112820c technical revor 06-06 - tronair

Operation & Service Instructions

Technical Manual

Model: 112820C 28.5 VDC Ground Power Unit

02/2006 –− Rev. OR

Tronair, Inc. 1740 Eber Road

Holland, Ohio 43528-9794 USA

Telephone: (419) 866-6301 • 800-426-6301 Fax: (419) 867-0634

Web Site: www.tronair.com E-mail: [email protected]


06/2006 − Rev. OR

TABLE OF CONTENTS

PAGE 1.0 Product Information .......................................................................................................................................... 1

1.1 Description ............................................................................................................................................. 1 1.2 Complete Model & Serial Number ......................................................................................................... 1 1.3 Manufacturer .......................................................................................................................................... 1 1.4 Function ................................................................................................................................................. 1 1.5 Requirements......................................................................................................................................... 1

2.0 Safety Information ............................................................................................................................................ 1 2.1 Usage And Safety Information ............................................................................................................... 1 2.2 Explanation Of Warning & Danger Signs............................................................................................... 2 2.3 Component Safety Features .................................................................................................................. 2 2.4 Functional Safety Features .................................................................................................................... 3 2.5 Personal Protection Equipment ............................................................................................................. 3 2.6 Safety Guidelines ................................................................................................................................... 3 2.7 General Comment.................................................................................................................................. 3 2.8 General Comment.................................................................................................................................. 3

3.0 Preparation Prior To First Use.......................................................................................................................... 3 3.1 General .................................................................................................................................................. 3 3.2 Pre-Use Inspection................................................................................................................................. 3

4.0 Training............................................................................................................................................................. 4 4.1 Training Requirements........................................................................................................................... 4 4.2 Training Program ................................................................................................................................... 4 4.3 Operator Training ................................................................................................................................... 4

5.0 Operation.......................................................................................................................................................... 4 5.1 Operating Parameters............................................................................................................................ 4 5.2 Numerical Values ................................................................................................................................... 4

5.2.1 Model: 112820C........................................................................................................................ 4 5.2.2 Physical..................................................................................................................................... 4 5.2.3 Engine ....................................................................................................................................... 4 5.2.4 Chassis ..................................................................................................................................... 5 5.2.5 Alternator................................................................................................................................... 5

5.3 Location & Layout Of Controls ............................................................................................................... 6 5.3.1 Control Panel (External)............................................................................................................ 6 5.3.2 Control Panel (Internal) ............................................................................................................. 9 5.3.3 Controls, Engine Compartment............................................................................................... 10

5.4 Start Up Procedures............................................................................................................................. 10 5.4.1 Pre-Use Inspection.................................................................................................................. 10 5.4.2 Starting Sequence................................................................................................................... 11 5.4.3 Supplying DC Power To The Aircraft ...................................................................................... 11 5.4.4 Emergency Shut Down Procedure.......................................................................................... 12

5.5 Description Of Alarm Systems ............................................................................................................. 12 5.5.1 DC Over Voltage Lamp........................................................................................................... 12 5.5.2 DC Under Voltage Lamp......................................................................................................... 12 5.5.3 DC Over Current Lamp ........................................................................................................... 12 5.5.4 Low Oil Pressure Lamp........................................................................................................... 12 5.5.5 Over Temperature Lamp......................................................................................................... 12 5.5.6 Optional Low Coolant Lamp.................................................................................................... 12 5.5.7 No Fuel Lamp.......................................................................................................................... 13 5.5.8 Optional Fan Belt/Alternator Failure Lamp ............................................................................. 13 5.5.9 Optional Green Running Light ................................................................................................ 13

5.6 Safety Shutdown And Interlock Circuits............................................................................................... 13 5.6.1 Start Circuit ............................................................................................................................. 13 5.6.2 Stop Circuit.............................................................................................................................. 13 5.6.3 Engine Fault Circuits ............................................................................................................... 13 5.6.4 DC Load Monitoring Circuits ................................................................................................... 14 5.6.5 DC Fault Circuits ..................................................................................................................... 14

6.0 Packaging And Storage.................................................................................................................................. 14


