IND., INC.

TRAILER MOUNTED AIR START UNIT

MANUAL

MN2037
NO.
ASP250 DETROIT DIESEL SERIES 60 ENGINE W/DDEC IV
TRILECTRON
IND., INC.

TRAILER MOUNTED AIR START UNIT

MANUAL

MN2037
NO.
ASP250 DETROIT DIESEL SERIES 60 ENGINE W/DDEC IV
TRILECTRON

TECHNICAL
IND., INC.
TRAILER MOUNTED AIR START UNIT

REMOVE

MANUAL
LIBRARY
MANUAL

DO NOT

MN2037
NO.
ASP250 DETROIT DIESEL SERIES 60 ENGINE W/ DDEC IV
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
ASP250
AIR START UNIT
RECORD OF CHANGES
This manual is published by TRILECTRON INDUSTRIES INC. Palmetto, Florida. Please log
changes to your manuals as they are inserted, indicating the date of the change and the date the
revision is inserted in the manual. If any revisions or pages are missing, contact TRILECTRON
INDUSTRIES. INC. for additional copies.

CHG ISSUE DATE CHG ISSUE DATE

BY BY
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November 1, 1999 RECORD OF CHANGES

Original Page 1
ASP250
AIR START UNIT

Page 4 Change 2
ASP250
AIR START UNIT

INTRODUCTION

This manual contains Start-up procedures, Functional Description, Operating Instructions and
Maintenance information.
The Operation Instructions are designed for new, or experienced operators, and fully describes
the Control Panel operation in a step-by-step sequence. The operator is also made aware of
normal operating indications, and indication of a defective unit.
A set-up preparation section show all necessary details on how the unit is prepared for opera-
tion, and gives a basic introduction to the control circuitry.
The Function Description and Theory of Operation fully describes the Air Start System and can
be used in conjunction with maintenance and troubleshooting procedures. Illustrations are pro-
vided to indicate various component locations in the unit.
The Maintenance portion of this manual provides a Maintenance Schedule, and a Trouble-
shooting chart to enable a quick location of defective components. Additionally provided, are
manuals for the engine, air compressor and other major components of the unit.
This manual also contains descriptions and operations for optional configurations. Refer to the
configuration placard for each delivered unit to determine actual unit configuration.

November 1, 1999 Introduction

Original Page 1
ASP250
AIR START UNIT

This page intentionally left blank.

Introduction November 1, 1999

Page 2 Original
ASP250
AIR START UNIT
EQUIPMENT WARRANTY
1. GENERAL WARRANTY
All materials, workmanship and design features of Trilectron Ground Support Equipment
(GSE), which includes Ground Power Units, Air Start Units and Air Conditioning Units
shall be guaranteed as follows:
a. For equipment shipped to destinations in the continental United States, WARRANTY
IS ONE (1) YEAR FROM THE DATE OF SHIPMENT.
b. For equipment shipped to destinations outside the continental United States, WAR-
RANTY IS ONE (1) YEAR PLUS 90 DAYS (455) DAYS FROM DATE OF SHIPMENT,
TO ALLOW FOR SHIPPING AND START UP.
c. Failure to perform Trilectron Industries recommended operation, maintenance, and
prescribed inspection procedures may void all warranties. Should investigation or
inspection reveal that the necessity for repair, replacement, etc., was caused by failure to
follow the procedures prescribed, claim will be declined.
2. COVERED PRODUCTS AND COMPONENTS
Components of manufacturers, other than Trilectron Industries, such as engines, gener-
ators, compressors, pumps, valves and other mechanical or electrical accessories, are
guaranteed only to the extent Trilectron’s warranty claim is accepted by the manufac-
turer. In no event will Trilectron Industries, extend warranty coverage beyond that
extended to Trilectron by the manufacturer.
3. REFRIGERANT CASES
Trilectron Industries, Inc., warrants that any closed refrigerant system to be leak free at
the time of unit shipment from Trilectron Industries plant.
Because Trilectron Industries, cannot control the manner in which the unit is handled
while in shipment or service, the qualifications of the operators, or the ability of people to
properly maintain the refrigerant system, the Company extends no warranty with respect
to the loss of refrigerant gases, or refrigerant oils.
4. EXCLUDED COMPONENTS
Ground hose fittings, hose adapters, air delivery hoses, cables and plugs are not
included as part of this warranty with exception that these components will comply with
all applicable specifications at the time of delivery of the unit.

October 28, 2002 Warranty

Change 3 Page 1
ASP250
AIR START UNIT

5. TERMS OF REPLACEMENT
Warranty with respect to all items, whether of Trilectron Industries or vendor manufac-
ture, is based on shipment of replacement parts ex-works with parts replaced under war-
ranty returned to Trilectron Industries.
a. This Warranty or Guarantee is expressly made in lieu of all other warranties expressed
or implied, and of all other obligations on our part and we neither assume, nor authorize
any other person to assume for us, any other liability in connection with the sale of this
equipment. Under no circumstances shall the Company be liable for the loss of profits,
or any other consequential damage.
b. If said replacement part is supplied prior to the return of the defective component, the
customer shall be invoiced for the full price of said part and appropriate credit issued
promptly upon receipt and examination of the returned part.
c. Installation or operation of this machine in any manner other than that recommended
in the instructions, or operation beyond its rated capacity will void this guarantee.

Warranty Inquires:
Customer Support Coordinator
In the USA: Telephone (877) 874-5322, FAX (877) 874-5321
Outside the USA: Telephone (941) 721-1093, FAX (941) 721-1091
E-Mail: cs@trilectron.com

d. If this unit has malfunctioned during warranty period, and the defect cannot be located
by the user, the user should contact Customer Service Department to request the follow-
ing as required:

(1.) Request for return authorization. Unit to be returned to the Company pre-
paid, and will be shipped from the Company collect.
(2.) Request field service for which travel and expenses, plus a nominal differen-
tial charge between ship and field labor rates are imposed.

Warranty October 28, 2002

Page 2 Change 3
ASP250
AIR START UNIT

LIST OF FIGURES

SUBJECT PAGE

CHAPTER 1 - GENERAL INFORMATION & OPERATING INSTRUCTIONS

SECTION 1 - DESCRIPTION
Figure 1. ASP250 Air Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Figure 2. Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Figure 3. ASP250 Overall Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure 4. Air Start Mechanical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure 5. Delivery Air System Control Components . . . . . . . . . . . . . . . . . . . . . . . .7
Figure 6. Air Start Pneumatic Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 7. GHH-RAND® CD42HS Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 8. DDEC IV System Electronic Control Module . . . . . . . . . . . . . . . . . . . . . .11
Figure 9. DDEC IV Electronic Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Figure 10. Pro-Link 9000® Engine Diagnostic Data Reader (DDR) . . . . . . . . . . . .12
Figure 11. Typical CEL Code Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
CHAPTER 1 - GENERAL INFORMATION & OPERATING INSTRUCTIONS
SECTION 2 - OPERATION 1
Figure 1. Fluid Level Checkpoints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Figure 2. Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
CHAPTER 2 - MAINTENANCE
SECTION 1- SERVICING
Figure 1. ASP250 Air Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Figure 2. Fan Hub Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Figure 3. Engine Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
CHAPTER 2 - MAINTENANCE
SECTION 2- TROUBLESHOOTING
Figure 1. Electrical Panel (DDEC IV Configuration) . . . . . . . . . . . . . . . . . . . . . . . .4
Figure 2. Typical Fault Code Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure 3. Electronic Control Module (ECM) (Left Side View) . . . . . . . . . . . . . . . . .7
Figure 4. Pro-Link 9000® Engine Diagnostic Computer/DDR . . . . . . . . . . . . . . . . .7
Figure 5. ASP250 Overall Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 6. Continuous Flow Jet Start Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 7. Air Start Unit ASP250 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 8. Continuous Flow Jet Start Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 9. Air Start Unit ASP250 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .13
CHAPTER 2 - MAINTENANCE 1
SECTION 3 - REMOVAL/INSTALLATION
Figure 1. Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Figure 2. Engine Jacking Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure 3. Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure 4. Engine/Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Figure 5. Coupler Component and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Table of Contents November 1, 1999

Page 6 Original
ASP250
AIR START UNIT

LIST OF FIGURES

SUBJECT PAGE

CHAPTER 2 - MAINTENANCE 1
SECTION 4 - ADJUSTMENTS AND TESTS
Figure 1. Delivery System Components and Controls . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2. Electrical Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3. Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 4. Delivery Air Pressure Switch (S10) Adjustment . . . . . . . . . . . . . . . . . . . 8
Figure 5. Safety Air Pressure Relief Valve (RV1) Adjustment . . . . . . . . . . . . . . . 9
CHAPTER 4 - ILLUSTRATED PARTS LIST
SECTION 3 - DETAILED PARTS LIST
Figure 1. ASP250 Top Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2. ASP250 Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 3. Chassis / Electrical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 4. Chassis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 5. Engine/Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 6. Radiator & Charge Air Cooler Piping Installation . . . . . . . . . . . . . . . . . . 27
Figure 7. Engine Air System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 8. Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 9. Maintenance Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 10. Electrical Panel Assembly (Units w/ Serial No.s Prior to 501558) . . . . . 36
Figure 11. Contactors Panel Assembly (Units w/Serial No.s Prior to 501558) . . . 41
Figure 12. Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 13. Compressor Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 14. Compressor Air SystemAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 15. Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 16. Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 17. Air Start Coils Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 18. Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 19. Piping, Hose, and Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 20. Air Delivery Pipe w/Valves Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 21. Transducer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 22. Terminal Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 23. Battery and Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 24. Acoustical Dampener Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 25. Trailer 5th Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 26. Front Axle Assembly - Standard Configuration . . . . . . . . . . . . . . . . . . . 73
Figure 27. Front Axle - With Brake Option (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . 75
Figure 28. Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 29. Cross Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 30. Hand Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 31. Air Start Hose With Scuffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 32. Remote Compressor Oil Drain Assembly . . . . . . . . . . . . . . . . . . . . . . 85

November 1, 1999 Table of Contents

Original Page 7
ASP250
AIR START UNIT

LIST OF FIGURES

SECTION 4 - SHIPPING AND RECEIVING
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. PREPARATION FOR SHIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3. RECEIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

CHAPTER 1 - GENERAL INFORMATION & OPERATING INSTRUCTIONS

SECTION 5 - STORAGE
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. PREPARATION FOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
A. Short Term Storage (less than 3 months) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
B. Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
C. Returning to Service: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

CHAPTER 2 - MAINTENANCE
SECTION 1 - SERVICING
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. CONSUMABLE SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3. LUBRICATION INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
A. Fan Hub Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
B. Engine Oil Change Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
C. Arctic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4. COOLANT SPECIFICATIONS & RECOMMENDATIONS. . . . . . . . . . . . . . . . . . . .5
A. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
B. Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
C. Concentration Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
D. Coolant Change Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
5. FUEL RECOMMENDATIONS/SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . .6

SECTION 2 - NUMERICAL INDEX

CHAPTER 4 - ILLUSTRATED PARTS LIST

SECTION 3 - DETAILED PARTS LIST
1. EXPLANATION OF COLUMNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
A. Figure/Item Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
B. TI Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
C. Vendor Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
D. FVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
E. Airline Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
F. Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
G. Units Per Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. INSTRUCTIONS FOR ORDERING PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

CHAPTER 5 - MANUFACTURER'S APPENDICES

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

November 1, 1999 Table of Contents

Original Page 5
ASP250
AIR START UNIT

Table of Contents November 1, 1999

Page 6 Original
ASP250
AIR START UNIT

CHAPTER 1
GENERAL INFORMATION & OPERATING INSTRUCTIONS
SECTION 1
DESCRIPTION
1. GENERAL
The ASP250 is a self-contained, trailer mounted, aircraft jet engine air start unit (see figure 1).
The unit is capable of providing a continuous supply of jet engine start air up to 250 lbs/min
nominal at a pressure of 40 psig when operating in the JET START mode. The unit will also sup-
ply 30 psig air flow for the AIR COND (AIR CONDition) operating mode (or Pneumatic AIR
CONDition, PAC). This setting may be set as high up to 40 psig if desired. Engine speed, moni-
toring, and safety circuitry operation are different for the two modes of operation. In both modes,
excess air is eliminated through a combination of automatic engine speed control based on
bypass air flow and an automatic bypass.
The unit utilizes a steel channel frame and base, sheet metal enclosure with hinged latching
doors and access panels. An illuminated control panel is mounted behind a weather/dust proof
see-through panel (see figure 2). Service hose storage is provided by a full width, frame
mounted tray basket located at the rear of the unit.

ASP250

Figure 1. ASP250 Air Start Unit

The standard unit assembly is mounted on a fifth wheel trailer assembly with the rear axle fitted
with drum type brakes, actuated by an Orschelin® type lever mounted at the front of the unit.
(As an option, the front axle may be equipped with a similar drum type brake system.)
The compressor (see figure 7) is driven by a Detroit Diesel® Electronically Controlled Series 60
engine (DDEC IV). The DDEC IV system offers advantages over conventional mechanically
speed governed engines. The DDEC IV system optimizes control of critical engine functions
which affect fuel economy, smoke, and emissions.The DDEC IV system provides the capability
to protect the engine from serious damage resulting from conditions such as high engine tem-

August 30, 2000 1-1

Change 1 Page 1
ASP250
AIR START UNIT

peratures or low oil pressure.The major subsystems of the DDEC IV system include: the elec-
tronic control module (ECM), electronic unit injectors (EUI), and engine sensors. Real time data
is exchanged between the engine and ECM via the SAE J1708 bus.
System bus voltage is provided by the engine driven self-excited automotive type alternator.
The alternator outputs 24 VDC to control circuitry and storage batteries. The engine is cranked
by an electric starter motor. The starter motor is energized by a start signal from the engine con-
trol circuitry.
The Detroit Diesel® engine is electronically controlled by the electronic control module
(ECM).The system optimizes control of critical engine functions which affect fuel economy,
smoke, emissions and speed.The ECM provides the capability to protect the engine from seri-
ous damage resulting from conditions such as high engine temperatures or low oil pressure.
The ECM receives electronic inputs from sensors on the engine and uses the information to
control engine operation by computing fuel injection timing and fuel quantity based upon cali-
bration tables stored in its electronically erasable programmable read only memory (EEPROM).
The ECM outputs diagnostic signals at two priority levels. Level II diagnostic signals can only be
read using the microprocessor based Digital Data Reader (DDR). These faults are date
stamped and can only be reset using the DDR. Level I diagnostic signals are generally of a
more immediate nature and are indicated by the presence of the Stop Engine Light (SEL) or
Check Engine Light (CEL) signals. The ECM is configured for 24 volt operation.
The GHH-RAND® compressor is a screw-type compressor providing continuous air flow, with
fewer moving parts and no inlet or outlet valves, requiring less maintenance, having a much
lower failure rate, and greatly reduced vibration, all of which are shortcomings normally associ-
ated with piston-type compressors.
Air compression in the GHH-RAND® compressor is accomplished by two interlocking lobed
rotors, each rotating toward the other. A small gap is maintained between the lobes of the rotors
through the function of the unit’s timing gears. This controlled spacing increases efficiency while
reducing wear and friction generated heat. The compression chamber is isolated from the gear-
ing and other oil lubricated components by a vented air chamber, eliminating the possibility of oil
vapor contamination of the compressed air output.
A balanced diaphragm Air Bypass Valve Assembly (Leslie® Valve) (see figures 3 and 5) is used
to maintain the desired output pressure. The set point pressure and the output pressure are
applied to opposite sides of a flexible stainless steel diaphragm. The diaphragm deflects air
away from the higher pressure air proportional to the pressure difference. A shaft is connected
to the diaphragm to open and close a bleed valve. If the output pressure is higher than the set
point, the valve opens more and allows more air to bleed into the air bypass exhaust piping (air
bypass dump); this lowers the output pressure back to the set point. If the output pressure is too
low, the set point pressure pushes the diaphragm in the other direction and closes the valve
proportionally (less air is bled), which brings the output pressure to the set point.

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Two separate pressure regulators provide the control reference air pressure used as the set
point for the air bypass valve. Regulator No. 2 is for AirCOND (PAC or Pneumatic AirCOND)
mode and Regulator No. 1 is for the JET START mode. Each regulator has a preset setting that
may be adjusted in the field as required. The settings are 40 psig for JET START mode and 25-
40 psig for AirCOND (PAC). The unit is factory set at 25 psig for AirCOND (PAC).
An engine speed interconnect is incorporated in the air bypass valve system. When excess air
pressure is being bled, the volume of the flow is sensed by the bypass air flow transmitter (PFT)
via two delivery air manifold mounted pilot tubes. The current signal output of the PTF is routed
to the Demand Variable Speed Governor Control (VSG) circuit card assembly A5 where it is
processed. The processed engine speed signal is routed from the VSG circuit card assembly
A5 pin 14 to the DDEC Electronic Control Module (ECM J2-D1) as 0.7-4.5 volt power takeoff
speed adjust (PTOSA) signal. The PTOSA signals the governor to reduce engine speed propor-
tionately. When greater demand is sensed by the reduction of bleed air, the governor system is
signaled to increase engine speed to meet the new demand. This feature provides a significant
reduction in engine wear, fuel consumption, and increases operational unit life, particularly dur-
ing periods of unit standby when it is in the AIR START or AIR CONDition mode, but output has
not yet been selected by the operator or serviced aircraft.
The engine speed interconnect and air bypass valve assembly system also function in conjunc-
tion with delivery air over pressure switch (S10), normally set at 45 psig. During the air start
function, once aircraft engine start has occurred and aircraft valves are suddenly closed, a rapid
rise in air pressure is felt within the unit. As the unit internal pressure rises above this 45 psig
level, the delivery air over pressure switch (S10) activates, in turn activating the air unload sole-
noid valve (ULSOV) (AS3) which functions to drive the low pressure side of the air bypass valve
to the full open position, dumping excess pressure. This opening of the air bypass dump valve
also signals the governor system to decrease engine speed, both the bypass valve and engine
speed then function to again stabilize the system output at the desired pressure.
Safety pressure relief valve (RV1) is utilized in the event of control system failure. Should unit
pressure reach 50 psig, a high volume dumping valve plug within the RV1 is unseated and held
open until unit pressure falls below the 50 psig level, at which time it will re-seat. Operation of
this valve is a rare occurrence and is designed primarily as a fail-safe air pressure dump safety
device.
Output air gauges are provided to allow the operator and maintenance personnel to monitor unit
output air pressure and temperature. A manual ball valve controls the unit output and has a
built-in safety feature. When the valve is in the closed position it vents air pressure between the
output hose and the valve. The hose will deflate when the valve is in the closed position, allow-
ing safe operator disconnect from the aircraft.

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Figure 10. Pro-Link 9000® Engine Diagnostic Data Reader (DDR)

(2) Engine Troubleshooting

Engine troubleshooting is performed using the hand held external Diagnostic
Data Reader (DDR) (see figure 10). The ECM’s built-in-test (BIT) feature utilizes
an electronically erasable programmable read only memory (EEPROM) chip.
The EEPROM chip controls basic engine functions, such as rated speed and
power, timing of fuel injection, engine governing, torque shaping cold start logic,
transient fuel delivery, diagnostics and engine protection. Refer to the Detroit
Diesel® Troubleshooting Guide-DDEC IV, for specific information regarding
troubleshooting the ECM.
(3) Engine Diagnostic Functions (see figure 9)
Whenever the FAULT MODE CHECK ENGINE light (CEL) or the FAULT MODE
STOP ENGINE light (SEL) come on, the ECM computer will determine where
the problem is, and will then store this information in its memory. If the malfunc-
tion is intermittent, the lights will come on and go off as the computer senses the
changing engine condition. The CEL will flash stored fault codes when com-
manded by holding the Engine Fault Status Read Switch (DS18), located on

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AIR START UNIT

electrical panel, to down (read). Once a malfunction has been corrected, the
ECM will return the engine to normal operation. However the malfunction code
recorded in the ECM computer memory will remain until erased by a technician
using the DDR. Engine malfunction codes stored in the ECM memory may be
recalled and displayed by means of the DDR or DS18 switch.
(4) Diagnostic Data Reader (Figure 10)
The Diagnostic Data Reader (DDR) is a microprocessor-based test instrument
(Pro-Link 9000®) designed to tap into the ECM computer. It is programmed to
interpret computer signals and provide readouts the technician can use for diag-
nosis. The technician has instant access to any of the engines operating data. A
six-pin DDR receptacle (see figure 9) is mounted in the Electrical Panel Assem-
bly for connection of the DDR data link.
(5) Engine Speed Control
The engine operating speed, as part of its on-board computer system, is auto-
matically governed to precisely maintain programmed engine speeds. An inte-
gral magnetic sensor monitors engine speed and provides this data to the ECM
for control. Constant speed is maintained by regulating engine fuel and operat-
ing parameters. The idle (UNLOADED) speed is factory set by the ECM’s inter-
nal program.
(6) Engine Fault Status Switch (see figure 11)
NOTE
The safety fault circuits react differently between the two modes of
operation. When in the AIR CONDition mode, a compressor or engine
fault will cause the unit to immediately shutdown. When in the JET
START mode, faults will illuminate a warning light only and WILL NOT
shut down the unit.

A series of diagnostic codes flash on the ENGINE FAULT MODE CEL indicator
light. CEL stands for Check Engine Light. The flashes correspond to individual
error codes which identify the engine system reporting an error. To read stored
engine malfunction codes, the unit is shut-down with the ENGINE ON/OFF
switch in the OFF position, then turned ON without the engine running. Switch
DS18 (Fault Engine Status switch), located on the Electrical Panel, is placed in
the down position (read). When DS18 is held in the down position, the CEL will
flash stored diagnostic codes. A table providing an explanation and listing of the
CEL codes is located in the troubleshooting section, Chapter 2, Section 2.
DDEC IV detected engine fault conditions will not shut-down the engine. The Tri-
lectron fault system will shut down the engine only in AIR CONDition and
UNLOADED modes. The DDEC IV system only monitors the engine, stores fault
information, and flashes warnings and alerts on the CEL and SEL warning lights
to alert the operator that a fault exists. When safe to do so, the engine should
then be shut-down, and the fault corrected.

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Figure 11. Typical CEL Code Response

D. Air Start Compressor Assembly
The Air Start Compressor Assembly CD42HS is a dry screw compressor producing 250
lbs/min air flow, with a maximum pressure of 40 psig. The “dry” designation refers to the
total absence of oil vapor or residue in the compression of atmospheric air. The compres-
sor utilizes an air-cooled jacket rather than water cooling. The compressor stage is
flanged to the step-up gear. Sealing systems on the air side and oil side of the shaft are
separated by a connection to the atmosphere.
This screw-type compressor operates on the positive displacement principle in the same
way as reciprocating compressors. Screw-type compressors do not require inlet or outlet
valves which allow uninterrupted air flow. Since there are no valves, and no component
contact inside the compression camber, component wear is minimal.
(1) Compressor Oil System (see figure 4)
The compressor gear unit oil pump is flanged to the gear casing on the com-
pressor side and is powered by the drive shaft. The oil tank is attached to the
gear casing with a sight gauge for checking oil level. The oil tank is provided with
a connection for the installation of an oil heater for cold weather operation.
Lubricating oil is taken from the oil tank by the pump, through a suction strainer.
An oil pressure relief valve (open at 43.5 psi) routes excess oil back to the oil
tank. From the pump, the oil passes through the oil cooler (mounted with the
engine radiator), cooled to an inlet temperature of 149-194° F (65-90°C). A tem-
perature switch will shut down the system when oil temperature exceeds 195° F
(90°C), unless the unit is in JET START mode. From the cooler, the oil passes
through a filter to the gear unit, suction-side compressor bearing assembly, and
the discharge-side compressor bearing assembly, and then returns to the tank.

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(2) Compressor Monitoring, Safety, and Control System

• Delivery Air Pressure Switch S10: Should the adjusted maximum delivery air
pressure level (45 psig) be exceeded in the AIR CONDition mode the unit will
automatically shut down. In the JET START mode, shutdown will occur only
when the system leaves the JET START mode, unless the J/S safety bypass
jumper is removed (See figure 1, Sect. 2-2 -TROUBLESHOOTING).
• Delivery Air Temperature Switch S9: If the adjusted maximum discharge air
temperature exceeds 500°F (260°C), in the AIR CONDition mode, the unit will
automatically shut down. In the JET START mode, the COMPRESSOR FAULT
MODE HIGH AIR TEMP fault light will illuminate and shutdown will occur only
when the system leaves the JET START mode, unless the J/S safety bypass
jumper is removed (See figure 1, Sect. 2-2 -TROUBLESHOOTING).
• Oil Pressure Switch S7: If an oil pressure of 4.5 psig (.3 bar) is not built up
within 10 seconds after start-up, or should drop below 4.5 psig (.3 bar) during
operation, in the AIR CONDition mode the unit will automatically shut down. In
the JET START mode, the COMPRESSOR FAULT MODE LOW OIL PRESS
fault light will illuminate and shutdown will occur when the system leaves the
JET START mode, unless the J/S safety bypass jumper is removed (See fig-
ure 1, Sect. 2-2 -TROUBLESHOOTING).
• Oil Temperature Switch S8: If the oil temperature exceeds 195°F (90.6°C), in
the AIR CONDition mode the unit will automatically shut down. In the JET
START mode the COMPRESSOR FAULT MODE LOW OIL PRESS fault light
will illuminate and shutdown will occur once the system leaves the JET START
mode, unless the J/S safety bypass jumper is removed (See figure 1, Sect. 2-2
-TROUBLESHOOTING).
*For more detailed information on compressor function, refer to Chapter 5 for
the manufacturer's reference material.
3. OPERATIONAL DESCRIPTION
A. Air Flow (See figure 3)
With the engine running at operational speed, air is drawn into the compressor through
the air inlet filter/silencer, where dust and foreign matter are removed and the air inlet
noise is reduced.
Two rotors inside the screw compressor casing rotate in opposite directions with a pre-
cise clearance maintained and controlled by timing gears arranged outside the compres-
sion chamber. As these rotors are rotating, the volume of the interlobal space is
continuously increased from zero to its maximum value. This increase in volume causes
air to be sucked in until the rotor lobes pass over the inlet, closing the opening. As rota-
tion continues, the volume is reduced compressing the air and forcing it out the dis-
charge nozzle.
The compressed air leaves the compressor and enters the delivery air piping. An Air
Bypass Valve Assembly will maintain desired output pressure by venting the excess to
the atmosphere.

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A reference pressure is taken from the delivery air piping through a check valve, to an
accumulator. This air pressure is used and pressure controlled by the Air Pressure Reg-
ulator Assembly to provide reference control pressure to the Air Bypass Valve.
The Air Bypass Valve operates on the principle of balanced pressure on a stainless steel
diaphragm to either open or close the valve. A controlled pressure is supplied from the
regulator valves to a control pressure input on the bypass valve that is used to maintain
the desired pressure. A reference pressure from the delivery air piping enters on the
bypass valve on other side of the diaphragm, when the pressure from this is greater than
the pressure on the controlled side the bypass valve allows air to be vented to the atmo-
sphere. A differential pressure transmitter is constantly monitoring the amount of air flow
being vented. When a flow is detected, a variable output is sent to the engine speed con-
trol to ramp down the engine speed in direct relation to how much air is being vented to
the atmosphere.
When aircraft requirements call for more or less air flow, the line pressure will drop or rise
respectively, unbalancing the forces on the diaphragm. The valve will open or close until
a new balance is achieved. Excess air capacity is vented to the atmosphere. In cases
when the aircraft engines have started and it’s valves have shut quickly, a transient pres-
sure buildup is possible within the air start system. For controlling momentary buildups, a
safety pressure relief valve will vent these transient high pressure surges. In case of a
control system failure a pressure safety valve will purge to atmosphere should the line
pressure exceed 50 psi.
NOTE
The safety fault circuits react differently between the two modes of
operation. When in the AIR CONDition mode, a compressor or engine
fault will cause the unit to immediately shutdown. When in the JET
START mode faults will illuminate a warning light only, unless the
safety J/S jumper is removed (See figure 1, Sect. 2-2 -TROUBLE-
SHOOTING).
4. ELECTRICAL SYSTEM OPERATION
A. Unit Start (Units with Serial #s prior to 501558) (See Section 2-2, Electrical Sche-
matic Diagram)
With the ENGINE ON/OFF control power switch (S2) in the ON position (POWER ON
lamp DS1 illuminated) and the MODE SELECTOR switch (S1) is in the UNLOADED
(idle) position, the unit is ready to start. When the ENGINE START push-button switch
(S3) is pressed, power from the storage batteries (B1-B4) is provided to the start circuit
through Circuit Breaker 1 (CB1) to the Starter Contactor (K1). Contacts in the MODE
SELECTOR switch (S1) which are in the start circuit prevent the unit being started unless
the selector switch is in the UNLOADED (idle) position.
Should the fuel level in the tank be low, the Low Fuel Warning Switch (S6A) will be
closed, energizing the Low Fuel Warning Relay (K3), and the roof top mounted low fuel
warning beacon (Optional) (DS10) will be illuminated. Should the fuel level be at or below
the critical level, as soon as Time Delay Relay 1 (TD1) activates, Fuel Low Level Switch

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S6B will close to energize low fuel shutdown relay (K9). K9's contacts 5 and 6 opens to
provide a “drop out” fault signal to master fault relay (K2).
K2 contacts 7 and 4 open removing +24 VDC from Ignition input at Electronic Governor
A2, pin 1. Loss of Ignition +24 VDC at A2 will shut the unit down.
Power is also applied at this time through the ENGINE ON/OFF control power switch
(S2):
• to the Compressor Low Oil Level Relay (K6) through the closed contacts of the Com-
pressor OIL Level Switch (COLSW) S11, assuming the compressor oil level is cor-
rect.
• energizes the Master Fault Relay (K2), whose closed contacts 4 & 7 maintain power
to the Electronic Governor (A2) run circuit.
• to Time Delay Relay 1, which energizes until after a 30 second delay. TD1 delay locks
in (contacts 5 & 6) the Fault Monitoring PCB (A1) after the unit has started and had
sufficient time to stabilize at idle speed.
• to Time Delay Relay 2, whose normally open contacts close and will remain closed
for a period of 90 seconds after power is removed from TD2. The closed contacts of
TD2 in the primary power circuit of the engine control ensures that a 90 second
engine cool-down idle period will occur whenever an operator shuts the engine down.
B. Unit Start (Units with Serial #s 501558 and Subsequent) (See Section 2-2, Electrical
Schematic Diagram)
With the ENGINE ON/OFF control power switch (S2) in the ON position (POWER ON
lamp DS1 illuminated) and the MODE SELECTOR switch (S1) is in the UNLOADED
(idle) position, the unit is ready to start. When the ENGINE START push-button switch
(S3) is pressed, power from the storage batteries (B1-B4) is provided to the start circuit
through Circuit Breaker 1 (CB1) to an AUTO START TIMER (TD3). When energized, the
TD3 coil closes a contact to the Starter Contactor (K1) for 5-6 seconds. This time delay-
allows sufficient starter engagement time to accomodate lower-energy avaition fuels.
The Electronic Control Module (ECM) senses engine speed (RPM) to ensure engine
start. When sufficient engine speed is attained (approximately 500 rpm), the ECM ener-
gizes the STARTER LOCKOUT RELAY (K16) to prevent excessive engine starter
engagement. The K16 relay will reset once engine low speed (less than 50 rpm) is
detected and will allow additional engine start attempts. Contacts in the MODE SELEC-
TOR switch (S1) which are in the start circuit prevent the unit being started unless the
selector switch is in the UNLOADED (idle) position.
Should the fuel level in the tank be low, the Low Fuel Warning Switch (S6A) will be
closed, energizing the Low Fuel Warning Relay (K3), and the roof top mounted low fuel
warning beacon (Optional) (DS10) will be illuminated. Should the fuel level be at or below
the critical level, as soon as Time Delay Relay 1 (TD1) activates, Fuel Low Level Switch
S6B will close to energize low fuel shutdown relay (K9). K9's contacts 5 and 6 opens to
provide a “drop out” fault signal to master fault relay (K2).
K2 contacts 7 and 4 open removing +24 VDC from Ignition input at Electronic Governor
A2, pin 1. Loss of Ignition +24 VDC at A2 will shut the unit down.

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Power is also applied at this time through the ENGINE ON/OFF control power switch
(S2):
• to the Compressor Low Oil Level Relay (K6) through the closed contacts of the Com-
pressor OIL Level Switch (COLSW) S11, assuming the compressor oil level is cor-
rect.
• energizes the Master Fault Relay (K2), whose closed contacts 4 & 7 maintain power
to the Electronic Governor (A2) run circuit.
• to Time Delay Relay 1, which energizes until after a 30 second delay. TD1 delay locks
in (contacts 5 & 6) the Fault Monitoring PCB (A1) after the unit has started and had
sufficient time to stabilize at idle speed.
• to Time Delay Relay 2, whose normally open contacts close and will remain closed
for a period of 90 seconds after power is removed from TD2. The closed contacts of
TD2 in the primary power circuit of the engine control ensures that a 90 second
engine cool-down idle period will occur whenever an operator shuts the engine down.
C. Unit Running - Standby (Unloaded) Mode (See Section 2-2, Electrical Schematic
Diagram)
With the unit started and running in the UNLOADED Mode (idle), once TD1 has timed-
out and energized:
• contacts TD1/ 1 & 4 open approximately 30 seconds after control power is applied,
opening the start circuit to prevent the starter being engaged while the engine is run-
ning. Should the engine shut down, restart it by setting the ENGINE ON/OFF control
power switch (S2) to OFF, then back to ON, to clear and reset TD1.
• contacts TD1/8 & 6 close, applying power to the HOUR METER (which records
engine run time).
• with contacts TD1/6 & 8 closed and power applied to the Fault Monitor PCB (A1), the
fault monitoring circuits are now active:
• Should engine oil pressure be below 15 psig, the Engine Oil Pressure Switch
(EOP) (S4) will close, energizing the Engine Oil Pressure Fault Relay (K4),
which will cause the Low Engine Oil Pressure warning light (DS11) to illumi-
nate, the Master Fault Relay (K2) to de-energize removing power to electronic
governor A2, and the unit will shut down.
• Should engine water temperature be above 225°F (107°C), the Water Tem-
perature Switch (S5) will close, energizing the Engine Water Temperature
Fault Relay (K5), which will cause the High Engine Water Temperature warn-
ing light (DS12) to illuminate, the Master Fault Relay (K2) to de-energize
removing power to the electronic governor A2, and the unit will shut down.
• Should the compressor oil level drop below the minimum level, the Compres-
sor Low Oil Level Switch (COLSW) S11 will close, energizing the Low Com-
pressor Oil Level Fault Relay (K6), which will cause the Low Compressor Oil
Level warning light (DS17) to illuminate, the Master Fault Relay (K2) to de-
energize removing power to the electronic governor A2, and the unit will shut
down.

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• Since the compressor is coupled directly to the engine and is operating when-
ever the engine is running, the compressor oil pressure should now be at its
operating level of 20 psig minimum. Should the compressor oil pressure be
below 20 psig, the Compressor Low Oil Pressure Switch (S7) will close, ener-
gizing the Compressor Low Oil Pressure Fault Relay (K7), which will cause the
Compressor Low Oil Pressure warning light (DS14) to illuminate, the Master
Fault Relay (K2) to de-energize removing power to the electronic governor,
and the unit will shut down.
• The Engine Over-Speed fault (AIR CONDition mode only) is independent of
the Fault Monitor PCB (A1) except for fault light operation (DS13). Should an
over-speed condition occur, it will be sensed by the Over-Speed Switch (A3),
which will apply power to the Over-Speed Contactor (K8). The Over-Speed
Contactor (K8) will de-energize, opening contacts 5 and 6, which causes Mas-
ter Fault Relay K2 to de-energize removing power from the Electronic Gover-
nor (A2) and shuts-down the engine. K8 contacts 8 and 9 will also cause the
engine over-speed warning light (DS13) to illuminate.
D. Unit Running - AIR CONDition Mode (See Section 2-2, Electrical Schematic Dia-
gram)
With the unit running in the UNLOADED (Idle) mode, and the MODE SELECTOR switch
(S1) set to the AIR CONDition, the following occurs:
• S1-F - Closed S1 Contacts “F” signals the Demand VSG Circuit Card Assembly
(CCA) A5, to set the engine maximum speed to approximately 1500 rpm. CCA A5
adjusts the actual engine speed according to the amount of air being dumped out the
Bypass Air Valve. The Bypass Air Flow Transmitter (PTF), senses the flow of air out
the valve and converts the flow to a 4-20 mA electrical current signal. The Demand
VSG CCA A5 detects the current signal and increases or decreases the engine
speed to maintain proper airflow in the Bypass Air Valve. During full bypass (outlet
ball valve(s) closed) the engine speed should be reduced to approximately 1300 rpm
by the demand system. Lower speeds are used to: decrease engine fuel consump-
tion, decrease engine wear and increase life, and to abate noise.
• S1-E - Open contacts “E” inhibits unload air bypass dump relay K13 and AS3 from
dumping (blow-off) of air at the Air Bypass Valve Assembly.
• S1-D - Closed contacts “D” energize the AIR COND Air Solenoid Valve (AS2) open
through the normally closed contacts of the Delivery Air Over Pressure Switch (S10).
If the delivered air pressure rises above a preset level, the Delivery Air Over Pressure
Switch will switch and the following sequence of events will occur: 1) Air Delivery
Solenoid AS2 is de-energized, 2) the Unload Air Solenoid AS3 is energized, 3) the
Bypass Air Set Point Pressure is vented, and 4) the Bypass Air Valve opens immedi-
ately to relieve the excess pressure. When the pressure is relieved the Delivery Air
Over Pressure Switch S10 returns to its normal position and normal operation is rees-
tablished.

