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Operation & Service Manual - Victory Ground Support Equipment

1. A 24 Does Not Exit Board veda 29 datus nente JS PIN E ere 26 0 JS PIN G Pss T 28 20 Volts Adjust Potentiometer tes Mis eid PIN J JO PIN K DT PIN gu Dateien Veces Low Fuel Lamp ere tz Pan Belt Lamp 4 20 Fan Belt Lamp 20 High Water Temperature Lamp ns 36 Emergency Stop iu BT isnt Dec nea censeas RUD Switch ina around Frame E EE E Governor M M 41 8 20 EXCitation Transformer Phase iio 2 EXCitation Transformer Phase B 20 Excitation Transformer Phase MA VW is OM Pressure Gauge 45 esee ZO usse Water Temperature Gauge m P DO Gauge LBL AB na n NOt Used YARVICO 07 2004 Rev OR 41 Model 282000 28 5 VDC Ground Power Unit w 5
2. 1 07 2004 Rev OR 63 282000 28 5 VDC Ground Power Unit This page left blank intentionally fyARvICO 07 2004 Rev OR 64 282000 28 5 VDC Ground Power Unit Parts List ENGINE CONTROL ASSEMBLY 11 NYY CONTACT BREAKER PRESS TO RESET CB CB 0 N lt KYU 54 CURRENT LIMITER 1 LOW yt I t 0000 5 2 e m a Y ANES Ne e oz 1007 AUPS FINO REPLACEMENT PARTS PART NUMBER DESCRIPTION TY A Power On Off Switch Complete 2 3 LADA Switch 1 14044 retient te ees Red Green Contact Block 1 14083 iiie tes Green Contact Block id 2 14055 es Switch Start Complete 1 T40 195 eene I EI 1 VAO3 Oui Switch E ER TT UI UE 1 14045 titi nee Lens OPA Que m 1 14047 Front Ring 1 T408 Switch M 1 14082 1 1408 Green Contact 1
3. 5 ede duc 5 8 aii iii 4 Ha Bolt 4 aes M16 x 70MM Bolt tet 1 Diao A 6 errata 1 09054 4 3 Hump diia 1 09005 4 1 Adapte 1 PA 09186 Intake Pitra 1 29 ssa 9058 3 im Rubbet ELD vecinos E 2 09007 iniecit rte 5 3 09008 SEES aap 3 y 090031 Pl gged tete etse tea ede 1 905 secet A 1 09059 3 in Tube RO 1 Not Shown 09189 FilierE Iement u ee ie ere dto A R Not Shown 09193 utis nitens Oil Drain 1 fyARvICO 07 2004 Rev OR 72 282000 28 5 VDC Ground Power Unit Parts List SENSING COMPONENTS ASSEMBLY REPLACEMENT PARTS PART NUMBER DESCRIPTION TY A Sensing Components Final Assembly REF 09009 es Water Temperature
4. 2 1 090 is NN 1 09036 Press Sender 1 09037 Magnetic Pick Up ss ect 1 09049 Fan Belt Break 1 YARVICO 07 2004 Rev OR 273 282000 28 5 VDC Ground Power Unit Parts List ENGNE FILTER ASSEMBLY REPLACEMENT PARTS PART NUMBER DESCRIPTION TY 11008 Engine Filter Final REF 0906 Fuel Water a attenta 1 09068 Fuel skay 1 09067 Oik PIET MM MT 1 07 2004 Rev OR 74 282000 28 5 VDC Ground Power Unit Parts List RADIATOR AND FAN ASSEMBLY REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION TY 11009 ttes Radiator and Fan Final REF 09048 iii Radiator and Shroud 1 09039 Radiator Hose upper 1 34 16 1 09040 Radiator Hose lower 2 4 x 18 20 00 000000 1 I6 X usnu 6 Reg Not Used 09045 tette Upper Hose CGI Impu suu a 2 Tikaqa asas 09046 cete Lower Hose Clamp erre tret
5. a 19 5 3 1 RN 19 5 3 2 ici a dad 19 6 0 Power Systema 20 61 Manual Control ee idas 20 6 2 Voltage Control oia 20 6 3 Over And Under Voltage 20 6 4 NN 20 65 A 21 6 6 Temperature Protec 21 6 7 Soft Start Current Easmitatio on 21 6 8 Aircraft Cables u s uma 21 6 9 21 NT 21 7 0 nil Scion 22 11 EE IN 22 7 2 Current Putin 22 7 3 Current Lanitmg euenire ERE SSS Says Sau Gu Sia BSD SSS 22 TA 2 A 22 MEE DESCRI 22 7 5 22 7 6 Reduced DC Ripple Option tanab stasa 22 TT Grounding Reel Option miii 22 8 0 Operating Procedutes rete eda edad ena 23 8 1 aa 23 8 2 Starting Sequence See Figure 11 23 8 3 Supplying Dc Power To The Aircraft See Figure 11 25 84 Fault Identificati
6. n 56 3 3 Engine Alternator Installation eene enne nnne nennen inneren enne 58 3 31 Installation rere 58 3 3 2 Engine Alternator Attachments 58 3 4 Alternator Removal From Engine See Figures 15 16 17 58 3 5 Alternator Installation To Engine See Figures 15 16 17 59 3 6 Radiator Removal See Figures 15 16 17 59 3 7 Engine Qil Change codi tede eae te ua ee RD 60 3 8 Pilter sse RID RUF Ue nine Du I eds 60 4 0 E 61 61 AD EDINE us agua aueia NN 61 4 3 Electrical Components teret 61 SA O O 62 10 ERE 62 JA AAA AAA 62 10 62 2 0 A 62 APPENDIX 1 28 5 Electrical Schematics APPENDIX II Speed Control Unit APPENDIX III Electric Actuator APPENDIX IV Alternator Operation and Maintenance Manual APPENDIX V Engine Operation and Maintenance Manual APPENDIX VI Engine Parts Catalog YWARVICO LII 07 2004 Rev OR 282000 28 5 VDC Ground Power Unit REVISION DATE TEXT AFFECTED OR 07 2004 Original Release 07 2004 Rev OR 282000 28 5 VDC Ground Power Unit SECTION 1 GENERAL INFORMATION A
7. iei naked 65 16 Fuel Solenoid 6 12 Engine Alternator 2 1 Use of the troubleshooting chart continued on following page YARVICO 07 2004 Rev OR 40 282000 28 5 VDC Ground Power Unit 21 USE OF THE TROUBLESHOOTING CHART continued P10 HARNESS WIRE NO PIN WIRE SIZE AWG TO rU 23 20 a aaa High Volt Test Button Air dis LOW Volt Test Button nis eit ais LB A Over Load Test Button Buin Volt Lamp Ke Volt Lamp Wisin 20 ns Over Load Lamp 11 20 Lamp Test Switch inte 36 Vai Pz ita Fault Reset nthe 15 20 Current Limiter Potentiometer 16 20 Current Limiter Potentiometer y BI n 20 Power On Switch CA Power Off Switch 20 ZO iaa Emergency Stop sees 2 KLI Coll
8. 69025 e Alternator 38KW Em 1 0090235 Cummins Engine es 1 09046 Cummins Radiator Assembly see Figure 9 1 ER 09026 OS Cummins Fan 1 1 0902 T iiec PM LET 1 E 50 4 pm Lock wWasbet eire ertet trecenta a 4 A Cummins Engine 2 x 30 MM Allen Cap 2 5 09066 HE Intake 1 09032 IA 2 09034 esee Ground Cable 1 09035 eder te tenes Positive Cable arriere eee 1 09033 aasma 1 ek nes Hex Head MO x 30 sere 8 aii Lock washer aii 8 il Bolt MIO x 30 itecto hc rot diet ET ER Eee 12 19 2 Lock Washer eec tid teer ias 12 09057 Store dii erc 5 E A E Washer 5 8 In x 2 010
9. Figure 1 Major Components Arrangement Side View 07 2004 ads 282000 28 5 VDC Ground Power Unit 2 2 ARRANGEMENT SEE FIGURES continued Figure 1 B Major Components Arrangement Rear View 07 2004 2 282000 28 5 VDC Ground Power Unit 2 2 ARRANGEMENT SEE FIGURES continued Figure 1 Major Components Arrangement Plan View 2 3 DESIGN OF THE GROUND POWER UNIT The design and arrangement of the Ground Power Units is dictated by the chassis as follows 2 3 1 Chassis Description The GPU chassis frame is fabricated from heavy duty rectangular steel tubes providing a torsionally stiff weldment This weldment also consists of cross members to properly support the engine and alternator a battery support box the lower panels and unit access doors assembly A power coated Skydrol resistant paint is used on the chassis frame The fore and aft bumpers and side swipe bumpers and cable tray are part of this weldment Fork lift slots are provided under the chassis to allow the unit to be lifted with a suitably rated fork lift A hoop is installed which matches the chassis side members The hoop acts as a door landing and latch plate support for the access doors 2 3 2 Support Frames One internal support frame is bolted to the chassis It provides support for the pul
10. J8 P Oil Pressure Gauge 20 DC Plug Green WIre TB2 6 J8 R Inter Lock Switch 54 K2 Auxiliary Contact 54 18 5 Inter Lock Switch 56 ns K2 Auxiliary Contact 53 J8 T DC Off Switch 21 PA Rec Thermal Switch J8 U K9 Coil B 65 16 ld K18 Coil J8 g Engine Fuel Solenoid 67 20 T 1 J8 V CB 4 68 20 dcs J8 W 5 69 X secessit 20 assis haqa J8 X CB 6 PR 0 Shunt Minus J8 s TB1 10 Ammeter Minus A K2 AUX TB2 7 J8 r TB1 4 DC Volt Meter K9 3 9 20 K14 1 Contact 7 J8 G TB2 4 F 2 Excitation 89 K14 2 Contact 9 J8 F TB2 3 F 1 Excitation 90 Det K14 2 Contact 6 38 N 12 Volt Battery NOTE Keep plug orientation standard Twisted pair to magnetic pick up P9 HARNESS WIRE NO PIN WIRE SIZE AWG TO ne 60 Battery Plus TB2 Ground eee Starter Solenoid 5 Terminal Col jos Basses A EAO
11. 1 A tasta 15074 Radiator Access Panel 1 15073 iat TS 130 Door Latch 1 Door Lateh 1 Keyed Door Latch A R 15110 Keyed Door Latch LO iens Instrument Door Louver 86 1 16034 1 19 ue 15267 ii deesse 6 1 EPA 15208 Control Box HOUSING comicas re vti eere R 1 14082956 Instrument Panel Case 80000 1 US E Pall L y u 1 15253 Protectseall UL eter eet 1 AAA 15038 idet uqa u S Fuel Tank Sender 1 Not Shown Ol 1 ninm 1 Not Shown 09192 Fuel id 1 Not Shown 15245 A A S oDe sette amet a CERES ER a a e ERAT A R Not Shown 15192 cete eet teet Fire Extinguisher zer i e aee et A R E 07 2004 Rev OR 78 282000 28 5 VDC
12. Indicates low coolant levels WARNING The unit is fitted with an emergency shut down switch This switch is fitted for emergency only and shall not be used for normal machine shutdown Damage may be caused to the diesel engine if insufficient time is allowed to stabilize the temperatures YARVICO 07 2004 Rev OR 544 282000 28 5 VDC Ground Power Unit 40 INSTRUMENT PANEL continued POWER START 4 6 Figure 9 Generator Controls 4 0 Instrument panel continued on following page J ARVICO TRONAIR 07 2004 Rev OR 15 282000 28 5 VDC Ground Power Unit 4 0 INSTRUMENT PANEL continued 4 1 2 Generator Controls See Figure 9 The following are installed on the instrument panel DESCRIPTION FUNCTION DC Voltmeter 1ndicates DC power voltage 28 5 VDC TE Over Voltage Lamp Red Lights up is DC volts exceed specification Under Volts Lamp Red Indicates low DC volts DE DC Ammeeter 5 DC AMPS power output NUM DC Over Current Indicator Red Lights up if DC amps are exceeded DC ON OFF Switch In the ON position it turns on DC power to aircraft if cable is correctly connected to aircraft Switching to the OFF position disconnects DC power from GPU to Aircraft 5 AMP
13. 1 21 Empine 33 1 2 2 O EEE 33 1 Inspection Schedule il 34 1 3 1 Preventive Maintenance 34 1 3 2 Delivery Inspection and Preparation of Unit eene 36 fyARvICO 07 2004 Rev OR 282000 28 5 VDC Ground Power Unit 1 3 3 Returning Unit From An Extended Storage 36 134 Cable E 36 133 7 36 1 3 6 Door Removal and Adjustment See Figure 13 37 1 37 Wheel Hub Lock Nuts 37 2 0 Troubleshooting iii 37 2 1 Use Of The Troubleshooting 38 22 SA RT 53 2 3 Gam st bihty NO RA 53 2 4 ASA ierit 53 3 0 Installation Td PAR e ROO Ee bed tope bp 54 3 1 Torque Values For General Assembly n eene nnne ener 54 3 2 Engine Alternator Removal teer rie wed 56 3 2 1 Enclosure Removal u ctt rette ie zx 56 3 2 2 Engine Alternator See Figures 15 16 amp 17
14. 18 245 10 32 31 7 20 494 1 4 20 75 2 Conversion Factor 1 4 28 94 Nm to foot pound 0 7376 5 16 18 132 Nm to inch pound 8 851 5 16 24 142 3 8 16 236 3 8 24 259 7 16 14 376 7 16 20 400 1 2 13 517 1 2 20 541 9 16 12 682 9 16 18 752 5 8 11 1110 5 8 18 1244 3 4 10 1530 3 4 16 1490 7 8 9 2328 7 8 14 2318 1 8 3440 1 14 3110 07 2004 Rev OR 55 282000 28 5 VDC Ground Power Unit 3 0 REMOVAL INSTALLATION continued 32 ENGINE ALTERNATOR REMOVAL 3 2 1 Enclosure Removal 1 Unplug instrument panel drawer P8 and P9 2 Disconnect twisted pair to magnetic pickup 3 Remove front and rear louvers 4 Remove the two doors by removing the pin on each door Unbolt and remove the top panel pr 3 2 2 Engine Alternator See Figures 15 16 amp 17 1 Remove clamp holding intake hose to engine and remove complete with intake filter 2 Loosen clamp holding exhaust manifold to engine and pull down to clear 3 Remove fuel lines and electric leads to fuel sender Figure 15 Slinging Engine Alternator NOTE Tag identify all leads required for engine power platform disassembly Disassemble only those necessary to accomplish this task 4 Usinga lift and chains attach chains to the engine lift post and generator lifting eye WARNING Use hoist with a minimum load of 2000 Ibs to lift engine and generator to avo
15. 5 2 10 8 71 P10 X 447 PARTS INDRAWER BS LETTER ps WIRE NUMBER Ej Parra wane coNTroOLMODULE x PLUG CONNECTION 1 F YO FUEL OFF TA Oh STARY Electrical Schematic 07 2004 42 Model 282000 28 5 VDC Ground Power Unit E 2 z NINE PLATFORM fuii WAVE RECTESER GENERATOR 23 GHIA DO SUNT SE PRIV PRA Co 2O ON FROM De 4 RDN SVOTE DC CONTROL X JUNCTION TEST T LETTERS WERE PARTS ENGINE Electrical Schematic JWARVICO TRONAIR 07 2004 Rev OR 43 Model 282000 28 5 VDC Ground Power Unit o LONE MU MEME MM E INSTRUMENT T1 Electrical Schematic 07 2004 44 282000 28 5 VDC Ground Power Unit 21 USE OF THE TROUBLESHOOTING CHART continued TROUBLESHOOTING CHART SECTION CHASSIS FAULT CAUSE CORRECTION Excessive towing force Low tire pressure Inflate to 75 psi 5 2 Bar Brake binding Jack under axle check rotation adjust Dry wheel bearing Check all hubs repack with correct grease replace seal if required Excessive steering Turntable bearing Check