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6.1 Packaging Requirements..................................................................................................................... 14 6.2 Handling ............................................................................................................................................... 14 6.3 Packaging Protection ........................................................................................................................... 14 6.4 Labeling Of Packaging......................................................................................................................... 14 6.5 Storage Compatibility ........................................................................................................................... 15

6.5.1 Short Term Storage (Less Than 3 Months) ............................................................................ 15 6.5.2 Long Term Storage ................................................................................................................. 15

7.0 Transportation ................................................................................................................................................ 16 8.0 Servicing......................................................................................................................................................... 16

8.1 General (Daily Checks) ........................................................................................................................ 16 8.2 Short Term Preventive Maintenance Schedule ................................................................................... 17

9.0 Maintenance/Illustrated Parts Lists ................................................................................................................ 19 9.1 General (Daily Checks) ........................................................................................................................ 19 9.2 Filters.................................................................................................................................................... 19 9.3 Engine Cooling System........................................................................................................................ 20 9.4 Engine Sensors.................................................................................................................................... 21 9.5 Air Intake System................................................................................................................................. 22 9.6 Exhaust System ................................................................................................................................... 23 9.7 Engine/Alternator/Engine Mounting ..................................................................................................... 24 9.8 Batteries ............................................................................................................................................... 26 9.9 Fuel Tank ............................................................................................................................................. 27 9.10 Actuator................................................................................................................................................ 28 9.11 Elecrical Assemblies ............................................................................................................................ 30

9.11.1 Rectifier/Contactor/Battery Switch/Output Cable.................................................................... 30 9.11.2 Instrument Panel Drawer (Outside) ........................................................................................ 32 9.11.3 Instrument Panel Drawer (Inside) ........................................................................................... 34

9.12 Sheet Metal Components .................................................................................................................... 36 9.12.1 Instrument Panel Mounting ..................................................................................................... 36 9.12.2 Outer Sheet Metal ................................................................................................................... 37

9.13 Replacement Labels ............................................................................................................................ 38 10.0 Trouble Shooting ............................................................................................................................................ 39 11.0 Provision Of Spares........................................................................................................................................ 48

11.1 Source Of Spare Parts ......................................................................................................................... 48 11.2 Recommended Spare Parts Lists ........................................................................................................ 48

1.2.1 Spare Electrical Parts.............................................................................................................. 48 12.0 In Service Support .......................................................................................................................................... 48 13.0 Warranty ......................................................................................................................................................... 48


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REVISION DATE TEXT AFFECTED

OR 06/2006 Original Release


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This product can not be modified without the written approval of Tronair, Inc. Any modifications done without written approval voids all warranties and releases Tronair, Inc., it suppliers, distributors, employees, or financial institutions from any liability from consequences that may occur. 1.0 PRODUCT INFORMATION

1.1 DESCRIPTION

Ground Power Unit Model Number: Equipment Type:

112820C................................. Diesel Powered GPU, 28.5 VDC Output

1.2 COMPLETE MODEL & SERIAL NUMBER

Reference nameplate on unit.

1.3 MANUFACTURER

TRONAIR, Inc. Telephone: (419) 866-6301 or 800-426-6301 1740 Eber Road Fax: (419) 867-0634 Holland, Ohio 43528-9794 USA Email: [email protected] Website: www.tronair.com

1.4 FUNCTION

The 112820C Ground Power Unit (GPU), is a diesel powered unit designed to serve as a 28.5 volt DC power source for parked aircraft. It can provide 800 amps continuous for aircraft servicing, and up to 2000 amps peak for starting. The Current Limit (Soft Start) feature allows the user to select current limits for operations requiring current limit below the maximum output.

1.5 REQUIREMENTS

The GPU can run on Diesel Fuel or Jet A. (Check to see if local restrictions allow the use of Jet A for ground service equipment.) The fuel filter is a disposable lubricity additive type designed to supply adequate lubrication to the fuel pump when running on Jet A. The filter must be changed every 250 hours of running time.

2.0 SAFETY INFORMATION

WARNING! CALIFORNIA PROPOSITION 65 – DIESEL ENGINES. Diesel engine exhaust and some of its constituents are known by the State of California to cause cancer, birth defects, and other reproductive harm.

2.1 USAGE AND SAFETY INFORMATION

The GPU provides 28.5 Volts DC for performing aircraft service and maintenance.