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AIR START UNIT

All Fault Monitor circuits are operational in the AIR CONDition (PAC) mode. Should any
of the following conditions occur, the unit will shut down:
• Engine oil pressure fall to 15 psig or lower.
• Engine water temperature rise to 225°F(107°C) or higher.
• A low compressor oil level condition occur.
• Compressor oil pressure fall to 4.5 psig (.3 bar) or lower.
• Engine over-speed, if engine speed should exceed 2450 rpm.
• Fuel level falls to or below the critical level.
• Output air temperature exceeds 500°F(260°C).
• Compressor oil temperature exceeds 195°F(90°C).
E. Unit Running - JET START Mode (See Section 2-2, Electrical Schematic Diagram)
With the unit running in the Unloaded (Idle) mode or the AIR CONDition mode and the
Mode Selector Switch (S1) is moved to the JET START position, the following occurs:
• S1-B - Closed S1 Contacts “B” signals the Demand VSG Circuit Card Assembly
(CCA) A5, to set the engine maximum speed to approximately 2300 rpm (full rated
engine speed). CCA A5 adjusts the actual engine speed according to the amount of
air being dumped out the Bypass Air Valve Assembly. The Bypass Air Flow Transmit-
ter (PTF) senses the flow of air out the valve and converts the flow to a 4-20 mA elec-
trical current signal. The Demand VSG CCA A5 detects the current signal and
increases or decreases the engine speed to maintain proper airflow in the Bypass Air
Valve. During full by pass (outlet ball valve(s) closed) the engine speed should be
reduced to approximately 1800 rpm by the demand system. Lower speeds are used
to: decrease engine fuel consumption, decrease engine wear and increase life, and
to abate noise. During jet engine spool, Bypass Air Flow is set to zero and the engine
runs at full rated speed (2300 rpm).
• S1-A - Open contacts “A” inhibits unload air bypass dump relay K13 and AS3 from
dumping (blow-off) of air at the Air Bypass Valve Assembly.
• S1-D - Open contacts “D” inhibits the AIR CONDition Delivery Solenoid (AS2) and
closes the AIR CONDition Delivery valve (AS2).
• S1-C - Closed contacts “C” energizes Jet Start Solenoid Valve (AS1) open through
the normally closed contacts of the Delivery Air Over Pressure Switch (S10). If the
delivered air pressure rises above a preset level, the Delivery Air Over Pressure
Switch will switch and the following sequence of events will occur:
(1) AS2 is de-energized,
(2) Air Unload Solenoid AS3 is energized,
(3) the Bypass Air Set Point Pressure is vented,
(4) the Bypass Air Valve opens immediately to relieve the excess pressure. When
the pressure is relieved the Delivery Air Over Pressure Switch (S10) returns to
its normal position and normal operation is reestablished.
• When the air delivery valves are opened to supply start air flow to the aircraft, engine
speed will increase and will be dependent on delivered air pressure, maintaining the

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AIR START UNIT

proper preset delivery pressure.

• In the normal factory configuration, sensed fault shutdown logic will cause a unit shut-
down in all modes except JET START. In the JET START mode, sensed faults will
light the appropriate warning indicator, but shutdown will not occur until the compres-
sor MODE SELECTOR switch is set to UNLOADED or AIR COND.
• Bypassing JET START mode fault logic shutdown inhibit is available as a user option.
Selecting this option will shut down the unit in JET START mode only when a fault is
present and engine speed exceeds 2000 rpm. This option can be engaged by discon-
necting the safety bypass jumper from electrical panel TB1-5 to TB2-18 (wire# 241)
(see figure 1, -Troubleshooting). The LED on A5 will illuminate above 14
• 0 rpm when safeties are disengaged.

NOTE
Unit automatic shutdown due to equipment faults is disabled in
the JET START mode. Due to potentially severe problems
which could occur to the jet engine/aircraft should the unit fail
during the JET START procedure, the unit will function to
destruction rather than remove start air from the aircraft,
unless the bypass jumper is removed (See figure 1, Sect. 2-2 -
TROUBLESHOOTING).

F. Fuel Filter/Heater Operation - Fuel Pro® 382 (Optional)

The Fuel Pro® 382 Diesel fuel filter system consists of a permanently mounted fuel pro-
cessor (primary fuel filter), a replaceable 5-micron filter element (secondary filter), a
removable filter element cover and collar mounting bracket with clamps, 24VDC/250W
fuel heater, primary heat source flow thermostat, and a wiring harness. The system is
installed between the fuel tank and fuel pump.
When the engine is running, the engine fuel pump draws fuel through the fuel processor.
Fuel within the filter is temperature sensed by the fuel processor’s thermostat. Fuel at
temperatures below 35oF (2oC) causes the sensing thermostat to close and energize
internal 24 VDC/250W fuel heater element (FFHTR). Operating current for FFHTR is
provided by the closure of fuel heater relay (K14) contacts which are series wired with
Filter Heater 20A circuit breaker (CB5). The Fuel Pro®382 uses engine heated fuel,
pumped through the processor by the engine fuel pump, as primary heat source. When
filtered fuel temperature reaches 75o F (24o C), the internal fuel processor’s thermostat
closes to stop primary heat source flow and hold filtered fuel temperature at a constant
75o F (24oC). Once the engine is warmed up and fuel temperatures are above 35o F
(2o C), FFHTR is inhibited.

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G. Miscellaneous Circuit Operation

(1) Low Fuel Warning Beacon (Optional)
The optional roof mounted beacon located on the canopy roof illuminates when-
ever fuel in the unit fuel tank reaches the preset low warning level. The unit will
continue to operate with the warning light illuminated until the fuel level reaches
the preset automatic shutdown level. At this lower limit, the unit is automatically
shut down (except in the JET START mode) to prevent engine starvation. A low
fuel warning light (optional) may also be mounted on the control panel for ease
of view by the operator.
(2) Panel Lights
Illumination panel lights are mounted over the control panel for night time opera-
tion. They are controlled by control panel mounted PANEL LIGHTS ON/OFF
toggle switch.
(3) Fault Light Test Circuit
Lamp operation for the system fault indicators is checked by activation of the
Fault Light Test Switch (S12) located on the electrical panel assembly (See fig-
ure 1, Sect. 2-2 -TROUBLESHOOTING). This momentary contact switch will
cause all seven fault lamps to illuminate.
(4) Clearance Lights (Optional)
Four clearance lights (ds23-DS26) are mounted one at each corner of the unit
and are energized via the 24 VDC system voltage whenever unit system power
is applied.
(5) Anti-Collision Beacon (Optional)
An anti-collision beacon is roof mounted. The beacon is energized via the 24
VDC system power whenever unit system power is applied.
(6) Low Coolant Shutdown (Optional)
The low coolant level circuit operates in parallel with high coolant temperature
circuits. Either fault condition will cause the engine FAULT MODE HIGH TEMP
indicator light to illuminate. Engine Coolant Level Sensor (CLS) S20 generates a
Coolant Level low ground signal at Terminal Board (TB3-11) when coolant level
drops below its design level. This low level signal is routed to the DDEC ECM at
J2-H3 and to Low Coolant Relay Driver Board A6. The DDEC processes this
signal as a Check Engine Light (CEL) fault (CEL fault #43) causing the CHECK
ENGINE and STOP ENGINE lights to illuminate. A low coolant level condition
will shut down a running engine in all operating modes except JET START. An
engine shut down due to low coolant level can not be started until the low cool-
ant level fault is cleared.
(7) Block Heater (Optional)
The engine block heater is energized upon application of 110 VAC at external
receptacle P106-2. The engine block heater can be energized as long as the
engine is not running. When the engine is on, but not running, contactor K15’s

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AIR START UNIT

N.C. contacts 3 and 4 provide a 100 VAC current path through the block heater.
When the engine is on and is in the run mode, Time Delay Relay (TD1) closes
after 45 seconds enabling K15. K15 contacts 3 and 4 open to de-energize the
block heater.
Additionally, when the engine attains idle speed and the engine oil pressure
reaches 15 PSI, Oil Pressure Sensor S4 contacts 1 and 2 open circuit and inhibit
the engine block heater by removing K15’s ground path. The maximum length of
time that the block heater could remain energized is also limited by TD1’s time
delay (45 seconds after start-up). Contactor K15, diodes CR20 and 21 are
mounted in common within the engine compartment, on the engine support
mount, just above the fuel pick-up port.

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CHAPTER 1
GENERAL INFORMATION & OPERATING INSTRUCTIONS
SECTION 2
OPERATION
1. GENERAL
This section contains operating instructions and information for the ASP250 Air Start Unit.
The operator must read all Air Start instructions before attempting to operate the unit. All
Cautions and Warning must be followed to prevent damage to the equipment and/or injury to
personnel.
WARNING
PROLONGED EXPOSURE TO HAZARDOUS NOISE MAY RESULT IN
PERMANENT HEARING LOSS. EAR PROTECTION DEVICES MUST BE
WORN WHEN WORKING WITHIN A CLOSE PROXIMITY OF THIS
EQUIPMENT.
2. PREPARATION FOR USE
The following steps must be accomplished prior to starting the engine.

CAUTION
A PRIOR-TO-USE INSPECTION MUST BE PERFORMED BEFORE
EACH OPERATION TO ENSURE SAFE AND RELIABLE OPERATION
OF THE AIR START UNIT. FAILURE TO PERFORM THE PROCEDURES
LISTED BELOW MAY RESULT IN SEVERE DAMAGE TO THE EQUIP-
MENT.
NOTE
If the unit is being operated for the first time, refer to Section 1-4,
Shipping/Receiving for initial inspection and preparation for use pro-
cedure, or if the unit has been in extended storage, refer to Section 1-
5, Storage, before performing the preoperational inspection.
A. Pre-Operation/Inspection
For cold weather operation, the unit is optionally equipped with 110/220 VAC engine
block heater, engine oil heater, and battery heater. The power receptacle for these is
located mounted under the frame at the left front corner of the chassis. Power should be
applied to the receptacle for at least one hour prior to cold weather starting.
Prior to the first operation of the day, the unit must be inspected to ensure safe and reli-
able operation. The engine service panel portion of the control panel must be observed
to ensure that the engine oil pressure, temperature, and alternator are functioning prop-
erly. Perform the preoperational inspection as follows:

(1) Enclosure: Visually inspect for obvious defects, i.e., security of common hard-

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ware. Verify that there are no unsecured items or debris which could be sucked
into the units cooling fan. Also check that all doors are secured.
(2) Towbar: Excessive movement and security of hardware.
(3) Brakes: Check for proper operation.
(4) Tires: Inspect tread wear and tire inflation pressure (60 psig)
(5) Engine hoses and clamps: Inspect for leaks and security.
(6) Check Engine Oil Level: With the engine off, open the engine access door.
Remove engine oil dipstick (see figure 1) and check oil level mark on dipstick.
Add oil if necessary to bring the level up to the full mark.
CAUTION
NEVER OPERATE ENGINE WITH OIL LEVEL BELOW THE “LOW”
MARK OR ABOVE THE “FULL” MARK. WAIT AT LEAST 5 MINUTES
AFTER SHUTTING OFF ENGINE BEFORE CHECKING OIL. THIS
ALLOWS TIME FOR THE OIL TO DRAIN TO THE OIL PAN.
(7) Check Radiator Fluid Level: Check the fluid level in the radiator overflow tank
mounted at the side of the radiator. Always check the level with the engine cold.
The fluid level should be within the NORMAL range.
(8) Check Compressor Oil Level: Open the compressor access door on the front left
side of the unit. Visually inspect the oil level in the sight glass. book date With
the unit not operating, oil level should be approximately 1/4 inch below the top of
the glass. After the unit has been run for three to five minutes, the unit should be
shut down and the oil level rechecked. Refer to Section 2-1, SERVICING, for
instructions on adding oil.
(9) Open the unit access doors and inspect the following items located in the unit
interior:
• Radiator fan drive belts for cuts and cracks.
• Radiator fan drive belts for proper tension. Pressure with the heel of the hand should
move the center of the belt approximately 3/8” out of line.
• Check for loose hardware and foreign objects that may interfere with rotating parts
with the unit operating.

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Figure 1. Fluid Level Checkpoints

(10) Check Fuel Level: Set ENGINE ON/OFF switch to ON, and observe the fuel
gauge. Set ENGINE ON/OFF switch to OFF. Fuel as required.
WARNING
NEVER SMOKE OR ALLOW AN OPEN FLAME WITHIN THE IMMEDI-
ATE VICINITY OF THE UNIT WHILE SERVICING WITH FUEL. NEVER
SERVICE THE UNIT WITH THE ENGINE OPERATING. FAILURE TO
COMPLY WILL RESULT IN PERSONNEL INJURY.
WARNING
TO PREVENT SPARKING BETWEEN FILLER NOZZLE AND THE FUEL
TANK, ALWAYS MAINTAIN METAL TO METAL CONTACT BETWEEN
THE FILLER AND THE FUEL TANK, AND GROUND THE UNIT TO A
CERTIFIED GROUND POINT. FAILURE TO COMPLY WILL RESULT IN
PERSONNEL INJURY.

(11) Prepare to start engine: Ensure both Air Delivery Ball Valves are in the full

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AIR START UNIT

“closed” position.
(a) Set ENGINE ON/OFF switch to ON. The POWER ON indicator lamp will be
illuminated.
(b) Set MODE SELECTOR switch to UNLOADED.

(c) Press the START switch. Engine will start and come up to idle speed.
Engine oil pressure must be indicated on the oil pressure gauge within 15
seconds of starting, or the engine will shut down.
(d) Allow the engine to run for 2-3 minutes for proper warm-up. When at oper-
ating temperature, the engine indicator gauges shall read as follows:
• WATER TEMP (Engine Coolant): 186° to 210°F (85.5°C to 98.9°C)
• ENGINE OIL PRESS: 20 psig minimum at IDLE, 63 psig minimum when in the
JET START or AIR COND. modes.
• BATTERY: 24 Volts minimum.
(e) Visually inspect the outside and underneath of the unit for signs of loose
hardware, fluid leaks, or any condition which could be potentially damaging
or hazardous to the equipment or personnel.
(f) This completes the pre-operation inspection. To shut down the unit, set
ENGINE ON/OFF switch to OFF. The engine will shut down and the
POWER ON indicator light will go out.

3. UNIT OPERATING INSTRUCTIONS

A. Engine Start
(1) Connect air duct to the aircraft. Ensure output air valve is in the CLOSED posi-
tion.
(2) Set ENGINE ON/OFF switch to ON. The POWER ON indicator lamp will be illu-
minated.
(3) Set MODE SELECTOR switch to UNLOADED.

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AIR START UNIT

CAUTION
TO PREVENT DAMAGE TO THE STARTER, DO NOT ENGAGE THE
STARTING MOTOR FOR MORE THAN 30 SECONDS AT A TIME. WAIT
TWO MINUTES BETWEEN EACH ATTEMPT TO START. FAILURE TO
COMPLY MAY CAUSE STARTER DAMAGE.
(4) Press ENGINE START switch. Engine will start and come up to idle speed.
Engine oil pressure must be indicated on the oil pressure gauge within 15 sec-
onds of starting or the engine will shut down.
(5) Allow the engine to run for 2-3 minutes for proper warm-up. When at operating
temperature, the engine indicator gauges shall read as follows:
• WATER TEMP (Engine Coolant): 186° to 210°F (85.5°C to 98.9°C)
• ENGINE OIL PRESS: 20 psig minimum at IDLE, 63 psig minimum when in the
JET START or AIR COND. modes.
• BATTERY: 24 Volts minimum.

NOTE
IF AN EMERGENCY SITUATION OCCURS REQUIRING IMMEDIATE
UNIT SHUTDOWN, PRESS “EMERGENCY STOP” SWITCH ON CON-
TROL PANEL. THIS SWITCH BY-PASSES ALL SHUT-DOWN DELAYS.
THIS SWITCH MUST THEN BE MANUALLY PULLED OUT TO “SET”
POSITION BEFORE THE UNIT CAN BE RESTARTED.

January 15, 2001 1-2

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ASP250
AIR START UNIT

Figure 2. Control Panel Assembly

1-2 January 15, 2002

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Table 1: Control Panel Assembly

Fig. 2
Item Description Purpose
No.

1 ENGINE FAULT MODE fault indi- LOW OIL PRESS indicates that oil pressure is less than 5
cators: psi.
LOW OIL PRESS, OVERSPEED indicates that engine speed has exceeded
OVER SPEED, 2800 rpm.
HIGH TEMP. HIGH TEMP indicates that engine coolant temperature has
exceeded 225° F (107°C).
CHECK ENGINE indicates engine operating parameter is
incorrect. Service engine as soon as possible.
STOP ENGINE indicates that engine must be manually
shut down. Fault is received via on-board DDEC computer
or automatically shut down via overspeed switch. Service
engine immediately.

2 ENGINE WATER TEMP gauge Indicates engine coolant temperature over normal operat-
(M3) ing range of 186°F to 210°F (85.5°C to 98.9°C).

3 POWER ON indicator light (DS1) Indicates system 24 VDC buss power is available and
engine is ready for starting.

4 TIMED COOL DOWN indicator Yellow flashing indicator indicates that engine operation is
(DS8) in it's cooled down mode.

5 HOURS hourmeter (M1) Indicates elapsed engine running hours.

6 COMPRESSOR FAULT MODE HIGH OIL TEMP indicates: compressor oil temperature has
fault indicators: exceeded 195° F (90.6° C).
HIGH OIL TEMP, LOW OIL PRESS indicates: Compressor oil pressure has
LOW OIL PRESS, dropped below 4.5 psig (0.3 bar).
LOW OIL LEVEL, LOW OIL LEVEL indicates: Compressor oil level has fallen
HIGH AIR TEMP. below it's instrumentation set point. HIGH AIR TEMP indi-
cates: Delivery air temperature has exceeded 500° F (260°
C).

7 AIR PSI gauge Indicates delivery air pressure.

8 PANEL LIGHTS ON/OFF switch Turns on panel lights for night viewing of gauges and con-
(S13) trols.

9 MODE SELECTOR switch: Selects following modes: JET START for aircraft starting.
JET START, UNLOADED for no delivery of air. AIR COND. for aircraft air
UNLOADED, conditioning air supply.
AIR COND.

10 EMERGENCY STOP push-button Emergency stop slap switch. Once depressed, it must be
switch manually pulled out to set point.

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AIR START UNIT

Table 1: Control Panel Assembly (Continued)

Fig. 2
Item Description Purpose
No.

11 J/S RUNTIME EXCEEDED Light goes on, and stays on until reset, when unit is in
indicator light continuous Jet Start (J/S) mode of operation for a period of
time exceeding 7 minutes. The light’s operation does not
inhibit Jet Start operation. An internal counter records and
displays the number of times the unit has been run at “J/S
EXCEEDED 7-minutes times”.

12 RESET switch This key-lock switch turns off the J/S RUNTIME
EXCEEDED light and resets light on circuit.

13 ENGINE START push-button Applies +24 VDC power to engine starting circuit.
switch (S3)

14 ENGINE ON/OFF switch (S2) Applies +24 VDC system power to unit.

15 BATTERY gauge (M5) Indicates system battery voltage (+24 V nominal). Indicates
whether batteries are charging when ENGINE ON/OFF
switch (S2) is ON.

16 ENGINE FUEL gauge (M2) Indicates fuel tank quantity level.

17 ENGINE OIL PRESS gauge (M4) Indicates engine oil pressure of 20 psi (138 kPa) at idle
speed and 63 psi (434 kPa), minimum, at run speed.

18 LOW FUEL indicator light (DS31) Indicates when fuel tank level reaches 1/8 full. Operates in
unison with roof mounted yellow low fuel beacon.

19 ETHER START push-button Pressed during starting to inject ether fluid into intake mani-
switch (Optional) fold.

20 Panel lights (DS18 & DS19) Provides panel illumination for night time use.

B. AIR CONDition Mode Operation

WARNING
AN OPEN AIR DELIVERY BALL VALVE ON AN UNUSED OR UNSECURED
DELIVERY DUCT WILL DISCHARGE A HIGH VOLUME OF LOW PRESSURE
AIR CAUSING THE DUCT AND ITS COUPLING TO BE FLUNG ABOUT IN AN
UNCONTROLLED MANNER. ENSURE THE DUCT IS CONNECTED TO AN
AIRCRAFT/TEST STAND, OR THAT IT’S AIR DELIVERY BALL VALVE IS
CLOSED. FAILURE TO COMPLY MAY RESULT IN EQUIPMENT DAMAGE
AND/OR SEVERE INJURY TO PERSONNEL.
(1) With the delivery air hose connected to the aircraft, open the Air Delivery Ball
Valve.
(2) Set COMPRESSOR MODE SELECTOR switch to AIR COND. Engine speed
will increase and air delivery will begin. Engine speed will vary as the automatic

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AIR START UNIT

pressure control system regulates output pressure. Excess air will be vented
through the automatic bypass system.
(3) Should a fault condition occur, the appropriate control panel fault lamp will be
illuminated, and the unit will automatically shut down. Once the fault has been
corrected, set ENGINE ON/OFF switch to OFF to reset the fault circuit, and the
unit may be restarted.
C. JET START Mode Operation
WARNING
AN OPEN AIR DELIVERY BALL VALVE ON AN UNUSED OR UNSE-
CURED DELIVERY DUCT WILL DISCHARGE A HIGH VOLUME OF
LOW PRESSURE AIR CAUSING THE DUCT AND ITS COUPLING TO
BE FLUNG ABOUT IN AN UNCONTROLLED MANNER. ENSURE THE
DUCT IS CONNECTED TO AN AIRCRAFT/TEST STAND, OR THAT ITS
AIR DELIVERY BALL VALVE IS CLOSED. FAILURE TO COMPLY MAY
RESULT IN EQUIPMENT DAMAGE AND/OR SEVERE INJURY TO PER-
SONNEL.
(1) With delivery air hose connected to aircraft, open the Air Delivery Ball Valve.
(2) Set COMPRESSOR MODE SELECTOR switch to JET START. Engine speed
will increase and air delivery will begin.
(3) If a fault condition occurs, the appropriate control panel fault lamp will be illumi-
nated, but the unit WILL NOT shut down. After jet start operations are completed
and the MODE SELECTOR switch is set to AIR COND or UNLOADED, the unit
will automatically shut down. Once the fault has been corrected, set ENGINE
ON/OFF switch to OFF to reset the fault circuit, and the unit may be restarted.

D. Unit Shut-Down
To shut down the unit, set COMPRESSOR MODE SELECTOR switch to UNLOADED.
Engine speed will drop to idle.
(1) Close the Air Delivery Ball Valve.
(2) Disconnect air delivery duct from aircraft.
(3) Allow unit to idle for 5 minutes for cool down.
(4) Set ENGINE ON/OFF switch to OFF to shut down operation.
NOTE
If the ENGINE ON/OFF switch is set to OFF while the unit is in the JET
START or AIR COND modes, the engine will be reduced to idle speed
and continue to run for 1 1/2 minutes for cool down prior to automatic
shutdown. In the UNLOADED mode, the TIME COOL DOWN indicator
lamp will be illuminated.

November 1, 1999 1-2

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ASP250
AIR START UNIT

4. SYSTEM FAILURE SHUT-DOWN

NOTE
If an emergency situation occurs requiring immediate unit shutdown,
press “emergency stop” switch on control panel. This switch by-
passes all shut-down delays. This switch must then be manually
pulled out to the “set” position before the unit can be restarted.

If a compressor or engine fault occurs during operation (UNLOADED or AIR CONDition

modes only), the corresponding fault lamp will be illuminated and the unit will automatically
shut down.
If a compressor or engine fault occurs during JET START operation, the corresponding fault
lamp will be illuminated but the unit WILL NOT shut down, unless the optional safety bypass
jumper is removed. This is to prevent damage or an unsafe condition to the aircraft during its
engine start operation. Once the in-progress start operation is completed, immediately shut
the unit down and service as required. Depending on the fault encountered, the unit may be
severely damaged or destroyed during this fault/jet start operation.

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CHAPTER 1
GENERAL INFORMATION & OPERATING INSTRUCTIONS
SECTION 3
SPECIFICATIONS & CAPABILITIES
1. GENERAL
• Length (overall): 153 inches (388.6 cm)
• Width (overall): 88.7 inches (225.3 cm)
• Height (overall): 75 inches (190.5 cm)
• Weight (approximate): 13,360 lbs (6060 kg)
• Operating temperature: -30oF to 125oF (-34.4oC to 51.6oC)
• Storage temperature: -40oF to 150oF (-40oC to 65.5oC)
2. AIR START UNIT ENGINE AND ACCESSORIES
A. Engine
• Detroit Diesel Series 60 DDEC IV, type 6063-HK33
• Engine Type: Six cylinder, 4-cycle
• Aspiration: Turbocharger
• Dry weight: 2510 lbs (1139 kg)
• Horsepower: 550 BHP @ 2100 RPM
• Total Engine Oil Capacity w/filters: 38 qts (36 liters)
• Oil pan capacity:
• High Limit: 32 qts (30 liters)
• Low Limit: 26 qts (24.6 liters)
• Trailer Mounted
• 24 Volt System
• Tri-Silentron Plus Level 2 Sound Attenuation
• Coolant capacity: 20 gals (75 liters)
• Electrical System: 24 VDC
• Governor: Electronic DDEC IV controlled

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B. Air Compressor
• GHH-RAND Model CD42HS
• Gear Set 9, 4.8438 gear ration
• Dry rotary screw
• Ball and roller bearings
• Forced feed lubrication, radiator cooled
• Oil capacity: 32 qts (30 liters)(Compressor Oil Sump Capacity)
80 qts (75 liters)(Total System Oil Capacity)
• Jet Start Operation
• 250 lbs/min
• 40 psig @400oF (204oC)
• Air Condition Operation
• 250 lbs/min
• 30 psig
C. Accessories
• 20’, 30’, 40’, or 50’ Air Delivery Hose length options with Standard Coupler and
scuffer
• Roof mounted “In Operation” beacon light (Amber) (Optional)
• Clearance/Marker lights (Optional)
• Roof mounted “Low Fuel” warning beacon light (Blue or Red) (Optional)
• Engine block heater - 110VAC/220VAC (Optional)
• Electrically operated automatic ether injection system (Optional)

1-3 October 28, 2002

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AIR START UNIT

CHAPTER 1
GENERAL INFORMATION & OPERATING INSTRUCTIONS
SECTION 4
SHIPPING AND RECEIVING
1. GENERAL
When shipped domestically, the Air Start Unit does not normally require crating, skidding or
a solid external container. It may be shipped completely assembled.
2. PREPARATION FOR SHIPMENT
To prepare the Air Start Unit for shipment, perform the following procedures:
• Disconnect the unit battery cables.
• Ensure all doors are closed and securely fastened.
• Place air start ducts in the storage basket at the rear of the unit. Secure the duct within
the basket using rope.
• Inspect the fuel tank cap for proper seal and security.
CAUTION
UNDE R NO CIRCUMSTANCES S H O U L D T H E A I R S TA R T B E
ANCHORED BY PASSING BANDS OR CABLES OVER THE SUPER-
STRUCTURE.
When deemed advisable by the shipping activity, the unit should be covered with waterproof
canvas or polyethylene material in such a manner as to prevent the entry of natural ele-
ments into the electrical and instrument areas.
Application of the covering material should be accomplished in such a manner as to avoid
the formation of water pockets or interfere with the mobility of the unit. The covering material
should be of sufficient strength to preclude rupture or tearing when exposed to conditions
encountered during open transportation.
3. RECEIVING
The Air Start Unit is shipped from the factory fully assembled. Do not move the unit any
great distance before performing the initial inspection procedures.
Initial Inspection:
• Remove any envelope of weather resistant material.
• Thoroughly inspect the exterior of the unit for any damage which may have occurred
during shipment. Open and close all doors checking latches for proper operation.
• Inspect all indicator glass and light lenses for evidence of cracks or damage.
• Open access doors and inspect the interior of the unit.
• Check the fuel system for leakage.
• Check the electrical wiring for breaks or exposed wiring.
• Check the entire unit for loose connections, parts, blots, nuts or other hardware that
may have been loosened during transit. Tighten or repair all discrepancies.
November 1, 1999 1-4
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AIR START UNIT

CAUTION
BEFORE ATTEMPTING TO CONNECT THE BATTERIES, MAKE SURE
THE ENGINE ON/OFF SWITCH ON THE CONTROL PANEL IS SET TO
OFF.
Connect batteries as follows:
• The unit utilizes two sets of batteries, each tied together in parallel, and the two sets
joined in parallel to provide 24VDC. Connect the engine positive battery cable (red) to
the vacant positive battery terminal. Connect the engine negative battery cable
(black) to the vacant negative battery terminal.
• Check engine oil level. Do not operate the unit if the oil level is below the low or add
mark on the dipstick. Service with oil until the oil level is at the full mark. Refer to Sec-
tion 2-1, Servicing, for proper oil grade.
• Remove the radiator cap and inspect the coolant level. Service as required to bring
the level within the radiator to one inch below the top of the radiator, and the level
within the overflow tank to within the "Normal" level. Refer to Section 2-1, Servicing,
for the proper coolant mixture.
Check the compressor oil level:
• The compressor oil level is indicated by a sight glass located at the lower right on the
compressor. Proper oil level is approximately 1/4 inch below the top of the glass. Do
not operate the unit if the oil level is below this point. Refer to Section 2-1, Servicing,
for the proper oil, and procedure.

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AIR START UNIT

CHAPTER 1
GENERAL INFORMATION & OPERATING INSTRUCTIONS
SECTION 5
STORAGE
1. GENERAL
This section provides instructions for preparing the Air Start Unit assembly for both short and
long term storage.
When the unit is to be stored or removed from operation, use the following procedures to
protect the internal and external components from rust, corrosion, and gumming in the
engine fuel system.
2. PREPARATION FOR STORAGE
A. Short Term Storage (less than 3 months)
The following steps are recommended if the unit is to be placed out of service for three
months or less. The unit should be prepared for storage as soon as possible after being
removed from service.
(1) Check that the thoroughly mixed coolant is adequate for the lowest anticipated
temperatures during storage period.
(2) Add oil to engine until the engine oil dip stick level indicates at FULL mark.
(3) Drain a small portion of fuel from fuel tank by removing drain plug at bottom of
tank. This will remove any water that may have accumulated at the bottom of the
fuel tank.
NOTE
Do not drain the fuel system or crankcase.
(4) Install new fuel filters.
(5) Fill fuel tank to capacity. A full fuel tank prevents moisture laden air from entering
the tank during the cool periods and allowing rust or corrosion to form.
(6) Compressor:
If the unit is to be stored for three months or less, no special preservation mea-
sures should be required. However, the oil film on the compressor bearings and
in the gear unit must be renewed by running the unit for a ten minute period
each week. If this is not practical, then long term storage preparation should be
followed.
The discharge piping and non-return valve must also be prepared for storage by
applying a protective film of preserving oil. This application, depending on cli-
matic conditions, will protect for approximately three months. It should be
inspected monthly, and reapplied as required.
(7) Close all access doors and covers to minimize buildup of foreign particles in the
unit.

November 1, 1999 1-5

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AIR START UNIT

(8) Store unit in a building that is dry.

(9) In storage areas with high humidity, place moisture absorbing chemicals inside
the unit.

B. Long Term Storage

Special precautions are necessary to protect the Air Start 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.
(1) Drain the cooling system: Flush with clean water. Refill only with Pre-blended,
50:50, Detroit Diesel Power Cool® IEG (Inhibited Ethylene Glycol) Antifreeze
(Detroit Diesel Part No. 23518918-55 gallon drum) Antifreeze, or Concentrated
Detroit Diesel Power Cool® IEG (Inhibited Ethylene Glycol) Antifreeze (Detroit
Diesel Part No. 23512139-55 gallon drum). Mix the concentrate antifreeze
according to ratio for temperature anticipated per the product manufacturer's
recommendation.
(2) Circulate the coolant by operating the engine to normal operating temperature.
(3) Drain the engine crankcase and fill with new lubricating oil.
(4) Replace oil filter elements.
(5) Drain the fuel tank. Add additives, fill with fuel.
(6) Replace fuel filter elements.
(7) Operate the engine for about ten minutes.
NOTE
If the unit is stored where water or condensation may be a
problem, add Methyl Carbitol or Butyl Cellousolve to the fuel, at
the rate of 1 pint to 25 gallons of fuel (.010% by volume). Where
biological contamination may be a problem, add a biocidal
such as Biobor JF® or equivalent to the fuel. Follow the bio-
cidal manufacturer's concentration recommendations and
observe all warnings and cautions.

(8) Remove and clean battery terminals and cables with baking soda-water solu-
tion, rinse with fresh water. Do not allow the soda water to enter the battery. Add
distilled water to the electrolyte, if necessary fully charge the battery. Store the
battery in a cool dry place separate from the unit. Storage temperature should
never be below 32°F (0°C). Periodically inspect the batteries to keep them fully
charged and check the specific gravity of the electrolyte regularly.

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(9) Seal all engine openings, including the exhaust outlet, with moisture resistant
tape. Use cardboard, plywood, or metal covers where practical.
(10) Tag Control Panel “DO NOT RUN, STORAGE READY”.
(11) Compressor:
If the unit is to be stored for more than three months, or can not be run weekly,
all the lube oil should be completely drained and replaced with preserving oil.
Running the unit for five to ten minutes will coat the bearings and gear unit with
a protective film of preserving oil.

(12) The discharge piping and non-return valve must also be prepared for storage by
applying a protective film of preserving oil. This application, depending on cli-
matic conditions, will protect for approximately three months. It should be
inspected monthly, and reapplied as required.

C. Returning to Service:
The preserving oil must be removed from the oil tank and piping system and replaced
with normal lubricating oil according to Section 2-1. The suction strainer in the oil pump
suction pipe must be cleaned, and the oil filter cartridge replaced.

November 1, 1999 1-5

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CHAPTER 2
MAINTENANCE
SECTION 1
SERVICING
1. GENERAL
This section provides information and procedural instructions for the normal maintenance
requirements of the Air Start Unit.
2. CONSUMABLE SUPPLIES

Table 1: Consumable Supplies For Operation & Scheduled Maintenance

Component Trilectron
Description Quantity
Application Part No.

Fuel Tank Diesel (ASTM D975 No.2-D) 130 gal.(492 ltr)

Engine Crankcase 15W/40 Delvac® Synthetic Series 1300, 23512703 PX5171 40 qt. (38 ltr)
(Detroit Diesel©)

Compressor Crank- Note:

case When compressor oil sump is empty add 32 qts.
Run unit for 2 minutes. Stop unit, then add remain-
der of 80qts. total.
** Lubrication Oil/Lowest Ambient Operating Tempera-
tures
32 qt. (30 ltr)(Com-
SAE 10W40/(Down to -20°C/-4°F) PX5066 pressor Oil Sump Capac-
ity)
Turbine oil ISO VG 100 (DIN51515)/(Down to 0°C/32°F) — 80 qt. (75 ltr) (Total
System Oil Capacity)
Hydraulic oil ISO VG 100 (DIN 51524) /(Down to 0°C/32°F) —

Lube Points Grease, General Purpose N/A as required

Door Hinges Oil, OE30 N/A as required

Engine Cooling Fan Belt, Poly-Vee, Detroit Diesel© PN: 23517136 N/A 1

Antifreeze - IEG Pre-blended (50:50) Power Cool® IEG Antifreeze, PX5172 20 gal. (75.7 ltr)
(Inhibited Ethylene 23518918 (Detroit Diesel®)
Glycol)
Concentrated Power Cool® IEG Antifreeze, 23512139 N/A 10-12 gal.(38-45 ltr)
(Detroit Diesel®)

Filters, Fuel Filter Element, Primary, 23518481 (Detroit Diesel®) EB5632 1 each

Filters, Fuel Filter Element, Secondary, 23518482 (Detroit Diesel®) EB5599 1 each

Engine Oil Filter Spin-On filter Element, 23527033 (Detroit Diesel®) EJ5149 2 each

Engine Air Filter Cartridge, 71338-003 (Detroit Diesel®) EB5476 1 each

Compressor Oil Filter Cartridge, 839000022 (GHH-Rand®) AA5441 1 each

Compressor Air Filter Cartridge, CS-10 (Universal Silencer®) EB5520 1 each

October28, 2002 2-1

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AIR START UNIT

Table 1: Consumable Supplies For Operation & Scheduled Maintenance (Continued)

Component Trilectron
Description Quantity
Application Part No.