16. 9 For heavy duty harness Socket 10 control box module disconnect Relay Start Relay K9 DC contactor Relay K 13 Battery charge alternator Relay K18 Fuel shut off m TB Terminal block Relay 21 LOW coolant level option fyARvICO 07 2004 Rev OR 16 282000 28 5 VDC Ground Power Unit 4 0 INSTRUMENT PANEL continued Figure 10 Adjustments and Other Compoents 42 CABLE HARNESS 4 2 1 Cable Harness P8 Harness P8 connects directly into the back of the Instrument Panel Drawer This harness connects all engine systems requiring less than 10 amps 24 VDC It also interfaces with the auxiliary switches on the DC contactor thermostat on the rectifier sense lines and current measuring conductors from the DC Shunt 4 2 0 Cable Harness P9 WARNING Always remove the 24 volt battery negative ground cable before working on any of the engine components or on the electrical control panel as electrical shock may seriously injure personnel This harness connects the battery charging alternator starter motor solenoid ground battery posi
17. Do not use solvents as flushing oil in running engines Always use clean containers funnels etc 1 Provide a container for catching used oil Capacity should be greater than 5 gallons Remove the drain plug and allow oil to drain completely 3 Change the oil filter cartridge a Unscrew the spin off filter from the filter head discard the filter b Apply a light even coat of lubricating oil to the gasket sealing surface of the new filter prior to installing c Position the filter to the filter head Tighten by hand until the seal touches the filter head tighten and additional one turn 4 Clean the drain plug and install securely after engine oil had drained completely 5 Remove oil filler cap or valve cover cap and refill the system with new clean oil which meets engine manufacturer s recommendations 6 Re secure oil pan access cover CAUTION 1 Do not forget to reinstall the drain plug 2 Install a new oil filter 7 Install filler cap and check oil level on dipstick It should indicate over full until the engine is started and oil is circulated to fill the oil filters 38 AIR FILTER The air filter is a replaceable filter cartridge A definite time schedule for changing the filter cartridge cannot be determined because of varying operating and environmental conditions To change the cartridge perform the following Remove clamp Remove elastic hold in strap Discard air filter and install new filter Replace elastic hold
18. Isolate failed component and rectify Ifall P2 fed components okay then inspect the three 30 amp relays for failure replace Power ON Select 24 VDC should be available at the switch Test switch Switch inoperative for correct operation Power circuit Reset CB7 Refer to schematic of other possible contactor off component failures in the power on circuit Power OFF select Power OFF select Check switch for correct operation if okay delay timing switch does not remove switch inoperative circuit on PCB within panel NOTE The engine will not power NOTE Upon stop 1f battery power is removed or P9 15 disconnected engine shut down the GPU will continue to run at idle for approximately one minute before stopping Power switch locks in Main Breaker Out Reset and power ON lamp amber is on but J9 Feed to starter Reconnect If starter still does not turn jumper battery engine starter motor will disconnected to solenoid if motor turns check 30 amp pilot relay in not turn panel and replace if required 24 VDC power Charging alternator Check P9 to alternator cable if okay Check 30 amp pilot gradually fades voltage inoperative charge relay in panel if required Ifrelay wiring okay below 18 VDC check alternator output current if zero replace 2 1 Use of the troubleshooting chart continued on following page 07 2004 46 282000 28 5 VDC Ground Power Unit 2 USE OF
19. Only first lamp lit for fault will remain lighted 85 EMERGENCY SHUT DOWN An emergency shut down switch 5 is offered as standard Operation of this switch will shut off the fuel and the entire GPU will come to an instant stop YARVICO 07 2004 Rev OR 26 282000 28 5 VDC Ground Power Unit 9 0 SPECIFICATIONS AND CAPABILITIES Model Number 282000CDC 9 1 9 2 9 3 9 4 9 5 GENERAL Length approx Width approx Height approx Weight approx Operating Temperature Storage Temperature CHASSIS Chassis And Running Gear Tire Pressure Chocks Enclosure ENGINE Engine Horsepower Aspiration Cylinders Displacement Usable Fuel Fuel Tank Capacity ALTERNATOR Model Speed Frequency Voltage AC Phase Power Factor Ambient Temp C Temperature Rise C Excitation Insulation Single Bearing SHUT DOWN Low oil pressure High water temperature Overspeed Fan Belt Failure option Low Fuel 78 ins 198 cm 72 ins 183 cm 61 ins 155 cm 1350 Ibs 612 kg Minus 40 to 125 degrees F minus 40 to 51 degrees C Minus 65 to 180 degrees F minus 54 to 82 degrees C Welded structural steel tandem axles with leaf springs and towbar 75 psig 5 2 bar Option Steel Panels with sound proof material optional Cummins Diesel Engine 98 at 1800 rpm Turbocharged and Aftercooled 4 4 5 liters 275 cubic inch Diesel or Jet fuel 15 US Gallons
20. These values should be used only if torque values are not otherwise specified for a particular assembly For an example refer to the Appendices for engine assembly or other components assemblies which may require special torque specifications The following conditions must be observed when using the general assembly torque values e Joints are assumed to be metal and rigid Do not use these values where gaskets or compressed material may be damaged by over torquing e During disassembly note bolt head marking and always reassemble the same hardware or equivalent new hardware in the correct locations e Asa general rule when reusing previously removed hardware apply the minimum values from the Torque Values table e Torque Values table pertains to Stainless Steel hardware 3 1 Torque values for general assembly continued on following page YARVICO 07 2004 Rev OR 54 282000 28 5 VDC Ground Power Unit 3 1 TORQUE VALUES FOR GENERAL ASSEMBLY continued US STANDARDS TORQUE VALUES METRIC TORQUE VALUES BOLT SIZE 18 8 S S THREAD DIAMETER Nm 2 56 2 5 M 1 6 0 35 2 64 3 0 M2 0 4 3 48 3 9 M 2 5 0 65 3 56 44 M3 1 6 4 40 5 2 4 3 5 4 48 6 6 5 6 95 5 40 7 7 6 11 8 5 44 9 4 8 28 7 6 32 9 6 0 58 6 40 12 1 12 100 8 32 19 8 M 14 159 8 36 22 0 16 245 10 24 22 8
21. 5 VDC Ground Power Unit 3 0 SYSTEM DESCRIPTION continued 34 FUEL SYSTEM See Figure 6 The fuel system is designed to provide enough fuel for nominal 8 hours of operation of the GPU at rated load The tank has a baffle system to prevent surges during towing WARNING During re fueling of the GPU always maintain metal contact between the filler hose and the fuel tank to reduce the possibility of sparking and explosion WARNING At no time should an open flame or smoking be permitted within the immediate vicinity of the GPU during re fueling or maintaining the engine fuel system as injury to personal will occur if fuel is ignited and causes a fire or explosion The fuel suction and return lines are located on the top of tank immediately below the engine lift pump The suction line draws from the bottom of the tank and the return line drains excess fuel into the top of the tank Both suction and return hoses are connected to the engine suction and return lines via flexible fuel lines and clips A fuel drain plug is fitted to the bottom of the tank to facilitate draining The fuel contents gauge sender is attached to the top of the tank and sends a signal directly to the operators panel providing an instantaneous readout of fuel contents A signal is obtained from this sensor in the microprocessor which warns the operator when the tank reaches 10 capacity CAUTION Care should be taken when lifting the GPU with a fork lift Severe d
22. Circuit Breaker Protects fuel solenoid 5 AMP Circuit Breaker Protects control power 10 AMP Circuit Protects governor 5 AMP Circuit Breaker Protects phase 1 of excitation transformer 5 AMP Circuit Breaker Protects phase 2 of excitation transformer 5 AMP Circuit Break Protects phase 3 of excitation transformer moss Current Limiter Adjusts peak current by percents of 2000 amps 50 15 1000 amps 4 1 3 Adjustments and Other Components See Figure 10 The following adjustment controls can be seen by pulling out the control module drawer DESCRIPTION FUNCTION Engine Governor Adjustments Adjustment to settings shown Interlock Places interlock at GPU or at aircraft plug usui Test Buttons check out shut down circuits for overvolt undervolts and overload n Reset reset after test or malfunction of unit Transformer Excitation transformer T Socket P8 For engine alternator harness Meu Module 218 5 WDC control board module Socket
23. GPU or prevent efficient operation 1 Unit Visually inspect outside of GPU for loose hardware loose parts frayed wires cables and general appearance 2 Towbar Check for loose joints hardware and other damage 3 Brakes Check brakes operate correctly and that towbar latches 4 Tires Check treads for wear and tires for pressure 5 Radiator Coolant Open radiator access door and remove radiator cap Ensure that coolant is just above radiator core Service as required 6 Engine Hoses Check integrity of hoses and clamps for tightness and Clamps 7 Fuel Level Turn power on and check fuel level on fuel gauge 14 Top up as required with fuel 8 Engine Inspect all fuel lines and fittings for traces of fuel leakage Visually inspect cylinder block oil pan and valve covers for oil leakage 9 Oil Level Remove dipstick to ensure oil level is at full mark Replenish as required 10 Fan Belt Check belt for correct tension Look for wear 11 Air Intake Filter Ensure that plugged filter indicator shows clean if not replace air filter Check again once unit is running 12 Doors Check that both doors are securely latched before towing 82 STARTING SEQUENCE See Figure 11 The following sequence must be followed in the order shown 1 Select Power ON 1 This will turn on the 24 VDC GPU power from the battery Power On Lamp 13 will light 2 Hold on Power ON 1 This is a lamp test of all red warning lights on the Instrument Panel
24. Ground Power Unit Parts List DOOR LOWER PIN ADJUSTMENT ASSEMBLY REPLACEMENT PARTS PART NUMBER DESCRIPTION TY 1101 ua nus Door Lower Pin Adjustment Final Assembly REF cia ns Ya IDONSISCKSSu u uuu 2 16040 Hinge Pin Assembly 55 2 19 169 sita tei sette i 2 VENE te disait de 16039 Pin 2 fy ARvICO 07 2004 Rev OR 79 28 5 282000 VDC Ground Power Unit Parts List RUNNING GEAR ASSEMBLY REPLACEMENT PARTS PART NUMBER DESCRIPTION TY VIOUS i ie ttes Running Gear Final Assembly REF 152376 asas Tire Wheel Assembly 5 70 8 4 Hub Asma li 4 1527 Sic M 4 EA SPL alicia 4 YWARVICO 07 2004 80 282000 28 5 VDC Ground Power Unit Parts List DC CABLE ASSEMBLY E EE REPLACEMENT PARTS PART NUMBER DESCRIPTION TY LOMA DC Cable Final Assembly REF 17076 sii ici DC Cable 258 1 17086 DC Cable Assembly 408 1 17083 asilos Cable GPU
25. JWARVico 07 2004 Rev OR 65 282000 28 5 VDC Ground Power Unit Parts List ENGINE CONTROL ASSEMBLY REPLACEMENT PARTS PART NUMBER DESCRIPTION TY MOT eerie Idle Run Switch Complete a as 1 140177 ioter lundium 1 14044 Red Green Contact 1 T4088 Switch 1 14 122 Red Red Contact 1 14042 Panel Plug cui iaa bici 1 TAPO Red Lamp siii iii 4 14001 1 TATUS ise teretes Water Temperature 1 awas Amber amp aus 1 14 VOD Oil Pressure Gauguin caricia 1 141 Ho rmetetr uie app pU I 1 Tos Tachometer A 1 14059 ts Emergency Stop Switch Complete 1 14018 hong cS 1 14045 n tette Lens cei eerie ed eoe dee beer ope 1 14047 aaa Front Ring Vinyl iii 1 1408 Switch tese ttes 1 14082 EE 1 14084 Red Contact BlOCK u u 1 VAT WS Voltm elter 1 YARVICO 07 2004 Rev OR 66 282000 28 5 VDC Ground Power Unit Parts List GENERA
26. Start GPU and allow unit to warm up Select RUN Locate GAIN and STABILITY adjusting screws on the electronic governor in the Engineers Panel Turn the GAIN adjustment slowly clockwise until engine starts to search Turn adjustment slowly counterclockwise until engine smooths out and continue adjustment an additional 1 8th turn Turn stability adjustment slowly clockwise until engine starts to search Turn adjustment slowly counter clockwise until engine smooths out and continue adjustment an additional 1 8th turn A slight additional counter clock wise adjustment may be required if when a load 15 applied the engine starts to search again 24 IDLE SPEED ADJUSTMENT Increase IDLE speed adjustment slightly clockwise and by carefully choosing incremental adjustments try to finish with an IDLE RPM that produces a smooth non resonating engine IDLE fyARvICO 07 2004 Rev OR 53 282000 28 5 VDC Ground Power Unit 3 0 REMOVAL INSTALLATION This section contains assistance for removal and installing major components on the Ground Power Unit The modular design will allow sub assemblies to be removed for work Removal Installation instruction for alternator and engine sub assemblies 1 e water pump fuel pump injectors etc can be found in the manuals in the Appendices 31 TORQUE VALUES FOR GENERAL ASSEMBLY The torque chart values are provided for reference when performing general assembly of various components