To insure safe operations please read the following statements and understand their meaning. Also refer to your equipment manufacturer’s manual for other important safety information. This manual contains safety precautions, which are explained below. Please read carefully.

WARNING! — Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning notice is ignored.

CAUTION! — Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution notice is ignored.

2.0 Safety Information continued on following page


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2.0 SAFETY INFORMATION (continued)

2.2 EXPLANATION OF WARNING & DANGER SIGNS

WARNING! Accidental Starts! . Always turn off and lock out the battery switch before servicing this GPU. Only qualified service personnel may service this equipment. Read and understand the technical manual before servicing this equipment. WARNING! Rotating Parts! Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the GPU with doors open or panels and guards removed. WARNING! Electrical Shock! Caution: This GPU produces voltages and current sufficient to cause burns and death by electric shock! Always inspect cables and plugs for damage before use. Do not use if damaged. Always turn DC power to off before connecting or disconnecting cables. The human body has decreased resistance when wet; keep hands, feet and clothes dry when operating electrical equipment. Do not open doors or remove panels while the GPU is running. High current electrical components will be exposed. Always turn off and lock out the battery switch before servicing this GPU. WARNING! Hot Surfaces! Engine components such as turbo chargers, exhaust pipes, and mufflers will remain hot after the engine has been shut down. Allow engine to cool before servicing. WARNING! Batteries! Batteries give off flammable hydrogen gas and can explode if ignited. When servicing, do not allow arcing, sparks, or open flame near the battery. Acid and arcing from a ruptured battery can cause fires and additional damage. WARNING! Fuel Hazard! Use only approved containers for transferring fuel. Shut down GPU before refueling. Fires and explosions can occur if the fuel tank is not grounded. Ground fuel tank before and during fuel transfer. Clean up all fuel spills immediately. WARNING! Carbon Monoxide! Engine exhaust fumes can kill. If indoors, always pipe or vent exhaust fumes to a suitable exhaust duct. Never locate engine exhaust near air conditioner intake ducts. WARNING! CALIFORNIA PROPOSITION 65 – DIESEL ENGINES Diesel engine exhaust and some of its constituents are known by the State of California to cause cancer, birth defects, and other reproductive harm. No Access for Unauthorized Persons! Only qualified personnel may service this equipment. Read Operation Manual! Read and understand the operation manual before using this equipment. Failure to follow operating instructions could result in death or serious injury. Read Technical Manual! Read and understand technical manual before servicing. Lockout! Shut down engine. Turn off and lockout battery switch before servicing. If working near the batteries or the battery switch, also disconnect the negative battery cable, at the battery, on the fuel pump side of the engine. Loud Noise Hazard! Ear protection must be worn while operating this equipment.

2.3 COMPONENT SAFETY FEATURES

• Fan guard • Circuit breakers • Muffler guard • Hand actuated rear drum brakes • Sheet metal panels


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2.0 SAFETY INFORMATION (continued)

2.4 FUNCTIONAL SAFETY FEATURES

• Emergency shut off switch • Over voltage protection circuit • Timed engine shut down • Cable interlock protection circuit • Over current protection circuit • Battery shut off switch

2.5 PERSONAL PROTECTION EQUIPMENT

• Safety glasses and ear protection must be worn when operating the GPU. • Additional equipment required by employer (gloves, vest, etc).

2.6 SAFETY GUIDELINES

• Operator must be properly trained prior to operating the GPU. • Pre-operation check must be performed before each use. (Refer to operating instructions) • DC power switch must be OFF when connecting and disconnecting the cable from the aircraft. • Use emergency stop for emergency only. Normal shut down is accomplished by selecting engine

idle, then power off. This allows the engine to cool for one minute at idle speed before shutting off.

• Always shut the unit off, allow to cool, and turn the battery switch to OFF before performing service or maintenance. If working near the batteries or the battery switch, also disconnect the negative battery cable, at the battery, on the fuel pump side of the engine.

2.7 GENERAL COMMENT

The GPU is intended to be operated by personnel trained in the proper use in conjunction with the aircraft maintenance manual.

2.8 GENERAL COMMENT

The GPU must be used in accordance with the Technical and Operator Manuals and the intended aircraft.