NOTES:
Antifreeze concentration level should not exceed recommended levels. Equipment failure may result.
a. A mixture of 50% antifreeze and 50% water is required for temperatures above -34o F. (-37o C.)
b. A mixture of 60% antifreeze and 40% water is required for temperatures below -34o F. (-37o C.) This provides pro-
tection to - 65o F. (-54o C.). NEVER exceed 60% antifreeze and 40% water mix.
c. NEVER use 100% antifreeze for make-up coolant.
** Motor oil can be used for temperatures down to -4o F (-20o C), and turbine/hydraulic oils down to 32o F (0o C). Where
ambient temperatures are lower, an oil heater should be installed. Never mix oil types.

3. LUBRICATION INSTRUCTIONS (Figure 1)

(Refer to Detroit Diesel Service Manual) To ensure that the unit is kept in correct operating
condition, it must be inspected and maintained on a regular basis. Proper replacement of fil-
ters, lubricating oil, etc., at recommended intervals will prevent damage to or failure of the
unit, and provide optimum performance. The use of quality engine lubricating oils combined
with appropriate oil drain and filter change intervals is a critical factor in maintaining the
engine performance and durability. See figure 1 for lubrication access locations.
A. Fan Hub Bearing Assembly (Figure 2)
The engine cooling fan hub bearing assembly is provided with a grease fitting. Use a
hand grease gun and lubricate the bearings with lithium base multi-purpose grease after
750 hours of operation. Every 4,000 hours of operation, the fan bearing hub assembly
should be cleaned, inspected, and repacked with lithium base multi-purpose grease. Fan
hub bearings should be replaced with new bearings at major engine overhaul. Refer to
Detroit Diesel Service Manual, for specific information concerning fan hub bearing
assembly.

2-1 October 28, 2003

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AIR START UNIT

ASP250

Figure 1. ASP250 Air Start Unit

November 1, 1999 2-1

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Figure 2. Fan Hub Bearing Assembly

B. Engine Oil Change Schedule
Time schedules indicated in Table 3 is based on average operating conditions. It may be
necessary to change oil and air filters more frequently under severe operating conditions,
such as; operating in dry, hot, dusty climates (desert), areas of high humidity (tropical),
excessive periods of heavy load or frequent intermittent operations. Check the oil level
after every 8-10 hours of operation during the break-in period (first 50 hours). Add oil as
necessary.
NOTE
Always drain lubricating oil immediately after the unit has been run
for some time. Most of the sediment will be in suspension and will
drain readily.
NOTE
Change oil and filter after first 50 hours of operation, then every 250
hours of operation or every six months, which ever comes first.
(1) Always clean around oil filler openings before removing caps or plugs.
(2) Do not over-lubricate or overfill the engine crankcase. Use engine oil level dip-
stick to check oil level.
(3) Prevent dust, dirt or water from contaminating lubricants.
(4) Do not mix brands, weights or types of oil when servicing unit.
(5) Use 15W-40 Delvac® Synthetic Series 1300 oil (Detroit Diesel Part No.
23512703)

2-1 November 1, 1999

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C. Arctic Operation
If an engine is operated in ambient temperatures consistently between 0°F to -25°F
(-18°C to -31.7°C) and there are no provisions to keep the engine warm when it is not in
operation, the use of multi-viscosity grade 15W-40 or mono-grade SAE30 will improve
stability.

CAUTION
THE USE OF A 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.
NOTE
Additional information regarding lubricating oil availability through-
out the world is available in the “E.M.A. Lubricating Oils Data Book
for Heavy Duty Automotive and Industrial Engine.” The data book
may be ordered from the Engine Manufacturers Association, One Illi-
nois Center, 111 East Wacker Drive, Chicago, Il U.S.A. 60601.
4. COOLANT SPECIFICATIONS & RECOMMENDATIONS
A. Specifications
Use Ethylene Glycol or Propylene Glycol antifreeze containing a corrosion inhibitor pack-
age and which meets an appropriate heavy duty specification (i.e., TMC RP-329 for eth-
ylene glycol or TMC RP-330 for propylene glycol).
B. Concentration
Antifreeze must be used in any climate for both freeze and boiling point protection. A
50% concentration level (40 to 60% range) of ethylene glycol, propylene glycol is recom-
mended in most climates. Antifreeze at 68% concentration provides the maximum freeze
protection and must never be exceed under any condition. Antifreeze protection
decreases above 68%.
C. Concentration Testing
Antifreeze concentration must be checked using Detroit Diesel POWER Trac® Coolant
Test Strips1 (P/N 23522774). The test strips will indicate glycol percentage and inhibitor
value. “Floating Ball” type density testers are NOT accurate enough for heavy duty die-
sel cooling systems.
D. Coolant Change Recommendations
Trilectron recommends the cooling system be drained and replaced every 3000 hours or
yearly (whichever occurs first) to eliminate buildup of harmful chemicals.

1. Florida Detroit Diesel Allison North Inc., 5040 University Blvd. W., Jacksonville, FL 32245-6595

November 1, 1999 2-1

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AIR START UNIT

Table 2: Antifreeze Concentration Protection

Percentage of Protection to
Antifreeze Type
Antifreeze Temperature

Ethylene Glycol 40% -10o F. (-23o C.)

50% -34o F. (-37o C.)

60% -65o F. (-54o C.)

68% -90o F. (-71o C.)

Propylene Glycol 40% -6o F. (-21o C.)

50% -27o F. (-33o C.)

60% -56o F. (-49o C.)

68% -82o F. (-63o C.)

5. FUEL RECOMMENDATIONS/SPECIFICATIONS
Trilectron recommends the use of ASTM D 975 fuel. The use of No.2 Diesel fuel will result in
optimum engine performance. At operation temperatures below 32°F (0°C), acceptable per-
formance can be obtained by using blends of No.2 D and No.1 D. The use of lighter fuels
can reduce fuel economy.
The sulfur content of the fuel should be as low as possible to avoid premature wear and
excessive deposit formation. Fuel containing no more that 0.5% sulfur are recommended. If
the use of fuels with sulfur contents above 0.5% are unavoidable, lube oil drain intervals
(less) and lubricant selection need to be changed.

WARNING
DO NOT MIX GASOLINE OR ALCOHOL WITH DIESEL FUEL, THIS MIX-
TURE CAN CAUSE AN EXPLOSION RESULTING IN DEATH OR PER-
SONNEL INJURY.

2-1 August 30, 2000

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6. INSPECTION (Refer to tables 3, 4, and 5)

A. Preventive Maintenance Inspection Schedule
A periodic inspection schedule should be established and maintained. A suggested
inspection/check schedule is provided below. The criteria listed meets the minimum
requirements necessary to ensure safe reliable service under normal operating condi-
tions. It should be modified as required to meet varying operating and environmental
conditions.
CAUTION
BEFORE ATTEMPTING TO START UNIT, PERFORM A PRE-OPERA-
TIONAL INSPECTION (Refer to section 1-2).
B. Initial Inspection and Preparation
(1) Remove all packaging material from unit.
(2) Inspect exterior of unit for damage that may have occurred during shipment.
(3) Open the canopy access doors. Inspect interior of unit for foreign material.
(4) Inspect all wiring connections for security.
(5) Remove radiator cap. Check to make certain that the coolant level is one inch
below the filler neck. Inspect radiator overflow tank, ensure coolant level is
within the normal range.
(6) Inspect battery electrolyte level. Service batteries as necessary, using distilled
water.
(7) Connect batteries.
(8) Check fuel level by setting ENGINE ON/OFF switch (ignition) to ON. (Refer to
section 1-2). Observe fuel gauge. Service as necessary with Diesel fuel.
C. Returning Unit To Service After Extended Storage
(1) Remove covers and tape from all engine, exhaust and fuel tank openings.
(2) Remove covers and tape from electrical system components.
(3) Drain and refill radiator with a mixed solution of water and antifreeze (ethyl gly-
col) or according to a ratio for temperature requirements. Coolant capacity is 20
gallons (75 ltr).
(4) Drain and refill engine crankcase. Change oil filter.
(5) If isopropyl alcohol (isopropanol) was added to fuel for storage, drain and refill
fuel tank with diesel fuel.

August 30, 2000 2-1

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Table 3: Engine Preventive Maintenance Schedule

125 250 375 500 625 750

Daily
HR HR HR HR HR HR

Lubrication System

1. Inspect for leaks X

2. Check oil level X

3. Change oil & filter every 250 hours, or yearly, whichever occurs first.

Engine Cooling System

1. Inspect for leaks X

2. Inspect radiator core for cleanness X X X X X X

3. Condition of belts X

4. Check coolant level and add coolant as required X

5. Change antifreeze solution each 3000 hours or yearly, whichever occurs first.

Air Intake System

1. Inspect for leaks. X

2. Inspect for air restrictions. X

3. Inspect for corrosion. X X X X X X

Turbocharger

1. Inspect oil line to turbocharger. X

2. Inspect for excessive noise. X

3. Inspect exhaust manifold retaining nuts, flange clamp, X

and other connectors.

2-1 August 30, 2000

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Table 3: Engine Preventive Maintenance Schedule

125 250 375 500 625 750

Daily
HR HR HR HR HR HR

Fuel System

1. Inspect fuel lines for leaks, chaffing, and excessive X

bends.

2. Change fuel filters. X X X X X X

3. Drain sediment from fuel tank. X X X X X X

Exhaust System

1. Inspect for leaks. X

2. Inspect system for restrictions. X

3. Inspect clamps for tightness. X

4. Inspect for corrosion. X

5. Inspect muffler for security. X X X X X X

Engine Electrical System

1. Inspect battery electrolyte level above plates. X

2. Check battery state of charge. X X X X X X

3. Inspect battery hold-down. X

4. Inspect battery terminal for security and corrosion. X

Electrical System

1. Inspect all wiring for cuts, excessive bends, and chaff- X

ing.

2. Control Panel X

a. Gauges for proper operation or cracked glass. X

b. Switches for proper operation. X

c. Panel lights for proper operation. x

d. Electronic governor for security and loose terminals. X

November 1, 1999 2-1

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Table 4: Compressor Preventive Maintenance Schedule

125
Daily Weekly Yearly
Hrs

Lubrication System

1. Inspect for leaks. X

2. Check oil level. Add oil as required. Oil level must not be allowed to X
be below the minimum level.

3. Change Oil and filter every 125 hours, or 3 months, whichever X

occurs first

4. Clean suction strainer. X

Air Intake System

1. Inspect for leaks X

2. Clean or replace suction filter. X

System Operation

1. Check system for proper operation, i.e. switches, valves, etc. X

2. Check safety air pressure relief valve (RV1) for proper operation. X
Refer to Sect. 2-4, para. 2-D, for checkout procedure.

Table 5: Chassis Preventive Maintenance Schedule

125 250 375 500 625 750

Daily
HR HR HR HR HR HR

Chassis and Running Gear

1. Inspect doors & hinges. X X X X X X

2. Loose nuts, bolts, and missing hardware. X X X X X X

2-1 November 1, 1999

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D. Engine Fuels (Refer to table 6.)

The Diesel engine uses #2 Diesel, or fuels meeting ASTM D975 Standard Specification
of Diesel Fuels, or the following lighter fuels: No. 1 Diesel; kerosene; Jet-A fuel, or blends
of these fuels.

Table 6: Engine Fuels

Viscosity (ASTM D-445) 1.3 -4.1 CeniStroke

Cetane Number 45 minimum. In cold weather or prolonged low (ASTM D-445) load
(ASTM D-613) service, use higher cetane number.

Sulfur Content (ASTM D-129 or Not to exceed 0.5% by weight.

1552)

Carbon Residue (Ransbottom ASTM Not to exceed 0.35% by weight on 10% residue.
D-524 D189)

Flash Point (ASTM D-93) 100o F. (38o C.)

Density (ASTM D-287) 30 to 42o F. (-1 to 6o C.) A.P.I. at 60o F. (16o C.) (.816 to .876 Sp. Gr).

Cloud Point (ASTM D-97) 10o F. (-12o C.) below the lowest temperature expected to operate.

Active Sulfur-Copper Strip Corrosion Not to exceed No. 2 rating after 3 hours at 122o F. (50o C.)
(ASTM D-130)

ASH (ASTM D-482) Not to exceed 0.01% by weight.

Distillation (ASTM D-86) Curve should be smooth and continuous. Minimum 90% of fuel should
evaporate at less then Ash (ASTM D-482). Not to exceed 0.01% by
weight.

November 1, 1999 2-1

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Figure 3. Engine Fuel Filter Replacement

2-1 November 1, 1999

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7. ENGINE FUEL FILTER REPLACEMENT (See Figure 3.)

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

November 1, 1999 2-1

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AIR START UNIT

9. ENGINE AIR CLEANER

The air cleaner contains a long life filter element. To avoid severe engine damage, no
attempt to clean or reuse the element should be made.
10. COMPRESSOR OIL DRAIN & OIL FILTER REPLACEMENT (See Figure 3.)
(1) Loosen oil fill/vent port.
(2) Remove oil drain plug, compressor left side, catch oil in container and dispose of
used oil in accordance with environmental safety policies.
(3) Replace drain plug.
(4) If oil is not being replaced, screw out oil return screw one inch (30mm) to pre-
vent oil draining when filter is removed.
(5) Remove old oil filter.
(6) Moisten rubber gasket of new filter with oil.
(7) Install new filter, screwing on hand tight. With a filter wrench, tighten and addi-
tion 1/4 turn.
(8) If oil is not being replaced, screw in oil return screw one inch (30mm).
(9) Remove oil fill plug.
(10) Add oil until proper level is displayed in oil level sight glass (1/4” below top of
glass).
(11) Replace oil fill plug.

11. COMPRESSOR AIR FILTER CLEANING INSTRUCTIONS

A. Water Cleaning
(1) Tap filter element gently to dislodge accumulated dirt. Soak thoroughly approxi-
mately 15 minutes in warm water and mild detergent. Rinse thoroughly under
low pressure water. Air dry - do not dry with compressed air.
B. Compressed Air Cleaning
(1) Carefully direct clean compressed air (100 psi maximum) through the filter ele-
ment, opposite normal direction of air flow.
(2) After cleaning, inspect for holes or cracks. If damaged, replace element.

2-1 November 1, 1999

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CHAPTER 2
MAINTENANCE
SECTION 2
TROUBLESHOOTING
1. GENERAL
This section contains troubleshooting information to assist in locating and correcting operat-
ing troubles which may develop in the Air Start Unit. Each malfunction for an individual com-
ponent, unit or system is followed by a list of tests or inspections to aid in the determination
of the probable causes and corrective action required.
Perform the tests/inspections and corrective actions 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 opera-
tional checkout of the Air Start Unit. After verifying the trouble, identify all components whose
failure could cause the symptoms observed during the operational checkout. Start by check-
ing those items having the highest in probability of failure. Inspect and test each component,
until the exact cause of the problem is determined and corrected.

WARNING
FUEL, 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.

2. COMPRESSOR FAULT MONITORING

The ASP250 provides fault monitoring and indication of the following vital compressor func-
tions:
• High Oil Temperature - Compressor oil temperature has exceeded 195°F (90.6°C).
• Low Oil Pressure - Compressor oil pressure has dropped below 4.5 psig (0.3 bar).
• Low Oil Level - Compressor oil level has fallen below it's instrumentation set point.
• High Air Temperature - Indicates that delivery air temperature has exceeded 500°F
(260°C).
In the UNLOADED and AIR CONDition modes, a compressor fault will illuminate the
appropriate fault light, and shut down the unit. In the JET START mode, only a fault light
will illuminate, the unit will NOT shut down. Rather than risk aircraft damage, the ASP250
will function to destruction in the JET START mode. When a fault light illuminates in the
JET START mode, the unit should be shut down as soon as safely practical. For correc-
tive procedures, refer to troubleshooting table 3 and manufacture’s appendices, Chapter
5, as indicated under "Fault Finding" within the GHH-RAND® compressor literature.

November 1, 1999 2-2

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ASP250
AIR START UNIT

3. ENGINE FAULT MONITORING

The ASP250 engine fault monitoring is dependent upon operator observance of the
engine monitoring gauges. If the operator observes or suspects an engine fault while In
the JET START mode, the unit must NOT shut down when engine speed is above 2000
RPM. Rather than risk aircraft damage, the ASP250 must be allowed to function to
destruction in the JET START mode. Should a fault light illuminate in the JET START
mode below 2000 RPM, the unit should be shut down as soon as safely practical.
NOTE
An optional low rpm JET START "safety system bypass" is available on VSG
Demand Control Circuit Card Assembly (CCA) A5. Normally CCA A5 will engage
shut down safeties at engine speeds below 2000 RPM, and allow the unit to run in
the JET START mode over it's operating speed of 1750 to 2350 RPM. The “safety
bypass” option can be engaged by disconnecting the “safety bypass” jumper from
electrical panel TB1-5 or TB2-18 (see figure 1, Section 2-2). This feature allows safe
operation of the Air Start Unit when it is in the JET START mode while aircraft is in
standby for engine start. As soon as the engine air start sequence begins, the
engine speed is raised above 2000 rpm and the safeties are disengaged.

4. ENGINE TROUBLESHOOTING (DDEC IV)

Proper maintenance and troubleshooting of the Detroit Diesel® Electronically Controlled
Series 60 engine (DDEC IV), requires the engine manufacturer's Series 60 Service Man-
ual, Sections 1 through 15, and the DDEC IV Troubleshooting Guide. Engine trouble-
shooting is performed using the hand held external Diagnostic Data Reader (DDR). The
Electronic Control Module’s (ECM's) built-in-test (BIT) feature utilizes an electronically
erasable programmable read only memory (EEPROM) chip.The EEPROM chip controls
basic engine functions, such as rated speed and power, timing of fuel injection, engine
governing, torque shaping cold start logic, transient fuel delivery, diagnostics, and engine
protection. Refer to Detroit Diesel® Troubleshooting Guide-DDEC IV, for specific infor-
mation regarding troubleshooting the ECM. For the purpose of simplicity, and to assist
maintenance personnel in the understanding of the system, basic test procedures and
operations have been included in the following pages. The information provided is not
intended to replace the Detroit Diesel® manuals, but to augment them for the conve-
nience of the user.

A. Engine Operation Description

Engines equipped with the DDEC IV are provided with a variety of options designed to
warn the operator of an engine malfunction. These options include CHECK ENGINE and
STOP ENGINE FAULT MODE panel lights located on the engine side of the main control
panel and in the electrical panel assembly (see figure 1). The red Stop Engine Light
(SEL) and yellow Check Engine Light (CEL), located on the electrical panel, are plac-
arded DS29 and DS30, respectively.
Fault lamp illumination is activated by low coolant level, low oil pressure, high engine oil

2-2 November 1, 1999

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AIR START UNIT

or coolant temperature, or overspeed.

When the ENGINE ON/OFF switch is first placed to ON, both the CEL and SEL illumi-
nate for approximately 5 seconds. This not only functions as a bulb test, but is the result
of the DDEC computer diagnosing the system to ensure everything is functional. Both
lights go out when all systems test normal.
CAUTION
DO NOT START THE UNIT IF THE CEL OR SEL FAULT MODE LIGHTS STAY ON, OR
IF THEY DO NOT COME ON MOMENTARILY AFTER SETTING ENGINE ON/OFF
SWITCH TO ON. THE FAULT MUST BE CORRECTED PRIOR TO OPERATION. FAIL-
URE TO COMPLY MAY RESULT IN SEVERE ENGINE DAMAGE.
(1) Fuel Injection System: The DDEC engine is equipped with an electronically con-
trolled fuel injection system. There are no control racks or mechanical linkage to
adjust.
(2) Governor System: The DDEC engine has no mechanical governor. Engine
horsepower, torque, idle and engine speed are contained in the internal elec-
tronics. Therefore there are no mechanical adjustments for idle and high speed
control.
(3) System 24 Volt Power Requirements: The DDEC operates at 24 volts. Should
voltage be too low for proper operation, the unit will start, but will operate only at
reduced rpm, and the CHECK ENGINE light will come on. When battery voltage
reaches a point where the DDEC will no longer function, the engine will shut
down. The storage battery must be in a fully charged condition to provide oper-
ating control voltage.

NOTE
Battery must be fully charged to provide control voltages. Do not attempt to start
engine if BATTERY voltmeter indicates less than 20 volts.

November 1, 1999 2-2

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ASP250
AIR START UNIT

Figure 1. Electrical Panel (DDEC IV Configuration)

2-2 November 1, 1999

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B. Engine Diagnostic Functions

Whenever the FAULT MODE CHECK ENGINE Light (CEL) or the FAULT MODE STOP
ENGINE Light (SEL) come on, it indicates that the ECM computer has diagnosed a fault and
will then store this information as a diagnostic code in its memory. The SEL will flash "active
diagnostic codes" and the CEL will flash "inactive diagnostic codes." A fault occurring at the
Electrical Panel (DDEC IV Configuration) any time an operator is checking codes is an
"active" fault. The active codes are those which are currently keeping the SEL or CEL light
on. Active codes are flashed via the SEL light.Inactive codes are all codes logged in the
ECM (whether or not they are currently turning on the SEL or CEL light). Inactive codes can
be cleared by using the external Pro-Link® 9000 Engine Diagnostic Computer, also referred
to as the Digital Data Reader (DDR). Inactive codes are flashed via the CEL light. Inactive
codes are logged into the ECM and time stamped with the following information: first occur-
rence of the code in engine hours, last occurrence of the code in engine hours, and total
time in seconds that the diagnostic code was received. The CEL lights if a minor fault
occurs. This indicates the problem should be addressed as soon as possible.
Once a malfunction has been corrected, the malfunction code recorded in the computer
memory will remain until it is erased by a technician using the DDR.
(1) Obtaining and Understanding Malfunction Codes: Engine malfunction codes
stored in the computer memory may be recalled and displayed in either of two
ways:
• Pro-Link® 9000 Engine Diagnostic Computer (See Figure 2) hereafter
referred to as the Digital Data Reader (DDR).
• The DDR is a microprocessor-based test instrument designed to tap into
the Detroit Diesel®'s DDEC computer within the ECM. It is programmed to
interpret the computer signals and provide readouts the technician can use
for diagnosis. The technician has instant access to any of the engines
operating data.
• A six pin electrical connector, mounted on the electrical panel (figure 1),
permits the connection of the DDR to the ECM.
• Engine Fault Status Switch (S18) (Figure 1) with coded CEL flashes.
• A series of coded light flashes on the CEL which correspond to individual
"inactive" error codes which indicate the system error. Active error codes
are flashed on the SEL.

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CAUTION
DO NOT HOLD ENGINE STATUS SWITCH S18 (FIGURE 1) IN DOWN POSITION
(READ) WHILE THE UNIT IS OPERATING. IF THIS IS DONE, THE DIAGNOSTIC MODE
LINE WILL BE GROUNDED, AND THE THROTTLE WILL BE FORCED TO IDLE.

• To read stored engine malfunction codes, the unit is shut-down, then

turned on by setting the ENGINE ON/OFF switch to ON without starting the
engine. The Engine Fault Status switch S18 (Figure 1) is held down to
read. The CHECK or STOP ENGINE lights will flash any stored codes.

Figure 2. Typical Fault Code Response

C. DDEC System Components and Configuration
The Electronic Control Module (ECM) (Figure 3) is mounted at the top forward end of the
engine, with the connector side to the right side of the unit. Wiring harnesses from the ECM
provide sensor signals from various engine components; injectors; oil temperature and pres-
sure; fuel temperature and pressure; timing and sync reference sensors; and turbo boost
pressure

Before repairing or replacing any system component as indicated by the diagnostic charts:
• Disconnect the appropriate connector(s) associated with the suspected defective
component and check for bent, broken, or dirty terminals or mating tabs. Clean,
straighten, or replace as required.
• If a problem was found, reconnect all connectors previously disconnected. Then
recheck the system to see if the problem has been corrected.

NOTE
Don't probe the back of a connector or pierce the DDEC IV wiring for pur-
poses of taking measurements. This can cause intermittent faults or system
failures and may affect the DDEC IV warranty.

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Figure 3. Electronic Control Module (ECM) (Left Side View)

Figure 4. Pro-Link 9000® Engine Diagnostic Computer/DDR

D. Check Engine Light (CEL) Diagnostic Codes

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Whenever the DDEC IV system detects an engine fault, the CHECK ENGINE or STOP
ENGINE light will illuminate. The DDEC computer will determine where the problem is, and
will then store this information in its memory.
If the malfunction is intermittent, the "lights" will come on and go off as the computer senses
the changing engine condition.
The malfunction code can be obtained by the operator by causing the CEL light to flash a
code number which will identify the malfunction. It will, for example, flash
twice....pause....flash five times....pause. This is code 25, indicating normal system opera-
tion.
To read CEL Diagnostic Codes, proceed as follows:
(1) Shut-down unit, with ENGINE ON/OFF switch in the OFF position.
(2) Set ENGINE ON/OFF switch (Figure 1), to ON. DO NOT START ENGINE.
CAUTION
DO NOT HOLD ENGINE STATUS SWITCH S18 (FIGURE 1) IN DOWN POSITION
(READ) WHILE THE UNIT IS OPERATING. IF THIS IS DONE, THE DIAGNOSTIC MODE
LINE WILL BE GROUNDED, AND THE THROTTLE WILL BE FORCED TO IDLE.
(3) Press and hold Engine Fault Status switch (S18) (Figure 1) to down position
(read).
(4) The Check Engine Light (CEL) will flash out stored codes, and will continue to
flash and repeat as long as the Engine Fault Status switch (S18) is set to read.
Record the codes flashed, and refer to table 1 for their description.
Check engine built-in-test as follows:
(a) Press and hold Engine Fault Status switch to down (read). Observe FAULT
MODE CHECK ENGINE lights. Verify a system "go" CEL code 25 (flash
twice,.. pause... flash five times... pause). Refer to table 1 for complete
code listing.
The SEL light may flash out active codes which are high priority faults and require imme-
diate operator attention to avoid engine damage. A SEL fault will be indicated when any
or all of the following conditions occur:
• Low coolant level
• High coolant temperature
• High oil temperature
• Low oil pressure
• Engine overspeed

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The CEL light may flash out inactive codes if a low priority fault is present (happening
now) or past fault(s) remain stored in the ECM memory. The inactive codes are low prior-
ity faults and only affect engine performance. Eventual operator attention is required.
E. Diagnostic Procedure
When diagnosing the cause for engine performance, fuel economy or exhaust system
complaints, perform normal check on the engine and systems prior to considering DDEC
IV as the possible source of the problem.
The codes and procedures listed in this manual are an abbreviated adaptation of the
Detroit Diesel® Troubleshooting Manual, and are provided as a first reference. Refer to
the Detroit Diesel® Troubleshooting Manual for further information and for procedures
not covered in this manual.
If no CEL codes were recorded by the DDEC IV, but a operational symptom remains,
Refer to the START chart in the Detroit Diesel® Troubleshooting Manual which can iden-
tify fault trees to use based on the user's complaint.

F. Using The Pro-Link® 9000 Diagnostic Data Reader (DDR)

Proper use of this reader is described in the instruction manual supplied with the unit.
This device is infinitely more useful in reading fault codes and diagnosing engine elec-
tronic faults than the Check Engine Light code process.
(1) Clearing Codes: This can only be done using the DDR. Note that removing the
battery cables on the GPU will not clear codes.
(2) EEPROM Reprogramming: The DDR is equipped with capabilities to reprogram
part of the engine calibration in the ECM. Specifically, the following calibration
changes can be made using the DDR:
• Change DDR, EEPROM password.
• Set idle shutdown timer to any whole number between 3 and 100 minutes.
• Enable/Disable shutdown override feature.
• Change engine run speeds.
• Add/Delete engine shutdown feature.

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Table 1: CEL Diagnostic Codes

CODE DESCRIPTION
CODE 11 Variable Speed Governor Sensor Input Voltage Low

CODE 12 Variable Speed Governor Sensor Input Voltage High

CODE 13 Coolant Level Sensor Input Voltage Low

CODE 14 Oil, Coolant, or Intercooler Temperature Sensor Input Voltage High

CODE 15 Oil, Coolant, or Intercooler Temperature Sensor Input Voltage Low

CODE 16 Coolant Level Sensor Input Voltage High

CODE 17 Bypass or Thottle, Valve Position Sensor Input Voltage High

CODE 18 Bypass or Thottle, Valve Position Sensor Input Voltage Low

CODE 21 EFPA Input Voltage High

CODE 22 EFPA Input Voltage Low

CODE 23 Fuel Temperature Sensor Input Voltage High

CODE 24 Fuel Temperature Sensor Input Voltage Low

CODE 25 No Active Codes, System Tests OK

CODE 26 Auxiliary Shutdown #1 or #2 Active

CODE 27 Air Inlet or Intake Air Temperature Sensor Input Voltage High

CODE 28 Air Inlet or Intake Air Temperature Sensor Input Voltage Low

CODE 31 Auxiliary High Side Output Open Circuit or Short to Ground

CODE 32 CEL or SEL Short to Battery (+) or Open Circuit

CODE 33 Turbo Boost Sensor Input Voltage High

CODE 34 Turbo Boost Sensor Input Voltage Low

CODE 35 Oil Pressure Sensor Input Voltage High

CODE 36 Oil Pressure Sensor Input Voltage Low

CODE 37 Fuel Pressure Sensor Input Voltage High

CODE 38 Fuel Pressure Sensor Input Voltage Low

CODE 41 Too Many SRS (Missing TRS) (Timing Reference Sensor)

CODE 42 Too few SRS (Missing SRS)

CODE 43 Coolant Level Low

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Table 1: CEL Diagnostic Codes

CODE DESCRIPTION
CODE 44 Oil, Coolant, Intercooler, or Intake Air Temperature High

CODE 45 Oil Pressure Low

CODE 46 ECM Battery Voltage Low

CODE 47 Fuel, Air Inlet, or Turbo Boost Pressure High

CODE 48 Fuel or Air Inlet Pressure Low

CODE 52 ECM Analog to Digital (A/D) Conversion Fault

CODE 53 ECM Nonvolatile Memory Fault

CODE 54 Vehicle Speed Sensor Fault

CODE 55 J1939 Data Link Fault

CODE 56 J1587 Data Link Fault

CODE 57 J1922 Data Link Fault

CODE 58 Torque Overload

CODE 61 Injector Response Time Long

CODE 62 Auxiliary Output Short to Battery (+) or Open Circuit or Mechanical Fault

CODE 63 PWM Drive Short to Battery (+) or Open Circuit

CODE 64 Turbo Speed Sensor Input Fault

CODE 65 Throttle Valve Position Input Fault

CODE 66 Engine Knock Sensor Input Fault

CODE 67 Coolant or Air Inlet Pressure Sensor Input Voltage Fault

CODE 68 Idle Validation Switch Open Circuit or Short to Ground

CODE 71 Injector Response Time Short

CODE 72 Vehicle Overspeed

CODE 73 Gas Valve Position Input Fault or Engine Synchro Shift (ESS) Fault

CODE 74 Optimized Idle Safety Loop Short to Ground

CODE 75 ECM Battery Voltage High

CODE 76 Engine Overspeed With Engine Brake

CODE 77 Fuel Temperature High

CODE 81 Oil Level, Crankcase Pressure, Dual Fuel Timing Actuator, or Exhaust Temperature
Voltage High

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Table 1: CEL Diagnostic Codes

CODE DESCRIPTION
CODE 82 Oil Level, Crankcase Pressure, Dual Fuel Timing Actuator, or Exhaust Temperature
Voltage Low

CODE 83 Oil Level, Crankcase Pressure, Exhaust Temperature, or External Pump Pressure High

CODE 84 Oil Level, Crankcase Pressure, Exhaust Temperature, or External Pump Pressure Low

CODE 85 Engine Overspeed

CODE 86 External Pump or Barometer Pressure Sensor Input Voltage High

CODE 87 External Pump or Barometer Pressure Sensor Input Voltage Low

CODE 88 Coolant Pressure Low

5. TROUBLESHOOTING CHART
This troubleshooting chart (See table 2) lists information under three headings as fol-
lows:
• Fault & Condition
• Probable Cause
• Test, Check, Remedy
A. Use of the Troubleshooting Chart
If the cause of a trouble is uncommon and cannot be located using the chart, a good
place to start your checks is at the last known source of power. Then proceed by check-
ing each component in the circuit/system thoroughly. Use the schematics and diagrams.
Electrical components in the troubleshooting chart (such as S1, T1, etc.), are identified
by a noun name an a corresponding symbol to identify the item on schematic diagrams.
It is assumed that wiring and connections in defective circuits have been thoroughly
checked before condemning any component(s).
B. Support Test Equipment Required
• Multimeter (FLUKE® Model No. 8060 or equivalent)
• At least two jumper leads with alligator clips and test prods are required.
• Pro-Link® 9000 Engine Diagnostic Computer (Optional).
• See engine Shop Manual tool requirements.

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6. SCHEMATICS AND WIRING DIAGRAMS

This troubleshooting section incorporates schematics and associated wiring diagrams for
use by the technician. They should be used in conjunction with the Troubleshooting
Chart (Table 2 & 3). When troubleshooting the Diesel engine, the troubleshooting chart
(Table 2) should be used in conjunction with the Engine Troubleshooting and Repair
Manual. The engine manual supplies an in-depth and comprehensive troubleshooting
guide with repair instructions. The schematic and wiring diagrams included in this man-
ual are:

Figure 5. ASP250 Overall Functional Diagram

Figure 6. Continuous Flow Jet Start Schematic
(Units with Serial #s prior to 501558)
Figure 7. Air Start Unit ASP250 Wiring Diagram
(Units with Serial # prior to 501558)
Figure 8. Continuous Flow Jet Start Schematic
(Units with Serial # 501558 and subsequent)
Figure 9. Air Start Unit ASP250 Wiring Diagram
(Units with Serial # 501558 and subsequent)

7. GENERAL ENGINE TROUBLESHOOTING INFORMATION

Stop the engine immediately should any component fail. Practically all engine failures
give some warning to the operator before the component fails and ruins the engine.
Many engines have been saved because alert operators heed warning signs such as a
sudden drop in oil pressure, unusual noises, etc., and immediately shutdown the engine.
Proper maintenance and troubleshooting of the Detroit Diesel® Electronically Controlled
Series 60 engine (DDEC IV) is provided in the Service Manual Series 60 and Trouble-
shooting Guide-DDEC IV.
For the purpose of simplicity, and to assist maintenance personnel in the understanding
of the system, basic test procedures and operations have been included in the following
pages. The information provided is not intended to replace the Detroit Diesel® Service
Manuals, but to augment them for the convenience of the user.
A. Locating a Misfiring Cylinder
The engine's ability to start and operate properly depends on an adequate supply of air,
compressed to sufficiently high pressure, and the injection of the proper amount of fuel at
the right time. Lack of power, uneven running, excessive vibration, can be caused by low
compression, faulty injectors in one or more cylinders or lack of sufficient air. For a pro-
cedure to locate a defective cylinder refer to Detroit Diesel® Troubleshooting Guide-
DDEC IV, Section V-D.1 Cylinder Cutout Test.

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B. Built in Test (BIT)

The Detroit Diesel® Electronically Controlled Series 60 engine (DDEC IV) provides a
variety of options designed to warn the operator of an engine malfunction. These options
include CHECK ENGINE fault light (CEL) and STOP ENGINE fault lights (SEL) located
on the Control Panel (figure 2, Sect. 1-1) and Electrical Panel Assembly (figure 1). The
lighting of either/or the SEL or the CEL fault light(s) indicates an engine problem. A SEL
fault is an active of "real time" fault that results in automatic engine power reduction, fol-
lowed by automatic engine shutdown is activated by any of the following conditions: low
coolant level, high coolant temperature, high oil temperature, low oil pressure, or engine
overspeed. A SEL fault is a high priority fault requiring immediate operator attention to
avoid engine damage. A CEL fault is an inactive fault. An inactive fault may be presently
occurring, but is a low priority fault indicating that an engine subsystem is providing sub-
standard performance.
With an active CEL indication the engine can still be operated until the fault is remedied.
When the ENGINE ON/OFF switch is first turned on, the CEL and SEL lights illuminate
for 5 seconds. This not only functions as a bulb test, but is the result of the DDEC com-
puter diagnosing the system to ensure everything is functional. If all systems test okay,
both lights will go out.
Whenever the CEL or the SEL stays on, the Electronic Control Module (ECM) computer
has detected and stored engine fault information in its memory. If the malfunction is inter-
mittent, the lights will come on and go off as the computer senses changing engine con-
ditions. Once a fault has been corrected, the DDEC system will return the engine to
normal operation. Engine malfunction codes stored in the ECM computer memory may
be recalled and displayed by the Diagnostic Data Reader (DDR). The fault code (s)
recorded in the ECM computer memory will remain until erased by a technician using the
DDR.
C. Reading Stored Flash Codes
Flash Codes and procedures listed in this manual are an abbreviated adaptation of the
Detroit Diesel® Troubleshooting Guide-DDEC IV, and are provided as a first reference.
Refer to Detroit Diesel® Operator's Guide Series 60 for further information and for proce-
dures not covered in this manual.
NOTE
If no CEL codes were recorded by the DDEC IV, but an operational symptom
remains, Refer to the START chart in the Detroit Diesel® Troubleshooting Guide-
DDEC IV which can identify fault trees to use based on the observed malfunction.