27. THE TROUBLESHOOTING CHART continued TROUBLESHOOTING CHART SECTION ENGINE FAULT CAUSE CORRECTION Engine will not start 24 Check contact breaker 1 Check power 24 VDC to fuel VDC power okay solenoid Listen to click when POWER Select starter turns engine switch is selected No click check power available with okay meter if yes replace solenoid power up solenoid with external 24 VDC AFTER disconnecting harness If solenoid clicks then fault is electrical check relay K4 Fuel Check fuel level Check fuel filter amp replace Check lift pump by loosening outlet fitting replace if faulty Electrical Check contact breaker 2 Disconnect injector actuator and start engine by manually controlling the injector Do not overspeed if 2500 RPM is exceeded the GPU will shut down and restart cycle must be repeated AFTER clearing overspeed fault on panel If engine runs then check operation of actuator by external 24 VDC power if okay replace governor in engineers panel After checking that no power is available on terminals A and B on the governor Engine starts and stops Low oil pressure or Restart Check oil pressure if normal engine will within 10 20 seconds empty oil gallery continue to run after oil change Electrical Check oil pressure gauge if no indication change oil pressure sender Reset low oil pressure fault lamp High coolant Low coolant Let engine cool down check coolant level temperature
28. all fluid levels and that the GPU 24 VDC batteries are fully charged then there should be no reason for the engine not to start If the engine fails to start after the above inspection then the fault may be isolated to Electrical harness e The instrument panel and switches electronic control module If an inspection shows that the cable harnesses are undamaged and properly connected then the instrument panel drawer assembly may be easily be changed for a spare unit and the GPU returned to immediate service 2 0 Troubleshooting continued on following page 07 2004 87 282000 28 5 VDC Ground Power Unit 2 0 TROUBLESHOOTING continued The following troubleshooting chart is laid out in this same sequence Commencing with the towbar and working through the machine to the aircraft connector This systematic fault finding technique will greatly speed up identification of where the fault exists which will then allow remedial action to be taken quickly 2 1 WARNING The GPU should not be operated for test purposes other than by fully qualified engineering personnel At all times avoid personal contact with electrical power components During servicing remove all jewelry which could cause a short circuit in any live circuit Failure to comply with the above basic rules may result in serious injury or death Prolonged exposure to high noise levels may cause hearing loss Ear pr
29. in strap Re torque clamp on induction hose AA bare fyARvICO 07 2004 Rev OR 60 282000 28 5 VDC Ground Power Unit 4 0 REPAIR This section contains general instructions for repair of components in the GPU The need for repair is usually identified during normal and periodic servicing operation of the GPU annotation of service records service bulletins etc 41 TIRES Replace if tread shows signs of wear Allowable tread wear is generally a matter of common sense However the major factors determining the condition of the tires may be such things as sun damage rot to the rubber worn out bearings causing uneven wear misaligned steering mechanism etc In any case the tread should not be less than 1 8 inch deep 42 ENGINE Refer to Appendices for detailed repair information 43 ELECTRICAL COMPONENTS Control switches circuit breakers engine gauges and control valve solenoids are normally not considered to be repairable The normal procedure is to remove and replace these components when defective Wire terminals should be cleaned inspected for signs of corrosion and repaired as necessary 07 2004 61 1 0 1 0 2 0 282000 28 5 VDC Ground Power Unit SECTION 3 OVERHAUL MAJOR REPAIR GENERAL Under normal operating conditions and proper preventive maintenance the GPU will provide excellent service for a period of 20 000 to 30 000 h
30. of the drawer assembly is an instrument panel with engine and generator controls Pulling out the drawer provides easy access for adjustments and maintenance Inside the drawer is one Master Control PCB module located inside a sealed box A 48 pin quick disconnect plug and socket are used to quickly replace the module This module carries a full five year warranty fyARvICO 07 2004 Rev OR 12 282000 28 5 VDC Ground Power Unit 4 0 INSTRUMENT PANEL continued CONTACT PRESS RESET CB 4 5 O Figure 8 Engine Controls 4 0 Instrument panel continued on following page YWARVICO 07 2004 Rev OR 243 282000 28 5 VDC Ground Power Unit 4 0 INSTRUMENT PANEL continued 41 CONTROLS 411 Engine Controls See Figure 8 All engine controls are located on an instrument panel located on the rear of the unit Engine Controls and Indicators are as follows ITEM DESCRIPTION FUNCTION Mn Power on Position Turns on 24 VDC power from battery and lights all warning lamps red when held in Power Off Position Turns OFF 24 VDC power from battery Start Button Starts engine electronics automatically by passes low oil pressure switch for 10 seconds engine will idle only Will only operate with idle run selector s
31. os leen ee p eed RE De viuda 12 4 0 Instrument Panel See Figures 8 9 10 2 41 0 20 000010 12 41 14 4 1 1 Engine Controls See Figure 8 enne en nnne 14 4 1 2 Generator Controls See 9 16 4 1 3 Adjustments and Other Components See Figure 10 16 4 27 Cable iia 17 4 2 1 Cable Harness P8 etr rettet 17 422 Cable Harness a 17 COME 18 44 Contact Breakers u eR e inici 18 4 5 Test Buttons 18 5 0 DC Control Module 18 51 Monitoring 18 5 1 1 Fel Level 18 5 1 2 Lamp 18 5 2 Safety Shutdown And Interlocks n asss 19 521 Start uu A T 19 522 EngineSh tdgdoWn nSs u uu 19 523 IEEE 19 YWARVICO 07 2004 Rev OR 282000 28 5 VDC Ground Power Unit 5 3 Summary Of Safety Shutdown And Interlock Sequence
32. tenere 2 rr e Drain Cock 1 Not Usada 09056 Plus EET 1 Flatwasher 5 16 eed 2 Lockwasher 5 16 56 2 40 404184 1 0040006000000000000000000000000005003 2 NUES TG SS 2 07 2004 Rev OR 75 282000 28 5 VDC Ground Power Unit Parts List EXHAUST SYSTEM ASSEMBLY REPLACEMENT PARTS PART NUMBER DESCRIPTION TY rra Exhaust System Final REF 18039 ires ENDO 1 180512 3 in Exhaust Pipe Flexible 1 1800 7 isset eines 3 im Guillotine Clamp u a aa tct a rte 3 udis 3 n Rain 1 A Mounting 2 fyARvICO 07 2004 Rev OR 76 Parts List OSURE AND FUEL TANK ASSEMBLY 282000 28 5 VDC Ground Power Unit REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION TY en Enclosure and Fuel Tank Final Assembly REF ACCESS DOO 2 Hs TODAS ceda Sound Proof A R 152 T A
33. the Fuel Lubricity Filter must be changed at 200 250 hour intervals The correct viscosity if 1 3 T 5 8 Millimeters per second at 104 degrees F 40 degrees C The normal cetane number should be 40 minimum however in cold weather use a higher cetane number ASTM D 613 Sulphur content should be Per ASTM D129 or 1552 Carbon residue should not exceed ASTM D524 and ASTM D 189 Other relevant ASTM numbers are flashpoint D 93 density D 287 corrosion D 130 ash D 482 and distillation D 86 OIL VISCOSITY See Figure 12 The viscosity of the oil being greatly influenced by the ambient temperature the choice of the SAE grade should be governed by the ambient temperature at engine site If temperatures temporarily fall below the limit of the SAE grade selected this will merely affect the starting performance but cause no engine damage Since a too viscous oil causes starting difficulties the choice of the viscosity grade during winter operation should be governed by the temperature prevailing at the time of starting the engine Oil changes as a function of ambient temperatures can be avoided by using multigrade oils which are again subject to the oil change intervals recommended The required oil capacities are given under Specification Data in Section 1 3 fyARvICO 07 2004 Rev OR 32 282000 28 5 VDC Ground Power Unit 1 1 OIL VISCOSITY continued SAE IOW SAE 20 20 SAE 15 40 SAE 10 40 SAE IOW 30_ SAE 5
34. the exhaust outlets with moisture resistant tape Use cardboard plywood or metal covers where practical Tag engine Control Panel DO NOT RUN READY FOR STORAGE YARVICO 07 2004 Rev OR 31 282000 28 5 VDC Ground Power Unit SECTION 2 1 0 SERVICING As with all Ground Support Equipment it is very important to provide proper preventative maintenance and service This will increase the service life of the diesel engine which can be expected to operate for 30 000 hours without a major overhaul this may vary according to local operating conditions The following specifies consumable service requirements COMPONENT DESCRIPTION 1 1 Fuel Diesel Fuel see below Engine Oil 15W 40 is suitable for most operating temperatures however attached is an oil viscosity recommendation for high and low temperature extremes Cooling System Use ethylene glycol see below for mixture levels Filters Fuel Filter Engine oil filter Air cleaner filter Cooling air filter NOTES Coolant Mixtures 50 50 antifreeze to water mixture 15 suitable for temperatures above minus 35 degrees minus 37 degrees C Temperatures below this require a 60 percent antifreeze content which will provide protection to minus 165 degrees F minus 54 degrees C Under no circumstances should the ratio of antifreeze exceed the above stated amounts Diesel Fuel Insure that the correct diesel fuel ASTM D 975 is used If using Jet A Fuel
35. 004 Rev OR 67 282000 28 5 VDC Ground Power Unit Parts List ADJUSTMENT ASSEMBLY DC FAULT TEST INTERLOCK O OVERVOLTS O UNDERVOLTS O OVERLOAD ENGINE GOVERNOR ADJUST REPLACEMENT PARTS PART NUMBER DESCRIPTION TY 13004 setis Adjustment Final Assembly REF OWE u ul n steterat a ee rte ees 12014 A O E ede o aues I ET 12016 2 eo G ER T 12015 isis DUATIDICB uei cete ane 12009 a DEOL Toggle SWitchu u a 07 2004 68 REPLACEMENT PARTS PART NUMBER DESCRIPTION TY 11005 ieu ene Instrument Panel Final Assembly REF 13008 anal E 1 IE NAAA htm 1 130175 A 2 A eter JU 2 12032 Relay 24 eee ERR 3 12001 cte tenete Excitation 1 4009 87 1 4009 89 J OS Cb OR Ee A 1 1309 DC PCB Mo
36. 3 Set Idle Run switch 3 to idle NOTE An automatic interlock will inhibit a start when this switch is in the run position CAUTION Both batteries must be fully charged to supply sufficient voltage for starting 4 Push Start Switch 2 for 2 3 seconds to start the engine Engine will idle at 700 rpm CAUTION Check oil level on gauge after 15 20 seconds of operation If none appears immediately select off 1 Failure to shut down engine with low or zero oil pressure could result in severe engine damage 8 0 Operating procedures continued on following page fyARvICO 07 2004 Rev OR 23 282000 28 5 VDC Ground Power Unit 8 0 OPERATING PROCEDURES continued 5 Oil pressure gauge 12 will read 10 psig minimum while engine is idling CAUTION Check that battery indicator 9 reads above 24 volts 6 Check engine temperature gauge 11 It should read between 170 195 degrees F 77 to 91 degrees C when engine is warm CAUTION Prolonged running at idle could result in engine damage Two to four minutes should be sufficient to warm the engine 7 All lamps except power on 13 should now be off 8 Bring engine up to operating speed by rotating switch 3 clockwise to RUN position 9 Check temperature gauge 11 is indicating a rise THE GPU IS RUNNING CORRECTLY 10 After engine has warmed up return the idle run selector 3 to idle before connecting aircraft cable CONTACT BREAKER PRESS TO RES
37. ARVICO TRONAIR Operation amp Service Manual e 4 Model 282000 28 5 VDC Ground Power Unit 07 2004 Rev OR Includes lllustrated Parts Lists Tronatr Inc 1740 Eber Road Holland Ohio 43528 9794 USA Telephone 419 866 6301 e 800 426 6301 Fax 419 867 0634 Web Site www tronair com E mail mail tronair com 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 282000 28 5 VDC Ground Power Unit INTRODUCTION ARVICO CORPORATION IS PROUD TO INTRODUCE YOU TO THE FINEST GROUND POWER EQUIPMENT AVAILABLE IN THE WORLD The purpose of this manual is to provide all the necessary information for you to maintain and service the equipment in a way that will ensure trouble free operation for many years This manual contains a general description specification recommendations for safe operation technical description of chassis and suspension technical description of engine and power alternator and a description with illustrations and schematics of the complete electrical system Also included in this publication is an operators manual a troubleshooting chart and an illustrated parts breakdown At the end of the manual the Appendices detailed information on the engine power alternator and the governor system ARVICO A Tronair C