3.0 PREPARATION PRIOR TO FIRST USE

3.1 GENERAL

Prior to operating the GPU, the user must become familiar with this Operator Manual.

3.2 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 GPU or prevent efficient operation.

1. Unit Visually inspect outside of GPU for loose hardware, loose parts, frayed

wires/cables and general appearance. 2. Tow Bar Check for loose joints, hardware and other damage. Check tow bar latch. 3. Brakes Check brake operation. 4. Tires Check treads for wear and tires for pressure. 5. Radiator Open radiator access door and remove radiator cap (cold only). Ensure that

coolant is up to the bottom of the fill neck. Service as required. 6. Engine Hoses Check integrity of hoses and clamps for tightness. 7. Fuel Level Turn power on and check fuel level on fuel gauge. 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.

3.2 Pre-use inspection continued on following page


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3.2 PRE-USE INSPECTION (continued)

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 or starting

4.0 TRAINING

4.1 TRAINING REQUIREMENTS

The employer of the operator is responsible for providing a training program sufficient for the safe operation of the GPU.

4.2 TRAINING PROGRAM

The employer-provided operator training program should cover safety procedures concerning use of the GPU in and around the intended aircraft at the intended aircraft servicing location.

4.3 OPERATOR TRAINING

The operator training should provide the required training for safe operation of the GPU.

NOTE: Maintenance and Trouble Shooting are to be performed by a skilled and trained technician.

5.0 OPERATION

5.1 OPERATING PARAMETERS

• The user shall use the GPU in accordance with the aircraft manufacturer's instructions. • The user shall operate the GPU in accordance with the Technical and Operator Manuals. • The employer of the operator shall provide all necessary training.

5.2 NUMERICAL VALUES

5.2.1 Model: 112820C

Serial Number: (See Nameplate on GPU)

5.2.2 Physical

• Weight (Dry): 2900 lbs (1315 kg) • Dimensions: Width 66.25 in (168 cm) • Height 61 in (155 cm) • Length 96.5 in (245 cm) • Output Cable: 30 ft (9.14 m) long

5.2.3 ENGINE

• Cummins B4.5T...................4.5 Liter turbocharged, 4 cylinder, 4 stroke diesel engine • Horsepower .........................99 hp (73 KW) at 2000 rpm • Weight..................................745 lb (338 kg) engine only • Idle Speed ...........................1000 rpm +/- 50 rpm • Electrical System .................24 volt, negative ground • Capacities

- Lubricating oil ...................11.5 quarts (10.9 liters) w/filter - Coolant (Engine Only) ......12 quarts (11.4liters) - Fuel tank...........................23 U.S. gallons (87 liters)


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5.2 NUMERICAL VALUES (continued)

5.2.4 CHASSIS

• Capacity...............................3500 lbs (1587kg) GVW • Tires..................................... 5.30 x 12 load range C • Tire Pressure .......................80PSI (5.5 bar)

5.2.5 Alternator

• Marathon..............................Magna Plus 284PSL1530 • Output Voltage.....................21 volts AC, 3 phase • Output Power.......................23 KW

- Power Factor ....................0.8 - Ambient Temp °C.............40 - Temperature Rise °C .......80 - Speed ...............................2000 RPM - Frequency ........................60HZ - Excitation..........................Externally regulated 66 volts DC, 3 amps - Insulation ..........................Class F - Single Bearing ..................Sealed, pre-lubricated

• Weight..................................350 lb (159 kg) 5.0 Operation continued on following page


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5.0 OPERATION (continued)

5.3 LOCATION & LAYOUT OF CONTROLS

5.3.1 Control Panel (External)

OPERATOR BUTTONS ITEM DESCRIPTION FUNCTION

1.......................Power ON Position........................... Turns ON 24 VDC power from battery and lights all red warning lamps when held in

.......................Power OFF Position......................... Turns OFF 24 VDC power from battery. Allows engine to run for 1 minute at idle before stopping

2.......................Start Button ...................................... Starts engine (automatically by-passes low oil pressure switch for 10 seconds) engine will idle only. Will only operate with idle/run selector set at idle

