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TLD GPU-406, Manual

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TLD GPU-406 Manual Download Page 23

 

Creation: 01.31 - 2014 

                     

       2-3-1

 

 
  
 

GPU - 406 
GPU - 409 

 

3. Removal / Installation 

This section explains the removal and installation of major components. Detailed instructions and diagrams 
help the mechanic, while cautions and warnings make the mechanic aware of potential hazards.  

 

 

 

 

 
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

WARNING: 

UNIT MUST BE DISCONNECTED AND SHUT-OFF BEFORE 
ATTEMPTING TO WORK ON OR REMOVE ANY COMPONENT.  
DISCONNECT THE ENGINE BATTERY TO PREVENT 
ACCIDENTAL ENGINE STARTING OR SHOCK.  

 

Property of American Airlines

Summary of Contents for GPU-406

Page 1: ...Creation 01 31 2014 GPU 406 GPU 409 CHAPTER 2 MAINTENANCE MINOR REPAIR P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 2: ...g 2 3 3 C Electrical Box Removal Installation 2 3 4 D Radiator Removal Installation 2 3 4 E Cable Removal Installation 2 3 5 4 Troubleshooting 2 4 1 A General Practice 2 4 1 B Troubleshooting Chart 2...

Page 3: ...Creation 01 31 2014 GPU 406 GPU 409 This page intentionally left blank P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 4: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 5: ...NCE NOTE Wet stacking Wet stacking is common and may be expected in diesel engines operated under light load Light loads do not allow the engine to reach the most efficient operating temperature for c...

Page 6: ...fth wheel hub Repack bearings every 24 months Steam wash engine radiator 250 hours Torque wheel lug nuts 500 hours or 6 months Repack bearings on wheel hubs and fifth wheel hub 24 months Inspect cable...

Page 7: ...048606 15w40 1048606 15w40 API CJ 4 or better oil Engine Fuel Filter 1037763 P2 Fleetguard FS19732 1076485 P1 Fuel filter water separator 1037763 P1 Fleetguard FF63004 1076484 P1 Fuel Filter Diesel Ex...

Page 8: ...the Manufacturer s Manual 5 Changing Engine Oil Filter Follow the instructions in the Manufacturer s Manual C Air Cleaner Maintenance The air filter contains a replaceable element refer to Chart 1 A...

Page 9: ...low straightener is removed the inlet cover is exposed Remove the inlet cover by unlatching the 4 metal latches on the right side of the cover and pulling the cover away from the air cleaner 4 The pri...

Page 10: ...Creation 01 31 2014 2 1 6 GPU 406 GPU 409 FIGURE 1A TIER 3 AIR FILTER FIGURE 1B TIER 4I AIR FILTER END CAP LATCHES P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 11: ...ll damage the catalyst permanently and void the engine warranty Further information on fuel specifications can be found in the Engine Manufacturer s Manuals 2 Fuel Filter Refer to the Manufacturer s L...

Page 12: ...eneral Motor s performance specification GM1899M or be formulated to GM6038M specification or equivalent Further information on coolant requirements may be found in the Manufacturer s Literature in Ch...

Page 13: ...leys 9 Remove the belt by moving it over the fan blades 10 Installation is the reverse of the removal G Generator Maintenance The 400 Hz generator requires no maintenance or service other than periodi...

Page 14: ...ce a 24 VDC system which supplies power for operation of the engine electrical system and the clearance and panel lights 1 Battery Location The batteries are located on the left side of the unit by th...

Page 15: ...ontainer I Cables and Cable Heads 1 Cables Inspect cable for any insulation damage frayed copper and any overheated areas If any of these are found the cable should be replaced 2 Cable Plugs a Inspect...

Page 16: ...lue into the fill port indicated with the DEF or AdBlue label and the blue cap Avoid overfilling the DEF tank by watching the gauge on the generator controller screen and stopping the fill when the ga...

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Page 18: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 19: ...or signs of rust or corrosion Inspect for signs of leakage Inspect hoses for deterioration or cracking 4 Exhaust System a Inspect muffler and pipe work for signs of approaching failure b Check for any...

Page 20: ...working correctly 1 Monitoring Instruments Ensure the Generator Control Module s display is in proper working condition each time the unit is started 2 Protective Circuits Check operation of all prote...

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Page 22: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 23: ...instructions and diagrams help the mechanic while cautions and warnings make the mechanic aware of potential hazards WARNING UNIT MUST BE DISCONNECTED AND SHUT OFF BEFORE ATTEMPTING TO WORK ON OR REMO...