(1) Ensure that unit is shut-down with the ENGINE ON/OFF switch set to OFF.

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NOTE
Do not set Engine Fault Status switch S18 to read while the generator set is operat-
ing. If this is done, the diagnostic mode line will be grounded, and the throttle will
be forced to idle.

(2) On electrical panel, press and hold down ENGINE FAULT STATUS switch S18
to READ.
(3) Set ENGINE ON/OFF switch to ON. The CEL will flash out stored Flash Codes,
and will continue to flash and repeat as long as the ENGINE FAULT STATUS
switch is set to Read. Record the codes flashed, and refer to table 1 for their
description. Additional information concerning troubleshooting with Flash Codes
can be found in Detroit Diesel® Troubleshooting Guide-DDEC IV.
D. Clearing Stored Flash Codes
Flash Code (s) recorded in the ECM computer memory will remain until erased by a
technician using the Diagnostic Data Reader (DDR). The clearing of stored Flash Codes
can only be done using the DDR. Disconnecting the generator set battery cables
will not clear codes. The DDR is more useful in reading Flash Codes and diagnosing
engine electronic faults than the CEL code process.
E. Reprogramming Engine Calibration
The DDR can be used to reprogram certain engine calibration parameters. Reprogram-
ming information can be found in Detroit Diesel® Troubleshooting Guide-DDEC IV.
F. ECM Connector Checkout
The Electronic Control Module (ECM) is mounted at the top forward end of the engine,
with the connector side to the right side of the unit.All system connections are environ-
mentally protected. Wiring harnesses of the ECM provide sensor signals from various
engine components; injectors; oil temperature and pressure; fuel temperature and pres-
sure; timing and sync reference sensors; and turbo boost pressure. Before repairing or
replacing any system component, as indicated by the diagnostic charts, you must dis-
connect the connector(s) associated with the suspected defective component. Check
connector for defects. Clean, straighten, or replace as required. If a problem was found,
connect all connectors previously disconnected. Then check the system to see if the
problem has been corrected.
G. Component Failure
Unless the unit is in the JET START mode and actively starting an engine, stop the
engine immediately should any component fail. Practically all engine failures give some
warning to the operator before the component fails and ruins the engine. Many engines
have been saved because alert operators heed warning signs such as a sudden drop in
oil pressure, unusual noises, etc., and immediately shutdown the engine.

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Table 2: Engine Troubleshooting

Probable
Fault & Condition Test, Check, Remedy
Cause
FUEL level gauge Defective FUEL Using DMM, check for 12 VDC between M2-S (send) and chassis
M2 not indicating. level gauge M2. ground. If voltage is OK replace M2. If no voltage troubleshoot Fuel
Level Sender (FLS).

FUEL level gauge Fuel Level Using DMM, measure FLS resistance between 43-P7-4 and chas-
M2 incorrect reading. Sender (FLS) sis ground as follows
defective. E-Tank (10% full) = 0.00 - 0.50 Ω
1/2-Tank = 14.5 - 15.5 Ω
F-Tank = 29.50 - 31.50 Ω. If tank level does not match resistance
of FLS replace FLS.

FUEL level gauge 1. Defective Using DMM, check for 12 VDC at gauge M2-S and M2-G (gnd).
M2 below zero. FUEL level gauge Replace gauge M2 if 12 VDC is present.
M2.

2. Defective Fuel Using DMM, check for 29.50-31.50Ω (tank full) or 0.00-0.50Ω (tank
Level Sender empty) between fuel level gauge M2-Send and chassis ground. If
(FLS). Ohmic check is OK check wiring to FLS. If Ohmic check fails
replace FLS.

3. Defective FLS Using DMM, check for continuity between fuel level gauge M2-
wiring. Send and FLS pin 2.

Coolant WATER Defective Water Using DMM, check for 12 VDC between M3-S (send) and chassis
TEMP gauge M3 temperature ground. If voltage is OK replace M3 if no voltage troubleshoot cool-
inoperative. Sender (WTS). ant Water Temperature Sender (WTS).

PANEL LIGHTS not 1. Lamps burned Replace lamp bulb.

working. out.

2. Defective Using DMM, check for continuity between S13-1 and S13-2 with
PANEL LIGHTS PANEL LIGHTS switch set to ON.
switch S13.

CEL and/or SEL One or more Replace defective lamp.

lights do not momen- lamps failed fila-
tarily go on during ment test during
engine pre-start up. engine pre-start.

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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Engine oil PRESS 1. Engine Oil Fault Code 45 indicates low engine oil pressure. If no Fault Code is
gauge M4 not work- Pressure Sender indicated check EOPS as follows:
ing or incorrect read- (EOPS) defective. a. Using DMM, measure EOPS resistance between 45-P7-15 and
ing. Possible Fault chassis ground as follows: 0 PSI = 0.00-0.50 Ω (engine not run-
Code 45 (refer to ning)
table 1) and CEL b. The following measurements taken using DMM, EOPS wire 45
indication. removed/stowed and external PSI meter in pressure line (engine
running).
5 PSI = 2.0-3.0 Ω
10 PSI = 4.5-6.0 Ω
20 PSI = 9.0-11.0 Ω
30 PSI = 11.5-13.5 Ω
40 PSI = 18.5-21.0 Ω
50 PSI = 25.5-28.5 Ω
60 PSI = 28.0-31.0 Ω

2. Defective wir- a. Using DMM, check for 12 VDC between M4-I and chassis
ing. ground. If voltage is present proceed to step b. If voltage is absent
check for 24 VDC at CB1-2. If OK replace defective wiring.
b. Using DMM, check for continuity between: M4-sender and
EOPS-1 (oil press. sender). Replace defective wiring.

3. Defective oil If wiring and oil pressure sender test OK replace oil pressure gauge
pressure gauge M4.
M4.

BATTERY gauge M5 Battery voltage Fault Code 75 indicates high battery voltage. Check voltage output
indicates 30-32 VDC. too high engine of engine alternator for 26-30 VDC. If voltage is 30-34 VDC,
Possible Fault Code: alternator over- replace alternator.
75 (refer to table 1). charging battery.

BATTERY gauge M5 1. Storage bat- Check battery post connections for corrosion and tightness. Clean
inoperative. tery high terminal terminal posts and tighten as necessary.
resistance.

2. Defective BAT- Connect DMM across M5 terminals and measure voltage. If M5

TERY gauge M5. and DMM voltages differ by more than 1 volt replace M5. If voltage
is OK check for defective wiring.

3. Defective wir- Using DMM, check for continuity between J6-30 and M5-39.
ing to BATTERY Replace defective wiring.
gauge M5.

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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
POWER ON light 1. Defective lamp Check lamp filament and replace lamp bulb if defective.
DS1 will not come on bulb (DS1).
and STOP ENGINE
light goes ON. 2. ECM power Relay K13 energized. Reseat connector J4.
Possible Fault connector J4 not
Codes: 43/45/84 properly seated.
(refer to table 1). 3. ECM harness Relay K13 energized. Reseat connector J2.
connector J2 not
properly seated.

4. Engine prob- a. Fault Code: 43 (refer to table 1). Low coolant level. Check radia-
lem. Master fault tor coolant level sight glass (coolant leaks) and coolant level sensor
relay K2 indicat- wiring for damage.
ing a STOP b. Fault Code: 45 (refer to table 1). Oil pressure low. Check low oil
ENGINE condi- pressure (oil leaks and crankcase level).
tion. c. Fault Code: 44 (refer to table 1). High oil temperature. Perform
diagnostic troubleshooting using DDR to identify fault. Refer to
Detroit Diesel® Troubleshooting Guide-DDEC IV.

5. Engine prob- Perform diagnostic troubleshooting using DDR to identify fault.

lem. Master fault Refer to Detroit Diesel® Troubleshooting Guide-DDEC IV.
relay K2 indicat-
ing CHECK
ENGINE condi-
tion.

ELAPSED time 1. Defective a. Ensure engine is idling.

meter M1 not run- Engine Oil Pres- b. Using DMM, check for zero VDC between S4-1 and S4-2. If 24
ning. sure Switch S4. VDC is indicated, replace S4.

2. Defective Using DMM, check for Continuity between the following points:
ELAPSED time S4-2 to chassis ground/
meter M1 wiring. S4-1 to P7-17(control box)
J7-17 to TB2-3
TB2-3 to K4-4.
Replace defective wiring.

Engine will not crank. 1. Fault Code 46 Low or no system 24 VDC. BATTERY meter indicates in 18-22
Possible Fault Code (refer to table 1). VDC. Recharge or replace battery. After replacement of battery,
46 (refer to table 1). check output of alternator at BATTERY meter for 26-30 VDC. If bat-
tery fails to charge when engine is in UNLOAD mode, replace bat-
teries. If BATTERY gauge remains at 18-22 VDC replace alternator
A1.

2. Engine starter Remove and replace starter motor.

motor defective.

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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Engine cranks but 1. No fuel in tank. Check fuel LEVEL gauge for indication above empty. Add fuel. If
will not start. CHECK fuel level is OK, check for aerated fuel. Possible Fault Code: 11
ENGINE light ON for (refer to table 1).
5 seconds then goes
out. 2. Aerated fuel. a. Loosen fuel return line and direct flow into bucket.
b. Observe fuel flow out of line while cranking engine. If no flow,
check fuel filters and supply lines. If flow is steady reconnect fuel
line and check for white exhaust smoke. If white smoke is present,
refer to Fault & Condition - Engine cranks but will not start (white
smoke).

3. Dirty primary Drain fuel - water separator or replace fuel filter.

fuel filter.

4. Worn or mal- Loosen high pressure line at two injectors and visual check fuel
functioning fuel delivery while cranking the engine. Replace pump if fuel is not
pump. being delivered.

5. Defective a. Check that Demand VSG Control Circuit Card Assy A5 -

Demand VSG POWER LED CR1 is turned on indicating 12 VDC regulated volt-
Control Circuit age is available (see figure 1). If not on check for +24 VDC at
Card assembly A5P1-1. If voltage is present replace defective CCA A5. If +24 VDC
A5. is not present check +24 VDC supply from TB1-1.
b. If LED is on check for +0.80 to 0.96 VDC between CCA A5 TP-
4(+) and TP-5(-) (PTOSA signal)(see figure 1). If voltage is not
present, replace CCA A5.

Engine cranks but Low cylinder a. Improper valve clearance adjustment. Adjust valve clearance.
will not start (white compression. Refer to Detroit Diesel® Service Manual Series 60.
smoke). b. Exhaust valves sticking or burned. Remove cylinder head and
recondition the valves.
c. Check for worn or broken compression (piston) rings. Refer to
Detroit Diesel® Service Manual Series 60.
d. Check for cylinder head gasket leakage by removing coolant
filler cap and operating engine. A steady flow of gases from coolant
filler indicates that a cylinder head gasket is damaged or cylinder
head is cracked. Remove cylinder head and replace gaskets or cyl-
inder head. Refer to Detroit Diesel® Service Manual Series 60.
e. Blower not functioning. Inspect blower. Refer to Detroit Diesel®
Service Manual Series 60.
f. Check that blower bypass valve piston is not stuck in open posi-
tion. Check valve piston or piston guide for scoring. Replace valve
assembly if the above conditions are found. Refer to Detroit
Diesel® Service Manual Series 60.

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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Engine starts, but will 1. Fault Code: 46 Low voltage to ECM. Check BATTERY meter for 26-30 VDC. If
not keep running. (refer to table 1). incorrect, replace or recharge batteries from external source. If bat-
Possible Fault Code: tery fails to charge when engine is in run mode, replace batteries. If
46 (refer to table 1). battery VOLTS gauge remains between 18-22 VDC, replace alter-
nator A1. If meter voltage is OK, check for 24 VDC at ECM-J4 (fig-
ure 5) and ECM-J2/pin B3 (Ignition). Repair defective wiring.

2. Aerated fuel. a. Loosen fuel return line and direct flow into bucket.
b. Observe fuel flow out of line while cranking engine. If no flow,
check fuel filters and supply lines. If flow is steady, reconnect fuel
line and check for white exhaust smoke. Bleed fuel system and
check for suction leaks.

3. Fuel filter Drain fuel-water separator or replace filter.

clogged or fuel
waxing due to
cold weather.

4. Fuel supply Clean or replace filters and check for fuel line restrictions.
restricted.

5. Fuel contami- Verify by draining fuel tank.

nated.

6. Injector Check for:

response time a. Bad injector electrical harness or connector (high resistance).
defect. b. Tripped circuit breaker CB3 (see figure 5) and/or CB4.
c. Sticky injector solenoid valve. Use DDR to determine faulty injec-
tor. Refer to Detroit Diesel® Troubleshooting Guide-DDEC IV, Sec-
tion 4/E. Fault Code: 61.

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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Engine will not reach 1. Fuel supply Refer to Fault & Condition - No Fuel or Insufficient Fuel.
rated speed in restricted.
UNLOAD/AIR
COND. or JET 2. Malfunctioning Refer to Fault & Condition - No Fuel or Insufficient Fuel.
START modes. fuel pump.

3. Defective Using DMM, with S1 set to JET START/check for continuity

MODE SELEC- between the following points:
TOR switch S1. UNLOAD - K13-9/10,
AIR COND. - S1F-1/2,
JET START - S1B-1/2.
If switch or relay contacts are open when mode is selected, replace
defective component.

4. Defective a. Operate unit in each mode, with air valves full open (demand
demand VSG system will not kick-in) and observe and record the following RPM
control circuit indications:
card assembly UNLOAD (idle) - 1100 to 1150 RPM,
A5. AIR COND. - 1800 to 1850 RPM,
JET START - 2300 to 2350 RPM.
If RPM is correct, proceed to step b below. If RPM cannot be
attained, proceed to Demand VSG trouble shooting table 4, ball
valve 1 and 2 open.
b. Operate unit in each mode/with air valve full closed (demand
system will kick-in) and observe and record the following RPM indi-
cations:
UNLOAD (idle) - 1100 to 1150 RPM,
AIR COND. - 1300 to 1500 RPM,
JET START - 1800 to 1950 RPM,
If RPM is not attained/ proceed to Demand VSG trouble shooting
table 4, ball valve closed.

5. Engine Fault Move switch from the read position (down).

Status switch S18
held in the read
position (down).

November 1, 1999 2-2

Original Page 21
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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Engine runs 1. Low coolant Check coolant TEMP gauge for 160o-197oF (71o- 92oC) with
unevenly or stalls fre- temperature. engine running. If temperature is too low, check for the following:
quently. a. Thermostat(s) may be opening at incorrect temperature.
Possible Fault Code:
Remove and inspect and test two thermostats for 180o F (82.2o C)
46, 48, 61, 71 (refer
opening. Refer to Detroit Diesel® Service Manual Series 60.
to table 1).
Replace thermostat as necessary.
b. Check for excessive coolant leakage past thermostat(s) at
seal(s). Replace seal(s) and recheck engine temperature.

2. Fault Code: 46 Low system 24 VDC. Battery voltage low. Check circuit breaker
(refer to table 1). CB3 and CB4 for open. BATTERY meter indicates 18-22 VDC.
Recharge or replace battery. After replacement of battery/check
BATTERY meter for 26-30 VDC. If voltage fails to charge when
engine is in UNLOAD (idle) mode, replace batteries. If BATTERY
gauge remains at 18-22 VDC, replace alternator A1.

3. Fault Code: 48 Fuel pressure low. Refer to Fault & Condition - No fuel or insuffi-
(refer to table 1). cient fuel.

4. Fault Code: 61 Injector response time long. Check for:

(refer to table 1). a. Bad injector harness, connection (high resistance), faulty alter-
nator, voltage regulator or poor, broken ground cables.
b. Sticky injector solenoid valve. Use DDR to determine faulty injec-
tor. Refer to Detroit Diesel® Troubleshooting Guide-DDEC IV, Sec-
tion 4, E. Fault Code: 61

5. Fault Code: Injector response time to short.

71(refer to table a. Aerated fuel: (1) Loosen fuel return line and direct flow into
1). bucket. (2) Observe fuel flow out of line while cranking engine. If no
flow, check fuel filters and supply lines. If flow is steady, re-connect
fuel line and check for white exhaust smoke. If white smoke is
present, refer to Low Cylinder Compression Fault & Condition or
restricted air intake.
b. Sticky injector solenoid valve. Use DDR to determine faulty injec-
tor. Refer to Detroit Diesel® Troubleshooting Guide-DDEC IV/Sec-
tion 4, E. Fault Code: 71 (refer to table 1).

Rough idle warm 1. Air in fuel sys- Bleed fuel system and check for suction leaks.
engine. tem.

2. Fault Codes: Injection timing incorrect, injector nozzles clogged or inoperative.

61, 71(refer to Check fuel injector timing using DDR. Time injectors. Refer to
table 1). Detroit Diesel® Troubleshooting Guide-DDEC IV.

2-2 November 1, 1999

Page 22 Original
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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Engine surges in 1. Low fuel level Check fuel LEVEL gauge. If low fill supply tank.
UNLOADED mode. in tank.
Possible Fault Code:
48 (refer to table 1). 2. UNLOADED Idle speed is fixed by DDEC IV program at 1100-1150 rpm. A
speed (idle) set change of engine rpm may be due to engine malfunction such as;
too low. Normal faulty injector, blown piston, air intake problem.
UNLOADED
speed (hot
engine) is 1100-
1150 rpm.

3. Fault Code: 48 Low fuel pressure. Malfunctioning fuel pump. Check pump for bro-
(refer to table 1) ken drive shaft or coupling by inserting the end of a wire through
one of the pump flange drain holes, then crank engine momentarily
and note if wire vibrates. Vibration will be felt if pump shaft rotates.
Remove pump and check for sticking relief valve. Troubleshoot fuel
flow and pump in accordance with procedures of Detroit Diesel®
Service Manual Series 60.

4. Fault Code: 61, Misfiring cylinders. Injection timing incorrect, injector nozzles
71 (refer to table clogged or inoperative. With coolant temperature minimum of
1). 160o F (71o C), check fuel injector timing using DDR. Time injec-
tors. Refer to Detroit Diesel ®Troubleshooting Guide-DDEC IV.

Engine knocks. Pos- 1. Poor quality Drain tank, fill with correct Diesel fuel (refer to table 1-4 Operating
sible Fault Codes: fuel. Fuels).
61, 71 (refer to table
1). 2. Air in fuel sys- Bleed fuel system and check for suction leaks.
tem.

3. Oil injection in Defective blower-to-block gasket. Refer to high lubrication oil con-
upstream air sumption - Fault & Condition, internal leaks.
intake.

4. Low coolant a. Check engine coolant TEMP oF gauge for reading of 160o -
temperature.
197o F (71o - 92o C) while engine is operating. If temperature is too
low, thermostat stuck open. Remove, inspect, and test thermostat.
Install new thermostat if necessary.
b. Excessive leakage of coolant past thermostat seal(s). Remove
thermostat and replace seals.

November 1, 1999 2-2

Original Page 23
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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Fuel or oil leaking 1. Intake air Check intake manifold vacuum. If indication is 20" of H20 or
from exhaust mani- restriction. greater, replace filter element. Review engine operation for exces-
fold. sive idling.

2. Injector needle Locate and replace malfunctioning injector. Refer to Detroit

valve stuck open. Diesel® Service Manual Series 60.

3. Obstructed tur- Check, clean line.

bocharger drain
line.

4. Turbocharger Check, replace turbocharger. Remove, disassemble, and inspect

seals leaking oil. turbocharger. Refer to Detroit Diesel® Service Manual Series 60.

Engine will not 1. Fault Code: 83 Lubricating oil level too high. Drain oil to proper level.
deliver rated power. (refer to table 1).
Possible Fault Code:
83, 44 (refer to table 2. Low intake air Allow engine to warm up to proper temperature before attempting
1) temperature. to bring it up to RUN speed.
(below 0oC
[32oF]).

3. Insufficient air Clogged air intake system or operation at altitude above 24.9 ± 0.2
or high altitude Hg (12,000 ft/3660 km). Check air cleaner and clean air intake
operation ducts.

4. High ambient Check for source of high air temperature.

air temperature.

5. Leak in engine Tighten all loose connections or replace exhaust manifold gaskets
air intake or as necessary.
exhaust manifold.

6. Blower bypass Check that blower bypass valve piston is not stuck in open position.
valve defective. Check for scoring of valve piston or piston guide. Replace valve
assembly if the above conditions are found. Refer to Detroit
Diesel® Service Manual Series 60.

2-2 November 1, 1999

Page 24 Original
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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Engine will not 7. Foreign mate- Shut down engine, remove air intake ducting and spin turbine
deliver rated power. rial lodged in wheel by hand. If wheel does not spin freely, remove, disassemble
Possible Fault Code: turbo charger and inspect turbocharger for damage. Refer to Detroit Diesel® Ser-
83, 44 (refer to table compressor or vice Manual Series 60.
1) (CONT.) turbine wheels.

8. Excessive dirt Clean air cleaner and check for air intake leaks. Thoroughly clean
build-up behind compressor assembly. Refer to Detroit Diesel® Service Manual
turbocharger Series 60.
compressor
wheel.

9. Excessive dirt Carbon build-up behind turbine wheel, coked oil, or combustion
build-up behind deposits. Remove, disassemble and clean turbocharger. Refer to
turbocharger tur- Detroit Diesel® Service Manual Series 60.
bine wheel.

10. Turbo- Check for excessive temperatures, imbalance, dirty oil, oil starva-
charger rotating tion, insufficient lubrication and abnormal wear. Remove, disas-
bearing seizure, semble and inspect turbocharger for bearing damage. Refer to
dirty or worn Detroit Diesel® Service Manual Series 60.
bearings.

11. Oil on turbo- Clogged engine oil breather, restricted exhaust flow (excessive
charger compres- back pressure), air intake restriction, clogged air cleaner element,
sor wheel or in collapsed air inlet line, excessive cranking or idling for long periods
compressor hous- of time.
ing. Check oil breathers, exhaust system, air intake system and/or elim-
inate excessive cranking and long idle periods. Repair as neces-
sary

12. High exhaust a. Check for 3.0 inches Hg (0.75 kPa) exhaust back pressure at
back pressure. 1800 rpm, refer to Detroit Diesel® Service Manual Series 60. If
high, check exhaust piping for damage, carbon formation or foreign
matter. Replace muffler and or defective piping as necessary.
b. Check air breather for obstruction. Clean or replace as neces-
sary.
c. Remove air box covers and inspect cylinder liner ports for
restriction. Clean ports if they are over 50% plugged.
d. Refer to Fault & Condition - Crankcase Pressure High.

13. Fault Code: Turbocharger inter-cooler temperature high. Clogged inter-cooler.

44 (refer to table Remove and inspect inter-cooler. Service if necessary. Refer to
1). Detroit Diesel® Service Manual Series 60.

November 1, 1999 2-2

Original Page 25
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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Engine misfiring. 1. Fault Code: 71 Fuel injector response time to short. Check for: a. Aerated fuel. b.
Possible Fault Code: (refer to table 1). High battery voltage (Fault Code: 75, refer to table 1). c. Failed
71 or Fault Code: 75 injector solenoid valve. Using DDR, locate defective injector. Refer
(refer to table 1). to Detroit Diesel® Troubleshooting Guide-DDEC IV.

2. Fault Code: 75 High battery (+) supply voltage. If BATTERY gauge indicates above
(refer to table 1). 30 VDC, check system voltage for 24-28 VDC. Correct high engine
alternator output. Check alternator for 26-30 VDC output voltage. If
alternator output voltage is 30-34 VDC, replace alternator A1.

3. Aerated fuel. Check for fuel injection lines leaking. Bleed fuel system and check
for suction leaks. Inspect and replace broken lines.
a. Loosen fuel return line and direct flow into bucket.
b. Observe fuel flow out of line while cranking engine. If no flow,
check fuel filters and supply lines. If flow is steady, reconnect fuel
line and check for white exhaust smoke. If white smoke is present,
refer to Fault & Condition - Low Cylinder Compression or restricted
air intake.

4. Incorrect valve Inspect push rods, springs, and adjust valves. Refer to Detroit
adjustment. Diesel® Service Manual Series 60.

5. Injector noz- Check fuel injector Timing using DDR. Time injectors. Refer to
zles clogged or Detroit Diesel® Troubleshooting Guide-DDEC IV.
inoperative.

Engine misfiring. 1. Fault Code 61 Fuel injector response time long. Check for:
Possible Fault Code: (refer to table 1). Bad injector harness, connection (high resistance), faulty alterna-
61 (refer to table 1). tor, voltage regulator, or poor or broken ground cables. Sticky injec-
tor solenoid valve. Use DDR to determine faulty injector. Refer to
Detroit Diesel® Troubleshooting Guide-DDEC IV.

2. Injector noz- Check for fuel injection lines leaking. Bleed fuel system and check
zles clogged or for suction leaks. Inspect and replace broken lines.
inoperative

3. Incorrect valve Inspect push rods, springs, and adjust valves. Refer to Detroit
adjustment. Diesel® Service Manual Series 60.

4. Injector timing Check fuel injector timing using DDR. Time injectors. Refer to
incorrect. Detroit Diesel® Troubleshooting Guide-DDEC IV.

2-2 November 1, 1999

Page 26 Original
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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Turbocharger noisy 1. Wheel shaft Locate cause of loss of oil pressure and repair. Remove, disassem-
operation or vibra- bearings are not ble and inspect turbocharger for bearing damage. Refer to Detroit
tion. being lubricated. Diesel® Service Manual Series 60.

2. Improper clear- Remove, disassemble and inspect turbocharger. Refer to Detroit

ance between tur- Diesel® Service Manual Series 60.
bine wheel and
housing.

3. Leak in engine Tighten all loose connections or replace exhaust manifold gaskets
air intake or as necessary.
exhaust manifold.

Engine will not crank. 1. MODE Set MODE SELECTOR switch to UNLOADED and start engine.
SELECTOR
switch not set to
UNLOADED
(idle).

2. Circuit breaker Reset circuit breaker CB2, 3, 4.

CB2, 3, or 4
open.

3. Dead storage Check BATTERY gauge for 22-26 VDC. If voltage is low, recharge
batteries or replace storage batteries.

4. Defective Check switch S3 for 24 VDC at S3-1 when pressed (ENGINE ON/
ENGINE START OFF switch S2 set to ON). Replace if defective.
push-button
switch S3.

5. Defective Using DMM, check for continuity between starter contactor K1

starter contactor holding coil. If no continuity, replace K1.
K1.

6. Starter motor Remove starter motor and check for broken teeth on engine fly-
operating, but not wheel or starter motor pinion gear and spring.
cranking the
engine.

7. Engine seizure. Hand rotate engine at least one complete revolution. If engine can
not be rotated, internal damage is indicated. Disassemble engine to
determine extent and cause of damage.

Engine cranks Wrong engine oil Use engine oil specified in Consumable Supplies, Section 2-1,
slowly. grade in crank- Table 1.
case.

November 1, 1999 2-2

Original Page 27
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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Engine smokes black 1. Wrong grade Refer to Engine Fuels, Section 2-1, Table 6.
or gray. of fuel.

2. Restricted air a. Check for AIR CLEANER for obstructions, replace air filter.
inlet to cylinders. b. Check for turbocharger inlet for obstruction.
c. Dirty inter-cooler fins. Inspect and clean as necessary.

3. High oil use. High oil use can be caused by defective turbocharger seals or air
inlet restriction above limit of 20" H2O (5 kPa), causing oil to be
pulled past oil seals. Check for indications of oil on compressor or
turbine sides of turbocharger. If oil is detected, refer to Detroit Die-
sel® Service Manual Series 60, for procedure to locate turbo-
charger oil seal leakage.

4. High exhaust Refer to Fault & Condition - High Exhaust Back Pressure.
back pressure.

Engine smokes white Misfiring cylin- With coolant temperature minimum of 160o F (71o C), check fuel
(coolant tempera- ders. injector timing using DDR. Time injectors. Refer to Detroit Diesel®
ture minimum of Troubleshooting Guide-DDEC IV.
160 0F (71 0C)) -
Fault Code: 61, 71
(refer to table 1).

Engine exhaust Lubrication oil not Remove and inspect exhaust manifold and stacks for wetness or oil
smokes blue. burned in cylin- discharge. Excessive clearance between valve stem and guide can
der. produce oil in cylinders and stack. Repair valve guides and/or
install valve stem. Refer to Detroit Diesel® Service Manual Series
60.

High exhaust back 1. Exhaust sys- With coolant temperature minimum of 160o F (71o C), use manom-
pressure. tem defect. eter to check for 3.0" Hg (0.75 kPa) exhaust back pressure at 1800
rpm, refer to Detroit Diesel® Service Manual Series 60. If exhaust
back pressure high, check exhaust system piping for damage, car-
bon formation or foreign matter causing obstruction. Replace muf-
fler and/or defective piping as necessary.

2. Injector timing Check fuel injector timing using DDR. Time injectors. Refer to,
off. Detroit Diesel® Troubleshooting Guide-DDEC IV.

2-2 November 1, 1999

Page 28 Original
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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
High lubrication oil 1. Fault Code: 83 Oil level high, crankcase pressure high. Check oil level dipstick for
consumption. Possi- (refer to table 1). overfilled crankcase. Adjust level as necessary. Check for plugged
ble Fault Code: 83 air breather causing high crankcase pressure. Replace as neces-
(refer to table 1). sary.

2. External leaks. Steam clean engine. Operate engine at no-load rpm and operating
temperature, then check for:
a. Oil lines and connections leaking.
b. Gasket and oil seal leaks.
c. Blue smoke condition. Refer to Fault & Condition - Blue Smoke.

3. Internal leaks WARNING: BLOWER ROTORS ARE EXPOSED AND ROTAT-

ING DURING TEST. CONTACT WITH ROTORS MUST BE
AVOIDED DURING CHECK. FAILURE TO COMPLY WILL
RESULT IN PERSONNEL INJURY.
a. Check for blower seal leakage by removing air inlet housing and
watching through the blower inlet for oil radiating away from rotor
shaft seals while engine is running. If oil is passing through seals,
over-haul blower.
b. Defective turbocharger seals or air inlet restriction above limit of
20" H2O (5 kPa), causing oil to be pulled past oil seals. Check for
indications of oil on compressor or turbine sides of turbocharger. If
oil is found, refer to Detroit Diesel® Service Manual Series 60 for
procedure to locate turbo-charger oil seal leakage.
c. Check for oil cooler core leak by pressure testing engine cooling
system. Refer to Detroit Diesel® Service Manual Series 60. If leak-
ing, replace oil cooler core. Inspect coolant for engine oil contami-
nation. Inspect crankcase oil for coolant contamination. If
contaminated, flush coolant and lubrication system in accordance
with procedures of Detroit Diesel® Service Manual Series 60.
d. Check for excessive clearance between valve stem and guide.
Repair valve guides and/or install valve stem. Refer to Detroit
Diesel® Service Manual Series 60.

November 1, 1999 2-2

Original Page 29
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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
4. Oil control at WARNING: HOT OIL COULD BE BLOWN OUT OF AIR BOX
cylinder. DURING THIS CHECK. EYE AND FACE PROTECTION IS
REQUIRED. FAILURE TO COMPLY MAY RESULT IN SEVERE
BURNS.
a. Parking the generator set at an angle greater than 8o. Decrease
parking angle to less than 8o.
b. Check for low cylinder compression. Refer to Detroit Diesel®
Service Manual Series 60. Remove and replace cylinder kits as
necessary.
c. Piston pin retainer loose or oil control rings worn, broken,
improperly installed or scored. To check, run engine at idle speed
with air box cover removed (one at a time) to determine if oil is
uncontrolled as indicated by slobbering out of the liner ports.
Inspect all cylinders.
d. Excessive oil in air box due to bad blower, turbo seals, worn oil
control rings or loose piston pin retainer.
e. Dirt in air intake system results in scored liners or pistons. Check
for faulty air induction system allowing contaminated air to enter
engine.

Engine oil in engine Cracked oil cooler Refer to Fault & Condition - High Lubrication Oil Consumption,
coolant or crank- core. Probable Cause - Internal Leaks, Remedy - c.
case.

Coolant in crank- Cracked oil cooler Refer to Fault & Condition - High Lubrication Oil Consumption
case. core. Probable Cause - Internal Leaks Remedy - c.

Oil loss from dipstick Crankcase pres- Refer to Fault & Condition - Crankcase pressure high.
hole, breather tube sure high.
or crankcase ventila-
tor. Fault Code: 83
(refer to table 1).

2-2 November 1, 1999

Page 30 Original
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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Crankcase pressure 1. Cylinder blow- Connect manometer to oil level dipstick opening and check for
high - Fault Code: 83 by. Head gasket pressure of 3" Hg (0.75 kPa) @1800 rpm. If high, check for leaking
(refer to table 1). leaking. head gasket, piston, or cylinder liner damage, piston rings worn or
broken, or faulty blower seals. Refer to Detroit Diesel® Service
Manual Series 60.

2. Breather Check engine air breather for damage or restriction.

Restriction

3. Blower or air a. Connect manometer to an air box drain tube and check for man-
box pressure low. ifold pressure of 60.9" Hg (206 kPa). b. Check for damaged blower-
to-block gasket or cylinder block end plate gasket leaking. Replace
gaskets as necessary.

4. High exhaust Refer to High Exhaust Back Pressure - Fault & Condition
back pressure.

No fuel or insuffi- 1. Air leaks in fuel a. Check for loose fuel line connections or cracked lines between
cient fuel. Possible system. fuel pump and tank or suction lines in tank. Replace and/or tighten
Fault Code: 48 (refer loose fuel lines.
to table 1). b. Check for damaged fuel filter gasket. Replace fuel filter.
c. Check for low fuel supply, Perform Fuel Flow Test contained in
Detroit Diesel® Service Manual Series 60.

2. Fault Code: 48 Low Fuel Pressure.

(refer to table 1). a. Fuel filter clogged. Replace filter.
b. Fuel lines restricted, perform Fuel Flow Test found in Detroit
Diesel® Service Manual Series 60. Replace clogged line.
c. Fuel pump relief valve not seating. Remove fuel pump and ser-
vice relief valve. Refer to Detroit Diesel® Service Manual Series
60.
d. Fuel pump not rotating, pump gears or body defective. Replace
fuel pump. Refer to Detroit Diesel® Service Manual Series 60.

Oil loss from dipstick Crankcase pres- Refer to Fault & Condition - Crankcase pressure high
hole, breather tube sure high.
or crankcase ventila-
tor. Fault Code: 83
(refer to table 1).

November 1, 1999 2-2

Original Page 31
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Table 2: Engine Troubleshooting (Continued)

Probable
Fault & Condition Test, Check, Remedy
Cause
Crankcase pressure 1. Cylinder blow- Connect manometer to oil level dipstick opening and check for
high-Fault Code: 83 by head gasket pressure of 3" Hg (0.75 kPa) @1800 rpm. If high, check for leaking
(refer to table 1). leaking. head gasket, piston or cylinder liner damage, piston rings worn or
broken or faulty blower seals. Refer to Detroit Diesel® Service
Manual Series 60.

2. Breather Check engine air breather for damage or restriction.

Restriction

3. Blower or air a. Connect manometer to an air box drain tube and check for man-
box pressure low. ifold pressure of 60.9" Hg (206 kPa).
b. Check for damaged blower-to-block gasket or cylinder block end
plate gasket leaking. Replace gaskets as necessary.

4. High exhaust Refer to Fault & Condition - High Exhaust Back Pressure.
back pressure

2. Fault Code: 48 Low Fuel Pressure.

3. Bad fuel line a. Restrictive fitting (No. 8924185) 0.070" (1.778 mm) diameter fit-
installation. ting missing from fuel line. Replace fitting.
b. Defective or incorrectly installed fuel intake line check valve.
Ensure that valve arrow is on top or points upward. Replace check
valve if defective.

Fuel pump leaks Defective fuel Fuel pump see page normal with running engine and right after
pump seal. shut down. Replace seals if leakage exceeds one (1) drop per
minute.

Engine oil being Crankcase is Check oil level. Remove any excess oil until oil level is at the FULL
blown out through overfilled. mark on the dipstick
crankcase breather.

2-2 August 30, 2000

Page 32 Change 1
ASP250
AIR START UNIT

Table 3: Compressor Troubleshooting Chart

Probable
Fault & Condition Test, Check, Remedy
Cause
HIGH AIR TEMP Delivery air dis- Adjust delivery air discharge pressure to lower level. Refer to Sec-
fault lamp illumi- charge pressure tion 2-4, para. 2.
nates during opera- too high.
tion.

LOW OIL PRESS 1. Suction Clean suction strainer.

fault lamp illumi- strainer plugged
nates during opera-
tion

2. Oil filter Replace oil filter cartridge.

plugged

3. Insufficient oil Add oil to proper level.

level

4. Defective oil Replace oil pump.

pump

LOW OIL LEVEL Low oil level in Check oil level, add as required.
fault lamp illumi- compressor
nates during opera- crankcase.
tion.

HIGH OIL TEMP 1. Insufficient oil Check oil level, add as required.
fault lamp illumi- level.
nates during opera-
tion. 2. Clogged oil fil- Replace filter.
ter.

Oil in compressor 1. Incorrect type Replace oil and filter.

sight glass seen to of oil.
be foaming.

