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       Creation: 1.31 – 2014 

                                                                                   2-7-13  

 

GPU - 406 
GPU - 409 

 

90KVA ACOP Limit

 – Set to Off or On, on GPU with 2 AC Outputs, Limit the overload to 90KVA when 

only one OP is switched ON. Default = On. 

 

DC Microswitch Enable

 – Set to Off or On, on GPU with 28.5VDC TR option, if optional DC Cable 

Micro-switch is fitted change this to ON. Function is to switch OFF the DC Output if the DC Cable is un-
plugged from the aircraft. Uses Pin 35 Input to GCM2. Default = Off (not fitted).

 

 

Remote Control Enable

 – Set to Off or On. On Tug-Mounted GPU, a Remote Control Panel is fitted in 

the drivers cab with two illuminated push switches to control the Engine Start/Stop and AC400Hz 
Off/On. The switches connect to Pins 35 and 36 Inputs to GCM2 respectively. The Engine Run Beacon 
output drives the engine start indicator light and  flashes to indicate starting or stopping, when this 
option is used. Default = Off (no remote panel fitted). 

 

Ground Power Unit characteristics 

 

These parameters are normally configured using the “Load Defaults” 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 regulation are set differently for Build A and later 
Build B hardware GCM2 with serial numbers of 600 or higher.  The firmware will detect which 
hardware build is used and set the defaults automatically when “Load Defaults” is used. 

 

KVA Machine

 – Set this number to the proper KVA rating (i.e. 90 for 90KVA units). This setting 

affects the allowed overload output, and the model designation that appears at the top left of the 
main operation screen. It also affects the output current sensing scaling.  
Default = 120kVA but will be set by the Load Defaults and not need further adjustment.  

  

Ena AC Output

 – Change this to the available number of 400 Hz AC outputs (00, 01, or 02). 

Default = 02  

  

Ena DC Output

 – Change this to the available number of 28.5VDC outputs (00 or 01). Default = 00  

 

Idle RPM

 – Change this to the appropriate engine idle RPM. Default = 1000  

Note- The Idle RPM adjustment has no effect on machines fitted with Tier4f exhaust after 
treatments 

Property of American Airlines

Содержание GPU-406

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 17: ...Creation 01 31 2014 2 1 13 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...

Страница 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...

Страница 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...

Страница 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...

Страница 21: ...Creation 01 31 2014 2 2 3 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 28: ...Creation 01 31 2014 2 3 6 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 47: ...Creation 01 31 2014 2 4 19 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 53: ...Creation 17 10 2013 2 5 3 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...

Страница 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...

Страница 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...

Страница 56: ...Creation 1 31 2014 2 6 2 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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