38. Broken fan belt Replace Excessive black Injectors out of Check engine manual in Appendices exhaust smoke when adjustment or one or engine is running at more worn steady state Excessive engine Injector or engine Check engine manual in Appendices vibration at steady state valve out of 1800 rpm adjustment or worn All other engine faults NENNEN Consult engine manual in Appendices fy ARvICO 07 2004 Rev OR de 282000 28 5 VDC Ground Power Unit 2 USE OF THE TROUBLESHOOTING CHART continued TROUBLESHOOTING CHART SECTION ALTERNATOR FAULT CAUSE CORRECTION High frequency Ingress or digress Check intake air filter is fitted if not fit a spare With vibration or sound battery disconnected remove any foreign objects metal particles in base of alternator Bearing overheat Check bearing housing if hot allow GPU to cool inspect and replace bearing according to manual in Section Five Any one phase not Broken or frayed Check alternator output cables and connections to producing rated voltage connections contactors or current phase balance Electrical Test diodes in the non driven end of the alternator Consult manual in Appendices TROUBLESHOOTING CHART SECTION EXHAUST SYSTEM FAULT CAUSE CORRECTION Cooling air outlet Leakage within the Check all joints adjust tubes and secure clamps Any louver blackened with exhaust plenum tubes that have corroded should be replaced soot c
39. Comedia 1 17084 Locknut Connector 07 2004 Rev OR 81 ARVICO A TRONA IR Company APPENDIX 28 5 VDC ELECTRICAL SCHEMATICS pages 1 4 ARVICO A TRONA IR Company APPENDIX Il SPEED CONTROL UNIT IR Company APPENDIX Ill ELECTRIC ACTUATOR IR Company APPENDIX IV ALTERNATOR OPERATION AND MAINTENANCE MANUAL IR Company APPENDIX V ENGINE OPERATION AND MAINTENANCE MANUAL IR Company APPENDIX VI ENGINE PARTS CATALOG
40. ET 11 Instrument Panel 07 2004 Rev 24 282000 28 5 VDC Ground Power Unit 8 0 OPERATING PROCEDURES continued 83 SUPPLYING DC POWER TO THE AIRCRAFT See Figure 11 1 Connect 28 5 VDC power start cable to aircraft Make sure that power plug is fully and correctly inserted into the aircraft receptacle CAUTION Ensure that the soft start 6 is set in the correct position for the aircraft to be started Consult aircraft technical manual for proper switch setting Severe aircraft engine damage can occur if incorrect setting are used Soft start control located on instrument panel is only to be adjusted by competent maintenance personnel Helicopters and some small jets and turbo prop aircraft will require limit on peak power Half peak 50 Do not use soft start on hard start engines 2 Bring GPU to the RUN mode and select DC ON 4 Lamp 7 will light and remain on while the power cable is connected to the aircraft 3 The aircraft may now use DC power During a start cycle the DC Voltmeter 8 will fluctuate above and below 28 5 VDC THIS IS NORMAL The GPU will automatically compensate for the voltage drop in the cable to supply the starting voltage within specification at the aircraft receptacle During the start the Ammeter 10 which show high amps initially and then quickly decay to show the continuing current draw Check all engine
41. Marathon 284PSL1530 1800 rpm 60 21 3 1 40 80 Externally regulated 66 Volts DC 3 AMPS Class F Sealed pre lubricated Engine shuts down Engine shuts down Engine shuts down Engine shuts down Light on panel 9 0 Specifications and capabilities continued on following page fyARvICO 07 2004 Rev OR 27 282000 28 5 VDC Ground Power Unit 9 0 SPECIFICATIONS AND CAPABILITIES continued 9 6 DC PROTECTION SYSTEM Overvoltage Trips at 32 volts Undervoltage Trips at 22 volts High Temperature Rectifier will trip at 90 C 194 F DIMENSIONS IN INCHES CM AND WEIGHTS IN LBS KG MODEL A B WEIGHT 282000 109 277 76 193 72 183 2200 998 JWARVICO TRONAIR 07 2004 Rev OR 28 10 0 SHIPPING 282000 28 5 VDC Ground Power Unit When GPU s are shipped within the North American continent they do not normally need crating skidding or a solid crate Shipping outside North America will require the use of a solid crate or shipping container 10 1 PREPARATION FOR SHIPMENT 1 The following procedure is to be used a Disconnect battery link and negative cable Secure battery link to the engine securely Ensure fuel 15 secure Stow external power cable in the cable tray Securely close and fasten doors It 1 prudent to remove any protrusions on the machine such as beacons and avoid damage during shipment Any items so removed mus
42. ND OPERATING INSTRUCTIONS 1 0 GENERAL The 282000C series alternator are diesel and serve as a 28 5 VDC power source for aircraft servicing The electrical power source utilizes an Alternating Current alternator a solid state regulator and a rectifier assembly The series 282000C units will provide up to 800 amps continuous 2000 amps peak starting current at 28 5 VDC for aircraft engine starting and on board DC systems checkout The SOFT START current limit feature allows the user to select current limits for operations requiring current below the maximum output 2 0 MAJOR COMPONENTS 2 1 2 2 ALTERNATOR AND DIESEL ENGINE The alternator is directly coupled to the diesel engine A governor electronically governs the engine speed An overspeed protection circuit is integrated into the electronic governor which will automatically shut down the engine should the engine rpm s exceed 2500 rpm ARRANGEMENT SEE FIGURES 1A 1B 1C The Ground Power Unit s GPU s are totally self contained and trailer mounted Maximum towing speed is 15 mph 24 km hr The GPU will continue to operate at rated power when set on a maximum incline of 15 degrees with ambient temperatures of minus 40 to plus 125 degrees F minus 40 to plus 51 degrees C and a relative humidity of 100 percent The ground power unit will operate efficiently from sea level to an altitude of 6000 feet Please note the Safety Warnings printed in this manual when operating the GPU
43. TOR CONTROL ASSEMBLY 6 N CONTACT PRESS TO RESET HIGH CB ye hi IAE 6 4 6 VOLTS E 8 O 5 Os 60 corres LIMITER 0000 Se E 2 AMER Cy oz 1007 gt xO a POWER START ENGINE DC EMERGENCY ON IDLE um ud NA S N N 8 REPLACEMENT PARTS PART NUMBER DESCRIPTION TY 11003 tiic ee Generator Controls Final Assembly REF 14009 DO VoltMEtE 1 14008 enirn DG Slut 1 12008 Adjust Potentiometer a 1 DC ON Off Switch 1 140431 Switch us as tente eerte Hie e reo e ee Pete a EP Re 1 14044 Red Green Contact 1 A Green Contact Block ttm tret inne eae 2 14044 cites Contact Block tte ertt e re 1 1412 Green A O 1 14126 Red Lamp m 3 12001 IAS ated cde 1 12002 ires 5 Amp CB isses 5 12031 iet DM 1 ak E 1 14 129 5 Blue xi Ee 1 07 2
44. W 30 SYNTHETIC 0 20 30 1495 a9 72 25 4 9 1423 241 50899 6 77 95 SAE 15 30 SAE 154 40 SAE 204 20 30 ISAE40 XONLY W ENGINE OIL PREHEATING Figure 12 Oil Viscosity 12 LUBRICATING INSTRUCTIONS 1 2 1 Engine Lubrication Refer to attached table for engine maintenance schedules These recommended service intervals will insure a long life for the engine and its components These figures are based on an average operating environment If the engine operates in desert areas or other dusty environments or areas of high humidity or infrequent basis then the service schedule should be changed accordingly The engine oil level should be checked every 10 hours of operation CAUTION Do not over lubricate the engine as damage may occur Always use the engine oil level dip stick to ensure the correct level Always use the same brand of engine oil When topping up the oil level always prevent dirt from entering by cleaning around the oil filler prior to filling 1 2 2 Chassis and Running Gear 1 Lubricate chassis and running gear grease points at designated intervals 2 Running gear bearings and joints should be greased with lithium based grease refer to the Table for maintenance schedule The following grease fittings are installed on the GPU Front and Rear wheels are lubricated by grease packing the wheel bearing For grease packing it is recommended that a number 2 lithium base hydroxy steara
45. al module Electronic module okay Indeterminate Replace instrument panel complete if fault clears then but specific fault still troubleshoot the panel on the bench returning GPU to not rectified service If fault persists check P8 and P9 harness and operators panel fy ARvICO 07 2004 Rev OR 51 282000 28 5 VDC Ground Power Unit 2 USE OF THE TROUBLESHOOTING CHART continued TROUBLESHOOTING CHART SECTION CIRCUIT BREAKER CIRCUIT BREAKER FAULT CAUSE CORRECTION CB 1 POPS Fuel solenoid or Replace solenoid or relay relay shorted Engine will not start or stops without apparent reason CB 2 POPS Control Circuit Short Check control circuit and remedy fault 4 5 6 POPS Excitation Change excitation transformer transformer short CB 3 POPS Governor fault Replace governor TROUBLESHOOTING CHART SECTION ERRATIC ENGINE RPM FAULT CAUSE CORRECTION Engine Control Erratic Loose linkage to injector Reset and tighten linkage pump Actuator arm will not Reset If not possible replace actuator return to left 1 sticking Reset Faulty fuel solenoid Replace solenoid Magnetic pickup collected Replace magnetic pickup metal dirt or is faulty Loose electrical Fix loose connection connection Replace Governor Actuator shaft slipping in Either drill and pin or replace actuator armature 2 0 Troubleshooting continued on fol
46. amage to the GPU will occur particularly the fuel tank if the fork lift tines are not engaged in the guides provided SPEED CONTROL ACTUATOR TANK DRAIN PLUG Figure 6 Fuel System 07 2004 Rev OR 10 282000 28 5 VDC Ground Power Unit 3 0 SYSTEM DESCRIPTION continued 3 5 CRANK CASE BREATHER A crank case breather tube is attached to the side of the engine and exits towards the rear of the GPU This tube should always be kept clear and outside the GPU housing 3 6 COOLING FAN CUMMINS See Figure 7 Cooling fan attached to the engine is a 9 blade high efficiency aero dynamic fan suitable for tropical conditions The pitch of the fan is adjustable but is set at the factory to meet the conditions and end use of the GPU The use of an aero dynamic fan reduces operating noise from the GPU 37 TEMPERATURE The temperature sender is a long life device however if it is necessary to replace the sender this may be done when the engine is cold and the radiator cap is removed The radiator level may be drained below the cylinder head level to minimize liquid loss 2 25 A LOWER RADIATOR HOSE 3 8 OIL Figure 7 The oil pressure sender is a long Radiator Assembly life device however in the case of a fault may be removed without draining fluids from the engine Although a small amount of oil loss may occur This pressure sensor includes a low oil pressure switch set
47. at 8 psi when the engine has been sitting for a long time and the oil has been drained it is possible that a period in excess of 20 seconds may be required to bring the oil gallery up to full pressure during this period of time the control module signal may interpret this as long term oil pressure loss and switch off the engine fuel solenoid stopping the engine It is only necessary to restart the engine until the oil gallery has achieved its full fluid level and reaches operating pressure 3 9 SPEED CONTROL The injector pump actuator or speed control fitted to the engine has been specifically matched to the engine injector pump force requirements This actuator is driven by a 24 VDC signal controlled from the electronic engine governor No service is required for this actuator 3 0 System description continued on following page 07 2004 Rev 21 282000 28 5 VDC Ground Power Unit 3 0 SYSTEM DESCRIPTION continued 3 10 INJECTOR PUMP Standard Cummins engine rotary injector pumps will operate with all types of standard diesel engine fuel To use both diesel or Jet fuel Cummins offer an inline pump Ensure that your unit has the correct inline pump before using Jet fuel or see engine manual in the Appendices for procedure for adding lube oil to the fuel The engine oil filter should be replaced according to the standard maintenance procedures included in this manual The engine fuel filter fit