2. Water present Replace oil and filter.

in oil.

August 30, 2000 2-2

Change 1 Page 33
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Table 4: Demand VSG Circuit Card Assy (CCA) A5 Troubleshooting

Air
Voltage Delivery
Measured OPERATING MODE Output Ball
at Circuit Valve
Card Test Setting REMEDY
Point
(Referenced AIR JET
UNLOAD
to TP-5 (-)) COND START
VDC
VDC VDC
TP-1(+) 11.40-12.60 11.04-12.60 11.40-12.06 Open If green LED A5CR1 is not on
(12 V power and voltage is incorrect the
supply) 11.40-12.60 11.40-12.60 11.40-12.06 Closed onboard power supply has
failed. Replace CCA A5

TP-2(+) 1.46-1.62 2.40-2.70 3.13-3.46 Open MODE switch S1 an/or wiring

(Set point between switch and CCA A5
voltage) 1.46-1.62 2.40-2.70 3.13-3.46 Closed is defective. Check switch and
wiring. If Ok, replace CCA A5.

TP-3(+) .078-.086 .112-.124 .025-.028 Open Pressure Differential Trans-

(PTF input) ducer (PTF) failure. Replace
.816-.902 .978-1.08 .816-.902 Closed PTF.

TP-4(+) 1.38-1.53 2.32-2.56 2.80-3.12 Open CCA A5 or electronic gover-

(Current nor A2 defective. Replace
compen- 1.38-1.53 1.40-1.66 2.30-2.50 Closed each one in turn. Check for
sated volt- correct voltage.
age)

2-2 November 1, 1999

Page 34 Original
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Table 5: Schematic Diagram Component Key and Description

Item Nomenclature Location and Functional Description

A1 Fault Printed Circuit Board Electrical Panel: Board which has mounted major components of
the fault monitoring circuits.

A2 Electronic Governor Electrical Panel: Sets and controls engine speed.

A3 Electronic Overspeed Switch Electrical Panel:

A4 Diode Logic Board Electrical Panel: Board which contains the majority of diodes uti-
lized within the electrical system.

A5 Demand VSG control board Electrical Panel: Regulates Air Start Unit engine speed to maintain
proper output air pressure.

AD1-3 Meter Adapter, 24/12VDC Reduces 24VDC supplied by system to 12VDC for meter opera-
tion.

AD4-6 Meter Adapter, 24/12VDC Reduces 24VDC supplied by system to 12VDC for meter opera-
tion.

AS1,4 Solenoid Valve, Jet Start Air Compressor Air System Assy:

AS2 Solenoid Valve, A/C Air Compressor Air System Assy: A/C Mode control

AS3 Solenoid Valve, Air unload Compressor Air System Assy: Dump Air

B1-4 Battery, 12VDC Left Front of Enclosure: Provides 24VDC operating power.

C12 Capacitor, 1000 uF, 35V Electrical Panel: TB1

CB1, 2 Circuit Breaker, 10 Amp Electrical Panel, Outside Edge: Provides over current protection
for operating system.

COATE Output Air Temperature, Sender Delivery Air Manifold Assy: Output deliver air temperature analog
signal to M9.

COTSE Oil Temperature, Sender Compressor: Signal to M4.

COPS Oil Pressure, Sender Compressor: Signal to M6

CR1-12 Diode, 5 A, 600V, Electrical Panel: Diode Logic CCA A5. Individual circuit diodes.

DS1 Lamp, Control Power ON Control Panel: When lit, signifies that the engine power switch is
in the ON position.

DS2 Lamp, Fuel Gauge Control Panel Fuel Gauge: Illuminates gauge for night time opera-
tion.

DS3 Lamp, Meter, Engine Water Control Panel Water Temperature Gauge: Illuminates gauge for
Temp. night time operation.

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Table 5: Schematic Diagram Component Key and Description (Continued)

Item Nomenclature Location and Functional Description

DS4 Lamp, Meter, Engine Oil Pressure Control Panel Oil Pressure Gauge: Illuminates gauge for night
time operation.

DS5 Lamp, Meter, Voltmeter Control Panel: Voltmeter: Illuminates gauge for night time opera-
tion.

DS8 Lamp, Cool-down Indicator Control Panel: Indicates that engine is operating at reduced coo
down speed for shut down.

DS9 Beacon, Operational Roof Mounted: Illuminates when Unit is in Operation.

DS10 Beacon, Low Fuel Warning Roof Mounted: Illuminates when engine fuel level is low.

DS11- Lamp, Fault Indicators, 24VDC Control Panel: Provides visual indication of a system fault.
17

DS18/ Panel Light, 24VDC Control Panel: Provides control panel illumination for night time
19 use.

DS23- Clearance Lamps, 24VDC Air Start Enclosure: Marker lights for night time operation.
26

ECM Electronic Control Module Engine: Detroit Diesel® Electronic Control module (DDEC IV)

ES Solenoid, Ether Start (optional) Frame: Energized when S15 is pressed and ambient temperature
is <60°. Delivers ether to engine intake manifold

FLS Fuel Level Sender Fuel Tank: Provides fuel level measurement to gauge.

G1 Engine Mounted Alternator Engine: Provides 24VDC to operate controls and charge batter-
ies.

J6 Control Panel/Electrical Panel Control Panel: Electrical interface

Harness Connector

J7 Engine/Electrical Panel Harness Control Panel: Electrical interface

Connector

J8 Engine/Electrical Panel Harness Control Panel: Electrical interface

Connector

J9 Canopy Connector Canopy: Electrical interface for roof mounted accessories.

K1 Relay, Engine Start, 24VDC Electrical Panel: Engages engine solenoid for engine start.

K2 Master Fault Relay, 24VDC Electrical Panel: When activated, shutdown engine.

K3 Relay, Low Fuel Warning, 24VDC Electrical Panel: Activates when fuel level is low.

K4 Relay, Engine Oil Pressure, Electrical Panel: Activates fault circuit when oil pressure is low.
24VDC

K5 Relay, High Water Temperature, Electrical Panel: Activates fault circuit to light DS12 when water
24VDC temp. is high.

2-2 August 30, 2000

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Table 5: Schematic Diagram Component Key and Description (Continued)

Item Nomenclature Location and Functional Description

K6 Relay, Compressor Oil Level, Electrical Panel: Activates fault circuit to light DS17 when oil level
24VDC is low.

K7 Relay, Compressor Low Oil Pres- Electrical Panel: Activates fault circuit to light DS14 when com-
sure, 24VDC pressor oil pressure is low.

K8 Relay, Engine Overspeed, Electrical Panel: Activates fault circuit to light DS13 when engine
24VDC Overspeed Switch A3 is active

K9 Relay, Low Fuel Shut-Down Electrical Panel: Energized when S6B close circuits due to low
(optional) fuel.

K12 Relay, High Output Air Temp., Electrical Panel: Energized when output delivery air temp. switch
24VDC S9 exceeds 500°F.

K13 Relay, Unload Air Bypass Blow- Electrical Panel: When energized, activates “Air dump” solenoid
off, 24VDC valve AS3.

M1 Hourmeter Control Panel: Displays to engine operating hours.

M2 Meter, Fuel Level Control Panel: Displays fuel tank fuel level.

M3 Meter, Engine Water Temperature Control Panel: Displays engine operating temperature.

M4 Meter, Engine Oil Pressure Control Panel: Displays engine oil pressure.

M5 Meter, Voltmeter Control Panel: Displays battery/alternator voltage.

M6 Meter, Compressor Oil Tempera- Electrical Panel: Indicates air compressor oil temperature 100-
ture 250°F (40-120°C)

M7 Meter, Compressor Oil Pressure Electrical Panel: Indicates air compressor oil pressure 0-30 psi (0-
2 kPa/cm2)

M8 Meter, Output Air Temperature Electrical Panel: Indicates delivery air temperature 90-750°F
(electrical type) or optional 50-750°F (mechanical type).

M9 Meter, Engine Tachometer Electrical Panel: Indicates engine speed over range of 0-4000
(This meter not found on all units) rpm.

PTF Pressure Differential Transducer Delivery Air Weldment: Provides delivery air pressure signals to
demand VSG PCB A5 for use in engine speed control.

EOPS Sender Unit, Engine Oil Pressure Engine: Provides analog signal to engine oil pressure.

S1 Switch, Mode Selector, Three Control Panel: Used to select mode of operation, i.e. Unloaded,
Position Multiple Pole Air Condition, Jet Start

S2 Switch, Power, ON/OFF Control Panel: Turns system power ON or OFF.

S3 Switch, Engine Start Control Panel: Push-button switch used to engage engine starter.

S4 Switch, Pressure, Engine Oil Engine: Pressure switch used to trigger fault circuit should oil
pressure not rise above 10 psig.

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Table 5: Schematic Diagram Component Key and Description (Continued)

Item Nomenclature Location and Functional Description

S5 Switch, Engine Water Tempera- Engine: Temperature switch used to trigger fault circuit when
ture engine temperature exceeds 225°F.

S6A Switch, Dual Purpose, Low Fuel Fuel Tank: Illuminates warning light when fuel level drops to low
Warning Contacts point.

S6B Switch, Dual Purpose, Low Fuel Fuel Tank: Triggers fault circuit to shutdown engine when fuel
Shut-Down Contacts level drops to critical point.

S7 Switch, Compressor Oil Pressure Compressor: Triggers fault circuit to shutdown engine should
compressor oil pressure drop to 4.5 psi or below.

S8 Switch, Compressor Oil Tempera- Compressor: Triggers fault circuit to shutdown engine should
ture compressor oil temperature rise above 195°F.

S9 Switch, Discharge Air Tempera- Delivery Air Weldment: Triggers fault circuit to shutdown engine
ture should output air temperature rise to 500°F or above.

S10 Switch, Delivery Air Pressure Compressor Air System Assy: Controls Air Delivery Solenoid

S11 Switch Compressor Oil Level Compressor: Triggers fault circuit to shutdown engine should
compressor oil level drop to a critical level.

S12 Switch, Test, Fault Light Outside of Electrical Panel: Used to test fault light bulbs.

S13 Switch, Panel Light Control Panel: Used to turn control panel illumination lights ON
and OFF for night time operation.

S14 Switch, Air Flow Pressure Operates to limit output air flow in Jet Start mode.

S15 Switch, Ether Start Control Panel: Used to activate Ether start in cold weather.

S16 Switch, Emergency Stop Control Panel: Used to Shutdown the Unit. Not to be used for nor-
mal shutdowns.

S17 Switch, Ether Start, <60 °F. Control Panel: Permits use of ether start only when ambient tem-
perature is less than 60°.

SS1 Solenoid, Engine Starter Engine Starter: Engages starter to engine for start.

SM1 Motor, Engine Starter Engine: Rotates engine during start cycle.

TB1-3 Terminal Block Connection Electrical Panel:

TD1 Relay, Time Delay, 24VDC Electrical Panel: Locks out fault monitor circuits during engine
start cycle. 0-30 seconds.

TD2 Relay, Time Delay, 24VDC Electrical Panel: “Off delay for Cool-Down”

WTS Sender, Engine Water Tempera- Engine: Provides signal to water temperature gauge to display
ture engine water temperature.

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Figure 5. ASP250 Overall Functional Diagram 2-2

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Units with Serial #s prior to 501558 Figure 6. Continuous Flow Jet Start Schematic 2-2
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Units with Serial #s prior to 501558 Figure 7. Air Start Unit ASP250 Wiring Diagram (Sheet 1 of 3) 2-2
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Air Start Unit

Units with Serial #s prior to 501558 Figure 7. Air Start Unit ASP250 Wiring Diagram (Sheet 2 of 3) 2-2
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Air Start Unit

Units with Serial #s prior to 501558 Figure 7. Air Start Unit ASP250 Wiring Diagram (Sheet 3 of 3) 2-2
August 30, 2000 Change 1 Page 49 / 50
ASP250
Air Start Unit

Units with Serial # 501558 and Subsequent Figure 8. Continuous Flow Jet Start Schematic 2-2
January 15, 2001 Change 2 Page 51 / 52
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Units with Serial # 501558 and Subsequent Figure 9. Air Start Unit ASP250 Wiring Diagram (Sheet 1 of 3) 2-2
January 15, 2001 Change 2 Page 53 / 54
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Units with Serial # 501558 and Subsequent Figure 9. Air Start Unit ASP250 Wiring Diagram (Sheet 2 of 3) 2-2
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Units with Serial # 501558 and Subsequent Figure 9. Air Start Unit ASP250 Wiring Diagram (Sheet 3 of 3) 2-2
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CHAPTER 2
MAINTENANCE
SECTION 3
REMOVAL/INSTALLATION
1. GENERAL
Removal/Installation instructions for engine sub assemblies, i.e., water pump, fuel pump,
injectors, etc., can be found in the Detroit Diesel® engine Operation and Maintenance Man-
ual, Parts Catalog, and the Maintenance Shop Manual.
The Air Start Unit is designed for rugged, dependable, efficient performance. Component
selection, assembly and design have been directed toward dependability and extended trou-
ble-free operation. Major component removal, i.e., engine, compressor, etc., is not consid-
ered to be necessary. Removal of any major component may require extensive system and
structural disassembly, and should only be accomplished when all other methods of repair
and/or refit have been eliminated. Should major component removal become necessary, Tri-
lectron should be contacted for guidance. This chapter will concern itself with general
assembly/disassembly information.
2. TORQUE VALUES FOR GENERAL ASSEMBLY
The torque chart value (Chapter 5) is provided for reference when performing general
assembly of various components. These values should be used only if torque values are not
otherwise specified for a particular assembly.
The following conditions must be observed when using the general assembly torque values:
• Joints are assumed to be metal and rigid. Do not use these values where gaskets or
compressed material may be damaged by over-torquing.
• During disassembly, note bolt head marking and always reassemble the same hardware
or equivalent new hardware in the correct locations.
• When reusing previously removed hardware, apply the minimum values from the table.
• Reduce the table values by 20% when assembling plated hardware or phosphate coated
hardware.
• Reduce table values by 30% when molykote, white lead, or similar mixtures are used to
lubricate threads.
• Reduce the table values by 35% when torquing jam nuts (thin nuts).
• Special use column values in the table are for cap screws in gray iron castings when
thread length engagement is at least 1.5 times the cap screw diameter.
WARNING
BEFORE PERFORMING INSTALLATION OR REMOVAL PROCE-
DURES, TURN ENGINE OFF BY SETTING ENGINE ON/OFF SWITCH
TO OFF. DISCONNECT BATTERY LEADS FROM THE BATTERY (NEG-
ATIVE GROUND LEAD DISCONNECTED BEFORE THE POSITIVE
LEAD).

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3. ENGINE/COMPRESSOR REMOVAL
The majority of all maintenance operations and rebuild can be accomplished with the engine
assembly mounted within the unit. Should the need arise where the engine or compressor
must be removed for replacement or other major maintenance operation, the removal must
be facilitated vertically through the roof. For engine removal, the radiator shroud and fan,
along with the engine air filter and exhaust system, must be removed.
For the actual removal step, a fork lift with a modified heavy pipe extension, or similar
device, is required. The engine or compressor must first have all associated hardware and
fittings removed, lifted sufficiently to clear lower members, then drawn out laterally until the
structural members are cleared.
A. Panel Removal (Refer to illustrations in Chapter 4)
The removal of the roof panels for engine or compressor removal is self-explanatory.
Remove only those panels necessary to provide clearance and access. Panels are
bolted in place utilizing insert nuts on the tubular members of the chassis frame.
B. Engine Removal/Installation (See figure 1)
Refer to Section 4-3 for assembly illustrations of various unit components and assem-
blies to aid in equipment removal and installation.
Refer to paragraph 4 for disassembly/assembly instructions for the engine/compressor
drive coupling.
• Equipment required:
• Hand and power tools normally found in any well equipped ground support
equipment maintenance facility.
• Fork lift with modified long reach rail for slight vertical lift and horizontal move-
ment of the engine.
(1) Drain and remove the radiator, shroud, and engine mounted fan blade.
(2) Disconnect all electrical wiring and cabling attached to the engine. Tag all dis-
connected cables and wires to aid in reassembly.
(3) Disconnect and remove fuel lines to the engine. Tag all disconnected fuel lines
to aid in reassembly.
(4) Disconnect and remove the engine exhaust assembly. The entire assembly
must be removed to provide the maximum clearance for the raising and removal
of the engine.
(5) Disconnect the flexible coupling from the engine drive shaft. Refer to paragraph
4 and to coupling manufacturer's information, Chapter 5.

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Figure 1. Engine Removal

WARNING
COUPLING COMPONENTS ARE HEAVY, USE LIFTING DEVICES OF
APPROPRIATE CAPACITY TO MANEUVER COMPONENTS. FAILURE
TO COMPLY MAY RESULT IN PERSONNEL INJURY.
(6) To lift the engine, use a suitable lifting device. See figure 1. A spreader bar
should be used with a sling and adequate chain hoist when lifting any engine.
The lifting device should be adjusted so the lifting hooks are vertical to prevent
bending the engine lift brackets. To ensure proper weight distribution, all three
engine lift brackets provided must be used in lifting the engine. Be sure the
spreader bar is adequate to prevent lifter brackets from contacting the engine
rocker cover and causing damage.
(7) Utilizing a fork lift, with modified long reach rail, place the rail above the unit
through the removed roof panel opening. Extreme care must be taken to avoid
striking or damaging unit components, plumbing or wiring. This is a limited
space area - care must be exercised.

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(8) Attach the long reach rail to the engine spreader bar.
CAUTION
BEFORE REMOVING ENGINE MOUNTING BOLTS, REMOVE ALL
SLACK IN THE LIFT CHAINS. APPLY ENOUGH LIFTING FORCE TO
PREVENT THE ENGINE FROM SHIFTING WHEN MOUNTING BOLTS
ARE LOOSENED.
(9) Once the spreader bar and lifter hook has been attached to the engine, apply
enough lifting force to prevent the engine shifting when the mounting bolts are
removed. Remove front and rear engine mounting bolts.
(10) Raise the engine slightly to clear the mounting pad. Slowly withdraw the engine
from the unit interior. Utilize care that the engine does not snag or otherwise
damage unit wiring or equipment.
CAUTION
DO NOT PLACE ENGINE DIRECTLY ON TO THE GROUND OR FLAT
SURFACE, DAMAGE TO ENGINE OIL PAN WILL RESULT. PLACE
WOODEN BLOCKS UNDER THE FRONT AND REAR ENGINE MOUNTS
TO PROVIDE ADEQUATE CLEARANCE.
(11) To install the engine within the unit, reverse the removal procedure. Refer para-
graph 4 and to flexible coupling's manufacturer's installation instructions, Chap-
ter 5.
CAUTION
UTILIZE TORQUE VALUES FOR GENERAL ASSEMBLY WHEN
INSTALLING ENGINE MOUNTING BOLTS AND OTHER ATTACHING
HARDWARE.

C. Compressor Removal/Installation (See Figure 3.)

Refer to Section 4-3 for assembly illustrations of various unit components and assem-
blies to aid in equipment removal and installation.
Equipment required:
• Series 60 Engine Jacking Stand: Trilectron Part No. 18160 or equivalent. (See figure
2)
• Hand and power tools normally found in any well equipped ground support equipment
maintenance facility.
• Fork lift with modified long reach rail for slight vertical lift and horizontal movement of
the engine.

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Figure 2. Engine Jacking Stand

(1) Disconnect all electrical wiring and cabling attached to the compressor. Tag all
disconnected cables and wires to aid in reassembly.
(2) Disconnect the flexible coupling from the compressor drive shaft. Refer para-
graph 4 and to coupling manufacturer's information, Chapter 5.
(3) Unbolt and remove the engine exhaust system.

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Figure 3. Compressor Removal

(4) Remove the compressor intake filter assembly. Cover the compressor intake
and filter assembly exhaust to prevent foreign objects from entering. Foreign
objects entering the compressor could cause serious damage to the unit.
(5) Remove the compressor discharge silencer.
(6) Disconnect and plug the compressor oil to cooler lines.
(7) Install M16/28 eyebolts in the four corners of the compressor. Using a suitable
hoist or forklift, attach a lifting sling to these four points. Remove the bolts hold-
ing down the compressor and lift the compressor clear of the unit.
(8) Reassemble/install the compressor in the reverse sequence. When installing the
compressor to the engine, it is essential that the coupling is aligned correctly.
Refer to paragraph 4 and the manufacturer's literature for the flexible coupling
located in Chapter 5.
4. DRIVE COUPLING INSTALLATION/REMOVAL. (See figures 3, 4, and 5)
A. Removal
(1) Remove the coupling guard. (See Figure 4.)
(2) The coupling is a balanced assembly and should be reassembled in the same
orientation as originally installed to maintain optimum performance. Using a
marker pen, make an alignment reference line across the components to aid in
reassembly.

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(3) With the coupling guard removed, loosen and remove the 12 socket head
screws (M14x75) which mount the coupling hub (See Figure 5.) to the spacer/
coupling element.
(4) It should be possible to now slide the coupling element assembly slightly toward
the engine. Use cord or heavy tape diagonally across the rear of the engine to
hold the coupling element in place.
(5) With all other required components removed or disconnected, and using cau-
tion, it should now be possible to lift out the engine or compressor without further
coupling disassembly.

Figure 4. Engine/Compressor Assembly

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B. Coupling Installation
The following instructions are provided for installing both a new coupler assembly, or
reinstalling a previously disconnected/removed assembly. For reinstallation, ignore those
instructions which are not applicable to your degree of disassembly.
(1) Hub Installation (Compressor End)(See Figure 5.): Verify hub and shaft dimen-
sion to ensure that the proper size hub is being used. The hub will generally be
an "interference" or "shrink" fit which will require its being heated for installation.
Heating is generally accomplished in an oven or oil bath to a predetermined
temperature until the hub bore has expanded to the desired diameter. Identify
the final position of the hub with respect to the shaft and use a hose clamp or
similar device as a stop on the shaft to ensure proper positioning.
Measure and record the hub bore and shaft diameter using accurate microme-
ters. Compare the two measurements and determine the amount of hub bore
expansion required to slide the hub into position on the shaft. Allow for a certain
amount of heat in the hub to be transferred to the cooler shaft, causing the hub
bore to begin contracting to its original size while it is being installed. Use the fol-
lowing formula for calculating the temperature to expand the hub to the prede-
termined diameter.
• T1 = Temperature of shaft in degrees Fahrenheit.
• B1 = Original diameter of hub bore in inches.
• B2 = Desired diameter of hub in inches required to slide hub into position on
shaft.
Example: Shaft diameter 3.000 inches and hub bore 2.999 inches.
• T1 = 85°F; B1 = 2.999 inches, B2 = 3.002 inches
• T2 = 85 + [(166.7 x 1000) x (3.002/2.999 - 1)]
• T2 = 85 + [(166.7 x 1000) x (0.001)]T2 = 85 + 166.8 = 252°F
• T2 = T1 + [(166.7 x 1000) x (B2/B1 - 1)]
• T2 = Temperature in degrees Fahrenheit to expand hub bore to B2.

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Figure 5. Coupler Component and Assembly

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CAUTION
DO NOT HEAT A HUB WITH A CUTTING TORCH AND DO NOT HEAT A
HUB ABOVE 500°F (260°C), CRACKING OR BREAKING WILL OCCUR.
WARNING
DO NOT HEAT AN OIL BATH ABOVE THE FLASH POINT OF THE OIL,
AN EXPLOSION/FIRE WILL OCCUR.
(a) Heat the hub in an oven or oil bath to the predetermined temperature.
While the hub bore is being enlarged by heat, the shaft diameter may be
reduced by chilling with dry ice or other suitable means.
(b) Slide the hub onto the shaft to the predetermined stopping point.
(c) Check the runout of the hub for concentricity and squareness with the
shaft. The hub must run true with respect to the shaft or vibrations and
damage to the equipment will occur. If the runout for concentricity or
squareness exceeds 0.008 inches total, the reason for the excessive
runout must be found and corrected.
(2) Coupling Element Assembly (See Figure 5.): Bolt the ring inner coupling (Item 3)
to the coupling element (Item 4). Use Loctite® 242 thread locker on all fasteners
used in assembly. Tighten bolts evenly around circumference of the inner cou-
pling ring. Torque bolts (Item 8) to 34 to 37 ft.-lbs.
(3) Flanged Housing Assembly (See Figure 5.): Place the coupling element assem-
bly within the flanged housing (Item 1). Place the spacer ring (Item 9) against
the flanged side of the flanged housing assembly and position on engine fly-
wheel. Bolt the flanged housing (1) along with the spacer ring (9) to the engine
flywheel. Use Loctite® 242 thread locker on all fasteners used in assembly.
Tighten bolts evenly around circumference of the flanged housing. Torque bolts
(Item 2) to 95 to 100 ft.-lbs.
(4) Hub to Coupling Element Assembly (See Figure 5.): Insert the spacer (Item 5)
between the coupling element (4) and the Hub (6). Using socket head screws
(7) bolt through the hub, through the spacer to the coupling inner ring (3)
attached to the backside of the coupling element (4). Use Loctite® 242 thread
locker on all fasteners used in assembly. Tighten bolts evenly around circumfer-
ence of the hub. Torque bolts (Item 7) to 95 to 100 ft.-lbs.
(5) Coupler Guard: Install the coupler guard (See Figure 5.) to the completed
assembly.

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CHAPTER 2
MAINTENANCE
SECTION 4
ADJUSTMENTS AND TESTS
1. ENGINE ELECTRONIC GOVERNOR
A. Magnetic Pickup Unit
The Magnetic Pickup Unit (MPU) is located on the engine flywheel housing, right side.
With engine stopped, adjust the MPU to 0.020 inches (0.45 mm) from flywheel ring teeth.
Usually, backing out the MPU 3/4 turn after touching the ring gear teeth will achieve a
satisfactory air gap. Do not decrease to below 0.010 inches (0.25 mm). The MPU voltage
should be at least 1.5 VRMS during cranking. The MPU will have a measurable resis-
tance of 50-350 ohms.
NOTE
Magnetic Pickup Unit (MPU) voltage between terminals 5 and 6
should be at least 1.5 VRMS while cranking.
B. Electronic Governor
The engine operating speed, as part of its on-board computer system, is automatically
governed to precisely maintain programmed engine speeds. An integral magnetic sensor
monitors engine speed and provides this data to the ECM for control. Constant speed is
maintained by regulating engine fuel and operating parameters. The engine speeds of
table 1 are developed by the unit and are set by command signals from the Demand
VSG Control CCA A5.
2. AIR SYSTEM ADJUSTMENT AND SET-UP PROCEDURE

Table 1: Engine Speed vs. Mode Setting

Air Delivery Outlet Ball Valve Air Delivery Outlet Ball Valve
Mode
(OPENED) (CLOSED)

UNLOAD (idle)** 1100-1150 RPM 1100-1150 RPM

AIR COND. 1800-1850 RPM 1300-1500 RPM

JET START 2300-2350 RPM 1750-1850 RPM

* *High altitude operation may require changing the idle speed to 1300 RPM.

The following procedure is only performed when a major component to the air flow or gover-
nor system has been replaced, or when unstable operation requires system setup. During
the procedure, should the adjustment of a component fail to provide the expected results, it
should be taken as an indication that the component is faulty. Replace the questionable
component and continue with the setup. Refer to paragraph 1 for basic governor control and

November 1, 1999 2-4

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magnetic pickup adjustment.

A. Adjustment Procedure - Engine Not Running

(1) Unlock and adjust Air Delivery Regulators 1 and 2 (see figure 1) to the minimal
position. To adjust each regulator, turn in a counter-clockwise (CCW) direction
(lowers pressure).
(2) Adjust potentiometer on Overspeed Circuit Card Assembly A3 fully clockwise
(CW).
(3) Set Air Unload Solenoid Valve (ULSOV) AS3 to maximum blow-off (see figure
1) by adjusting the Delivery Air Pressure Switch S10 (paragraph C, figure 4).

B. Adjustment Procedure - Engine Running

WARNING
PROLONGED EXPOSURE TO HAZARDOUS NOISE MAY RESULT IN
PERMANENT HEARING LOSS. EAR PROTECTION DEVICES MUST BE
WORN WHEN WORKING WITHIN A CLOSE PROXIMITY OF THIS
EQUIPMENT.
(1) Close air delivery outlet ball valve.
WARNING
AN OPEN AIR DELIVERY BALL VALVE ON AN UNUSED, UNSECURED
DELIVERY DUCT, WILL DISCHARGE A HIGH VOLUME OF LOW PRES-
SURE AIR CAUSING THE DUCT AND ITS COUPLING TO BE FLUNG
ABOUT IN AN UNCONTROLLED MANNER. ENSURE THE DUCT IS
CONNECTED TO AN AIRCRAFT/TEST STAND, OR THAT ITS AIR
DELIVERY BALL VALVE IS CLOSED. FAILURE TO COMPLY MAY
RESULT IN EQUIPMENT DAMAGE AND/OR SEVERE INJURY TO PER-
SONNEL.
(2) Connect outlet hose to a test stand, or other suitable fixture, which will secure
the hose in place preventing it’s movement and direct hot discharge air away
from personnel or equipment.
(3) Fully open air delivery outlet ball valve.
(4) Set ENGINE ON/OFF switch to ON (see figure 3). Engine and control panel
gauges will energize.
(5) Ensure that MODE SELECTOR switch S1 is set to UNLOAD. Press START
switch to start engine. Allow engine to warm, 2-3 minutes, until engine idle
speed of 1100-1150 rpm stabilizes.

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Figure 1. Delivery System Components and Controls

AIR CONDITIONER SET-UP
(6) Set MODE SELECTOR switch (see figure 3) to AIR COND.
(7) Adjust Air Delivery Regulator #2 (see figure 1) to obtain a reading of 25±2
psig(1) on control panel delivery air output pressure gauge (see figure 3).
Engine RPM will be 1800-1850 RPM. Lock Air Delivery Regulator #2. Engine
RPM will be 1800-1850 RPM. Lock Air Delivery Regulator #2.
(8) Close air delivery outlet ball valve and verify that engine speed drops to 1300-
1500 RPM and outlet air pressure indicates 25±2(1) psig on control panel deliv-
ery air output pressure gauge.
(9) Open and close air delivery outlet ball valve. Observe that engine speed, with
the ball valve open (UNLOADED), will increase to 1800 RPM and decrease to
1300-1500 RPM with the ball valve closed (LOADED). With the valve in the
open or closed position, the outlet air pressure maintains 25±2(1) psig on control
panel delivery air output pressure gauge (see figure 3).

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Figure 2. Electrical Panel Components

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(10) Set MODE SELECTOR switch S1 to UNLOAD (engine at idle speed). Verify that
engine speed goes to 1100-1150 RPM and the outlet air pressure indicates 10±2
psig on control panel delivery air output pressure gauge (see figure 3) with air
delivery ball valve closed and 3-4 psig with ball valve open.
JET START SET-UP
(11) Set delivery air over pressure switch as follows:
(a) Fully close air delivery outlet ball valve.
(b) Set MODE SELECTOR switch (see figure 3) to JET START.
(c) Adjust Air Delivery Regulator #1 (see figure 1) to obtain a reading of 45
psig on the control panel delivery air output pressure gauge (see figure 3),
and then adjust the Delivery Air Pressure Switch S10 (paragraph C, figure
4) until Air Unload Solenoid Valve (ULSOV) AS3 (see figure 1) energizes
and air starts bypassing each time the outlet pressure exceeds 45 psig.
(12) Open air delivery outlet ball valve. Observe that engine speed increases to
2300-2350 RPM.
(13) Adjust Air Delivery Regulator #1 (see figure 1) to obtain a reading of 40 psig on
the control panel delivery air output pressure gauge (see figure 3). Lock Air
Delivery Regulator #1.
(14) Close air delivery outlet ball valve. Verify that engine speed goes to 1750 -1850
RPM and the outlet air pressure indicates 40±2 psig on control panel delivery air
output pressure gauge (see figure 3).
(15) Open and close air delivery outlet ball valve. Observe engine speed with the ball
valve open (UNLOADED) will increase to 2300-2350 RPM and decrease to
1750 -1850 RPM with the ball valve closed (LOADED). With the valve in the
open or closed position, the outlet air pressure indicates 40±2 psig on control
panel delivery air output pressure gauge (see figure 3).
OVERSPEED SETUP
(16) Set MODE SELECTOR switch (see figure 3) to UNLOAD. Observe that engine
speed goes to 1100 -1150 RPM
(17) Open air delivery outlet valve.
(18) Set MODE SELECTOR switch (see figure 3) to JET START. Observe Jet Start
engine speed of 2300-2350 rpm. On Overspeed Circuit Card Assembly A3,
slowly adjust potentiometer on counter-clockwise until control panel OVER
SPEED fault light illuminates (see figure 2). Ensure Overspeed light (DS3) on
Fault Circuit Card Assembly A1 (see figure 2) illuminates. Engine will not shut
down when operating in Jet start mode.
(19) Set MODE SELECTOR switch (see figure 3) to UNLOAD. Engine will shut
down due to over speed fault.
(20) Adjust potentiometer on Overspeed Circuit Card Assembly A3 clockwise one full
turn. This completes Overspeed CCA A3 setup.

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(21) Restart unit and cycle MODE SELECTOR switch (see figure 3) between the
UNLOADED, AIR COND, and JET START positions, allowing unit to stabilize,
and verify that the proper readings are present:
• UNLOADED – Idle speed 1100-1150 rpm
• AIR COND – 25-40(1) psig output pressure
• JET START – Engine speed approximately 2300 - 2350 rpm, 40 psig output
pressure.
NOTE(1)
25 psig is a suggested pressure for light duty AIR PAC operation. The Air
Start Unit air conditioner output air pressure can be adjusted as high as
40 psig. Consult the facility planning requirements for the aircraft.

(22) Set MODE SELECTOR switch (see figure 3) to UNLOADED.

(23) Set ENGINE ON/OFF switch to OFF. The TIME COOL DOWN lamp will illumi-
nate and the engine will continue running for the time set duration of time delay
TD2 (1 1/2 minutes), then shut-off. This completes the Air System Adjustment
and Set-up Procedure. Ensure that Air Delivery Regulators #1 and #2 are
locked.
C. Delivery Air Pressure Switch (S10) Adjustment (see figure 4)

NOTE
The Delivery Air Pressure Switch S10 is set to close at 45 psi.

(1) Unlock Air Delivery Regulator #2.

(2) Adjust Air Delivery Regulator #2 (see figure 1) to obtain a reading of approxi-
mately 45 psig on the control panel delivery air output pressure gauge (figure 3),
then adjust the Delivery Air Pressure Switch S10 so that Air Unload Solenoid
Valve (ULSOV) AS3 (see figure 1) energizes and air starts bypassing.
(3) Turn Delivery Air Pressure Switch S10 adjustment wheel just to the point where
its contacts close.
(4) Lock Air Delivery Regulator #2.

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Figure 3. Control Panel Assembly

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Figure 4. Delivery Air Pressure Switch (S10) Adjustment

D. Safety Air Pressure Relief Valve (RV1) Checkout
Under normal operating conditions the Safety Air Pressure Relief Valve (RV1) does not
require adjustment. The valve is factory set for 50 psi by the manufacturer. However, it is
recommended that the valve be periodically (weekly) checked using the following proce-
dure:
(1) Operate the unit in the JET START Mode with air delivery ball valve open.
(2) Quickly close the open ball valve while monitoring output air pressure. Observe
that RV1opens by listening for a air pulse. The Safety Air Pressure Relief Valve
should open and dump air at 50 psi when the ball valve is suddenly closed.
E. Safety Air Pressure Relief Valve (RV1) Adjustment
Under normal operating conditions the Safety Air Pressure Relief Valve (RV1) does not
require adjustment. The valve is factory set for 50 psi by the manufacturer. However, if valve
adjustment is required, use the following procedure:
(1) (1) Allow unit to cool down to ambient temperature.

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Figure 5. Safety Air Pressure Relief Valve (RV1) Adjustment

(2) Remove lockwire(s) from Safety Air Pressure Relief Valve (RV1).
(3) Remove valve handle retaining pin and remove handle.
(4) Remove small hex head screw securing handle cover to body of valve.
(5) Remove handle cover.
(6) Loosen jam nut on collar of valve body (see figure 5)
NOTE
Each turn of the relief valve adjustment screw will change the valve
pressure relief set point value by approximately 1.5 psi.

(7) Hold jam nut (see figure 5) with one wrench, then turn adjustment screw down-
ward (CW) 1 full turn with second wrench.
(8) Tighten jam nut to secure adjustment screw at new position.
(9) Adjust the Delivery Air Pressure Switch S10 to a setting above 50 psi (CCW) on
the control panel delivery air output pressure gauge (figure 3).

WARNING
PROLONGED EXPOSURE TO HAZARDOUS NOISE MAY RESULT IN
PERMANENT HEARING LOSS. EAR PROTECTION DEVICES MUST BE
WORN WHEN WORKING WITHIN A CLOSE PROXIMITY OF THIS
EQUIPMENT.

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AIR START UNIT

(10) Ensure air delivery ball valve is closed.