3.......................IDLE Selector .................................. Returns engine to IDLE from RUN mode .......................RUN Selector ................................... Brings engine to RUN mode from IDLE 4.......................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.......................Emergency STOP Button................. Will immediately shut off power to the GPU and GPU will STOP. Use for emergency only

6.......................Current Limiter ................................. Adjusts peak current by percents of 2000 amps (i.e. 50% is 1000 amps)


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5.3.1 Control Panel (External) (continued)

POWER OUTPUT METERS ITEM DESCRIPTION FUNCTION

7.......................DC Voltmeter.................................... Indicates DC power voltage (28.5 VDC) 8.......................DC Ammeter .................................... Indicates DC AMPS power output

ENGINE GAUGES ITEM DESCRIPTION FUNCTION

9.......................Engine Oil Pressure ......................... Indicates engine oil pressure 10.......................Engine Temperature ........................ Indicates engine operating temperature 11.......................Fuel Gauge ...................................... Indicates fuel remaining in tank 12.......................Battery Indicator ............................... Indicates 24 VDC battery voltage 13.......................Tachometer ...................................... Indicates engine speed 14.......................Hour Meter ....................................... Records unit operating hours


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5.3.1 Control Panel (External) (continued)

INDICATOR LIGHTS

ITEM DESCRIPTION FUNCTION

15................ DC Over Voltage Lamp (Red) ................ Lights up is DC voltage exceeds specification 16................ DC Under Voltage Lamp (Amber) .......... Indicates low DC voltage 17................ DC Over Current Indicator (Red)............ Lights up if DC amps are exceeded 18................ Power ON Lamp (Green)........................ Lights up and remains on while power is ON 19................ DC ON Lamp (Green)............................. Indicates DC Contactor is "ON" 20................ Low Oil Pressure Lamp (Red) ................ Lights up if engine oil pressure falls below 8 psi 21................ Over Temperature Lamp (Red) .............. Lights up is engine temperature exceeds specification 22................ (Optional) Low Coolant Lamp (Red)....... Indicates low coolant level 23................ No Fuel Lamp (Blue) .............................. Lights when fuel remaining is less than one tenth. When

used with no fuel shut-off option, engine will shut off when light comes on (prior to fuel pump losing its prime)

24................ Optional Fan Belt/Alt Failure (Red) ........ Lights up and shuts down engine if engine alternator output is below specification

CIRCUIT BREAKERS


25................ 5 AMP Circuit Breaker ............................ Protects fuel solenoid 26................ 5 AMP Circuit Breaker ............................ Protects control power 27................ 10 AMP Circuit Breaker .......................... Protects engine governor 28................ 5 AMP Circuit Breaker ............................ Protects phase 1 of excitation transformer 29................ 5 AMP Circuit Breaker ............................ Protects phase 2 of excitation transformer 30................ 5 AMP Circuit Break ............................... Protects phase 3 of excitation transformer


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5.3 LOCATION & LAYOUT OF CONTROLS (continued)

5.3.2 Control Panel (Internal)


1.......................Engine Governor ............................. Controls engine throttle actuator 2.......................Aircraft Interlock ............................... Places interlock at GPU (for testing only) or at Aircraft

Plug (normal) 3.......................DC Fault Test Buttons...................... To test over-voltage, under-voltage, and overload shut

down circuits 4.......................Reset................................................ To reset after test or malfunction of unit 5.......................10 AMP Circuit Breaker ................... Protects 12 volt circuit coming direct from battery switch 6.......................50 AMP Circuit Breaker ................... Protects engine alternator charging circuit 7.......................Excitation Test Button ...................... Provides means of testing alternator excitation coil Not Shown ..............DC Module ....................................... Performs voltage regulation and fault monitoring 5.3 Location & layout of control continued on following page


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5.3 LOCATION & LAYOUT OF CONTROLS (continued)

5.3.3 Controls, Engine Compartment


1.......................Battery Switch .................................. Connects and disconnects Pos. 24 Volt and Pos. 12 Volt battery cables. Must be in the ON position for unit to run GPU is shipped with switch in the OFF position

2.......................Clogged Filter Indicator.................... Indicator will show red when air filter becomes dirty. Check daily. Reset after filter has been changed

5.4 START UP PROCEDURES

5.4.1 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 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. Check towbar latch. 3. Brakes Check brakes operate correctly. 4. Tires Check treads for wear and tires for pressure. 5. Radiator Coolant Open radiator access door and remove radiator cap (cold only). Ensure that

coolant is up to the bottom of the fill neck. Service as required. 6. Engine Hoses Check integrity of hoses and clamps for tightness. 7. Fuel Level Turn power on and check fuel level on fuel gauge. 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 or starting.