48. ceeds 32 volts A warning lamp is lighted if DC voltage drops below 22 volts 6 4 VOLTAGE ADJUSTMENT The DC control module will automatically control the DC voltage at the aircraft or at the GPU The module will modulate the AC generated voltage to maintain 28 5 VDC at the sensing point During periods of high demand the voltage will be driven upwards and during of periods of low demand the voltage will be stabilized close to nominal fyARvICO 07 2004 Rev OR 20 282000 28 5 VDC Ground Power Unit 6 0 POWER SYSTEM DC 6 5 6 6 6 7 6 8 6 9 6 10 OVERLOAD PROTECTION The rectifier is fitted with a shunt rated at the maximum peak power of the rectifier The shunt supplies a 50 millivolt max signal to the DC ammeter indicating the current usage The same signal is fed into the DC module which compares this against a set maximum peak current limit The DC contactor will be disabled when the peak current is reached however a timing circuit is included which will prevent premature shutdown TEMPERATURE PROTECTION The DC rectifier heat sink is fitted with a thermostat set at 90 degrees C If an over temperature condition exists in the rectifier assembly the DC power contactor pilot relay will be disabled The rectifier assembly is cooled by the GPU cooling air system SOFT START CURRENT LIMITATION The DC output is controlled by a separate DC module In series with the DC current monitoring circuit i
49. dule Complete 4410 2 22 000000 000000000000000000001 1 4002 25 O uu 1 4006 1 PIU 1 4002 22 ISO 1 4005 JS PIUS EE 1 206222 uu Q A amu 1 12063 iiiter PO Harness 1 A Rec u T m m MEUS 1 12003 Thermal Overload ba 1 13002 C Li u u uu u s 1 13013 Lu US ONS o 6 13049 Low Coolant Relay K 21 option a a 1 13053 iode ues Start Solenoid reed Eres 1 282000 28 5 VDC Ground Power Unit INSTR Parts List UMENT PANEL ASSEMBLY 07 2004 Rev 69 282000 28 5 VDC Ground Power Unit This page left blank intentionally fyARvICO 07 2004 Rev OR 70 282000 28 5 VDC Ground Power Unit REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION TY 11006 Engine Alternator Final Assembly REF 09024 Alternator 23KW 1
50. e readily replaceable Intake and Warm Air Outlet Louvers See Figure 2 The GPU when fully assembled forms a tube around the engine alternator and electronics One end of this tube has an intake louver the other end has a warm air outlet louver Both louver assemblies are attached to the chassis with three bolts and to the hoop at each end with three screws Each louver assembly is fitted with a slide to accept the air filter on the intake end and an anti bird screen on the warm air outlet end option Air Filter Option A full flow multiple mesh screen filter is fitted on the intake louver which maybe washed or steam cleaned periodically to insure full efficiency This filter removes large particles from the air flow and captures oil vapor which may be present in the atmosphere The primary purpose of this filter is to prevent an oil dust buildup on electrical components within the GPU fy ARvICO 07 2004 Rev OR Bio 282000 28 5 VDC Ground Power Unit 2 0 MAJOR COMPONENTS continued 2 4 CABLES See Figure 3 WARNING Power cable interlock safety circuits are built into the power cables running between the ground power unit and the aircraft When these cables are not connected to an aircraft or to an approved load bank the interlocks may be bypassed Bypass shall only be made by a qualified technician In this mode personnel are exposed to live power cable Only authorized personnel should attempt to run the
51. ent See FigureS 1A 1B 1 2 3 Design of the Ground Power 3 2 3 1 Chassis D eseription iia 3 2 3 2 Support ANT 3 2 3 3 Canopy 2 aaa RA 4 2 3 4 LS NO 4 2 3 5 Instrument Panel Door See Figure 2 4 2 3 6 Lower RN 4 23 7 A T 6 2 3 8 Wheels NN 6 2 3 9 Side Impact Bumpers See Figure IC 6 2 3 10 Fore and Att Bumpers A TA 6 2 3 11 Intake and Warm Air Outlet Louvers See Figure 2 6 2312 m 6 24 Cables See 7 2 0 System Description ia ua 7 3 1 las 7 3 2 Engine Sensors Cummins Sensors See Figure 5 9 3 3 And Water cce cede e 9 3 4 Fuel System See Figtire 6 10 35 Crank Case Breather 11 3 6 Cooling Fan Cummins See Figure 7 11 3 7 T mperature u an aaa 11 3 8 OW 11 E ME nk 11 3 10 Injector PUMP ULIS 12 3 11 Cooling System Ses REN LIO sedeo oun leves ke
52. equipment when the safety interlocks are de energized for test purposes only DC cables are nominally 25 feet 7 6 meters long Interlock and head voltage sensing is standard DC Cable Assembly 3 0 SYSTEM DESCRIPTION 31 ENGINE ALTERNATOR Model 282000C is powered by a Cummins diesel engine using diesel or Jet fuel option The engine and alternator assembly 15 attached using a five point suspension system that completely isolates vibration from the chassis Detailed manuals specific to the engine and alternator type appear in the Appendices of this manual 3 1 Engine alternator continued on following page fyARvICO 07 2004 Rev OR ST 282000 28 5 VDC Ground Power Unit 3 1 ENGINE ALTERNATOR continued Each diesel engine is fitted with the following equipment e Turbocharger as required Aftercooler as required Fuel filter spin on type Engine oil filter spin on type Fuel solenoid and fuel pump Injector pump actuator Magnetic pickup mounted on the engine fly wheel housing Water temperature high switch and water temperature indicator sender Low oil pressure switch and oil pressure sender Battery charging alternator 24 volts 24 Volt starter motor and solenoid Fan drive pulley with ratio 1 1 1 Engine speed Optional dual fuel injector pump The power alternator is fitted with e Solid state exciter control e Single bearing armature mounting lubricated for 100 000 hours of op
53. eration e SAE mounting flange to match the engine e Vibration isolator mounting pads forming part of the engine alternator assembly mounting system gt INTAKE SYSTEM ALTERNATOR 4 CHASSIS WELDMENT Figure 4 Engine amp Alternator Assembly 07 2004 Rev OR 8 282000 28 5 VDC Ground Power Unit 3 0 SYSTEM DESCRIPTION continued 3 2 ENGINE SENSORS CUMMINS SENSORS See Figure 5 The engine sensors feed signals into the microprocessor control module This system is designed to prevent damage caused by operation of the engine at out of tolerance levels WATER TEMPERATURE SENDER AND SWITCH FUEL ACTUATOR OIL PRESSURE SENDER AND SWITCH MAGNETIC PICKUP FAN BELT BREAK SWITCH OPTION 1 2 3 4 5 33 FUEL AND WATER Figure 5 Cummins Engine Sensors The engine fuel shutdown solenoid or relay will cut off the fuel to the engine in the event of 1 Low oil pressure Engine coolant temperature exceeds limits Engine exceeds system design speed by a factor of 5 percent In the event of a fan belt failure the engine will shut down option Pressing Emergency Stop water temperature fuel pressure senders are used to indicate the exact temperature and pressure of the engine systems on the operators panel 3 0 System description continued on following page 07 2004 Rev 9 282000 28
54. et at idle Button is fitted with a guard Jute Idle Selector and Returns engine to IDLE from RUN mode Brings engine Run Selector up to RUN mode from IDLE Ainas Emergency STOP Button Will immediately shut off power to the GPU and GPU will stop SLE Used for optional panel lighting Oudend Battery Indicator Indicates 24 VDC battery voltage T Fuel Gauge Indicates fuel remaining in tank Buone Low Fuel Lamp Red Lights when fuel remaining is less than one tenth ET Engine Temperature Indicates engine operating temperature Ii Over Temperature Lamp Red Lights up is engine temperature exceeds specification Engine Oil Pressure Indicates engine oil pressure AA Low Oil Pressure Lamp Red Lights up if engine oil pressure falls below 8 psi Fan Belt Failure Lights up and shuts down engine if fan belt fails p Power ON Lamp Lights up and remains on while power is ON esee Tachometer Indicates engine speed Hourmeter Records unit operating hours Low Coolant
55. first alarm so that even after the fault has cleared it is evident which one caused a shutdown It freezes the first alarm to occur thus indicating the primary or first alarm as opposed to subsequent ones which may come up later as a consequence shutdown POWER SUPPLIES The DC Module takes its power from the plus 24 volts line and thus is only powered when the machine is running normally REDUCED DC RIPPLE OPTION As an option a LC filter coil and capacitor can be installed on the output from the rectifier L is equal to 2 5 H and C is equal to 47 000 F at 40 volts The LC filter reduces the 28 5 VDC output ripple to one percent 1 or less A resistor is also installed to bleed down the capacitor in less than 10 seconds GROUNDING REEL OPTION A static grounding reel is offered as an option It is normally bolted to the underside of the rear bumper The 3 32 inch diameter cable has an instant acting lock and release The grounding clamp should be attached to a known ground The unit is equipped with a 100 amp clamp with rubber bumper The cable resistance is one ohm throughout its length fyARvICO 07 2004 Rev OR 22 282000 28 5 VDC Ground Power Unit 8 0 OPERATING PROCEDURES 81 PRE USE INSPECTION CAUTION A pre use inspection must be carried out prior to each use to ensure safe operation of the GPU Failure to carry out these procedures listed below may result in severe damage to the
56. gauges for correct operation during the engine start cycle To shut down the GPU select DC OFF 4 Lamp 7 will turn off Return rotary switch 3 to idle Stow DC plug and cable in cable tray Shut down GPU 8 4 FAULT IDENTIFICATION 8 4 1 Operating Faults faults and red warning information should immediately be referred to qualified service personnel operational faults falling with the operators scope are as follows ITEM FAULT REMEDY Low fuel lamp 15 lights Refuel immediately DR Engine starts then stops Restart press 2 oil pressure by pass will reset automatically CAUTION If more than ten seconds has elapsed since first pressing the start button switch power off and then on again to reset timer Then re press the start button Fan Belt Lamp Refer problem to service personnel One or more red lamp Refer problem to service personnel do not light when power on 1 is held on 6 0 Operating procedures continued on following page fyARvICO 07 2004 Rev OR 25 282000 28 5 VDC Ground Power Unit 84 FAULT IDENTIFICATION continued 8 4 2 Lamps WARNING Do not operate the GPU while any warning light is lit as severe GPU damage or Persomnel injury will occur Lamps 13 and 7 only indicate normal operation All other lamps are a warning CAUTION Warning lamps are valid in run position only
57. grease in upper and lower roller bearing Repack if force if installed required Seized towbar Lubricate joints and brake actuator pins Rain water retained Drain holes blocked Remove debris in each corner of lower panels Drain between chassis tubes Holes TROUBLESHOOTING CHART SECTION CANOPY HOUSING FAULT CAUSE CORRECTION Door stiff to open Dry hinge pin Lubricate with light graphite based oil Door difficult to latch Latch out of Close door against rubber extrusion on the hoop Adjust adjustment latch so that door just compresses the rubber Door not square with door frame Hinge pin out of The hinge pin adjuster is located at the bottom of each adjustment door at the hinge end Just loosen the 2 retainer nuts so that the door may be raised or lowered at the latch end When door is square re tighten adjuster nuts 07 2004 45 282000 28 5 VDC Ground Power Unit 2 1 USE OF THE TROUBLESHOOTING CHART continued TROUBLESHOOTING CHART SECTION 24 VDC POWER FAULT CAUSE CORRECTION No power when power Main breaker off Reset CB 7 switch 15 selected Loose battery Check clean and tighten terminals terminals Low electrolyte Check fluid and top up if required System leakage Check power input 19 connector to the panel if battery discharged current flow ceases with P9 disconnected check leakage to all systems fed by P9 plug
58. hamber Blackened components Leakage Failure or Ensure all tubes are fully inserted into the mating bell around exhaust on the loose tubes ends and reclamp Replace corroded or broken tubes engine side of the radiator 2 1 Use of the troubleshooting chart continued on following page JWARVICO 07 2004 Rev OR 48 282000 28 5 VDC Ground Power Unit 2 USE OF THE TROUBLESHOOTING CHART continued TROUBLESHOOTING CHART SECTION 28 VDC DC POWER SYSTEM FAULT CAUSE CORRECTION No volts or amps shown on operators panel No power output but AC system working No power at aircraft plug assuming all control electronics are operating correctly Sensing wires discomnected from TB2 and 50 MV shunt Rectifier diode heat sink overheat Blown diodes on rectifier Disconnected broken power cables Sensing lines disconnected with sensing switch in remote and interlock in remote Contactor inoperative Check wires are connected on P8 harness Let GPU cool down and re test Check continuity of 3 phase thermostat on rectifier at TB2 Disconnect flexible cables and check Blocking with meter Check continuity of positive and negative cables from GPU to plug Check sensing and interlock continuity between GPU TB2 and return to plus and minus power points and TB2 Disconnect contactor supplying power transformer Ope