(11) Set ENGINE ON/OFF switch to ON (figure 3). Engine and control panel gauges
will energize.
(12) Ensure that MODE SELECTOR switch S1 is set to UNLOAD. Press START
switch to start engine. Allow engine to warm, 2-3 minutes, until engine idle
speed of 1100-1150 rpm stabilizes.
(13) Set MODE SELECTOR switch S1 (figure 3) to AIR COND.
(14) Adjust Air Delivery Regulator #2 (figure 1) to obtain a reading of 50 psig on con-
trol panel delivery air output pressure gauge (figure 2). Observe that Safety Air
Pressure Relief Valve (RV1) releases air at 50psi.
(15) If Safety Air Pressure Relief Valve (RV1) requires further adjustment, repeat the
procedures of steps 7 through 14. If valve performs correctly proceed to step 16.
(16) Adjust Air Delivery Regulator #2 (figure 1) to obtain a reading of 25 psig(1) on
control panel delivery air output pressure gauge (figure 3).
(17) Adjust Air Delivery Regulator #2 (figure 1) to obtain a reading of approximately
45 psig on the control panel delivery air output pressure gauge (figure 3), then
adjust Delivery Air Pressure Switch S10 so that Air Unload Solenoid Valve
(ULSOV) AS3 (figure 1) energizes and air starts bypassing. Turn Delivery Air
Pressure Switch S10 adjustment wheel just to the point where its contacts close.
Lock Air Delivery Regulator #2.
(18) Replace Relief Valve (RV1) handle cover.
(19) Replace small hex head screw securing handle cover to body of relief valve
(RV1).
(20) Install valve handle and handle retaining pin.
(21) Install lockwire(s) on Safety Air Pressure Relief Valve (RV1).

NOTE
25 psig is a suggested pressure for light duty AIR PAC operation. The Air
Start Unit air conditioner output air pressure can be adjusted as high as
40 psig. Consult the facility planning requirements for the aircraft.

2-4 November 1, 1999

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AIR START UNIT

CHAPTER 2
MAINTENANCE
SECTION 5
CLEANING AND PAINTING
1. CLEANING
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 accumulations 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 rins-
ing with clean water. A bristle brush (never wire) or spray gun may be used. Unpainted sur-
faces are cleaned using plain water and brush, approved solvents, or steam cleaning
equipment. Degreasers may be used to remove grease accumulations from non-lubricated
metal parts. Care should be taken with degreasers, as some brands will also remove or
damage painted surfaces. Clean electrical parts with a lint-free cloth, moistened with
approved solvents for electrical equipment.
CAUTION
DO NOT ALLOW SOAKING, SPRAYING OR STEAM CLEANING TO
AFFECT ELECTRICAL COMPONENTS OR WIRING. RUBBER COMPO-
NENTS SHOULD NOT BE CLEANED WITH SOLUTIONS HAVING A
PETROLEUM BASE SUCH AS KEROSENE, MINERAL SPIRITS, STOD-
DARD SOLVENT OR DRY CLEANING SOLVENTS.
2. PAINTING
Painted surfaces, in addition to presenting a good appearance, etc., protect the unit from
deterioration. Paint should be maintained on a non-scheduled, as required, basis. Depend-
ing on environmental and operational conditions, repaint the entire unit whenever it
becomes necessary.

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CHAPTER 3
OVERHAUL / MAJOR REPAIR

Under normal operating conditions and proper preventive maintenance, the Air Start Unit should
provide excellent service for a period of 20,000 to 30,000 hours (depending on local conditions)
before considerations should be given to major repair or overhaul.
Overhaul or major repair of the air start power plant, i.e., the engine, should be accomplished in
accordance with the maintenance/overhaul recommendations of the manufacturer or their
authorized agents.
The compressor will normally require no overhaul other than normal maintenance or repair pro-
cedures. If a rebuild is found to be advisable, the manufacturer should be contacted for their
recommendations and/or procedures.
The Trilectron built and mounted equipment requires no scheduled overhaul. Normal mainte-
nance and repair of the unit and subsystems will maintain the equipment in proper working
order.

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CHAPTER 4
ILLUSTRATED PARTS LIST
SECTION 1
LIST OF VENDORS

1. GENERAL
This chapter contains a List of Vendors, a Numerical Index and a Detailed Parts List. It is
intended for use in provisioning, requisitioning, storing, issuing, and identification of parts
and components for the Model ASP250 Trailer Mounted Air Start Unit, built by Trilectron
Industries, Incorporated, Palmetto, Florida 34221 U.S.A.
The List of Vendors (refer to table 1) identifies the vendor sources by name, address and
Federal Vendor Code (FVC), if applicable.
The Locator refers to the Figure/Item numbers located on the assembly drawings, Chapter
4, Section 3.
The Numerical Index lists all Detailed Parts List Catalog part numbers and their Figure and
Item numbers in their alpha-numerical order.
The Detailed Parts List includes only those parts and components peculiar to this model Air
Start Unit.

Table 1: List of Vendors

FVC VENDOR NAME/ADDRESS

01276 AEROQUIP CORP., 1225 W. Main St., Van Wert, OH 45891

01364 RUTCO, 2602 E. Hwy 674, Ruskin, FL 33570

04034 IMO INDUSTRIES INC. (GEMS), 1 Cowles Rd., Plainville, CT 06062-1107

06504 WALBRO CORP. (AMATOM), 6242 Garfield Ave., Cass City, MI 48726-1342

08806 GENERAL ELECTRIC CO. Minature Lamps, Nela Park, Cleveland, OH 44112

0AT39 BRIERTON ENGINEERING, INC., Rt.2, 1200 S. Buckeye, Abilene, KS 67410

0BXW5 GOVERNORS AMERICA CORP., 720 Silver St., Agawam, MA 01001

0FREO STANCOR, INC., 515 Fan Hill Rd., Monroe, CT 06468

0FWK8 DIXIE BEARINGS, P.O. Box 45210, Atlanta, GA 30312

0J639 R&R SUPPLY, 613 Triumph Ct. Suite 1, Orlando, FL 32815

0KVE6 McMASTER-CARR SUPPLY, 6100 Fulton Ind. Blvd., Atlanta, GA 30336

0NLN2 SAGER ELECTRICAL SUPPLY, 6220 S. Orange Blossom Trail, Suite 105, Orlando, FL
32809

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Table 1: List of Vendors

FVC VENDOR NAME/ADDRESS

0P206 JOHNSON/YOKOGAWA, 4 Dart Rd., Shenadoah Industrial Park, Newnan, GA. 30265

0P2F7 POLYMER TECH., 7006 Pencader Dr., Newark, DE 19702

0RR12 RUBBER & ACCESSORIES INC., 2120 Edgewood Dr. South, Lakeland, FL 33803

0TW02 UNIVERSAL SILENCER DIV. (NELSON), Hwy 51/138W, Stoughton, WI 53589

0UEK2 FLORIDA PIPE AND SUPPLY CO. INC., 600 N. Prairie Industrial PKY, Mulburry, FL. 33860

0ZATA CHEVRON U.S.A. PRODUCTS CO., 1716 S. 5th St., Louisville, KY 40232

12867 TRILECTRON INDUSTRIES, INC., 11001 U.S. Hwy. 41 North, Palmetto, FL 34221

12965 LORD CORP, INDUSTRIAL PROD. DIV., 126 Grant St., Cambridge Springs, PA 17520

14449 WEISS INSTRUMENTS, 89-T Bell St., West Babylon, NY 11704

15434 CUMMINS ENGINE CO., P.O. Box 3005, Columbus, IN 47202-3005

15605 CUTLER HAMMER, 4201 N. 27th St., Milwaukee, WI 53216

16327 DAYTON ELEC. MFG. CO., 5959 W. Howard St., Chicago, IL 60648

16476 DATCON INSTRUMENTS CO., P.O. Box 128, East Petersburgh, PA 17520

18265 DONALDSON CO. INC., 1400 W. 94th St., Minneapolis, MN 55431

1FJ15 AMATOM ELECTRONIC HDWR., 445 Blake ST., New Haven, CT 06515

22938 PROTOTYPE DEVELOPMENT INC., 7750 Hub Parkway, Cleveland, OH 44125-5709

23826 FURNAS ELEC. CO., 1004 McKee St., Batavia, IL 60510

25795 GRAINGER INC., 6685 Whitfield Ind. Ave., Sarasota, FL 34243

27264 MOLEX INC., 2222 Wellington Ct., Lisle, IL 60532-1613

28081 NATIONAL CONTROLS CORP., 1725 Western Drive, West Chicago, IL 60185

2M626 AFCOM, P.O. Box 1119, Sanford, FL 32772

2S894 DIGI-KEY, 701 Brooks Ave. S., Thief River Falls, MN 56701

34165 IMLEC, Glenview, IL 60025

3Z148 CONTROL CENTER INC., 1013 E. Montana St., Orlando, FL 32803-2566

44512 SUPER RADIATOR COILS, 451 Southlake Blvd, P.O. Box 35687, Richmond, VA 23235

46576 PERKO, INC., 16490 NW 13th Ave., PO Box 64000D, Miami, FL 33164-0414

4K048 BOLD BAN INTERNATIONAL (KBI), LTD., 900 Pingree Rd, Lake In Hills, IL 60102

4N453 GULF CONTROLS CORP., 5201 Tampa West Blvd., Tampa, FL 33684

51377 DYSOR OF CADILLAC, 1100 Wright Street, Cadillac, MI 49601-9275

4-1 August 30, 2000

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Table 1: List of Vendors

FVC VENDOR NAME/ADDRESS

53453 FLORIDA DETROIT DIESEL ALLISON NORTH INC., 5040 University Blvd. W., Jacksonville,
FL 32245-6595

56380 THERMOID, INC., 1 Industrial Lane, P.O. Box 310, Oneida, TN 37841

57137 TRIM-LOK, INC., 57137 Hermosa Cir., P.O.Box 6180, Buena Vista, CA 90622-6180

59197 VDO-ARGO INSTRUMENTS INC., P.O. Box 2630, Winchester, VA 22601

5G982 GENERAL DEVICES CO. INC., 1410 S. Post Road, Indianapolis, IN 46239-932

5P059 TECH PRODUCTS CORP., 2348 Sandridge Dr., Dayton, OH 45439

5W026 AERO HARDWARE AND SUPPLY CO., DBA HYDRAULIC SUPPLY CO, 7200 E. Buffalo
Ave., Tampa, FL 33619-1130

5X849 EAGLE SIGNAL CONTROLS, 8004 Cameron Rd., Austin, TX 78753-6709

60248 AMERICAN VULKAN CORP., 2525 Dundee Rd., Winter Haven, FL 33880-9293

63902 GENERAL AUTO SPECIALTY CO., P.O. Box 1329, Selma, AL 36702

6E809 DELCO DIV. GMC, Oakland, CA

6V625 NAPA AUTOMOTIVE PARTS CO., 3389 E. Main St., Columbus, OH 43213-2744

71744 DRAKE, 1080 Johnson Dr., Buffalo Grove, IL 60089

72582 DETROIT DIESEL CORP., 13400 W. Outer Dr., Detroit, MI 48239

73559 CARLING SWITCH INC., 60 Johnson Ave., Plainville, CT 06062-1156

75382 KULKA ELEC. CORP., 520 S. Fulton Ave., Mt. Vernon, NY 43050

76385 MINOR RUBBER CO. INC., 49 Ackerman St., Bloomfield, NJ 07003

76700 NELSON DIVISION, P.O. Box 428, Stoughton, WI 52589

77342 POTTER & BRUMFIELD INC., 200 S. Richland Creek Rd., Princeton, IN 47671

78276 AVK INDUSTRIES PRODUCTS INC., 25323 Rye Canyon Rd., Valencia, CA 91355

78280 QUICK START PRODUCTS LTD., Hwy 251 South, Rochelle, IL 61068

79221 WATLOW ELECT. MFG, CO. 12001 Lackland Rd, St. Louis, MO 63146

79227 WATTS REGULATOR CO., 815 Chestnut Dr., North Andover, MA 01845

7B735 AUSTIN HARDWARE, P.O. Drawer 879, Rowlett, TX 75088

7G414 AERO HARDWARE, 4301 N.W. 36Th St., Miami Springs, FL 33166-7396

7G614 AMPHENOL CORP., Dayton, Ohio

7W514 GOODYEAR RUBBER CO., 329 McCarter Hwy., Newark, NJ 07114

80019 K-D LAMP CO., P.O. Box 5374, Cincinnati, OH 45201-5374

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Table 1: List of Vendors

FVC VENDOR NAME/ADDRESS

80089 HAMILTON STD. CONTROLS (Stancor), 131 Godfrey St., Logansport, IN 46947

81073 GRAYHILL INC., P.O. Box 10373, La Grange, IL 60525

81349 MILITARY SPECIFICATION, 4120 3-M

83330 DIALIGHT CORP., 1913 Atlantic Ave., Mannasquan, NJ 08736

83861 KAISER AEROSPACE, 1700 S. Redhill Ave., Irvine, CA. 92714-5676

85814 NASON CO., P.O. Box 505, West Union, SC 29696

94222 SOUTHCO FASTENERS, 210 N. Brinton Lake Rd., Concord, PA 19182

9B248 PARKER HANNIFIN CORP., 2445 S. 25TH Ave., Broadview, IL 60153-3891

9H249 PROTECTOSEAL, P.O. Box 95588, Chicago, IL 60694

BROAD BROAD WHEELS, P.O. Box 81, Oneonta, AL 35121

DWYER DWYER INSTRUMENT, 1505 Cobb Industrial Dr., Marietta, GA 30066

GHHRA GHH-RAND SCHRAUBENKOMPRESSOREN GmbH & Co. KG, Bahnhofstrasse 66, D-46145
Oberhausen, Germany

LESLI LESLIE CONTROLS, Inc. 12501 Telecom Dr., Tampa, FL. 33637

MURPH F.W. MURPHY, P.O. Box 470248T, Tulsa, OK. 74147

PRECI PRECISION GOVERNORS, 2322 7th Ave., Rockford, IL 61104

THERM THERMO-TEC, P.O. Box 946, Berea, OH 44017

WILKE WILKERSON, Englewood, CO 80150

4-1 August 30, 2000

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CHAPTER 4
ILLUSTRATED PARTS LIST
SECTION 3
DETAILED PARTS LIST
1. EXPLANATION OF COLUMNS
A. Figure/Item Number
Lists the figure on which the item is shown and the item number assigned to the detailed
part. Items listed but not illustrated are preceded by a dash (-).
B. TI Part Number
Lists the Trilectron Industries, Inc., part number assigned and required to procure the part
from Trilectron.
C. Vendor Part Number
Lists the Vendor's part number for purchased components.
D. FVC
Lists the Federal Vendor's Code for the vendor/manufacturer of purchased components.
E. Airline Part Number
Column is provided for the user to insert their system part number.
F. Nomenclature
Column presents the complete item name required for identification or procurement. Abbre-
viations used are in accordance with United States Military Standard MIL-STD 12D.
G. Units Per Assembly
Column provides the total quantity of the listed component utilized for that assembly.

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2. INSTRUCTIONS FOR ORDERING PARTS.

Trilectron Industries, Inc.

11001 US Hwy. 41 North
Palmetto, Florida 34221 U.S.A.
Telephone (941) 721-1000, Fax (941) 723-3160

Warranty Inquiries:
Customer Support Coordinator
Telephone 1-877-874-5622, FAX 1-877-874-5321
E-mail: cs@trilectron.com

Spare Parts Inquiries:

Terlephone 1-800-899-1841, FAX 1-941-723-3160

Important Facts: When ordering, give the serial number of the unit; model number; full
description of the part and the quantity required; and the Illustrated Parts List Figure and
Item number from this manual. Give shipping method preferred.

4-3 August 30, 2000

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Figure 1. ASP250 Top Assembly (Sheet 1 of 3)

August 30, 2000 4-3

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Figure 1. ASP250 Top Assembly (Sheet 2 of 3)

4-3 August 30, 2000

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Figure 1. ASP250 Top Assembly (Sheet 3 of 3)

August 30, 2000 4-3

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AIR START UNIT

Parts List of Figure 1. ASP250 Top Assembly

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

1- . . . . LF17930 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ASP250 TOP ASSEMBLY . . . . . . . . . . . . . .1

1-1 . . . B14225A. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, CAUTION HOT SURFACE. . . . . . . 3
1-2 . . . B14225B. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, ENGINE OIL DRAIN . . . . . . . . . . . . .1
1-3 . . . B14225C. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, COMPRESSOR OIL DRAIN . . . . . . .1
1-4 . . . B14225F . . 12867. . . . . . . . . . . . . . . LABEL, HAND BRAKE . . . . . . . . . . . . . . . . . .1
1-5 . . . B14225G . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, WARNING EXTREMELY HOT . . . . .3
1-6 . . . B14225R. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, WARNING HIGH CG . . . . . . . . . . . .1
1-7 . . . B14225Q . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, CAUTION MAXIMUM TOW SPEED .1
1-8 . . . B14225H. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, RATING PLATE (NAMEPLATE) . . . .1
1-9 . . . B14225N. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, PARK BRAKE WARN . . . . . . . . . . . .1
1-10 . . B11109E . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, DIESEL FUEL . . . . . . . . . . . . . . . . . .1
1-11. . . B11109G . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, ENGINE COOLANT. . . . . . . . . . . . . .1
1-12 . . B11109O . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, WARNING ROTATING PARTS . . . . .2
1-13 . . B11109P . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, CAUTION MAINTENANCE . . . . . . . .1
1-14 . . B11109T . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, CHECK LEVEL COLD FULL . . . . . . .1
1-15 . . B11109R . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, BATTERY BOX . . . . . . . . . . . . . . . . .1
1-16 . . B018608 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, OPERATING INSTRUCTIONS . . . . .1
1-17 . . KH5064. . . 4X025RHUSS . . . . . . . . . . . . . . . . . . . . . . . RIVET, DRIVE, #4 X 1/4” LG . . . . . . . . . . . .54
1-18 . . AA5335. . . M795093S3 . . . . . . 83861. . . . . . . . . . . . . . . COUPLING, AIRCRAFT . . . . . . . . . . . . . . . . .1
1-19 . . LF17929 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CHASSIS / ELECTRICAL ASSY . . . . . . . . . .1
(SEE FIG 3)
1-20 . . LF18048 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CANOPY ASSY ASP250 SUPER START . . .1
(SEE FIG 2)
1-21 . . NA5003. . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LOGO, VINYL TRI W/STRIPS 6” X 86” . . . . .2
1-22 . . AA5295. . . 51180-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . HOSE, AIR START, W/SCUFFER . . . . . . . . .1
3-1/2” X 40
(SEE FIG 31)
1-22A . AA5480. . . 51180-20 . . . . . . . . 56380. . . . . . . . . . . . . . . HOSE, AIR START, W/SCUFFER . . . . . . . . .1
3-1/2” X 20’ (OPTION)
1-22B . AA5338 . 51180-30 . . . . . . 56380. . . . . . . . . . . . . . . HOSE, AIR START, W/SCUFFER . . . . . . . . .1
3-1/2” X 30’ (OPTION)
1-22C . AA5472. . . 51180-50 . . . . . . . . 56380. . . . . . . . . . . . . . . HOSE, AIR START, W/SCUFFER . . . . . . . . .1
3-1/2” X 50’ (OPTION)
1-23 . . CY5036. . . 89581K. . . . . . . . . . 76700. . . . . . . . . . . . . . . CLAMP, HOSE T-BOLT, 3.5” ID . . . . . . . . . . .4
1-24 . . B19410B. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, ASP250, RHS . . . . . . . . . . . . . . . . . .1
1-25 . . B19410A. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LABEL, ASP250, LHS . . . . . . . . . . . . . . . . . .1

4-3 August 30, 2000

Page 6 Change 1
ASP250
AIR START UNIT

Parts List of Figure 1. ASP250 Top Assembly (Continued)

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

ELECTRONIC STROBE (OPTION)

1-26 . . IL5172 ... 2004BHBA . . . . . . 7B735. . . . . . . . . . . . . . BEACON, BLUE, 12/24V, (OPTION) . . . . . . . 1
1-26 . . IL5173 ... 2004BHRA . . . . . . 7B735. . . . . . . . . . . . . . BEACON, RED, 12/24V, (OPTION) . . . . . . . . 1
1-26 . . IL5174 ... 2004BHAA . . . . . . 7B735. . . . . . . . . . . . . . BEACON, AMB, 12/24V, (OPTION). . . . . . . . 1
1-26 . . IL5175 ... 2004BHCA . . . . . . 7B735. . . . . . . . . . . . . . BEACON, CLR, 12/24V, (OPTION) . . . . . . . . 1
1-26 . . IL5181 ... 01-0441566-00 . . . 7B735. . . . . . . . . . . . . . FLASH TUBE ASSY, FT10A, 10W . . . . . . . . 1

INCANDESCANT STROBE (OPTION)

Parts List of Figure 2. ASP250 Canopy

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

2- . . . . LF18048 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CANOPY W/O ACOUSTICAL INSUL . . . . REF

(SEE FIG 1)
2A- . . . LF19357 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CANOPY W/ ACOUSTICAL INSUL . . . . . REF
(OPTIONAL)
(SEE FIG 1)
2-1 . . . LF18120A . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WLDMT, ROOF. . . . . . . . . . . . . . . . . . . . . . . .4
2-2 . . . B18045A. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CORNER, FRONT RHS . . . . . . . . . . . . . . . . .1
2-3 . . . B18045B. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CORNER, FRONT LHS . . . . . . . . . . . . . . . . .1
2-4 . . . B018123 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . COVER, ACCESS PLENUM . . . . . . . . . . . . .2
2-5 . . . B18044B. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PANEL, FRONT SIDE. . . . . . . . . . . . . . . . . . .1
2-6 . . . B014549 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . COOLANT COVER. . . . . . . . . . . . . . . . . . . . .2
2-7 . . . B014550 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . FRAME COOLANT OPENING . . . . . . . . . . . .2
2-8 . . . B014678 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . HINGE, COOLANT COVER . . . . . . . . . . . . . .2
2-9 . . . KH5198. . . 43-1-2-0 . . . . . . . . . 2M626. . . . . . . . . . . . . . LATCH, ADJUST GRIP, STRAIGHT . . . . . . . .2
PAWL, MIDGET
2-10 . . B018716 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . COVER, CANOPY SLOT . . . . . . . . . . . . . . . .2
2-11. . . B18006D. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LOUVER, ACOUSTIC DOORS . . . . . . . . REF
(SEE FIG 18)
2-12 . . LF18093 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . .4
(SEE FIG 18)
2-13 . . LF18092 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
(SEE FIG 18)
2-14 . . B018062 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SILL, REAR RHS & LHS. . . . . . . . . . . . . . . . .2
2-15 . . B018063 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SILL, FRONT RHS & LHS . . . . . . . . . . . . . . .2
2-16 . . B018065 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . HEADER, REAR RHS & LHS . . . . . . . . . . . . .2
2-17 . . B018064 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . HEADER, FRONT RHS & LHS. . . . . . . . . . . .2
2-18 . . B018042 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PANEL, FUEL . . . . . . . . . . . . . . . . . . . . . . . . .1
2-19 . . B018043 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PANEL, MID SECTION RHS . . . . . . . . . . . . .1
2-20 . . LF14311 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . FUEL FILL WELL . . . . . . . . . . . . . . . . . . . . . .1
2-21 . . KH0118 . . . 4X639. . . . . . . . . . . 16327. . . . . . . . . . . . . . . RIVETS, POP, 3/16” DIA, (1/8”-1/4” GRIP). .19
2-22 . . B18044A. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2-23 . . B018039 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CORNER, CONTROL PANEL . . . . . . . . . . . .1
2-24 . . B018399 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CONTROL PANEL FRAME . . . . . . . . . . . . . .1
2-25 . . B014443 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PANEL, LEXAN, CONTROL . . . . . . . . . . . . . .1
2-26 . . LF15330 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . INSTRUMENT PANEL ASSEMBLY . . . . . . . .1
(SEE FIG 12)
2-27 . . B018046 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PANEL, FRONT CENTER UPPER. . . . . . . . .1
2-28 . . B018047 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PANEL, FRONT LOWER . . . . . . . . . . . . . . . .1
2-29 . . B018038 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CORNER, REAR LHS . . . . . . . . . . . . . . . . . .1
2-30 . . B019355 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PANEL, REAR CENTER LOWER . . . . . . . . .1
2-31 . . B018040 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PANEL, CENTER REAR UPPER . . . . . . . . . .1

4-3 August 30, 2000

Page 12 Change 1
ASP250
AIR START UNIT

Parts List of Figure 2. ASP250 Canopy (Continued)

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

2-32 . . B18006A . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . LOUVER, ACOUSTIC 11 X 54 . . . . . . . . . . . 1

2-33 . . B18006B . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . LOUVER, ACOUSTIC 51 X 24 . . . . . . . . . . . 1
2-34 . . B18006C . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . LOUVER, ACOUSTIC 38 X 25 . . . . . . . . . . . 1
2-35 . . B018081 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . FRAME, PLENUM OUTLET . . . . . . . . . . . . . 1
2-36 . . .. ... ... ............... ......... NOT ASSIGNED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-37 . . B018068 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . ROOF, RADIATOR. . . . . . . . . . . . . . . . . . . . . 1
2-38 . . B018069 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . ROOF, MID SECTIONS . . . . . . . . . . . . . . . . . 2
2-39 . . B018120B . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WLDMT, ROOF . . . . . . . . . . . . . . . . . . . . . . . 1
2-40 . . B018101 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BAND, ROOF. . . . . . . . . . . . . . . . . . . . . . . . . 4
2-41 . . KH5273 . . 24-19-302-35. . . . . 94222. . . . . . . . . . . . . . LATCH, DOOR ACCESS. . . . . . . . . . . . . REF
(SEE FIG 18)
2-42 . . B018127 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WALL, FIRE, LHS . . . . . . . . . . . . . . . . . . . . . 1
2-43 . . B018128 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WALL, FIRE, RHS . . . . . . . . . . . . . . . . . . . . . 1
2-44 . . B018078 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . SUPPORT, ROOF . . . . . . . . . . . . . . . . . . . . . 4
2-45 . . KH5354 . . H9505-120 . . . . . . 2K900. . . . . . . . . . . . . . SPRING, GAS . . . . . . . . . . . . . . . . . . . . . . . . 8
2-46 . . LF14646 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WLDMT, CYLINDER MT BRKT . . . . . . . . . . . 8
2-47 . . EB5092 . . 398G . . . . . . . . . . . 9H249. . . . . . . . . . . . . . CAP, FUEL FILL W/SCREEN . . . . . . . . . . . . 1
2-48 . . .. ... ... ............... ......... NOT ASSIGNED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-49 . . .. ... ... ............... ......... NOT ASSIGNED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-50 . . IN5074 . . . PABA-412-RMPB4 0P2F7. . . . . . . . . . . . . . FOAM INSUL, 1-1/2 THK,, 162 SQFT . . . . . . 1
METAL FACE FLR
(W/ ACOUSTIC INSUL OPTION)
2-51 . . IN5075 . . . PABA-412-BUB4 . . 0P2F7. . . . . . . . . . . . . . FOAM INSUL, 1-1/2 SIDES,, 216 SQFT . . . . 1
ROOF, BLACK
(W/ACOUSTIC INSUL OPTION)
2-52 . . B014646 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WLDMT, BALL MT BRKT. . . . . . . . . . . . . REF
(SEE FIG 18)
2-53 . . B014352 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . HINGE, DOOR. . . . . . . . . . . . . . . . . . . . . REF
(SEE FIG 18)
2-54 . . KH5160 . . AKS7-420-260. . . . 78276. . . . . . . . . . . . . . INSERTS, 1/4-20.165-.260 GRIP . . . . . . . 450
2-55 . . HHG075. . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOLT, HEX HD, 1/4-20 X 3/4, SST . . . . . . 450
2-56 . . HRGCB1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, 1/4, SST . . . . . . . . . . . . . . . 450
2-57 . . HRGCC1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, FL, 1/4, SST . . . . . . . . . . . . . . . 450
2-58 . . KH5306 . . AKS4-1032-130. . . 78276. . . . . . . . . . . . . . INSERT, 10-32,.080-.130 GRIP . . . . . . . . . . 20
2-59 . . HWF075 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . SCREW, PHIL PHD, . . . . . . . . . . . . . . . . . . 20
10-32 X 3/4, SST

August 30, 2000 4-3

Change 1 Page 13
ASP250
AIR START UNIT

Parts List of Figure 2. ASP250 Canopy (Continued)

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

2-60 . . HRFCB1 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, LK, #10, SST. . . . . . . . . . . . . . . .20

2-61 . . HRFCC1 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, FL, #10, SST . . . . . . . . . . . . . . . .20
2-62 . . B018264 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . HINGE, LOWER DOOR (REAR CANOPY) . .1
2-63 . . KH5353. . . 37-10-065-20 . . . . . 94222. . . . . . . . . . . . . . . LATCH, T-HANDLE, FLEXIBLE DRAW . . . . .2
WITH KEEPER
2-64 . . B018277 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . LOUVER PREP . . . . . . . . . . . . . . . . . . . . . . .1
2-65 . . B018263 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . DOOR, REAR LOWER . . . . . . . . . . . . . . . . . .1
2-66 . . B014507 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . COVER, OUTPUT AIR . . . . . . . . . . . . . . . . . .1
2-67 . . B18766 . . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ACOUSTICAL PANEL INSTAL . . . . . . . . . . . .1
(W/ LVL 2 ACOUSTICAL INSUL OPTION)
2-68 . . IN5016 . . . 14001 . . . . . . . . . . . THERM. . . . . . . . . . . . . EXHAUST WRAP, 10 SQFT . . . . . . . . . . . . . .1
2-69 . . LF19029 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ASSY, ROOF, PANEL & RETAINERS. . . . . . .1
(W/ ACOUSTICAL INSUL OPTION)
2-70 . . LF19149 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . VERTICAL RETAINERS & . . . . . . . . . . . . . . .1
SOUND PADS ASSEMBLY
(W/ ACOUSTICAL INSUL OPTION)
-2-71 . . IN0026 . . . PAF 100 NUBA . . . 0P2F7. . . . . . . . . . . . . . INSULATION, SIDE PANELS, FOAM, 1”, . .15
SHEET (388 SQFT)
(W/ ACOUSTICAL INSUL OPTION)
-2-72 . . TA5477 . . . 4T889 . . . . . . . . . . . 25795. . . . . . . . . . . . . . . EXTINGUISHER, FIRE, 10#, ABC . . . . . . . . .2
(OPTIONAL)
-2-73 . . TA5478 . . . 5T909 . . . . . . . . . . . 25795. . . . . . . . . . . . . . . BRACKET, EXTINGUISHER . . . . . . . . . . . . .2
(OPTIONAL)

- ITEM NOT ILLUSTRATED

4-3 August 30, 2000

Page 14 Change 1
ASP250
AIR START UNIT

Figure 3. Chassis / Electrical Assembly (Sheet 1 of 2)

August 30, 2000 4-3

Change 1 Page 15
ASP250
AIR START UNIT

Figure 3. Chassis / Electrical Assembly (Sheet 2 of 2)

4-3 August 30, 2000

Page 16 Change 1
ASP250
AIR START UNIT

Parts List of Figure 3. Chassis / Electrical Assembly

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

3- . . . . LF17929 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . CHASSIS/ELECTRICAL ASSEMBLY . . . REF

(SEE FIG 1)
3-1 . . . LF1792B . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . CHASSIS ASSEMBLY . . . . . . . . . . . . . . . . . . 1
(SEE FIG 4)
3-2 . . . LF18400 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BATTERY AND CABLE ASSEMBLY . . . . . . . 1
(SEE FIG 23)
3-3 . . . LF18250 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . MAINTENANCE BOX ASSEMBLY . . . . . . . . 1
(SEE FIG 9)
3-4 . . . LF18389 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . CONTACTORS PANEL ASSEMBLY . . . . . . . 1
(SEE FIG 11)
3-5 . . . LF15330 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . INSTRUMENT PANEL ASSEMBLY. . . . . REF
(SEE FIG 12)
-3-6 . . .. ... ... . . . . . . . . . . . . . . . NOT ASSIGNED ............................................
-3-7 . . .. ... ... . . . . . . . . . . . . . . . NOT ASSIGNED ............................................
3-8 . . . HGH075. . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOLT, HEX HD, 5/16-18 X 3/4, GR8 . . . . . . . 8
3-9 . . . HRHBC1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, FL, 5/16, GR8. . . . . . . . . . . . . . . . 8
3-10 . . HRHBB1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, 5/16, GR8 . . . . . . . . . . . . . . . 8
3-11 . . KH5145 . . AKS7-518-150. . . . 78276. . . . . . . . . . . . . . INSERT, 5/16-18, .027-.150 GRIP . . . . . . . . . 4
-3-12 . LF15356 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . ECM WIRING HARNESS ASSY . . . . . . . . . . 1
(SEE FIG 35)

- ITEM NOT ILLUSTRATED

August 30, 2000 4-3

Change 1 Page 17
ASP250
AIR START UNIT

Figure 4. Chassis Assembly (Sheet 1 of 2)

4-3 August 30, 2000

Page 18 Change 1
ASP250
AIR START UNIT

Figure 4. Chassis Assembly (Sheet 2 of 2)

August 30, 2000 4-3

Change 1 Page 19
ASP250
AIR START UNIT

Parts List of Figure 4. Chassis Assembly

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

4- . . . . LF19340 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CHASSIS ASSEMBLY . . . . . . . . . . . . . . . REF

(SEE FIG 4)
4-1 . . . LF18032 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . FUEL SYSTEM INSTALLATION . . . . . . . . . . .1
(SEE FIG 15)
4-2 . . . LF18024 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BOX, HOSE STORAGE . . . . . . . . . . . . . . . . .1
4-3 . . . LF18030 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ENGINE AIR SYSTEM ASSEMBLY . . . . . . .1
(SEE FIG 7)
4-4 . . . LF18027 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ENGINE EXHAUST SYSTEM . . . . . . . . . . . .1
(SEE FIG 8)
4-5 . . . LF18026 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ENGINE/COMPRESSOR ASSEMBLY . . . . .1
(SEE FIG 5)
4-6 . . . LF18036 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . FUEL TANK ASSEMBLY . . . . . . . . . . . . . . . .1
(SEE FIG 16)
4-7 . . . LF18134 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PIPING, HOSE & VALVE INSTAL . . . . . . . . . .1
(SEE FIG 19)
4-8 . . . LF17910 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . AIR DELIVERY PIPE W/VALVES . . . . . . . . . .1
(SEE FIG 20)
4-9 . . . LF18157 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . COMPRESSOR OIL SYSTEM . . . . . . . . . . . .1
(SEE FIG 13)
4-10 . . LF18025 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . RADIATOR & CHARGE AIR COOLER . . . . .1
PIPING INSTALLATION (SEE FIG 6)
4-11. . . B018033 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WLDMT, FENDER . . . . . . . . . . . . . . . . . . . . .2
4-12 . . LF17927 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . FRAME, AIR START ASP250. . . . . . . . . . . . .1
4-13 . . LF18235 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WLDMT, AIR INTAKE, CPRSR. . . . . . . . . . . .1
4-14 . . LF18275 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ACOUSTICAL DAMPER INSTAL . . . . . . . . . .1
(SEE FIG 24)
4-15 . . LF18437 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . COMPRESSOR AIR SYSTEM ASSY. . . . . . .1
(SEE FIG 14)
4-16 . . HGG075 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BOLT, HEX HD, 1/4 - 20X3/4, GR8. . . . . . . .29
4-17 . . HRGBC1. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, FL, 1/4, GR8 . . . . . . . . . . . . . . . .29
4-18 . . HRGBB1. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, LK, 1/4 . . . . . . . . . . . . . . . . . . . .29
4-19 . . KH5160. . . AKS7-420-260 . . . . 78276. . . . . . . . . . . . . . . INSERT, 1/4-20, .165-.260 GRIP . . . . . . . . .13
4-20 . . KH5221. . . AKS4-420-165 . . . . 78276. . . . . . . . . . . . . . . INSERT, 1/4-20, .027-.165 GRIP . . . . . . . . .16
4-21 . . HGI075 . . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BOLT, HEX HD, 3/8-16X3/4, GR8. . . . . . . . . .5
4-22 . . HRGBC1. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, FL, 3/8, GR8 . . . . . . . . . . . . . . . . .5
4-23 . . HRGBB1. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, LK, 3/8. . . . . . . . . . . . . . . . . . . . . .5
4-24 . . KH5226. . . AKS7-616-150B . . . 78276. . . . . . . . . . . . . . . INSERT, 3/8-16, .027-1.50 GRIP . . . . . . . . . .5

4-3 August 30, 2000

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Parts List of Figure 4. Chassis Assembly (Continued)