1 2


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5.4 START UP PROCEDURES (continued)

5.4.2 Starting Sequence

The following sequence must be followed in the order shown: Refer to figures 1 and 2

1. The battery disconnect switch must be selected to the ON position. 2. Select Power ON (1) at the control panel. This will turn on the 24 Volt DC power from the

GPU battery. The Green Power On Lamp will light. 3. Hold the Power ON switch to the ON position. This is a lamp test of all warning lights on

the Instrument Panel. 4. 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.

5. Push Start Switch (2) for 2-3 seconds to start the engine. Engine will idle at 800 to 1000 rpm.

CAUTION! Check oil pressure on gauge (9) after 15-20 seconds of operation. Select Power OFF immediately if pressure is not indicated. Failure to shut down engine with low or zero oil pressure could result in severe engine damage.

6. Oil pressure gauge (9) will read 10 psig minimum while engine is idling.

CAUTION!

Check that battery indicator gauge reads above 24 volts.

7. Check engine temperature gauge. It should read between 170-195º F (77 to 91º 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.

8. All lamps except Power ON (18) and Low Volt (16) should now be off. 9. Bring engine up to operating speed by rotating IDLE/RUN switch (3) clockwise to RUN

position. 10. Check temperature gauge (10) is indicating a rise. 11. Check DC Volt Meter for 28 VDC

5.4.3 Supplying DC Power to the Aircraft

Reference Figures 1 and 2 Control Panel (Exterior)

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 a "limit" on peak power. Half peak = 50%. Do not use soft start on hard start engines.

2. Check that IDLE/ RUN switch is set to Run and select DC ON (4). DC ON Lamp (19) will light and remain on while the power cable is connected to the aircraft.

5.4.3 Supplying DC power to the aircraft continued on following page


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5.4.3 Supplying DC Power to the Aircraft (continued)

3. The aircraft may now use DC power. During a start cycle, the DC Voltmeter (7) 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 (8) will show high amps initially and then quickly decay to show the continuing current draw.

4. Check all engine gauges for correct operation during the engine start cycle. 5. To shut down the GPU, select DC OFF (4). Lamp (19) will turn off. 6. Return IDLE/ RUN switch (3) to IDLE. 7. Shut down GPU by turning the Power ON switch to the OFF position. GPU will run at idle

for 1 minute to cool down before shutting off. 8. Stow DC plug and cable in cable tray.

5.4.4 EMERGENCY SHUT DOWN PROCEDURE

In the event an emergency shut down is necessary, press the emergency stop switch located on the electrical panel. The Emergency Stop button is for emergencies only.

CAUTION!

Do not use for normal shut down. The Emergency Stop bypasses the timed cool down circuit and may cause engine damage due to overheating.

5.5 DESCRIPTION OF ALARM SYSTEMS

Reference Figures 1 and 2 Control Panel (Exterior)

5.5.1 DC Over Voltage Lamp

The DC over-voltage lamp (red) lights when the output voltage exceeds 32 volts and causes the DC Power contactor open. The GPU continues to run but DC power is shut off. The fault is cleared by pressing the RESET button inside the control panel.

5.5.2 DC Under Voltage Lamp

The DC under voltage lamp (amber) comes on as a warning when the output voltage drops below 22 volts. The fault is cleared by pressing the RESET button inside the control panel.

5.5.3 DC Over Current Lamp

The DC over current lamp (red) lights when the output current exceeds the value of the comparator value in the DC module and causes the DC Power contactor to open. The GPU continues to run but DC power is shut off.

5.5.4 Low Oil Pressure Lamp

The low oil pressure lamp (red) lights anytime power is ON and engine oil pressure is below 8 PSI. If engine oil pressure drops below 8 PSI during operation, (after start up delay) the engine will shut off.