59. he latch plate on the hoop Each door is fitted with acoustical suppression material Keyed latches are available as an option for both doors Instrument Panel Door See Figure 2 The rear louver houses the operators instrument panel and control box Access into the operators panel and control box may be obtained by sliding the drawer out Any service or maintenance required to the operators panel is described in the electrical section of this manual Lower Panels The chassis is fitted with steel panels between each chassis cross member The engine oil drain is available via an access hole in the lower panel These panels are fitted with a sound barrier reducing radiated noise from the engine and alternator reflecting off the ground below the GPU The corner of each panel is notched to allow the drainage of any water which may collect in the of the chassis These drainage points should always be kept clear and free Both doors have drainage holes located at the bottom of the door panel 07 2004 4 282000 28 5 VDC Ground Power Unit ACCESS WR Figure 2 Doors Louvers and Instrument Drawer 2 3 Design of the ground power unit continued on following page fy ARvIcO TRONAIR 07 2004 Rev OR gt 282000 28 5 VDC Ground Power Unit 2 3 DESIGN OF THE GROUND POWER UNIT continued 2 3 7 Running Gear The complete chassis is supported by
60. id injury to personnel The lift is to be positioned to allow engine alternator to be lifted away from the radiator assembly WARNING Before removing the hold down bolts remove all slack in the chains Injury to personnel may occur particularly fingers 5 Remove the mount bolts securing the engine generator frame removing front engine bolt first 6 Lift engine and alternator from chassis CAUTION Place assembly on wooden blocks to prevent damage to oil pan Utilize torque values when assembling engine alternator hold down bolts and other attaching hardware 3 0 Removal installation continued on following page fy ARvICO 07 2004 Rev OR 56 282000 28 5 VDC Ground Power Unit 3 0 REMOVAL INSTALLATION continued CAUTION LMT UP WITH LUMBER PREVENT DAMAGE TO BOTTOM OF ENGINE CRANKCASE Figure 16 Blocking Engine Alternator 1 ENGINE SUPPORT FRONT 2 ENGINE SUPPORT REAR 2 3 ALTERNATOR SUPPORT 2 INTAKE SYSTEM ALTERNATOR 4 a Figure 17 Engine and Alternator Assembly 07 2004 Rev OR 57 282000 28 5 VDC Ground Power Unit 3 0 REMOVAL INSTALLATION continued 3 3 ENGINE ALTERNATOR INSTALLATION CAUTION Before installation inspect the shock Mounts for serviceability Replace if cracked or otherwise unserviceable 3 3 1 Installation e Attach suitable 2000 lb lift to engine alternator and reins
61. is reached Stop the engine Drain the engine crankcase Reinstall the drain plug Install new lubricating oil filter elements and gaskets Refill with high quality lubricating oil Shell code 66202 or Texaco Preservative oil 30 MIL S 21260C Grade 2 Drain the fuel tank of contaminants fuel water Add additives fill with fuel and operate the engine for about ten minutes JN ARVICO 07 2004 Rev OR 30 282000 28 5 VDC Ground Power Unit 11 1 2 Long Term Storage continued NOTE If the unit is stored where water or condensation may be a problem add pure waterless isopropyl alcohol isopropanol to the fuel at the rate of 1 pint to 125 gallons of fuel 010 by volume Where biological contamination may be a problem add a biocidal such as Biobor JF or equivalent to the fuel Follow the biocidal manufacturer s concentration recommendations and observe all warnings and cautions Remove the spin on fuel filters discard new filters with fuel and reinstall on the engine Remove and clean battery terminals and cables with baking soda water solution rinse with fresh water Do not allow the soda water to enter the battery Add distilled water to the electrolyte if necessary fully charge the battery Store the battery in a cool dry place never below 32 degrees F or 0 degrees C Keep the battery fully charged and check the specific gravity of the electrolyte regularly Seal all engine openings including
62. l out control module rectifier and contactor 2 3 Design of the ground power unit continued on following page 07 2004 Rev OR ug 282000 28 5 VDC Ground Power Unit 2 3 DESIGN OF THE GROUND POWER UNIT continued 2 3 3 Canopy See Figure 2 WARNING Under no circumstance should any operating personnel walk on the top of the GPU canopy This can be very slippery if footwear is oily or if the canopy is wet and can cause injury to personnel 2 3 4 The upper canopy consists of one panel bolted to the hoop The upper canopy panel is fitted with acoustical suppression material Doors See Figure 2 WARNING The access doors to the electrical equipment are fitted with an international warning symbol a yellow triangle with a Z shaped arrow No unauthorized personnel should attempt entry to the GPU via these access doors during operation of the equipment Two full length doors are fitted between the upper canopy and the chassis side members The doors are hinged in the upper canopy and rest on Teflon pads attached to the chassis A removable lower hinge pin passes from the door through the Teflon pad and into the upper chassis side member Adjustments to the door at the latch end in the vertical direction may be made by sliding the lower removable hinge pin holder fore and aft Doors are held shut by 90 degree turn latches which are adjustable for door thickness These latches fit behind t
63. lowing page 07 2004 52 282000 28 5 VDC Ground Power Unit 2 0 TROUBLESHOOTING continued 2 22 ENGINE SPEED Engine RPM is controlled by three components 1 2 3 The fuel actuator which is a servo device to control fuel flow to the engine The Governor located in the Instrument panel which monitors the engine RPM and governs the fuel actuator to maintain the set RPM The Magnetic Pick up mounted on the flywheel bell housing which receives magnetic pulses from the ring gear and sends this information to the Governor CAUTION Idle speed or set run speed cannot be adjusted by re setting the linkage between the actuator and fuel pump If attempted erratic engine operation will result The magnetic pulses are then compared to the preset value determined by the brass speed control screw in the governor The actuator is then continually adjusting position to match this value The Actuator is spring loaded and when its linkage is properly adjusted its rest position is full left which should be the fuel OFF position At engine start the actuator lever moves full right until the engine has started then it will return to the near rest position The Actuator is continuously in motion to maintain RPM When switching from IDLE to RUN or when generator load is applied the Actuator will move sharply to the right and return to center 2 3 GAIN STABILITY ADJUSTMENTS 1 2 3
64. med YARVICO 07 2004 Rev OR 21 282000 28 5 VDC Ground Power Unit 7 0 DC MODULE The Control Module contains the electronics to monitor the output voltage and current from a rectifier assembly producing plus 28 volt DC at up to 800 amps continuous 2000 amps peak Other values are available plus optional 112 volts DC The rectifier is powered from the A C generator 21 VAC 60 Hertz As well as monitoring circuits for Overvoltage Undervoltage and Overload the controller provides a Current limiting output 7 1 7 2 7 3 7 4 7 5 7 6 7 7 DC VOLTAGE INPUT This circuit monitors the DC voltage either locally or at the aircraft connector DC CURRENT INPUT This circuit monitors the output current by measuring the voltage produced across a DC shunt which gives 50 millivolts for 2500 amps of output current CURRENT LIMITING The output of the current monitor is compared with a limit set by a variable resistor on the module The response is delayed by the time constant of 7 5 milliseconds MONITORING CIRCUTS This circuitry provides a monitor of DC Output Under and Over Voltage and DC Output Over Load In addition it provides safety shutdowns for Overvoltage or Overload 7 4 1 Lamp Drivers Each of monitoring circuits described above connects to a lamp driver such that high level at the monitor output will turn the lamp driver on The alarms connect via a latch which is used to hold the
65. ng 30 ft 8m maximum If meter indicates 28 VDC check remote sense wiring to cable head via TB2 Voltmeter Check operation and replace if failed Check shunt and wiring measure MV output with clip leads attached prior to running 2500 amps 50 MV if okay check ammeter out of circuit power with 12 VDC only replace if failed Failure in DCM Replace unit and return to ARVICO A Tronair Company for analysis 2 1 Use of the troubleshooting chart continued on following page JVARVICO 07 2004 Rev OR 50 282000 28 5 VDC Ground Power Unit 2 USE OF THE TROUBLESHOOTING CHART continued TROUBLESHOOTING CHART SECTION INSTRUMENT PANEL FAULT CAUSE CORRECTION Contact breaker keeps Weakened CB Replace popping out AFTER correction of all discernable faults Erratic Engine Idle Faulty idle circuitin Replace and return unit to ARVICO provided governor replacement corrects the fault Transient engine Gain and stability Adjust to specification per manual in Section 2 3 performance not to adjustment specification TROUBLESHOOTING CHART SECTION GENERAL GENERAL FAULT CAUSE CORRECTION All action taken per this Electronic Replace complete If fault is cleared return failed module chart for any specific microprocessor to ARVICO A Tronair Company for analysis DO NOT fault still not rectified failure OPEN THE MODULE CASE THIS VOIDS WARRANTY If fault not cleared replace origin
66. nopy is lit B Start Provided idle is selected start closes K3 1 energizing the starter solenoid motor Engine shutdowns enabled after 10 seconds C Run Governor switched to operating mode D Idle Forces engine to idle speed E Power OFF This switches engine to idle speed and a 60 second delay before shutdown 5 3 2 Engine Shutdowns is energized opening K4 1 and de energizing fuel relay 1 Causes Low oil pressure high water temperature over speed 2 Active 10 20 seconds after start button is released fyARvICO 07 2004 Rev OR 19 282000 28 5 VDC Ground Power Unit 6 0 POWER SYSTEM DC The DC system consists of a rectifier assembly monitored by a DC controller located on the control module PC Board A standard power contactor for the DC is mounted on a platform The DC power supply contactor is enabled by a 24 VDC signal from a pilot relay With the DC power cable inserted into the aircraft the DC power ON switch may be selected The DC power ON switch enables the DC contactor to pull in providing that the cable is connected to the aircraft and the interlock has continuity or the interlock selector switch on the panel is in the GPU position For power to the aircraft this switch must be in the A C position Once the DC power contactor is enabled 21 VAC at 60 hertz is connected to a rectifier assembly utilizing power diodes The output from the rectifier is a nominal 28 5 VDC The positive sup
67. ome up later as a consequence of a shutdown fy ARvICO 07 2004 Rev OR 18 282000 28 5 VDC Ground Power Unit 5 0 DC CONTROL MODULE MICROPROCESSOR continued SAFETY SHUTDOWN AND INTERLOCKS This circuitry is responsible for engine safety shutdowns It monitors engine shutdown low oil pressure high water temperature starter button stop button and run idle switch as well as it s own internal alarm It can stop the engine in an emergency by activating fuel off 5 2 5 3 3 2 1 5 2 2 5 2 3 Start Circuit This circuit detects the release of the starter button indicating that the engine has started External circuitry ensures that the starter can only be engaged when idle mode is selected A 10 second delay allows time for the oil pressure to build up before the engine shutdowns are activated If run mode is selected before the 10 seconds has elapsed and before oil pressure is established it will result in a complete engine shutdown Engine Shutdowns The two main engine shutdowns are low oil pressure and high water temperature Either of these energizes the fuel off relay causing the engine to stop Stop Circuit This circuit detects operation of the power off switch and forces the system into idle mode for 1 minute before turning the power off and stopping the engine SUMMARY OF SAFETY SHUTDOWN AND INTERLOCK SEQUENCE 5 3 Normal A Power ON Energizes K1 latching plus 24V ON Lamps are lit ca