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

4-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOT ASSIGNED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-26 . . B018240 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . HAND BRAKE ASSEMBLY . . . . . . . . . . . . . . 1
(SEE FIG 30)
4-27 . . B018409 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . CROSS SHAFT ASSY (02-20676) . . . . . . . . 1
(SEE FIG 29)
4-28 . . B018241 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BRAKE CABLES . . . . . . . . . . . . . . . . . . . . . . 2
(SEE FIG 29)
4-29 . . EB5224 .. 11002 . . . . . . . . . . THERM. . . . . . . . . . . . . EXHAUST WRAP . . . . . . . . . . . . . . . . . . . . . 1
4-30 . . EB5225 .. 13001 . . . . . . . . . . THERM. . . . . . . . . . . . . TIE-WRAPS, SST . . . . . . . . . . . . . . . . . . . . . 8
4-31 . . EB5226 .. 12002 . . . . . . . . . . THERM. . . . . . . . . . . . . COATING, HI-HEAT . . . . . . . . . . . . . . . . . . .AR
4-32 . . TA5689 .. . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . MOUNTED TIRE & WHEEL ASSEMBLY . . . 4
235/85R16, 16X6
4-32A . TA5563 . . 796-725-475 . . . . . 7W514. . . . . . . . . . . . . TIRE, RADIAL, RIB DESIGN, 16X6. . . . . . . . 4
LT235/85R16
4-32B . TA5566 . . 16X6-8WS/4-1/2BS BROAD. . . . . . . . . . . . . WHEEL, 16X6, 8 BOLT, 3300# CAP . . . . . . . 4
4-33 . . . . . . . . . . 03-30396 . . . . . . . . 12867. . . . . . . . . . . . . . 5TH WHEEL ASSEMBLY . . . . . . . . . . . . REF
REAR AXLE (SEE FIG 25)
4-34 . . TA5796 . . 04-40273 . . . . . . . . 0AT39. . . . . . . . . . . . . . FRONT AXLE ASSEMBLY . . . . . . . . . . . . . . 1
(STD CONFIGURATION, W/O BRAKE)
(SEE FIG 26)
4-34A . TA5680 . . 04-40321 . . . . . . . . OAT39 . . . . . . . . . . . . . . FRONT AXLE ASSEMBLY . . . . . . . . . . . . . . 1
(W/BRAKE OPTION)
(SEE FIG 27)
4-35 . . LF18415 . 04-40360 . . . . . . . . 0AT39. . . . . . . . . . . . . . TRAILER 5TH WHEEL ASSEMBLY . . . . . . . 1
(SEE FIG 25)
4-36 . . EB5593 . . 22045 . . . . . . . . . . 4K048. . . . . . . . . . . . . . KBI® ETHER START SYSTEM . . . . . . . . . . 1
(OPTION, SEE FIG 33)
-4-37 . EC5474 . . 3916128 . . . . . . . . 15434. . . . . . . . . . . . . . BLOCK HTR, ENGINE, 220V, 750W . . . . . . . 1
(OPTION)

- ITEM NOT ILLUSTRATED

August 30, 2000 4-3

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OPTIONAL - ONLY UNITS

W/NALCOOL FILTER

Figure 5. Engine/Compressor Assembly (Sheet 1 of 3)

4-3 January 15, 2002

Page 22 Change 2
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Figure 5. Engine/Compressor Assembly (Sheet 2 of 3)

January 15, 2002 4-3

Change 2 Page 23
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Figure 5. Engine/Compressor Assembly (Sheet 3 of 3)

4-3 January 15, 2002

Page 24 Change 2
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Parts List of Figure 5. Engine/Compressor Assembly

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

5- . . . . LF18026A . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . ENGINE/COMPRESSOR ASSEMBLY . . REF

(SEE FIG 4)
5-1 . . . B018029 . . . . . . . . . . . . . . . . 72582. . . . . . . . . . . . . . ENGINE, DETROIT DEISEL® SERIES 60, . 1
DDEC IV (MODEL 6063-HK33)
5-2 . . . AA5715. . . . CD42HS, 4.8438 2139 . . . GHHRA. . . . . . . . . . . . . COMPRESSOR, 250PPM, . . . . . . . . . . . . . . 1
GEAR RATIO 4.8438, GEAR SET 9
(SEE FIG 13)
5-2A . . AA5822. . . . CD42HS,5.643,2139 . . . . GHHRA. . . . . . . . . . . . . COMPRESSOR, 250PPM, . . . . . . . . . . . . . . 1
GEAR RATIO 5.643, GEAR SET 11
(UNIT #501676 AND SUBSEQUENT)
5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . NOT USED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3 . . . EB5780 . . 1X30124225 . . . . . 60248. . . . . . . . . . . . . . COUPLING, T/SHAFT, VL3012-2810/14 . . . . 1
5-4 . . . EB5449 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . ADAPTER HOUSING (W/AA5715/5207). . . . 1
5-5 . . . . . . . . . . . 4035-35828 . . . . . . 72582. . . . . . . . . . . . . . FAN, 36" (PART OF ITEM 41) . . . . . . . . . REF
5-6 . . . B018272 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . HUB (MODIFIED) (PART OF ITEM 41) . . . . . 1
(SEE FIG 6)
5-6A . . . . . . . . . . 23517136 . . . . . . . 72582. . . . . . . . . . . . . . BELT, FAN, POLY-VEE . . . . . . . . . . . . . . . . . 1
5-7 . . . HGW300 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOLT, HEX, 3/8-24NF x 3.00” . . . . . . . . . REF
5-8 . . . EG5042 . . MSP6724 . . . . . . . 0BXW5. . . . . . . . . . . . . MAGNETIC PICKUP(MPU) . . . . . . . . . . . . . . 1
5-9 . . . HGK450. . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOLT HEX HD, 1/2 -13X41/2, GR8 . . . . . . . . 8
5-10 . . IYH070. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOLT, M16X2 DR10.9X70 MM . . . . . . . . . . . 3
5-11 . . B014990 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . PLATE GROUNDING . . . . . . . . . . . . . . . . . . 1
5-12 . . SR5037 . . SP2AB-10R. . . . . . 85814. . . . . . . . . . . . . . SWITCH, OIL PRESS, 10PSI, NC (S4) . . . . 1
5-13 . . ME5049 . . 102226 . . . . . . . . . 16476. . . . . . . . . . . . . . SENDER, OIL PRESSURE (OPS) . . . . . . . . 1
5-14 . . SR5088 . . 1002-05511-37 . . . 51377. . . . . . . . . . . . . . SWITCH, WATER TEMP, 225°F, NO (S5) . . . 1
5-15 . . ME0009 . . 202500 . . . . . . . . . 16476. . . . . . . . . . . . . . SENDER, WATER TEMP(WTS) . . . . . . . . . . 1
5-16 . . PX0045 . . 262 .34OZ BTL . . 12867. . . . . . . . . . . . . . LOCTITE, RED . . . . . . . . . . . . . . . . . . . . . . . 1
5-17 . . VM5018 . . 51512-4 . . . . . . . . . 5P059 . . . . . . . . . . . . SHOCK MT, RATED @ 1245 AXIAL LBS . . . 6
5-18 . . HJJ225 . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . SCREW, SOC HD, GR 8, .4375-14 x 2.25 . . 6
5-19 . . HROBA1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . NUT, HEX, 3/4-16, THREADED. . . . . . . . . . . 6
5-20 . . HRKBB1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, 1/2, SPLIT . . . . . . . . . . . . . . 12
5-21 . . IWFBC1 . . M12 BN717 B2. . . 12867. . . . . . . . . . . . . . WASHER, FL, M12 . . . . . . . . . . . . . . . . . . . 20
5-22 . . HWF100 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . SCREW, PHD, 10-32X1, SST . . . . . . . . . . . . 2
5-23 . . HRFCB1 . MS35338-138 . . . . 12867. . . . . . . . . . . . . . WASHER, LK, #10, SST . . . . . . . . . . . . . . . . 2
5-24 . . HRFCC1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, FL, #10, SST . . . . . . . . . . . . . . . . 2
5-25 . . HJJ150 . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . SCREW, SOC HD,GR 8 -.4372-14 x 1.50 . . . 6
5-26 . . IYH055. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . SCREW, HHD, M16X2 ,GR10.9 X55MM. . . . 5
5-27 . . IWHBB1. . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, M16 . . . . . . . . . . . . . . . . . . . . 8
5-28 . . HGR100. . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOLT, HEX HD, 5/8 -11 X 1 . . . . . . . . . . . . . . 1
5-29 . . HRNBB1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, 5/8 . . . . . . . . . . . . . . . . . . . . . 1
5-30 . . HGY400. . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . HEX BOLT, 3/4-10 X 4" . . . . . . . . . . . . . . . . . 6
5-31 . . HROBB1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, 3/4 . . . . . . . . . . . . . . . . . . . . . 6
5-32 . . HROBC1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, FL, 3/4 . . . . . . . . . . . . . . . . . . . . . 6
5-33 . . HGK150. . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOLT, HEX HD, 1/2-13X1-1/2, GR8 . . . . . . 12
5-34 . . HRKBA1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . NUT, HEX, 1/2-13 . . . . . . . . . . . . . . . . . . . . 12
5-35 . . FI5472 . . . 2024-12-12S . . . . . 01276. . . . . . . . . . . . . . ADAPTER, 90°, ELBOW . . . . . . . . . . . . . . . . 1
5-36 . . LF18395 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . HOSE - OIL DRAIN - ENGINE. . . . . . . . . . . . 1
5-37 . . FI5271 . . . 2043-12-12S . . . . . 1H123. . . . . . . . . . . . . . BULKHEAD FITTING, 90°, 3/4" . . . . . . . . . . . 1

January 15, 2002 4-3

Change 2 Page 25
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Parts List of Figure 5. Engine/Compressor Assembly (Continued)

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

5-
5-38 . . FI5725 . . . 210292-12S . . . . . . 01276. . . . . . . . . . . . . . . CAP, FLARE 3/4" . . . . . . . . . . . . . . . . . . . . . .1
5-39 . . PX5171. . . 23512703 . . . . . . . . 72582. . . . . . . . . . . . . . . OIL, ENGINE, QT, DELVAC® 15W40. . . . . .40
5-40 . . PX5172. . . 23518918 . . . . . . . . 72582. . . . . . . . . . . . . . . ANTIFREEZE, PRE-BLENDED, GAL . . . . .20
(SEE FIG 6)
5-41 . . EB5527. . . TRI-6BTA . . . . . . . . 12867. . . . . . . . . . . . . . . FLTR, WATER, NALCOOL® (Option). . . . . . .1
5-42 . . EJ5149 . . . 23518480 . . . . . . . . 72582. . . . . . . . . . . . . . . FLTR, OIL, ENGINE, SPIN-ON. . . . . . . . . . . .2
5-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NOT ASSIGNED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-44 . . AA5822 . . . CD42HS,5.643,2139RPM . GHHRA. . . . . . . . . . . . . COMPRESSOR, 5.643, GEAR SET 11 . . . . .1
(SEE FIG 5)
5-45 . . . . . . . . . . 256535S. . . . . . . . . 15434. . . . . . . . . . . . . . . BRACKET, WATER FLTR (Option) . . . . . . . . .1
5-45A . . . . . . . . . 204163S. . . . . . . . . 15434. . . . . . . . . . . . . . . FLTR HEAD, WATER (Option) . . . . . . . . . . . .1
5-46 . . EJ5112 . . . 10478911 . . . . . . . . 72582. . . . . . . . . . . . . . . STARTER, ENGINE, 24V . . . . . . . . . . . . . . . .1
5-47 . . EJ5111 . . . 01117900 . . . . . . . . 72582. . . . . . . . . . . . . . . ALTERNATOR, ENGINE, 24V . . . . . . . . . . . .1
5--48 . . BE5022. . . 5140185 . . . . . . . . . 72582. . . . . . . . . . . . . . . BELT, ALTERNATOR, 45”, SET OF 2. . . . . . .1
5-49 . . PT5383 . . . 7117280022 . . . . . . 60248. . . . . . . . . . . . . . . BUSHING, TAPER LOCK . . . . . . . . . . . . . . . .1
5-50 . . EB5782. . . 2X3012A003 . . . . . 60248. . . . . . . . . . . . . . . ELEMENT, FLEX REPL FOR ITEM 3. . . . . . .1

4-3 January 15, 2002

Page 26 Change 2
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Figure 6. Radiator & Charge Air Cooler Piping Installation

August 30, 2000 4-3
Change 1 Page 27
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Parts List of Figure 6. Radiator & Charge Air Cooler Piping Installation
FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

6- . . . . LF18025 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . RADIATOR & CHARGE AIR COOLER . . REF

(CAC) PIPING INSTALLATION
(SEE FIG 4)
6-1 . . . LF18084 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . AIR START COILS ASSEMBLY . . . . . . . . . . .1
(SEE FIG 17)
6-2 . . . AH5110 . . . 70-262 . . . . . . . . . . 0RR12. . . . . . . . . . . . . . HOSE, PUROSIL®, COOLANT, . . . . . . . . . .1
2.62 ID X 3’, 351PSI
6-3 . . . CY0041. . . 706-1024 #52 . . . . . 6V625. . . . . . . . . . . . . . CLAMP, HOSE, 1-7/8” TO 3-3/4”, SST . . . . . .4
6-4 . . . TQ5028. . . 2 5/8 ACR. . . . . . . . 0J639. . . . . . . . . . . . . . . COPPER, TUBING, HARD,.72’. . . . . . . . . . . .1
6-5 . . . TQ5076. . . W2087 . . . . . . . . . . 0J639. . . . . . . . . . . . . . . COPPPER, ELBOW, 90o SHT RADIUS . . . . .6
6-6 . . . TQ5028. . . 2 5/8 ACR. . . . . . . . 0J639. . . . . . . . . . . . . . . COPPER, TUBING, HARD, 2.9’ . . . . . . . . . . .1
6-7 . . . TQ5028. . . 2 5/8 ACR. . . . . . . . 0J639. . . . . . . . . . . . . . . COPPER, TUBING, HARD, 1.4’ . . . . . . . . . . .1
6-8 . . . TQ5047. . . W2387 . . . . . . . . . . 0J639. . . . . . . . . . . . . . . COPPER, ELBOW, SHT RADIUS, STR . . . . .1
6-9 . . . TQ5028. . . 2 5/8 ACR. . . . . . . . 0J639. . . . . . . . . . . . . . . COPPER, TUBING, HARD,.5’. . . . . . . . . . . . .1
6-10 . . TQ5028. . . 2 5/8 ACR. . . . . . . . 0J639. . . . . . . . . . . . . . . COPPER, TUBING, HARD, .75’ . . . . . . . . . . .1
6-11. . . TQ5028. . . 2 5/8 ACR. . . . . . . . 0J639. . . . . . . . . . . . . . . COPPER, TUBING, HARD, .9’ . . . . . . . . . . . .1
6-12 . . PX5172. . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ANTIFREEZE, ETHYLENE GLYCOL . . . . REF
(SEE FIG 5)
6-13 . . FI0065 . . . 2024-4-45. . . . . . . . 5W026. . . . . . . . . . . . . . ELBOW, 90o, 1/4 NPT TO 7/16 FLARE . . . . .2
6-14 . . FL0014 . . . 4797-4B . . . . . . . . . 5W026. . . . . . . . . . . . . . FITTING, SWL, 7/16-20, #4 HOSE . . . . . . . . .2
6-15 . . AH5113 . . . H148. . . . . . . . . . . . 6V625. . . . . . . . . . . . . . HOSE, 1/4 ID, HIGH TEMP, COOLANT . . . . .1
6-16 . . EB5711 . . . P532945. . . . . . . . . 53453. . . . . . . . . . . . . . . HOSE, CONNECTOR, SILICONE CAC 4” . . .1
6-17 . . CY5153. . . 8926958 . . . . . . . . . 53453. . . . . . . . . . . . . . . CLAMP, HOSE, 4”. . . . . . . . . . . . . . . . . . . . . .6
6-18 . . AH5111 . . . 364-450 . . . . . . . . . 0RR12. . . . . . . . . . . . . . HOSE, PUROSIL®, CHARGE AIR . . . . . . . .1
COOLER 4.5 ID X 6
6-19 . . CY5128. . . 89583K. . . . . . . . . . 76700. . . . . . . . . . . . . . . CLAMP, T-BAR . . . . . . . . . . . . . . . . . . . . . . . .8
6-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NOT ASSIGNED
6-21 . . LF18392 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WLDMT, CAC SUPPLY PIPING . . . . . . . . . . .1
6-22 . . LF18393 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WLDMT, CAC RETURN PIPING . . . . . . . . . .1
6-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NOT ASSIGNED
6-24 . . CY0035. . . 706-1107 . . . . . . . . 6V625. . . . . . . . . . . . . . CLAMP, HOSE, #4 . . . . . . . . . . . . . . . . . . . . .2
6-25 . . REF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP, RADIATOR, (PART OF FN27) . . . . . . . .1
6-26 . . REF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOSE, OVERFLOW . . . . . . . . . . . . . . . . . . . .1
6-27 . . EB5687. . . CRS150 . . . . . . . . . 72582. . . . . . . . . . . . . . . BOTTLE, OVERFLOW RECOVERY . . . . . . .1
6-28 . . B018272 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . HUB, ENGINE FAN. . . . . . . . . . . . . . . . . . . . .1
6-29 . . B18085E. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ORIFICE, HALF . . . . . . . . . . . . . . . . . . . . REF
6-30 . . B18085F . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ORIFICE, HALF . . . . . . . . . . . . . . . . . . . . REF
6-31 . . TQ5028. . . 2 5/8 ACR. . . . . . . . 0J639. . . . . . . . . . . . . . . COPPER, TUBING, HARD,.71’. . . . . . . . . . . .1
6-32 . . LF15553 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SCREEN, 40” DIA. . . . . . . . . . . . . . . . . . . . . .1
6-33 . . HGW300. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BOLT, HEX HD, 3/8-24 NF X 3, GR8 . . . . . . .6
6-34 . . LF18381 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BRACKET, RAD PIPING, W/CLAMP . . . . . . .1
6-35 . . EB5224. . . 11002 . . . . . . . . . . . THERM. . . . . . . . . . . . . WRAP, EXHAUST, INSULATING . . . . . . . . . .2
6-36 . . EB5225. . . 13001 . . . . . . . . . . . THERM. . . . . . . . . . . . . WRAP, SNAP STRAP TIE . . . . . . . . . . . . . . .1
6-37 . . EB5226. . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . COATING, HIGH TEMP, CAN . . . . . . . . . . . . .2
6-38 . . B018718 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BRACKET, OVERFLOW BOTTLE . . . . . . . . .1

- ITEM NOT ILLUSTRATED

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Figure 7. Engine Air System Assembly

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Parts List of Figure 7. Engine Air System Assembly

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

7- . . . . LF18030 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ENGINE AIR SYSTEM ASSEMBLY . . . . . REF

(SEE FIG 4)
7-1 . . . EB0293. . . P10-7844 . . . . . . . . 53453. . . . . . . . . . . . . . . ELBOW, RUBBER, 5-1/2” TO 7”. . . . . . . . . . .1
7-2 . . . EB5694. . . P15-9820 . . . . . . . . 18265. . . . . . . . . . . . . . . ELBOW, REDUCING . . . . . . . . . . . . . . . . . . .1
7-3 . . . EB5476. . . 71338-003 . . . . . . . 72582. . . . . . . . . . . . . . . CTRG, FLTR, ENGINE, AIR BREATHER . . . .1
7-4 . . . EB5477. . . 10-71921-003. . . . . 72582. . . . . . . . . . . . . . . BANDS, MTG, 13.44” DIA. . . . . . . . . . . . . . . .2
7-5 . . . B018382 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BRACKET, AIR CLEANER . . . . . . . . . . . . . . .1
7-6 . . . KH5145. . . AKS7-518-150 . . . . 78276. . . . . . . . . . . . . . . INSERT, STL, 5/17-18,.027-.150 GRIP . . . . .4
7-7 . . . HGH075 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BOLT, HEX HD, 5/17-18X3/4, GR8. . . . . . . . .4
7-8 . . . HRHBB1 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, LK, 5/16, GR8 . . . . . . . . . . . . . . . .4
7-9 . . . HRHBC1. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, FL, 5/16, GR8 . . . . . . . . . . . . . . . .4
7-10 . . KH5221. . . AKS4-420-165 . . . . 78276. . . . . . . . . . . . . . . INSERT, STL, 1/4-20,.027-.165 GRIP . . . . . .4
7-11. . . HGG100 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BOLT, HEX HD, 1/4-20X1, GR8 . . . . . . . . . . .4
7-12 . . HRGBB1. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, LK 1/4 . . . . . . . . . . . . . . . . . . . . . .4
7-13 . . HRGBC1. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, FL, 1/4, GR8 . . . . . . . . . . . . . . . . .4
7-14 . . CY0039. . . P11-5205 . . . . . . . . 18265. . . . . . . . . . . . . . . CLAMP, HOSE, T-BOLT, 5-1/4 - 7-1/8 . . . . . .3
7-15 . . CY5100. . . F14-8348 . . . . . . . . 18265. . . . . . . . . . . . . . . CLAMP, HOSE, T-BOLT, 7” ID . . . . . . . . . . . .1

-ITEM NOT ILLUSTRATED

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Figure 8. Engine Exhaust System (Sheet 1 of 2)

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Figure 8. Engine Exhaust System (Sheet 2 of 2)

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Parts List of Figure 8. Engine Exhaust System

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

8- . . . . LF18027 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . ENGINE EXHAUST ASSEMBLY . . . . . . . REF

(SEE FIG 4)
8-1 . . . B018117 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . SUPPORT, SILENCER . . . . . . . . . . . . . . . . . 1
8-2 . . . LF18119. . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WLDMT, SILENCER . . . . . . . . . . . . . . . . . . . 1
8-3 . . . EB5501 . . 89460A . . . . . . . . . 76700. . . . . . . . . . . . . . RAIN CAP, 6” DIA . . . . . . . . . . . . . . . . . . . . . 1
8-4 . . . EB5530 . . 89076A . . . . . . . . . 76700. . . . . . . . . . . . . . ELBOW, 45o, 6” DIA . . . . . . . . . . . . . . . . . . . 2
8-5 . . . B018116 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . SUPPORT, EXHAUST PIPE . . . . . . . . . . . . . 4
8-6 . . . VM0004 . . J4624-23 . . . . . . . . 12965. . . . . . . . . . . . . . MOUNT, VIBRATION . . . . . . . . . . . . . . . . . . . 4
8-7 . . . LF18267 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . ASSY, EXHAUST PIPE, 6” DIA . . . . . . . . . . . 1
8-8 . . . EB5686 . . 89798K . . . . . . . . . 76700. . . . . . . . . . . . . . CONNECTOR, CORRUGATED, EXH, . . . . . 1
6” IDX18”
8-9 . . . EB5497 . . 89278A . . . . . . . . . 76700. . . . . . . . . . . . . . REDUCER, 5” ID X 6” ID . . . . . . . . . . . . . . . 1
8-10 . . REF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-BAND, 5” . . . . . . . . . . . . . . . . . . . . . . . REF
8-11 . . EB5503 . . 90877A . . . . . . . . . 76700. . . . . . . . . . . . . . CLAMP, 5” . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8-12 . . EB5502 . . 90878A . . . . . . . . . 76700. . . . . . . . . . . . . . CLAMP, 6” . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8-13 . . HGG075 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOLT, HEX HD, 1/4-20X3/4, GR8 . . . . . . . . . 3
8-14 . . HRGBC1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, FL, 1/4, GR8. . . . . . . . . . . . . . . . . 7
8-15 . . HRGBB1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, 1/4, NORM . . . . . . . . . . . . . . . 7
8-16 . . KH5221 . . AKS4-420-165. . . . 78276. . . . . . . . . . . . . . INSERT, STL, 1/4-20,.028-.165 GRIP . . . . . . 7
8-17 . . HGI100 . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOLT, HEX HD, 3/8-16X1, GR8. . . . . . . . . . . 4
8-18 . . HRIBC1 . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, FL, 3/8, GR8. . . . . . . . . . . . . . . . . 8
8-19 . . HRIBB1 . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, 3/8 . . . . . . . . . . . . . . . . . . . . . 4
8-20 . . HRIBA1 . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . NUT, HEX, 3/8-16 . . . . . . . . . . . . . . . . . . . . . 4
8-22 . . B18270A . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BRACKET, EXHAUST, RHS . . . . . . . . . . . . . 1
8-23 . . HGR100. . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOLT, HEX HD, 5/8-11X1 . . . . . . . . . . . . . . . 4
8-24 . . HRRBC1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, FL, 5/8 . . . . . . . . . . . . . . . . . . . . . 4
8-25 . . HRRBB1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, 5/8 . . . . . . . . . . . . . . . . . . . . . 4
8-26 . . EB5224 . . 11002 . . . . . . . . . . THERM. . . . . . . . . . . . . WRAP, EXHAUST INSULATING . . . . . . . . . 6
8-27 . . EB5225 . . 13001 . . . . . . . . . . THERM. . . . . . . . . . . . . SNAP, STRAP TIE WRAP . . . . . . . . . . . . . . . 4
8-28 . . IN5016 . . . 14001 . . . . . . . . . . THERM. . . . . . . . . . . . . WRAP, EXHAUST 24X48 (10 SQ FT) . . . . . . 2

— ITEM NOT ILLUSTRATED

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Figure 9. Maintenance Box Assembly

4-3 August 30, 2000

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Parts List of Figure 9. Maintenance Box Assembly

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

9- . . . . LF18250 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . MAINTENANCE BOX ASSEMBLY . . . . . REF

(SEE FIG 3)
9-1 . . . B018164 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOX, ELECTRICAL MAINTENANCE . . . . . . 1
9-2 . . . B018249 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BRACKET, MAINTENANCE BOX . . . . . . . . . 2
9-3 . . . KH5352 . . 8-300-22 . . . . . . . . 5G982. . . . . . . . . . . . . . SLIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9-4 . . . HHG100. . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . BOLT, HEX HD, 1/4-20X1 . . . . . . . . . . . . . . . 8
9-5 . . . HRGCB1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, 1/4 . . . . . . . . . . . . . . . . . . . . . 8
9-6 . . . HRCC1 . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, FL, 1/4 . . . . . . . . . . . . . . . . . . . . . 8
9-7 . . . KH5221 . . AKS4-420-165. . . . 78276. . . . . . . . . . . . . . INSERT, 1/4-20, .027 - .165 GRIP . . . . . . . . . 8
9-8 . . . LF15341 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . ELECTRICAL PANEL ASSY W/DDEC . . . . . 1
(SEE FIG 10)
9-9 . . . HRFCA1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . NUT, HEX, 10-32, SST . . . . . . . . . . . . . . . . . 6
9-10 . . HRFCB1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, #10, SST . . . . . . . . . . . . . . . 12
9-11 . . HRFCC1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, FL, #10, SST . . . . . . . . . . . . . . . 12
9-12 . . HWF050 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . SCREW, PHD, 10-32 X .5” . . . . . . . . . . . . . . 6
9-13 . . VM0004 . . J4624-23 . . . . . . . . 12965. . . . . . . . . . . . . . MOUNT, VIBRATION . . . . . . . . . . . . . . . . . . . 6
9-14 . . B014215 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . HINGE, ELEC BOX DOOR . . . . . . . . . . . . . . 1
9-15 . . KH0118 . . 4X639 . . . . . . . . . . 16327. . . . . . . . . . . . . . RIVET, POP, 3/16 DIA, 1/8 - 1/4 GRIP. . . . . 12
9-16 . . B18164D . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . DOOR, MAINTENANCE BOX . . . . . . . . . . . . 1
9-17 . . IN5068 . . . R421-N . . . . . . . . . 7W514. . . . . . . . . . . . . INSULATION, CLOSED CELL SPONGE . . . 1
1” W X 1/8” THK X 9’ LG
9-18 . . KH0139 . . 4X580 . . . . . . . . . . 16327. . . . . . . . . . . . . . RIVET, POP, 1/8 DIA, 3/16-1/4 GRIP. . . . . . . 2
9-19 . . KH5264 . . 43-1-13-0. . . . . . . . 94222. . . . . . . . . . . . . . LATCH, ADJ GRIP, MIDGET . . . . . . . . . . . . . 2
9-20 . . KH5021 . . . . . . . . . . . . . . . . . 94222. . . . . . . . . . . . . . LATCH, “T”, RUBBER . . . . . . . . . . . . . . . . . . 1

— ITEM NOT ILLUSTRATED

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Figure 10. Electrical Panel Assembly (Units w/ Serial Numbers Prior to 501558) (Sheet 1 of 2)

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Figure 10. Electrical Panel Assembly (Units w/ Serial# 501558 and Subsequent) (Sheet 2 of 2)

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Change 2 Page 37
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Parts List of Figure 10. Electrical Panel Assembly

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

10- . . . LF15341 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ELECTRICAL PANEL ASSEMBLY . . . . . . REF

(SEE FIG 9)
10-1 . . CB5006. . . W58XB1A4A-10 . . . 77342. . . . . . . . . . . . . . . CIRCUIT BRKR, SYS PWR, 10A (CB1, 2) . . .2
10-2 . . LF13290A . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ASSEMBLY, FLT MONITOR, 24VDC (A1) . . .1
10-3 . . CO5219 . . 206151-1 . . . . . . . . 7G614. . . . . . . . . . . . . . RECEPTACLE, CONNECTOR (J6) . . . . . . . .1
10-4 . . CO5220 . . 206306-1 . . . . . . . . 7G614. . . . . . . . . . . . . . RECEPTACLE, CONNECTOR (J7) . . . . . . . .1
10-5 . . LF15691 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CCA, DEMAND VSG CONTROL (A5) . . . . . .1
10-6 . . SA0098. . . 8233-A-0632 . . . . . 1FJ15. . . . . . . . . . . . . . . STANDOFF. . . . . . . . . . . . . . . . . . . . . . . . . . .4
10-7 . . RE5135. . . T1K00180-462 . . . . 28081. . . . . . . . . . . . . . . RELAY, TIME DELAY (TD1) . . . . . . . . . . . . . .1
10-8 . . DA0025. . . 1N5552. . . . . . . . . . 81349. . . . . . . . . . . . . . . DIODE, 5A, 600V (CR2, 3, 7-12, 14, 19) . . .10
10-9 . . L01492B . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CCA, DIODE LOGIC (A4) . . . . . . . . . . . . . . . .1
10-10 . RE0013. . . R10-E1-X2-V700 . . 77342. . . . . . . . . . . . . . . RELAY, DPDT, 24V (K3, 5-9,12,13) . . . . . . . .8
10-11. . RE5136. . . KUP14D15-24 . . . . 77342. . . . . . . . . . . . . . . RELAY, 3PDT, 24V, 5A (K2) . . . . . . . . . . . . . .1
10-12 . LF16045 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . MODULE, OVERSPEED, DIGITAL (A3). . . . .1
10-13 . EH0063. . . 600J . . . . . . . . . . . . 75382. . . . . . . . . . . . . . . JUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
10-14 . ME5052 . . 350-516 . . . . . . . . . 59197. . . . . . . . . . . . . . . GAUGE, CPRSR OIL PRESS, 80PSI. (M7) . .1
10-15 . ME5040 . . 310-510 . . . . . . . . . 59197. . . . . . . . . . . . . . . GAUGE, CPRSR OIL TEMP, 250oF (M6) . . . .1
10-16 . GU5024 . . G2OUB3. . . . . . . . . 14449. . . . . . . . . . . . . . . GAUGE, AIR TEMP, 50-750oF . . . . . . . . . . .1
MECHANICAL (M8)
10-17 . ME5015 . . 391-704 . . . . . . . . . 59197. . . . . . . . . . . . . . . KIT, RESISTOR, 24V (AD6-8) . . . . . . . . . . . .3
10-18 . TB1122 . . . 600A-22 . . . . . . . . . 75382. . . . . . . . . . . . . . . BLK, TERMINAL, 22-POINT (TB1,2) . . . . . . .2
10-19 . B015342 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PANEL, ELECTRICAL . . . . . . . . . . . . . . . . . .1
10-20 . B014212 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . MOUNT, GAUGES . . . . . . . . . . . . . . . . . . . . .1
10-21 . KH5306. . . AKS4-1032-130 . . . 78276. . . . . . . . . . . . . . . INSERT, 10-32, .080-.130 GRIP . . . . . . . . . . .6
10-22 . HWF050 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SCREW, PHIL PHD, 10-32 X 1/2 . . . . . . . . . .6
10-23 . HRFCC1 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, FL, #10, SST . . . . . . . . . . . . . . . .16
10-24 . HRFCB1 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, LK, #10, SST. . . . . . . . . . . . . . . .12
10-25 . RE5140. . . 81-E-2-Z1-09 . . . . . 5X849. . . . . . . . . . . . . . RELAY, TIME DLY, 25.6-256 SEC (TD2) . . . .1
10-26 . RE0081. . . 27E121. . . . . . . . . . 0NLN2. . . . . . . . . . . . . . SOCKET, RLY (XK2, 13, XTD2) . . . . . . . . . . .3
10-27 . RE5106. . . 60SR2P06 . . . . . . . 3Z148 . . . . . . . . . . . . . . . SOCKET, RLY, 8-PIN (XTD1) . . . . . . . . . . . . .2
10-28 . RE0041. . . 27E162. . . . . . . . . . 77342. . . . . . . . . . . . . . . SOCKET, RLY (XK3, 5-9, 12, 13) . . . . . . . . . .7
10-29 . RE0007. . . 20C249. . . . . . . . . . 77342. . . . . . . . . . . . . . . CLIP, RELAY (XK3, 5-9, 12, 13) . . . . . . . . . . .7
10-30 . RE5104. . . ASY-STRAP-7.00L . 28081. . . . . . . . . . . . . . . STRAP, RELAY. . . . . . . . . . . . . . . . . . . . . . . .1
10-31 . RE5225. . . SS856806 . . . . . . . 59039. . . . . . . . . . . . . . . RELAY, TIME DELAY, 0.5-15, OCTALBASE. .1
(UNITS W/SERIAL #501558 AND HIGHER)
10-32 . CO5370 . . 206137-1 . . . . . . . . 7G614. . . . . . . . . . . . . . RECEPTACLE, CONNECTOR (J8) . . . . . . . .1
10-33 . SP0021. . . 10-9 . . . . . . . . . . . . 81073. . . . . . . . . . . . . . . SWITCH, PB, LAMP TEST (S12) . . . . . . . . . .1
10-34 . RE0082. . . 20C314. . . . . . . . . . 77342. . . . . . . . . . . . . . . CLIP, RLY HOLD DOWN (XK2, 13, TD2) . . . .6
10-35 . VM0002 . . ZB6109. . . . . . . . . . 76385. . . . . . . . . . . . . . . MTG BUSHING, VIBRATION . . . . . . . . . . . . .6
10-36 . CO0004 . . 26-03-4111 . . . . . . . 27264. . . . . . . . . . . . . . . CONNECTOR, 11 SKT . . . . . . . . . . . . . . . . . .4
10-37 . SA0024. . . 8218-A-0632 . . . . . 1FJ15. . . . . . . . . . . . . . . STANDOFF, HEX, 6-32 X 3/4” . . . . . . . . . . .12
10-38 . CO0247 . . 26-03-4121. . . . . . . 27264. . . . . . . . . . . . . . . CONNECTOR, 12 SKT. . . . . . . . . . . . . . . . . .1
10-39 . CO0005 . . 08-50-0189. . . . . . . 27264. . . . . . . . . . . . . . . TERMINAL, CRIMP . . . . . . . . . . . . . . . . . . .46
10-40 . HWD038 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SCREW, PHIL PHD, 6-32 X .38, SST. . . . . .28

4-3 August 30, 2000

Page 38 Change 1
ASP250
AIR START UNIT

Parts List of Figure 10. Electrical Panel Assembly (Continued)