5.5.5 Over Temperature Lamp

The over temperature lamp (red) lights anytime power is on and engine coolant temperature is above 225° F. If coolant temperature reaches 225° F during operation, the engine will shut off.

5.5.6 Optional Low Coolant Level Lamp

The low coolant lamp (red) lights when the coolant level in the radiator gets below the sensor in the upper radiator tank. If coolant level decreases to a level below the sensor during operation, the engine will shut off.


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5.5 DESCRIPTION OF ALARM SYSTEMS (continued)

5.5.7 No Fuel Lamp

The no fuel lamp (blue) lights when the fuel level in the tank is less than 1/10 capacity. When used with the no fuel shut-off option, engine will shut off when light comes on (prior to fuel pump losing its prime).

5.5.8 Optional Fan Belt/Alternator Failure Lamp

The fan belt / alternator lamp (red) lights anytime power is ON and the engine alternator output is below specification voltage. If the alternator output voltage drops below specification during operation (due to alternator failure or serpentine fan belt failure) the engine will shut off.

5.5.9 Optional Green Running Light

The green running light (on top of GPU) is on any time the engine is running. Should the unit shut off due to failure, the green light goes off and the panel lights indicating failure will remain on.

5.6 SAFETY SHUTDOWN AND INTERLOCK CIRCUITS

The 112820C GPU contains safety circuits controlled by the DC Module. The Dc Module (microprocessor located inside the control panel) is responsible for voltage regulation, line drop compensation, fault monitoring, and shut down. 5.6.1 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.

Note: This circuit will also prevent the engine from starting if oil pressure has not been

established in the 10 second period following the INITIAL release of the start button. If engine fails to start, reset the timer by turning the Power ON switch to OFF and back to ON.

5.6.2 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.

5.6.3 Engine Fault Circuits

These circuits are initiated by engine sensors and routed through the DC Module to perform engine shutdown.

- Low oil pressure- detects oil pressure is below 8 PSI. - Engine coolant over temperature- detects engine coolant is above 225° F. - Low coolant (optional)- detects low coolant level in the upper tank of the radiator. - No fuel (optional) – detects very low fuel condition but retains fuel in pump lines. - Fan belt/alternator failure (optional)- detects insufficient voltage output at engine

alternator.

5.6 Safety shutdown and interlock circuits continued on following page


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5.6 SAFETY SHUTDOWN AND INTERLOCK CIRCUITS (continued)

5.6.4 DC Load Monitoring Circuits

These circuits monitor DC loads using comparative values in the DC Module. - DC over voltage- causes DC output contactor to open. Engine continues to run. - DC over current- causes DC output contactor to open. Engine continues to run. - DC under voltage- lights warning light only.

5.6.5 DC Fault Circuits

Rectifier thermostat- opens DC output contactor when rectifier heat sink rises above 90° C. DC aircraft cable interlock- Allows DC Power On to be enabled only when the aircraft cable is plugged into the aircraft.

Note: The GPU/AIRCRAFT PLUG toggle switch inside the control panel overrides this feature for

test purposes only.

CAUTION!

The DC aircraft cable interlock 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.

CAUTION! When the GPU / AIRCRAFT PLUG toggle switch is in the GPU position, the DC output cable will be live. Only trained, authorized personnel should use the equipment in this condition.

6.0 PACKAGING AND STORAGE

6.1 PACKAGING REQUIREMENTS

a. Turn battery switch to OFF position. b. Drain fuel. c. Ensure fuel cap is secure. d. Stow external power cable in cable tray. e. Securely fasten doors and instrument panel drawer. f. Wrap for paint protection. Leave tow-bar and running gear functional. g. Strap unit in truck or shipping container using 4 cargo straps. Hook one strap through each tie-

down ring on the front. Hook one strap through each axle spacer on the rear. Raise tow-bar into latch. Set parking brake and block wheels.

NOTE: Use at least four (4) straps with a minimum 3,000 lb (136 kg) capacity each.

6.2 HANDLING

The unit is designed to be towed using a tug or forklift. Do NOT lift with a forklift!

6.3 PACKAGING PROTECTION

No special packaging material for cushioning or suspension is required for shipments within the continental United States.