68. ompany equipment is designed from concept to reduce the tasks in service and maintenance You will notice within this manual that some portions of the electronic system is explained in theory only the reason for this is that these particular components are warranted for five years and require no service The troubleshooting section of this manual is presented in the form of a tabulation showing a possible fault and its possible cause and correction The maintenance section also describes how to disassemble the complete GPU in the case of a major overhaul requirement These instructions are based on an anticipated life span of the equipment over several years However should a premature failure of a major component occur then we suggest you consult the factory for advice after first reviewing the detailed manuals in the Appendices The illustrated parts list is provided to define those parts of the GPU which may be ordered as a spare or replacement part Contact Tronair at Arvico A Tronair Company Telephone 419 866 6301 or 800 426 6301 1740 Eber Rd Fax 419 867 0634 Holland OH 43528 USA Email mail tronair com Website www tronair com JVARVICO 07 2004 Rev OR 282000 28 5 VDC Ground Power Unit TABLE OF CONTENTS PAGE SECTION LA acid 1 1 0 Generali is 1 2 0 Major Components 1 2 1 Alternator and Diesel Engine 1224 1 22 Arrangem
69. on atado ae 25 NN 25 8 4 Fault Identification 4 26 5 42 Lamps 26 8 5 Emergency Shut DoW u edite ti Re RUE eoe 26 9 0 Specifications And Capabilities eiie 27 91 General SPERM vr mw E E e Ee 27 022 ChasSsiSus 27 93 ENBE IET 27 9 85 Sri ME 27 9 5 NN 27 96 Protection Systeri ree sende etude 28 10 0 ii 29 10 1 Preparation For Shipment re eine 29 30 11 1 Preparation 50 30 11 1 1 Short Term Storage less than 3 5 30 11 1 2 Lone Term Stora Se 30 SECTION 2 32 1 0 32 11 Viscosity Figure 12 32 12 Lubricating Instructions xi 33
70. or attaching flex coupling to flywheel tightening the fan assembly and when installing engine alternator mount bolts 1 Install lifting hoist to alternator lifting eye Using lifting hoist align the alternator to the engine flywheel housing Attach alternator to engine using 12 bolts 3 Align the holes in the flex coupling plate with the holes in the flywheel and attach with 8 bolts CAUTION Do not use the fan as a prying surface 4 Install the alternator ventilation screen 3 6 RADIATOR REMOVAL See Figures 15 16 17 1 Using a suitable container open pet cock on of radiator and drain all fluid 2 Remove upper and lower radiator hoses CAUTION Inspect hoses carefully and replace if unserviceable Remove the six shroud bolts Remove the top vibration damper Remove the two nuts holding radiator to chassis Slide shroud over the fan and lift radiator straight up DAN dm po CAUTION Ensure that the shroud remains clear during removal and installation of the radiator fyARvICO 07 2004 Rev OR 59 282000 28 5 VDC Ground Power Unit 3 0 REMOVAL INSTALLATION continued 3 7 ENGINE OIL CHANGE The following procedure should be used when changing the engine oil Change the full flow spin on filter each time the oil is changed NOTE lubricating oil is drained immediately after the unit has been run for some time most of the sediment will be in suspension and will drain readily CAUTION
71. otection devices should be used when the machine access doors are opened Prolonged exposure to fuel products and oils may cause skin irritation and all exposed parts of the body should be immediately washed following any service work on the GPU No loose clothing should be worn in the vicinity of the GPU when it is operating with the access doors open The GPU has rotating parts which can be a hazard in the vicinity of loose clothing The 24 volt batteries under certain circumstances can produce explosive gasses and therefore smoking or open flames should not be permitted in the vicinity of the batteries during servicing The GPU should not be operated in an enclosed area unless exhaust discharge is properly vented to the outside Exhaust gases can be deadly In the event that the GPU is fitted with a fast start system using ether then under no circumstances should personnel smoke or expose the ether to an open flame when performing maintenance or service tasks Failure to conform can cause fires or explosions and serious personnel injury USE OF THE TROUBLESHOOTING CHART Electrical schematic and wiring diagrams are included in the Appendices of this manual and should be referred to in conjunction with the other manuals attached in the Appendices of this manual First step in troubleshooting is to list the circumstances of the failure and what happened exactly prior to this occurrence With experience of the machine it will then become qui
72. ours depending on local conditions At this time the GPU should be sent to a qualified depot All work must be performed by qualified mechanical and electrical technicians and should include replacement of accessories as necessary SECTION 4 ILLUSTRATED PARTS LIST GENERAL The Illustrated Parts List is intended for use in provisioning requisitioning storing and issuing replaceable parts and in the identification of new and reclaimed parts It contains all parts information for which maintenance is economically feasible PARTS PROCUREMENT Parts are obtainable through ARVICO A Tronair Company or its authorized agents and distributors When ordering replacement parts please include the following information e Ground Power Unit Serial Number Y ear of Manufacture The part number and item number Quantity and Description 07 2004 62 282000 28 5 VDC Ground Power Unit Parts List CHASSIS WELDMENT ASSEMBLY REPLACEMENT PARTS PART NUMBER DESCRIPTION TY Z 5973 01 Chassis Weldment 2 40 000 0001000000000000000000 1 Z 5972 01 Fifth Wheel Assembly hub not included 1 746051 Re nee eer 1 15109 IL 2 15287 Hub Fifth Wheel
73. ping and inform ARVICO A Tronair Company and the shipper immediately of any discrepancies CAUTION It is important to mark damage on the bill of lading Any insurance claim will need this action to be taken on delivery 3 Check all fluid levels in the GPU and fill to operating condition as required 4 Inspect all cables and wires including terminations for tightness and security and check all wires for abrasion to insulation 5 Complete an inspection according to the inspection and service schedule Section 1 2 prior to starting the GPU 6 Select the power ON switch and insure that the fuel gage is reading correctly Make sure that the exhaust system is free of any obstructions Returning Unit From An Extended Storage 1 Remove all covers and tape 2 Drain and refill the radiator with correct solution of water ethyl glycol 3 Drain oil change oil filter and refill 4 Ifany additive isopropyl alcohol is in the fuel tank drain it and refill with diesel fuel DC Output Cable The cable is stowed in a cable tray for the purpose of preventing the cable jumping out of the cable tray during towing and being run over by the GPU rear wheels When stowing the cable always use the entire length of the cable tray and ensure that the connector is stowed facing downwards in one of the loops of the figure eight stowage pattern Cleaning The GPU should be washed with a very mild detergent to remove oil mist deposits and other pollutan
74. ply of the 28 5 VDC nominal is tapped from one rectifier The negative 28 5 VDC supply is derived from the rectifier via a shunt rated at 2500 amps This shunt provides a 0 to 50 millivolt signal to the DC controller The negative side of the 28 5 VDC is grounded to GPU chassis Power is supplied to the aircraft via two 25 feet 8 meter cables 95 square millimeter cross sectional area or 3 0 cable size 6 1 MANUAL CONTROL DC power from the GPU may be selected at the operators panel by selecting the DC ON switch When DC interlock is in the GPU position then the DC output cable will be live Only authorized personnel should use the equipment in this condition DC output voltage is in direct proportion to the AC input voltage to the rectifier assembly under no load conditions sensed locally 6 2 VOLTAGE CONTROL Under no load conditions the DC output voltage is in direct proportion to the AC input voltage to the rectifier From zero to full DC load the DC voltage will vary according to the voltage drop in the power supply cables In order to maximize the voltage at a nominal 28 5 VDC at the aircraft a PC Board senses the voltage at the aircraft and adjusts the AC voltage to the rectifier in direct proportion 6 3 OVER AND UNDER VOLTAGE LIMITS The DC control module mounted inside the instrument panel drawer has factory pre set limits to prevent damage to the aircraft or GPU The DC control module will disable the DC contactor if the DC voltage ex
75. rate from external 24 VDC 30 amp source Replace if faulty JVARVICO 07 2004 Rev OR 49 282000 28 5 VDC Ground Power Unit 2 USE OF THE TROUBLESHOOTING CHART continued TROUBLESHOOTING CHART SECTION 28 VDC CONTROL SYSTEM Engine running correctly Select DC ON contactor does not pull in Power will not switch on Over volt light contactor drops out Overload light on contactor drops out 28 VDC no load available on remote sensing zero volts indicated low volts warning lamp 28 VDC no load available on remote sensing load is Increased but ammeter shows zero amps GPU continually shuts down when all faults have been corrected CORRECTION Contactor inoperative Check 24 VDC power to K9 if fault persists check pilot relay this should latch in if faulty replace ON switch inoperative Check signal on P9 with meter between this pin and ground if no signal when DC ON button is pressed check switch and wiring operators panel Pilot relay Listen for click at J9 socket of engineers panel if none 30 amp inoperative remove relay panel change relay DC interlock faulty Check interlock at cable head and TB2 for continuity DC controller within the DCM set to provide 22 32 VDC at GPU based of cable head sensing of 28VDC 25ft or 8 meters of cable Consult ARVICO Tronair Company rating Wiring fault DC cable too lo
76. s an external potentiometer fitted to the instrument panel The potentiometer is graduated as a percentage of peak power and should be set to limit the current when starting a small engine Adjustment to limit the output power should always be undertaken by personnel with the facilities manual of the specific aircraft to be started AIRCRAFT CABLES The standard DC power cable assembly consist of 25 feet or 8 meters from the cable tray to the connector of two conductors with a cross sectional area of 95 square millimeters or 3 0 size Two voltage sensing wires and one interlock wire form part of the assembly The positive cable is attached directly to the center tap on the rectifier inside the GPU The negative or ground cable is attached directly to the shunt mounted on the rectifier assembly INTERLOCK The DC power from the GPU is disabled until the connector is correctly inserted into the aircraft or until the interlock switch on the engineers panel is in the GPU position The interlock on the DC connector is enabled when the third and smallest pin on the aircraft receptacle completes the circuit in the split pin connector Under no circumstances should the split pin be bridged in order to switch on the DC SERVICE There are no service requirements for the rectifier assembly or for the DC module Should the DC module be suspected of a malfunction a replacement module can be plugged into the instrument panel internally and operations resu
77. t be clearly identified and packed with the unit CAUTION Do not attempt to cinch down the engine alternator assembly to the chassis weldment as damage to the shock mounts will result CAUTION Use a forklift to raise the GPU unit Take care not to damage the fuel tank 2 Carefully cover the unit with visquene and secure it to the unit with shrink wrap Care should be taken to avoid the creation of water pockets Leave the towbar exposed so that the shipping activity may move the unit around during transit 3 GPU Tie Downs Holes are provided in the fork lift slots to allow the unit to be tied down for shipping YARVICO 07 2004 Rev OR 29 11 0 STORAGE 282000 28 5 VDC Ground Power Unit This section provides instructions for preparing the GPU for both short and long term storage When the unit is to be stored or removed from operation use the following procedures to protect the internal and external parts from rust corrosion and gumming in the engine fuel system 11 1 PREPARATION FOR STORAGE 11 1 1 Short Term Storage less than 3 months The following steps are recommended if the unit is to be placed out of services for three months or less The unit should be prepared for storage as soon as possible after being removed from service 1 2 Refer to the vehicle owners guide and maintenance manuals for instructions on vehicle storage requirements sure that the mixed coolan