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

10-41 . HRDCC1 . ............... 12867. . . . . . . . . . . . . . WASHER, FL, #6, SST . . . . . . . . . . . . . . . . 31

10-42 . HRDCB1 . ............... 12867. . . . . . . . . . . . . . WASHER, LK, #6, SST . . . . . . . . . . . . . . . . 32
10-43 . KH5071 . . AKS7-832-80. . . . . 78276. . . . . . . . . . . . . . INSERT, 8-32, .020-.080 GRIP . . . . . . . . . . . 7
10-44 . HWE075 . ............... 12867. . . . . . . . . . . . . . SCREW, PHIL PHD, 8-32 X 3/4, SST . . . . . . 7
10-45 . HRECC1 . ............... 12867. . . . . . . . . . . . . . WASHER, FL, #8, SST . . . . . . . . . . . . . . . . . 7
10-46 . HRECB1 . ............... 12867. . . . . . . . . . . . . . WASHER, LK, #8, SST . . . . . . . . . . . . . . . . . 7
10-47 . HRFCA1 . ............... 12867. . . . . . . . . . . . . . NUT, HEX, 10-32, SST . . . . . . . . . . . . . . . . . 4
10-48 . B015343 . ............... 12867. . . . . . . . . . . . . . BRACKET, ELECTRONIC PNL, DDEC . . . . . 1
10-49 . B014575 . ............... 12867. . . . . . . . . . . . . . BRACKET, RLY . . . . . . . . . . . . . . . . . . . . . . . 1
10-50 . MS1122 . . MS670-22-1A . . . . 75382. . . . . . . . . . . . . . STRIP, MARKER . . . . . . . . . . . . . . . . . . . . . . 2
10-51 . CEI102. . . ECE-B1VGE102 . . 2S894. . . . . . . . . . . . . . CAPACITOR, 1000MF, 35V (C12) . . . . . . . . . 1
10-52 . WL0043 . . AA-821-08 . . . . . . . 27264. . . . . . . . . . . . . . LUG, #8, RED . . . . . . . . . . . . . . . . . . . . . . . . 4
10-53 . CO5321 . . 23513052 . . . . . . . 72582. . . . . . . . . . . . . . CONNECTOR (DDR). . . . . . . . . . . . . . . . . . . 1
10-54 . ST5017 . . 7307K38 . . . . . . . . 15605. . . . . . . . . . . . . . SWITCH, TGL, SPST, PNL LIGHT (S18) . . . 1
10-55 . IL0072 . . . 5131-038 . . . . . . . . 83330. . . . . . . . . . . . . . LAMP HOLDER (DS29, 30). . . . . . . . . . . . . . 2
10-56 . IL0044 . . . 131A-304R . . . . . . 71744. . . . . . . . . . . . . . LENS, RED (XDS29) . . . . . . . . . . . . . . . . . . . 1
10-57 . TB1118. . . 600-18 . . . . . . . . . . 75382. . . . . . . . . . . . . . TERMINAL BLK (TB9) . . . . . . . . . . . . . . . . . . 1
10-58 . MS1118 . . MS670-18-1A . . . . 75382. . . . . . . . . . . . . . MARKING STRIP (XTB9) . . . . . . . . . . . . . . . 1
10-59 . CB5009 . . W58XB1A4A-20 . . 77342. . . . . . . . . . . . . . CIRCUIT BREAKER, (CB3, 4). . . . . . . . . . . . 2
10-60 . IL0004 . . . 131A-304Y . . . . . . 71744. . . . . . . . . . . . . . LENS CAP, YEL, TRANS, RND (XDS30) . . . 1
10-61 . IL0012 . . . 387 . . . . . . . . . . . . 71744. . . . . . . . . . . . . . BULB, LAMP, T1-¾, 28V (XDS29, 30). . . . . . 2
10-62 . CO5227 . . 206150-1 . . . . . . . . 7G614. . . . . . . . . . . . . . CONNECTOR, PLUG (XP6) . . . . . . . . . . . . . 1
10-63 . CO5372 . . 206305-1 . . . . . . . . 7G614. . . . . . . . . . . . . . CONNECTOR, MALE PLUG (XP7) . . . . . . . . 1
10-64 . CO5371 . . 206136-1 . . . . . . . . 7G614. . . . . . . . . . . . . . CONNECTOR, FEM PLUG (XP8) . . . . . . . . . 1
10-65 . CO5388 . . 360XA002C. . . . . . 7G614. . . . . . . . . . . . . . BACKSHELL, 90o, SIZE 23 (XP6,7,8) . . . . . . 3
2316A-700A
10-66 . RE5227 . . 20C176 . . . . . . . . . 77342. . . . . . . . . . . . . . CLIP, FOR KRP SERIES RELAYS/TIMERS . 1
(UNITS W/SERIAL #501558 AND HIGHER)
10-67 . CO5350 . . 66101-4 . . . . . . . . . 7G614. . . . . . . . . . . . . . CONNECTOR (XP6, J7) . . . . . . . . . . . . . . . 74
10-68 . CO5239 . . 66099-4 . . . . . . . . . 7G614. . . . . . . . . . . . . . CONNECTOR (XJ6, P7) . . . . . . . . . . . . . . . 74
10-69 . CO5351 . . 66261-2 . . . . . . . . . 7G614. . . . . . . . . . . . . . CONNECTOR, PIN (XJ8) . . . . . . . . . . . . . . . 8
10-70 . CO5352 . . 66740-6 . . . . . . . . . 7G614. . . . . . . . . . . . . . CONNECTOR, SOCKET (XP8). . . . . . . . . . . 8
10-71 . CO5322 . . 23513053 . . . . . . . 72582. . . . . . . . . . . . . . TERMINAL (XDDR) . . . . . . . . . . . . . . . . . . . . 4
10-72 . CO5324 . . 23507136 . . . . . . . 72582. . . . . . . . . . . . . . PLUG (XDDR) . . . . . . . . . . . . . . . . . . . . . . . . 2
10-73 . CO5323 . . 23413054 . . . . . . . 72582. . . . . . . . . . . . . . CAP, PROTECTIVE . . . . . . . . . . . . . . . . . . . . 1
10-74 . RE0017 . . R10-E1X4-V700 . . 77342. . . . . . . . . . . . . . RELAY, 4PDT, 24V (K4) . . . . . . . . . . . . . . . . . 1
10-75 . RE0042 . . 27E163 . . . . . . . . . 77342. . . . . . . . . . . . . . RELAY, SOCKET (XK4) . . . . . . . . . . . . . . . . . 1
10-76 . RE0006 . . 20C250 . . . . . . . . . 77342. . . . . . . . . . . . . . RELAY, CLIP (XK4) . . . . . . . . . . . . . . . . . . . . 1
10-77 . CO0232 . . 89-00-3001 . . . . . . 27264. . . . . . . . . . . . . . KEY, POLARIZING . . . . . . . . . . . . . . . . . . . . 1
10-78 . CO0059 . . 26-03-4181 . . . . . . 27264. . . . . . . . . . . . . . CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . 1
10-79 . HRFEK1 . ............... 12867. . . . . . . . . . . . . . NUT, HEX, LK, 10-32, SST . . . . . . . . . . . . . . 6
10-80 . HWF075 . ............... 12867. . . . . . . . . . . . . . SCREW, PHIL PHD, 10-32 X 3/4, SST . . . . . 6

August 30, 2000 4-3

Change 1 Page 39
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Parts List of Figure 10. Electrical Panel Assembly (Continued)

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

10-81 . HWD100 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SCREW, PHIL PHD, 6-32 X 1, SST . . . . . . . .2

10-82 . KH5228. . . AKS7-632-130 . . . . 78276. . . . . . . . . . . . . . . INSERT, 6-32, .080-.130 GRIP . . . . . . . . . . .20
10-83 . KH5249. . . 92692A550. . . . . . . 0KVE6. . . . . . . . . . . . . . SASH, CHAIN, 6”, SST. . . . . . . . . . . . . . . . . .1
10-84 . HMD050 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SCREW, PHIL RD HD, 6-32 X 1/2, SST. . . . .4
10-85 . HWD063 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SCREW, PHIL PHD, 6-32 X 5/8, SST. . . . . . .4
10-86 . HWD075 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SCREW, PHIL PHD, 6-32 X 3/4, SST. . . . . .14
10-87 . B018260 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BRACKET, MOUNTING, TD2 . . . . . . . . . . . . .1
10-88 . . .CEI102M2DBE . ECE-B1VGE102/P5458. . . 2S894. . . . . . . . . . . . . . CAPACITOR, 1000M, 35V, 20% . . . . . . . . . . .1
(UNITS W/SERIAL #501558 AND HIGHER)
10-89 . HWB050 . . MS3275-217. . . . . . 12867. . . . . . . . . . . . . . . SCREW, PHD, 4-40 X 1/2, SST . . . . . . . . . . .3
10-90 . HWB063 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SCREW, PHD, 4-40 X 5/8, SST . . . . . . . . . . .1
10-91 . HRBCA1 . . MS35649-244. . . . . 12867. . . . . . . . . . . . . . . NUT, HEX, #4-40, SST . . . . . . . . . . . . . . . . . .4
10-92 . HRBCC2. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, FL, #4, SST . . . . . . . . . . . . . . . . . .8
10-93 . HRBCB1 . . MS35333-104. . . . . 12867. . . . . . . . . . . . . . . WASHER, LK, #4, SST. . . . . . . . . . . . . . . . . .4
10-94 . R52673FM. RLR07C2673FM . . 12969. . . . . . . . . . . . . . . RESISTOR, FILM, 267K,1/4W,1%,MFR (R7).1
10-95 . R52002FM. RLR07C2002FM . . 12969. . . . . . . . . . . . . . . RESISTOR, FILM, 20K, 1/4W, 1%, MFR (R8) 1
10-96 . CD5000 . . MS3102R28-9-P . . 0AAR4. . . . . . . . . . . . . . COUNTER,SWITCHED INPUT, . . . . . . . . . . .2
40/150CPS,INT BAT (M9, 10)

- ITEM NOT ILLUSTRATED

4-3 January 15, 2002

Page 40 Change 2
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AIR START UNIT

Figure 11. Contactors Panel Assembly (Units w/Serial Numbers Prior to 501558) (Sheet 1 of 2)

August 30, 2000 4-3

Change 1 Page 41
ASP250
AIR START UNIT

Figure 11. Contactors Panel Assembly (Units w/Serial# 501558 and Subsequent) (Sheet 2 of 2)

4-3 August 30, 2000

Page 42 Change 1
ASP250
AIR START UNIT

Parts List of Figure 11. Contactors Panel Assembly

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

11- . . . LF18389 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . CONTACTORS PANEL ASSEMBLY . . . . REF

(SEE FIG 3)
11-1 . . B018388 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . PANEL, CONTACTORS. . . . . . . . . . . . . . . . . 1
11-2 . . TB1106 . . 600-6 . . . . . . . . . . . 75382. . . . . . . . . . . . . . BLOCK, TERMINAL. . . . . . . . . . . . . . . . . . . . 1
(OPTIONAL)
11-3 . . MS1106 . . MS600-6 . . . . . . . . 75382. . . . . . . . . . . . . . MARKING STRIP. . . . . . . . . . . . . . . . . . . . . . 1
(OPTIONAL)
11-4 . . CA0045 . . 124-903 . . . . . . . . . 0FREO. . . . . . . . . . . . . CONTACTOR, 24V, 100A . . . . . . . . . . . . . . . 2
11-5 . . CA5100 . . 124-911/02F1143 . 0FREO. . . . . . . . . . . . . CONTACTOR, 24V, 100A, SPDT . . . . . . . . . 1
(OPTIONAL)
11-6 . . CB5009 . . W58XB1A4A-20 . . 77342. . . . . . . . . . . . . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . 1
(OPTIONAL)
11-7 . . KH5228 . . AKS7-632-130. . . . 78276. . . . . . . . . . . . . . INSERT, 6-32, .080-.130 GRIP . . . . . . . . . . . 2
11-8 . . HMD063 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . SCREW, 6-62 X .62, SST . . . . . . . . . . . . . . . 2
11-9 . . HRDCC2 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, FL, #6, SST . . . . . . . . . . . . . . . . . 2
11-10 . HRDCJ1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, #6, SST . . . . . . . . . . . . . . . . . 2
11-11 . KH5050 . . AKS7-1032-130. . . 78276. . . . . . . . . . . . . . INSERT, 10-32, . . . . . . . . . . . . . . . . . . . . . . . 6
11-12 . HMF063. . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . SCREW, PHIL RD HD, 10-32 X 5/8, SST . . . 6
11-13 . HRFCC1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, FL, #10, SST . . . . . . . . . . . . . . . . 6
11-14 . HRFCB1 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . WASHER, LK, #10, SST . . . . . . . . . . . . . . . . 6
11-15 . CA0045 . . 124-114111-3. . . . . 80089. . . . . . . . . . . . . . CONTACTOR, 24V COIL. . . . . . . . . . . . . . . . 1
(OPTIONAL)
11-16 . RE5226 . . 150-906 . . . . 80089 . . . . . . . . . POWER RELAY (K16) . . . . . . . . . . . 1
(UNITS W/SERIAL #501558 AND SUBSEQUENT)

- ITEM NOT ILLUSTRATED

August 30, 2000 4-3

Change 1 Page 43
ASP250
AIR START UNIT

Figure 12. Instrument Panel Assembly

4-3 January 15, 2002

Page 44 Change 2
ASP250
AIR START UNIT

Parts List of Figure 12. Instrument Panel Assembly

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

12- . . . LF15330 . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . INSTRUMENT PANEL ASSEMBLY. . . . . REF

(SEE FIG 2)
12-1 . . ME0027 . . 06290-0 . . . . . . . . . 16476. . . . . . . . . . . . . . ADAPTER, VOLTAGE, 24V (AD2-4) . . . . . . . 4

12-2 . . IL0017 . . . F151-24R . . . . . . . 34165. . . . . . . . . . . . . . LAMP, INDICATOR, 24V (DS11-17) . . . . . . . 9

(Units W/Serial # Prior To 501558)
12-2A . LF20616A . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . FAULT LAMP ASSY, LED . . . . . . . . . . . . . . . 1
(Units W/Serial # 501558 And Subsequent)
(ENGINE FAULTS)
12-2B . LF20616B . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . FAULT LAMP ASSY, LED . . . . . . . . . . . . . . . 1
(COMPRESSOR FAULTS)

12-3 . . IL0131 . . . 151-3202-2900-301 . 83330. . . . . . . . . . . . . . BULB ASSEMBLY, PANEL (DS18) . . . . . . . . 2

12-4 . . ME0003 . . 56458-10 . . . . . . . . 16476. . . . . . . . . . . . . . METER, HOUR, 12/24V (M1) . . . . . . . . . . . . 1
12-5 . . ME0012 . . 06339-01 . . . . . . . . 16476. . . . . . . . . . . . . . GAUGE, FUEL LVL (M2) . . . . . . . . . . . . . . . . 1
12-6 . . ME0013 . . 06350-01 . . . . . . . . 16476. . . . . . . . . . . . . . GAUGE, WATER TEMP (M3) . . . . . . . . . . . . 1
12-7 . . ME5050 . . A06395-01. . . . . . . 16476. . . . . . . . . . . . . . GAUGE, OIL PRESS, 125PSI (M4). . . . . . . . 1
12-8 . . ME0006 . . 06352-1 . . . . . . . . . 16476. . . . . . . . . . . . . . METER, VOLT, 16/32V (M5) . . . . . . . . . . . . . 1

12-9 . . SR5154 . . 31203B . . . . . . . . . 12867. . . . . . . . . . . . . . SWITCH, ROTARY, 3 DECK, 8 POS (S1) . . . 1

(3-POSITION SET BY FACTORY)
(On Units W/SeriaL #501558 And Subsequent)
12-9A . SR5081 . . 52SB2BAB . . . . . . 23826. . . . . . . . . . . . . . SWITCH, SELECTOR (S1) . . . . . . . . . . . . . . 1
(On Units W/Serial # Prior To 501558)

12-10 . CA5079 . . 52BAJ . . . . . . . . . . 23826. . . . . . . . . . . . . . . .BLOCK, CONTACT, NC (S1) . . . . . . . . . . . 2

12-11 . CA5080 . . 52BAK . . . . . . . . . . 23826. . . . . . . . . . . . . . . .BLOCK, CONTACT, NO (S1). . . . . . . . . . . 4

12-12 . ST0006 . . 8824K14 . . . . . . . . 15605. . . . . . . . . . . . . . SWITCH, DPDT, SCREW TERM (S2) . . . . . . 1

12-13 . SP0019 . . 4200 . . . . . . . . . . . 63902. . . . . . . . . . . . . . SWITCH, STARTER (S3) . . . . . . . . . . . . . . . 1
12-14 . B015329 . ............... 12867. . . . . . . . . . . . . . PANEL, INSTR, A/S, W/DDEC . . . . . . . . . . . 1
12-15 . IL0072 . . . 5131-038 . . . . . . . . 83330. . . . . . . . . . . . . . HOLDER, LAMP (DS1,8, 38). . . . . . . . . . . . . 3
12-16 . GU5029 . . 9694255/1487850 . . WILKE..... . . . . . . . . . GAUGE, AIR, 60PSI (AIR/PSI) . . . . . . . . . . . 1
12-17 . ST0049 . . 2FA53-73-TABS . . 73559. . . . . . . . . . . . . . SWITCH, TGL, SPST, 15A 125V (S13) . . . . . 1
12-18 . SP5047 . . 3SB02-PPR. . . . . . 23826. . . . . . . . . . . . . . SWITCH, EMERG STOP, RED (S16) . . . . . . 1
12-19 . IL0043 . . . 131A-304G . . . . . . 71744. . . . . . . . . . . . . . CAP, LENS, GRN (DS1,8) . . . . . . . . . . . . . . . 2
12-20 . ME0028 . . 06294 . . . . . . . . . . 16476. . . . . . . . . . . . . . ASSEMBLY, LIGHT KIT . . . . . . . . . . . . . . . . . 4

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Parts List of Figure 12. Instrument Panel Assembly (Continued)

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

12-21 . IL0012. . . . 387 . . . . . . . . . . . . . 71744. . . . . . . . . . . . . . . BULB, LAMP, T-1-3/4 FLG (DS1,8) . . . . . . . .2

12-22 . IL0101. . . . 6S6DC-24V . . . . . . 08806. . . . . . . . . . . . . . . BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
12-23 . . ... ... . . . . . . . . . . . . . . . . . . . . . . . . . . .NOT ASSIGNED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-24 . . ... ... . . . . . . . . . . . . . . . . . . . . . . . . . . .NOT ASSIGNED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-25 . SP5048. . . 3SB1400-OC . . . . . 23826. . . . . . . . . . . . . . . SWITCH, CONTACT BLK, NC . . . . . . . . . . . .1
12-26 . FI5443 . . . 2025-4-4S . . . . . . . 01276. . . . . . . . . . . . . . . ADAPTER, 90o, 1/4 FPT X 7/16 MPT. . . . . . .1
12-27 . SP0021. . . 10-9 . . . . . . . . . . . . 81073. . . . . . . . . . . . . . . SWITCH, PB, ETHER START (OPTION) . . . .1
12-28 . B04490K. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . PLACARD, ETHER START (OPTION) . . . . . .1
12-29 . IL0072. . . . 5131-038 . . . . . . . . 83330. . . . . . . . . . . . . . . LAMP HOLDER (OPTION) . . . . . . . . . . . . . . .1
12-30 . IL0020. . . . LC12RT2 . . . . . . . . 83330. . . . . . . . . . . . . . . LENS CAP, RED (OPTION) . . . . . . . . . . . . . .1
12-31 . IL0012. . . . 387 . . . . . . . . . . . . . 71744. . . . . . . . . . . . . . . BULB, LAMP, T1-3/4, 28V (OPTION) . . . . . . .1

12-32 . IL5234. . . . 131A-304G. . . . . . . 71744. . . . . . . . . . . . . . . CAP, LENS, CLEAR . . . . . . . . . . . . . . . . . . . .1

12-33 . IL5228. . . . 265-1833 . . . . . . . . 4K473. . . . . . . . . . . . . . LAMP, LED, YELLOW (DS32) . . . . . . . . . . . .1
12-34 . SR5172. . . 32C205NQ . . . . . . . 4K473. . . . . . . . . . . . . . SWITCH, KEYLOCK, SPST, 2A (S4) . . . . . . .1

- ITEM NOT ILLUSTRATED

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Figure 13. Compressor Oil System

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Parts List of Figure 13. Compressor Oil System

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

13- . . . LF18157 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . COMPRESSOR OIL SYSTEM . . . . . . . . REF

4-3 August 30, 2000

22- . . . LF18391 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . TERMINAL BOARD ASSEMBLY . . . . . . . REF

(SEE FIG 19)
22-1 . . B018390 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BRACKET, TERMINAL BOARD . . . . . . . . . . .1
22-2 . . TB1112 . . . 600-12 . . . . . . . . . . 75382. . . . . . . . . . . . . . . TERMINAL BOARD, 12 . . . . . . . . . . . . . . . . .1
22-3 . . MS1112. . . MS600-12. . . . . . . . 75382. . . . . . . . . . . . . . . MARKER STRIP, 12 . . . . . . . . . . . . . . . . . . . .1
22-4 . . HMD063 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SCREW, RD HD, 6-32 X .63. . . . . . . . . . . . . .2
22-5 . . HRDCJ1 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, LK, #6 . . . . . . . . . . . . . . . . . . . . . .2
22-6 . . HRDCC2. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, FL, #6 . . . . . . . . . . . . . . . . . . . . . .2
22-7 . . PL0005 . . . 2617-3A . . . . . . . . . 12867. . . . . . . . . . . . . . . CHANNEL, GLASTIC® . . . . . . . . . . . . . . . . .1
2” X 13/16” X 1/8” X 6.12’ LG
22-8 . . SA0052. . . 9764-SS-1032 . . . . 06504. . . . . . . . . . . . . . . STAND-OFF, 10-32. . . . . . . . . . . . . . . . . . . . .2
22-9 . . HWF050 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . SCREW, PHD, 10-32 X .5. . . . . . . . . . . . . . . .2
22-10 . HRFCB1 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, LK, #10 . . . . . . . . . . . . . . . . . . . . .2
22-11. . HRFCC1 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, FL, #10 . . . . . . . . . . . . . . . . . . . . .2
22-12 . LF16945 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . RELAY FAULT DRIVER, PCB, (A6) . . . . . . . .1
(LOW COOLANT SHUTDOWN OPTION)

- ITEM NOT ILLUSTRATED

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Figure 23. Battery and Cable Assembly

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Parts List of Figure 23. Battery and Cable Assembly

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

23- . . . LF18400 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BATTERY AND CABLE INSTALLATION . REF

(SEE FIG 3)
23-1 . . B018262 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BOX, BATTERY . . . . . . . . . . . . . . . . . . . . . . .1
23-2 . . BA5006. . . 1150 G31 . . . . . . . . 6E809. . . . . . . . . . . . . . BATTERY, 625CCA, TOP MNT THRD . . . . . .4
23-3 . . IN0015 . . . 41-1264-28. . . . . . . 7W514. . . . . . . . . . . . . . PAD, RUBBER, NEOPRENE, 1/8”X5’ . . . . . .1
23-4 . . B018401 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . HOLD DOWN, GLASTIC (PL5019) 3’. . . . . . .1
23-5 . . SB5012. . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ROD, ALL THRD, 1/4-20 X 5”, SST . . . . . . . .2
23-6 . . HRGCA1. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . NUT, HEX, 1/4-20, SST . . . . . . . . . . . . . . . . .4
23-7 . . HRGCB1. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, LK, 1/4, SST . . . . . . . . . . . . . . . . .4
23-8 . . HRGCC1 . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, FL, 1/4, SST . . . . . . . . . . . . . . . . .4
23-9 . . WI0012 . . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CABLE, 600V, 2/0, BLK NPRN, 1.8' . . . . . . .1
23-10 . WI0012 . . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CABLE, 600V, 2/0, BLK NPRN, 1.2’ . . . . . . .1
23-11. . WI0012 . . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CABLE, 600V, 2/0, BLK NPRN, 1.2’ . . . . . . .1
23-12 . WI0012 . . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CABLE, 600V, 2/0, BLK NPRN, 9’ . . . . . . . . .1
23-13 . WI0012 . . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CABLE, 600V, 2/0, BLK NPRN, 7.9' . . . . . . . .1
23-14 . WI0012 . . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . CABLE, 600V, 2/0, BLK NPRN, 1.2’ . . . . . . . .1
23-15 . WL5032 . . L395-38 . . . . . . . . . 27264. . . . . . . . . . . . . . . LUG, TERMINAL. . . . . . . . . . . . . . . . . . . . . . .2
23-16 . WL5026 . . J385-38 . . . . . . . . . 27264. . . . . . . . . . . . . . . RING, TERMINAL, 2/0, 3/8”DIA . . . . . . . . . .13
23-17 . WL5033 . . L-395-12. . . . . . . . . 27264. . . . . . . . . . . . . . . LUG, #4/0 X 0.5 DIA. . . . . . . . . . . . . . . . . . . .1
-23-18 . SR5142. . . 9601DP . . . . . . . . . 46576. . . . . . . . . . . . . . . SWITCH, MAIN BAT, 250A/360A PEAK . . . . .1

-ITEM NOT ILLUSTRATED

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Figure 24. Acoustical Dampener Installation

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Parts List of Figure 24. Acoustical Dampener Installation

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

24- . . . LF18275 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ACOUSTICAL DAMPENER INSTAL . . . . REF

(BASIC OPTION)
(SEE FIG 3)
24A- . . LF19399 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . ACOUSTICAL DAMPENER INSTAL . . . . REF
(LEVEL 1 OPTION)
(SEE FIG 3)
24-1 . . B018008 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . DAMPENER, ACST, EXH, BLEED AIR . . . . .1
(BASIC OPTION)
24A-1 . B019302 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . DAMPENER, ACST, EXH, BLEED AIR . . . . .1
(LEVEL 1 OPTION)
24-2 . . IN5014 . . . EDP . . . . . . . . . . . . 0P2F7. . . . . . . . . . . . . . DAMPENER, SELF ADH, .060 THK, . . . . . . .2
41X54
24-3 . . VM0004 . . J4624-23 . . . . . . . . 12965. . . . . . . . . . . . . . . MOUNT, VIBRATION . . . . . . . . . . . . . . . . . . .4
24-4 . . HRGCA1. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . NUT, HEX, 1/4-20, SST . . . . . . . . . . . . . . . . .8
24-5 . . HRGCB1. . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, LK, 1/4, SST . . . . . . . . . . . . . . . . .8
24-6 . . HRGCC1 . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WASHER, FL, 1/4, SST . . . . . . . . . . . . . . . . .8
24-7 . . EB5678. . . 89676K. . . . . . . . . . 76700. . . . . . . . . . . . . . . PIPE, 6” OD X 10” LG W/MALE END . . . . . . .1
24-8 . . EB5496. . . 89109A. . . . . . . . . . 76700. . . . . . . . . . . . . . . ELBOW, W/20” LEG . . . . . . . . . . . . . . . . . . . .1
24-9 . . EB5502. . . 90878A. . . . . . . . . . 76700. . . . . . . . . . . . . . . CLAMP, 6”. . . . . . . . . . . . . . . . . . . . . . . . . . . .3
24-10 . EB5678. . . 89676K. . . . . . . . . . 76700. . . . . . . . . . . . . . . PIPE, 6” OD X 49.25” LG . . . . . . . . . . . . . REF
W/FEMALE SOCKET END
24-11. . LF18125 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . WLDMT, LESLIE® RGLTR OUTLET . . . . REF
24-12 . B018761 . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . DEFLECTOR, ACST DAMPENER . . . . . . . . .1

-ITEM NOT ILLUSTRATED

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Figure 25. Trailer 5th Wheel Assembly

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Parts List of Figure 25. Trailer 5th Wheel Assembly

FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

25- . . . LF18415 . . 04-40360 . . . . . . . . 0AT39. . . . . . . . . . . . . . TRAILER 5TH WHEEL ASSEMBLY . . . . . REF

(SEE FIG 4)
25-1 . . TA5796 . . . 04-40273 . . . . . . . . 0AT39. . . . . . . . . . . . . . FRONT AXLE ASSY, 5TH WHEEL. . . . . . . . .1
(STD CONFIGURATION W/O BRAKE)
(SEE FIG 26)
25-1A . TA5680 . . . 04-40321 . . . . . . . . 0AT39. . . . . . . . . . . . . . FRONT AXLE ASSY, 5TH WHEEL. . . . . . . . .1
(W/BRAKE OPTION)
(SEE FIG 27)
25-2 . . TA5716 . . . 02-20453 . . . . . . . . 0AT39. . . . . . . . . . . . . . BOLT, QUEEN PIN, 1 X 8-3/4 LG . . . . . . . . . .1
25-3 . . . . . . . . . . 02-20540 . . . . . . . . 0AT39. . . . . . . . . . . . . . HUB ASSY, IDLER 8 ON 6-1/2 . . . . . . . . . . . .3
25-4 . . . . . . . . . . 03-30396 . . . . . . . . 0AT39. . . . . . . . . . . . . . REAR AXLE ASSY . . . . . . . . . . . . . . . . . . . . .1
(SEE FIG 28)
25-5 . . TA5805 . . . 390908039 . . . . . . . 0AT39. . . . . . . . . . . . . . BRAKE, LH, 12” DEXTER®, W/PARK . . . . . .1
25-6 . . TA5804 . . . 390908040 . . . . . . . 0AT39. . . . . . . . . . . . . . BRAKE, RH, 12” DEXTER®, W/PARK . . . . . .1
25-7 . . TA5803 . . . 02-20543 . . . . . . . . 0AT39. . . . . . . . . . . . . . HUB & DRUM ASSY, 8 ON 6-1/2 . . . . . . . . . .2
25-8 . . TA5440 . . . 02-20143 . . . . . . . . 0AT39. . . . . . . . . . . . . . DRAWBAR ASSY, 6 X 48 . . . . . . . . . . . . . . . .1
25-8A . B017413 . . . . . . . . . . . . . . . . . . 0AT39. . . . . . . . . . . . . . DRAWBAR ASSY, (TOW BAR . . . . . . . . . . . .1
MODIFICATION, EURO OPTION
25-9 . . TA5802 . . . 02-20539 . . . . . . . . 0AT39. . . . . . . . . . . . . . WLDMT, TRUNNION, 8 ON 6-1/2. . . . . . . . . .1
25-10 . TA5782 . . . 02-20676 . . . . . . . . 12867. . . . . . . . . . . . . . . CROSS SHAFT ASSY . . . . . . . . . . . . . . . . . .1
(SEE FIG 29)
25-11. . TA5037 . . . 03-18451 . . . . . . . . 0AT39. . . . . . . . . . . . . . LEVER, BRAKE, ORSCHELN® W/SPCR . . .1
(SEE FIG 30)
25-12 . TA5770 . . . 06-60094 . . . . . . . . 0AT39. . . . . . . . . . . . . . CLAMP, BRAKE CABLE . . . . . . . . . . . . . . . . .2
25-13 . TA5436 . . . 06-60495 . . . . . . . . 0AT39. . . . . . . . . . . . . . PLATE, TIE . . . . . . . . . . . . . . . . . . . . . . . . . . .2
25-14 . TA5580 . . . 06-60575 . . . . . . . . 0AT39. . . . . . . . . . . . . . CABLE, BRAKE, 57-5/8” LG. . . . . . . . . . . . . .2

-ITEM NOT ILLUSTRATED

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Figure 26. Front Axle Assembly - Standard Configuration

Parts List of Figure 26. Front Axle Assembly - Standard Configuration
FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

26- . . . TA5796 . . . 04-40273 . . . . . . . . 12867. . . . . . . . . . . . . . . FRONT AXLE ASSY - STD CONFIG . . . . REF
(SEE FIG 4)
26-1 . . TA5741 . . . 03-30395 . . . . . . . . 12867. . . . . . . . . . . . . . . FRONT AXLE, 5TH WHEEL ASSY . . . . . . . .1
26-2 . . TA5806 . . . 02-20540 . . . . . . . . 0AT39. . . . . . . . . . . . . . HUB ASSY, IDLER, 8 ON 6-1/2”. . . . . . . . . . .1
26-3 . . . . . . . . . . 02-20641 . . . . . . . . 0AT39. . . . . . . . . . . . . . HUB, CUPPED & STUDDED . . . . . . . . . . . . .3
26-4 . . TA5618 . . . 06-60403 . . . . . . . . 0AT39. . . . . . . . . . . . . . SEAL, GREASE, #42835 . . . . . . . . . . . . . . . .3
26-5 . . TA5252 . . . 130580500 . . . . . . . 0AT39. . . . . . . . . . . . . . CONE, INNER, #25580 . . . . . . . . . . . . . . . . .3
26-6 . . . . . . . . . . 130581100 . . . . . . . 0AT39. . . . . . . . . . . . . . CUP, INNER, #25520 . . . . . . . . . . . . . . . . . . .3
26-7 . . . . . . . . . . 130340200 . . . . . . . 0AT39. . . . . . . . . . . . . . CUP, OUTER, #14276 . . . . . . . . . . . . . . . . . .3
26-8 . . . . . . . . . . 130581300 . . . . . . . 0AT39. . . . . . . . . . . . . . CONE, OUTER, #14125A. . . . . . . . . . . . . . . .3
26-9 . . TA5726 . . . 06-60402 . . . . . . . . 0AT39. . . . . . . . . . . . . . CAP, GREASE, #38605 . . . . . . . . . . . . . . . . .3
26-10 . . . . . . . . . 06-80538 . . . . . . . . 0AT39. . . . . . . . . . . . . . STUD, WHEEL, 1/2-20 . . . . . . . . . . . . . . . . .24
26-11. . TA5237 . . . 06-60295 . . . . . . . . 0AT39. . . . . . . . . . . . . . WASHER, FL, SPINDLE. . . . . . . . . . . . . . . . .3
26-12 . TA5238 . . . 321415140 . . . . . . . 0AT39. . . . . . . . . . . . . . NUT, HEX, SLOTTED, 1-14 . . . . . . . . . . . . . .3
26-13 . TA5229 . . . 06-12103 . . . . . . . . 0AT39. . . . . . . . . . . . . . NUT, HEX, 1/2-12 . . . . . . . . . . . . . . . . . . . . . .8
26-14 . TA5452 . . . 06-12104 . . . . . . . . 0AT39. . . . . . . . . . . . . . WASHER, LK, 1/2. . . . . . . . . . . . . . . . . . . . . .8
26-15 . TA5736 . . . 06-13144 . . . . . . . . 0AT39. . . . . . . . . . . . . . NUT, HEX, TAPERED, 1/2-20. . . . . . . . . . . .16
26-16 . TA5239 . . . 324602100 . . . . . . . 0AT39. . . . . . . . . . . . . . PIN, COTTER, 5/32 X 1-1/2 . . . . . . . . . . . . . .3
26-17 . TA5716 . . . 02-20453 . . . . . . . . 0AT39. . . . . . . . . . . . . . PIN, QUEEN, 1-1/4 X 8-3/4 . . . . . . . . . . . . . .1
26-18 . TA5522 . . . 321700140 . . . . . . . 0AT39. . . . . . . . . . . . . . NUT, LK, 1-14 . . . . . . . . . . . . . . . . . . . . . . . . .1

-ITEM NOT ILLUSTRATED

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ASP250
AIR START UNIT

Figure 31. Air Start Hose With Scuffer

Parts List of Figure 31. Air Start Hose With Scuffer
FIG. TI VENDOR UNITS
ITEM PART PART AIRLINE PER
NO. NO. NO. FVC PART NO. NOMENCLATURE ASSY

31- . . . . . . . . . . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . AIR START HOSE WITH SCUFFER . . . . REF

(SEE FIG 1)
31-1 . . AA5335. . . M795093S3 . . . . . . 83861. . . . . . . . . . . . . . . COUPLING, W/HOSE BARB . . . . . . . . . . . . .1
31-2 . . CY009. . . . P14-8343 . . . . . . . . 76700. . . . . . . . . . . . . . . CLAMP, T-BOLT . . . . . . . . . . . . . . . . . . . . . . .4
31-3 . . AA5472. . . 51180-50 . . . . . . . . 56380. . . . . . . . . . . . . . . HOSE, AIR DLVY. 3.5” X 50’ (OPTION) . . REF
31-3A . AA5295. . . 51180-40 . . . . . . . . 56380. . . . . . . . . . . . . . . HOSE, AIR DLVY. 3.5” X 40’ (OPTION) . . REF
31-3B . AA5338. . . 51180-30 . . . . . . . . 56380. . . . . . . . . . . . . . . HOSE, AIR DLVY. 3.5” X 30’ (OPTION) . . REF
31-3C . AA5480. . . 51180-20 . . . . . . . . 56380. . . . . . . . . . . . . . . HOSE, AIR DLVY. 3.5” X 20’ (OPTION) . . REF
(SEE FIG 1)
31-4 . . B13547 . . . . . . . . . . . . . . . . . . . 12867. . . . . . . . . . . . . . . BARB, HOSE, 3” NPT. . . . . . . . . . . . . . . . REF
(SEE FIG 20)
31-5 . . VA5029 . . . 3-BC-1111AC-SE . . 79227. . . . . . . . . . . . . . . VALVE, BALL, 3”, NPT . . . . . . . . . . . . . . . REF
(SEE FIG 20)

-ITEM NOT ILLUSTRATED

4-3 August 30, 2000

Page 84 Change 1
ASP250
AIR START UNIT

Page 92 Change 1
ASP250
AIR START UNIT

CHAPTER 5
MANUFACTURER'S APPENDICES
1. GENERAL
This chapter contains Vendor's/Original Manufacturer’s Equipment (OEM) literature for com-
ponents/assemblies utilized in the manufacture of the air start unit. This information is pro-
vided to assist the user in the operation, disassembly, and repair of the individual component
or assembly.
Literature may be provided for equipment not included as an option on your unit. This litera-
ture is provided for informational purposes only.
2. CONTENTS
A. Bolt and Cap Screw Torque Values
B. Wilkerson® - Precision Air Regulator Type 16A (83-063-000)
C. Leslie Controls Inc. - Pressure Reducing Valves (Bypass Valve)
Installation, Operating, and Maintenance Manual (30/4.5.1)
D. GHH-Rand® - Compressor Operating Manual
E. Johnson-Yokogawa® - Electronic Differential Pressure Transmitters
Instruction Manual
F. American VULKAN® Corp - Service Manual, Flexible Coupling Type VL
G. KBI® - Automatic Turn-Key Starting Fluids Systems, Installation-Operation Manual
H. Detroit Diesel® - Series 60 Engine Operators Guide (6SE484)
I. Detroit Diesel® - Series 60 Engine Custom Parts Catalog

November 1, 1999 5 -0
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ASP250
AIR START UNIT

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