Page 24: ...4 Disconnect the fuel lines and plug the ends 5 Disconnect the electrical connector where the engine harness plugs into the electrical box Tag and disconnect any wires to frame mounted electrical comp...

Page 25: ...t the generator from the frame cross member 4 Attach a lifting hoist to the generator lifting point on the top of the engine Lift the generator end up slightly and place a wood block under the engine...

Page 26: ...tcock located on the radiator 2 Chock the rear wheels and release the tow bar to the down position and open the front nose of the unit by unlatching the body cover 3 Remove the radiator hoses 4 Unbolt...

Page 27: ...able is connected to 4 Loosen the terminal nuts that hold the A B and C phase wires to the contactor Loosen the nut that holds the Neutral wire to the distribution block 5 Remove cable assembly from u...

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Page 29: ...vel and the engine oil pressure should normal Unit Electrical System Check the battery disconnect switch emergency stop switch and F2 fuse Check all electrical connections for loose or broken wires E...

Page 30: ...e start screen press the blue button to start the engine A bar graph should appear to indicate that the engine cranking Make sure that the starter relay K4 is closing Replace the GCM if this does not...

Page 31: ...fuel Tighten all fittings and connections Replace any damaged hoses or fuel lines D Plugged or defective fuel filter D Check the fuel pressure with an engine diagnostic tool Refer to the engine manua...

Page 32: ...nections in the generator control circuit B The screen displays a power fault signal frequency voltage or overload B Perform a check for anything that may change the output of the GPU This includes fa...

Page 33: ...ct the engine manufacturer or TLD if necessary I Defective Fuel Pump I Replace the pump Contact the engine manufacturer 6 Engine is unsteady A Insufficient fuel A Check the fuel supply and return line...

Page 34: ...DY 7 Engine lacks power D The GCM is reporting diagnostic trouble codes D The engine may require maintenance or repair Refer to chapter 5 to troubleshoot engine performance problems Contact the engine...

Page 35: ...he output negative is grounded to the generator C Poor or no connection between the GCM Field and Field terminals and the exciter and terminals C Correct the wiring and check the connections D Then en...

Page 36: ...tions to the voltage sensing terminals from the contactor to the GCM A Correct the wiring to the regulator B Poor connections to the neutral sensing terminals from the distribution block to the GCM B...

Page 37: ...gine is not producing full power D Refer to chapter 5 to troubleshoot engine performance issues Contact the engine manufacturer or TLD if necessary E The engine charging voltage is less than 24VDC E R...

Page 38: ...ctor coil terminals X and Y on K16 or K17 If the contactor does not close then replace the contactor C Faulty contactor C Apply 24VDC across the X and Y terminals of the contactor If the contactor doe...

Page 39: ...o chapter 5 to troubleshoot engine problems Contact the engine manufacturer or TLD if necessary B Low fuel shut down has occurred B This is a normal operation for units equipped with a low fuel shutdo...

Page 40: ...contactor coil terminals X and Y on K16 or K17 If the contactor does not close then replace the contactor C Faulty contactor C Apply 24VDC across the X and Y terminals of the contactor If the contact...

Page 41: ...o chapter 5 to troubleshoot engine problems Contact the engine manufacturer or TLD if necessary B Low fuel shut down has occurred B This is a normal operation for units equipped with a low fuel shutdo...

Page 42: ...the wiring B The engine speed is set too low B Increase the engine speed setting within the GCM C The engine ECM is faulty C Contact the engine manufacturer Replace the ECM if necessary D The engine i...

Page 43: ...D OVERLOAD A There is too much load on the GPU A Reduce the load at the aircraft B The GCM is faulty B Replace the GCM C A faulty connection exists between the GCM and the voltage sensing terminals on...

Page 44: ...r neutral and 28VDC negative bus E Correct the wiring F A poor connection exists between the GCM and the voltage sensing wire F Correct the wiring G A poor connection exists between the GCM and the ge...

Page 45: ...ween thermal switch S30 and the GCM B Correct the wiring C The GCM is defective C Replace the GCM 5 Pressing the GREEN button to activate the 28VDC output causes the GCM to display CONTACTOR STUCK A A...

Page 46: ...is set too low C Increase the setting Contact TLD as this changes the GCM calibration D The GCM is limiting current D Increase the limit if necessary This setting appears when the 28VDC circuit is in...