78. t be traced to this module then it can be replaced with the faulty unit returned to the factory No service knowledge is required to change the complete electronics The control module contains the electronics to provide control of the AC generator field winding safety shutdown circuits low oil pressure high engine temperature and overspeed and interlock and delay circuitry to ensure correct operating sequences 5 MONITORING CIRCUITS 5 1 1 Low Fuel Level A circuit is provided to indicate a low fuel condition This monitors the voltage from the fuel tank sensor and compares it with a preset threshold equivalent to 1 8 full The voltage from the tank sensor varies as the plus 24V battery voltage varies and to compensate for this the circuit monitors the plus 24V supply and alters the threshold accordingly 5 1 2 Lamp Drivers Each of the monitoring circuits described above connects to a lamp driver such that a high level at the monitor output indicating an alarm will turn the lamp driver on The lamp drivers provide a current sink to when on the other end of the lamp connects to the plus 24V supply Apart from the low fuel lamp which is driven directly the other alarms connect via a latch which is used to hold the first alarm so that even after the alarm has cleared it is evident which one caused a shutdown It freezes on the first alarm to occur thus indicating the primary or first alarm as opposed to subsequent ones which may c
79. t is adequate for the lowest anticipated temperatures during time of storage Add oil to the FULL mark level on dip stick Drain a small portion of fuel from fuel tank by removing drain plug at of tank This will remove any water that may have accumulated on the of the fuel tank NOTE Do not drain fuel system or crankcase Install new fuel filters Fill fuel tank to capacity A full fuel tank prevents moisture laden air from entering the tank during the cool periods Close all access doors to minimize build up of foreign particles in the unit Store unit in a building that is dry If the storage area has high humidity levels place moisture absorbing chemicals inside the unit 11 1 2 Long Term Storage Special precautions are necessary to protect the GPU 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 requiring special attention are given below The unit should be prepared for storage as soon as possible after being removed from service 1 pa Drain the cooling system Flush with clean water Refill with 50 50 mix of water and antifreeze and add a rust inhibitor or mix according to ratio for temperature as shown in Chapter 2 Section 1 Table 1 Circulate the coolant by operating the engine until the normal operating temperature
80. tall on the mounts Take care to jockey the fan into the radiator shrouds without damaging the fan blades Cummins engine only e Insert the hold down bolts with the front engine bolt first Bolts are tightened until rubber shock mount forms a doughnut above the washer 3 3 2 Engine Alternator Attachments Re attach all hardware and components NOTE Clamps for exhaust and intake system must be securely fastened and torqued 34 ALTERNATOR REMOVAL FROM ENGINE See Figures 15 16 17 The engine alternator assembly may be disassembled from each other when removed from the unit 1 Attach lift chain to eye bolt Remove all slack in chains to prevent the generator from dropping when unbolted from engine CAUTION Ensure engine is firmly supported on all three mount points Remove the generator ventilation screen 2 Remove 8 bolts that secure the flex coupling to the flywheel and gently slide away from Engine 3 Uncouple the engine and alternator by removing the 12 bolts around the generator casing CAUTION Take care as alternator armature is now unsupported 3 0 Removal installation continued on following page 07 2004 Rev 58 282000 28 5 VDC Ground Power Unit 3 0 REMOVAL INSTALLATION continued 3 5 ALTERNATOR INSTALLATION TO ENGINE See Figures 15 16 17 CAUTION Utilize torque values for general assembly when attaching the engine to alternat
81. te grease containing an E P additive be used This grease should pass a load bearing test of 40 pounds minimum with a base pour point at minus 10 1 0 Servicing continued on following page YWARVICO 07 2004 Rev OR 33 282000 28 5 VDC Ground Power Unit 1 0 SERVICING continued 13 INSPECTION SCHEDULE 1 3 1 Preventive Maintenance Schedule The following table is provided as guidance to establish a proper service schedule It is recommended to change the engine oil filter after the first 50 hours of operation after the machine has first been delivered INSPECTION AND SERVICE SCHEDULE HOURS 20 Y e ame 07 2004 34 282000 28 5 VDC Ground Power Unit component pany wo so soo py py Battery Fluid O alg j x mem x eam A ES 1 3 Inspection schedule continued on following page AVARYICO 07 2004 Rev OR 35 282000 28 5 VDC Ground Power Unit 13 INSPECTION SCHEDULE continued 1 3 22 Delivery Inspection and Preparation of Unit 1 Remove all packing material from GPU Remove the battery inter connect cable strapped to the aft frame and attach across the batteries 2 Carefully inspect the complete unit for any damage that may have occurred during ship
82. te easy to determine what has actually happened to which component The charts list information under three headings e Fault e Cause e Correction 07 2004 Rev OR 38 282000 28 5 VDC Ground Power Unit pg 9 K14 9 21 OPTIONAL LOW COOLANT RELAY EXCITATION TRANSFORMER AND TB SPEED CONTROL Figure 14 Component Arrangement JVARVICO ARVIC 07 2004 Rev OR 39 282000 28 5 VDC Ground Power Unit 2 USE OF THE TROUBLESHOOTING CHART continued PS HARNESS WIRE WIRE SIZE NO PIN AWG FROM TO DC Plug TB2 1 J8 A TB1 1 P10 A DC Volt Meter P A DO scs Rectifier Plus 2 2 J8 C TB1 3 PC10 C Shunt Plus J8 D TB1 7 Ammeter Plus P10 G Buen Rec Thermal Switch J8 E P10 N Fuel Sender ees J8 H TB1 11 P10 c Fuel Gauge 20 Low Oil Pressure Switch J8 K P10 f 31 235 Less 20 5 iie High Coolant Temp Switch J8 L P10 g 49 20 ies Coolant Temp Sender J8 M Coolant Temp Gauge 50 20 Engine Alternator J8 N Tachometer Po 20 Oil Pressure
83. ted to the engine should be replaced regularly in accordance with the maintenance procedures in this manual 311 COOLING SYSTEM See Figure 7 The radiator used for the Cummins engine is carefully designed to provide adequate cooling regardless of engine size and operating altitude The radiator rests on 1 4 inch thick rubber strip and 18 located by two 1 4 inch diameter pins which pass through holes in the chassis The top tank of the radiator is supported by a vibration isolator to the forward frame forming the exhaust assembly The radiator is fitted with 2 25 inch diameter coolant outlet in the base tank and a 1 75 inch diameter cooler intake at the header tank The radiator is fitted with an 8 psi sealing cap and an overflow tube which allows any coolant overflow to pass through this tube exhausted at the of the GPU housing The radiator is fitted with a drain cock in the lower tank which when opened 90 degrees will drain the radiator and cooling system below the chassis via a dump line into a receptacle so that the coolant may be recycled No service is required for the radiator assembly other than to ensure that the fins are undamaged and that any leaks etc are quickly repaired 4 0 INSTRUMENT PANEL See Figures 8 9 amp 10 The operators panel is installed in a pull out drawer assembly in the rear louver Access to the back of the instrument panel and all other electronics is achieved by pulling this drawer assembly out The front
84. tive and the power drive conductors to the contactors 4 0 Instrument panel continued on following page 07 2004 Rev 37 4 0 5 0 282000 28 5 VDC Ground Power Unit INSTRUMENT PANEL continued 43 GOVERNOR Governor connections are made by screw connections to pigtails A twisted pair connects directly to the magnetic pickup in the fly wheel housing 44 CONTACT BREAKERS Contact breakers are printed with the current carrying capacity Six CB s are mounted on the right side of the instrument panel 4 5 TEST BUTTONS The GPU is fitted with three circuit test buttons as follows 1 over volts 2 under volts 3 over load and a reset button to cancel faults entered into the equipment These test buttons feed an exceedance value into the electronic circuits on these key functions The electronic module will then switch on warning lamps on the instrument panel to test the monitoring circuits To return the machine to normal operating mode press the reset button DC CONTROL MODULE MICROPROCESSOR The control module is housed in a separate sealed box mounted on four rubber feet and secured by two rubber draw latches A single cable connects directly into the instrument drawer components The entire control module is a microprocessor which cannot be serviced in the field The module is covered by a five 5 year warranty and is replaceable in its entirety in less than a minute Should a faul
85. ts All stainless steel parts may be wiped clean with a damp cloth After cleaning ensure that tow bar and brake pivot pins have not been washed clean of lubricant These pins may be oiled occasionally to ensure proper lubrication and prevention of corrosion YARVICO 07 2004 Rev OR 36 282000 28 5 VDC Ground Power Unit 1 3 INSPECTION SCHEDULE continued 1 3 6 Door Removal and Adjustment See Figure 13 The two access doors can be removed for servicing and then after re installation be adjusted for correct fit 1 3 7 Wheel Hub Lock Nuts After a run in period of five hours these nuts should be re torqued to 85 LB FT of torque 115 6 N m CAUTION Figure 13 Failure to re torque the hub lock nuts can Lead to Door Removal amp Adjustment premature failure of the rims and or racking of the hub due to out of balance loading CAUTION Do not tow the unit at speeds in excess of the placard speed Excess speed can lead to excessive stress on the running gear and Premature failure To Adjust Door 1 Loosen nuts 1 2 Raise or lower door and hold in position 3 Re tighten nuts To Remove Door 1 Remove lower hinge pin 2 2 Swing door out 3 Lower door from upper hinge pin 2 0 TROUBLESHOOTING This section outlines the probable cause of a malfunction The GPU is designed for fast fault detection Assuming that all daily checks have been undertaken and the GPU is properly serviced regarding
86. twin axles installed with leaf type suspension springs to reduce vibration during towing of the unit As an option the rear axle has two expanding shoe brakes that are operated by a hand brake lever mounted on the lower front right side Wheels The tires fitted to the GPU are 4 ply 5 70 x 8 heavy duty and require an inflation pressure of 50 psi This should be maintained at all times for proper handling and control of tire wear WARNING Always adhere to the correct tire pressure as shown on the equipment as damage to the GPU or injury to personnel may occur 2 3 10 2 3 11 2 3 12 Most components described above in this section on the chassis are available as service replacement items as described in the parts section of manual Side Impact Bumpers See Figure 1C The GPU is fitted with full length side impact bumpers These bumpers are constructed of rectangular steel tubing and will take a considerable side load before deformation Fore and aft protection is provided by two triangular frames mounted either end of the side swipe bumper The complete assembly which also acts as the cable tray and as mud guards for the wheels Fore and Aft Bumpers The rear of the GPU is protected by a straight rectangular steel tube bumper fitted with two rubber buffers The buffers will absorb small parking loads without damage to the GPU The cross bumper is able to transfer rear bump loads directly down the chassis tubes The buffers ar

Operation & Service Manual - Victory Ground Support Equipment

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Operation &amp; Service Manual - Victory Ground Support Equipment

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Operation & Service Manual - Victory Ground Support Equipment