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Page 48: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 49: ...OCKET HEAD SET SCREW S S CAP MACH NO 6 9 LB IN 9 6 LB IN NO 8 16 LB IN 20 LB IN NO 10 30 LB IN 23 LB IN 1 4 6 9 9 12 5 12 5 13 14 70 LB IN 75 LB IN 5 16 11 17 18 24 24 28 30 12 11 3 8 19 30 31 43 43 4...

Page 50: ...Creation 17 10 2013 2 5 2 GPU 406 GPU 409 RECOMMENDED ASSEMBLY TORQUE VALUES METRIC BOLTS CHART 6 P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 51: ...time the 28VDC output is used Maintenance Personnel Adjustments 400 Hz AC voltage setting Units are factory set at 115 VAC no load A large setting range is provided to allow for proving the over and u...

Page 52: ...drop compensation The goal is to maintain 28 5 VDC at the DC load bank when applying an 800 amp load to the GPU assuming a standard 4 0 30 cable is being used The units are factory set at approximate...

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Page 54: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 55: ...HR Heater K Relay L Solenoid or governor actuator P Port or plug R Resistor rheostat or sender S Switch T Transformer or thermostat TB Terminal block V Valve VR Voltage regulator W Jumper X Receptacle...

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Page 57: ...GCM2VXXX hex where XXX is the version number For example GCM2V285 hex is the version 2 85 firmware 3 Plug the flash drive into an available USB port on the computer where the update file is located A...

Page 58: ...ts original location into the window of the root folder of the flash drive accessed in the previous step The file is successfully copied when it appears in the root folder Ensure that this is the only...

Page 59: ...fely remove the flash drive from the computer using the Eject command The way this is accomplished on different versions of Windows can vary After the computer indicates that it is safe to remove hard...

Page 60: ...insert the USB flash drive with the update file into the USB port on the right side of the GCM2 The GCM2 will automatically detect the flash drive and a series of message will be displayed When the G...

Page 61: ...Creation 1 31 2014 2 7 5 GPU 406 GPU 409 Figure 7 USB Port on the GCM2 P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 62: ...ow the TLD logo Verify that this is the latest version The GCM2 will automatically detect the flash drive again When it arrives at the prompt Done Remove USB Memory The USB flash drive can be removed...

Page 63: ...ic switch contact inside the GCM2 and allow the adjustments menu to be accessed if the rotary dial is pushed in and held for two seconds Please note that the window for pushing and holding down the ro...

Page 64: ...Creation 1 31 2014 2 7 8 GPU 406 GPU 409 Figure 9 Rotary Dial with Built In Pushbutton P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 65: ...Creation 1 31 2014 2 7 9 GPU 406 GPU 409 Figure 11 Adjustment Menu Figure 10 Magnetic Switch Location P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 66: ...nged GCM2 into a GPU machine The LOAD DEFAULTS should be used first for initial setup It provides a base line setup in which all of the adjustable parameters are set to the normal value for the type o...

Page 67: ...ettings for a 90 KVA GPU with a single output cable and a 28VDC output change the setting to 1042 3 Press the rotary dial button down to activate the settings All of the adjustment settings associated...

Page 68: ...ecs Sets the maximum time in seconds that the ground power unit can spend producing an amount of AC or DC Current below the user adjustable threshold See Lowload Timer Amps Once this time limit is rea...

Page 69: ...efaults function as described above they may be viewed or adjusted individually if required but they do not normally require adjustment unless specified Note Some parameters affecting AC Voltage regul...

Page 70: ...ed in 30 counts per Volt Delay Max Hz Sets the time delay in seconds before the output unlatches due to an over frequency fault Default 0005 Delay Min Hz Sets the time delay in seconds before the outp...

Page 71: ...n Default 3 Idle RPM Enable Enable 1 or Disable 0 the GCM2 control of the engine RPM at Idle For Tier4f GPU fitted with Exhaust After Treatment this setting will automatically change 0 Disable For uni...

Page 72: ...ated on a calibrated DC Volt Meter Default 2343 AC Line Drop This adjustment sets the AC output voltage increase when the GPU is under load Default 0006 DC Line Drop This adjustment sets the DC output...

Page 73: ...lding down the rotary dial The GPU is now ready for use The following lists all of the parameters in the order they are shown on the Adjust Menu as the knob is rotated Parameters List at V2 85 DC Line...

Page 74: ...n RPM Language CAL Volts A CAL Volts B CAL Volts C CAL Amps A CAL Amps B CAL Amps C CAL Watts Warm Up Seconds Cool Down Seconds Idle Timer Seconds Lowload Timer Secs Lowload Timer Amps Low Fuel Option...

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