6.4 LABELING OF PACKAGING

Packaging should be labeled as follows: DO NOT DROP THIS SIDE UP DO NOT STACK


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6.0 PACKAGING AND STORAGE (continued)

6.5 STORAGE COMPATIBILITY

6.5.1 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. Make sure that the mixed coolant is adequate for the lowest anticipated temperatures

during time of storage. 2. Add oil to the FULL mark level on dip stick. 3. 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 the fuel system or crankcase. 4. Install new fuel filters. 5. Fill fuel tank to capacity. A full fuel tank prevents moisture laden air from entering the tank

during the cool periods. 6. Close all access doors to minimize build-up of foreign particles in the unit. 7. Store unit in a building that is dry. 8. If the storage area has high humidity levels, place moisture absorbing chemicals inside

the unit.

6.5.2 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. Drain the cooling system. Flush with clean water. Refill with 50/50 mix of water and

antifreeze or mix according to ratio for temperature as recommended in the Cummins Operation and Maintenance Manual section V.

2. Circulate the coolant by operating the engine until the normal operating temperature is reached.

3. Stop the engine. 4. Drain the engine crankcase. Reinstall the drain plug. Install new lubricating oil filter

element. Refill with high quality lubricating oil as recommended in the Cummmins Operation and Maintenance Manual section V.

5. Drain the fuel tank of contaminants, fuel/water. Add additives, fill with fuel, and operate the engine for about ten minutes.

NOTE: 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.

6. Remove the spin-on fuel filters, discard, fill new filters with fuel and reinstall on the

engine. 7. 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.

8. Seal all engine openings, including the exhaust outlets with moisture resistant tape. Use cardboard, plywood, or metal covers where practical.

9. Tag engine Control Panel "DO NOT RUN, READY FOR STORAGE".


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7.0 TRANSPORTATION

1. Do not stack. 2. Unit is designed to be towed with a tug or fork lift. 3. Strap unit in truck or shipping container using 4 cargo straps. Hook one strap through each tie-down

ring on the front. Hook one strap through each axle spacer on the rear. Raise tow-bar into latch. Set parking brake and block wheels.

4. Weight: 2900 lbs (1315 kg) 8.0 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:

Fuel Ensure that the correct diesel fuel ASTM D 975 is used. (If using Jet A Fuel, the Fuel/Lubricity Filter must be changed at 200 – 250 hour intervals.) Refer to section V of the Cummins Operation and Maintenance Manual (provided as a supplement to this manual) for other allowable fuels.

Engine Oil 15W-40 (API CH-4) is suitable for most operating temperatures. However, lower viscosity

oils can be used to aid starting at temperatures below -5° C (23° F). Refer to section V of the Cummins Operation and Maintenance Manual (provided as a supplement to this manual) for oil and viscosity recommendations.

CAUTION!

Do not over fill the engine as damage may occur. Always use the engine oil level dipstick 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. The engine oil level should be checked every 10 hours of operation.

Cooling System Use 50/50 ethylene glycol mixture for temperatures above -36° C (-33° F). Refer

to section V of the Cummins Operation and Maintenance Manual (provided as a supplement to this manual) for anti-freeze and water quality recommendations.

Filters Fuel lubricity filter.......... Change every 200 to 250 hours Engine oil filter .............. Change every 200 hours with oil change Air cleaner filter............. Check daily. Change when clog indicator shows clogged.

8.1 GENERAL (DAILY CHECKS)

1. Unit Visually inspect outside of GPU for loose hardware, loose parts, frayed wires/cables and general appearance.

2. Tow Bar Check for loose joints, hardware and other damage. Check tow bar latch. 3. Brakes Check brake operation. 4. Tires Check treads for wear and tires for pressure. 5. Radiator Open radiator access door and remove radiator cap (cold only). Ensure that




Check again once unit is running. 12. Doors Check that all doors and instrument panel drawer are securely latched before

towing or starting


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8.0 SERVICING (continued)

8.2 SHORT TERM PREVENTIVE MAINTENANCE SCHEDULE

It is recommended to change the engine oil and filter after the first 50 hours of operation. The following table is provided as a guide to for frequent service intervals. The Cummins Operation and Maintenance Manual (provided as a supplement to this manual) provides engine service interval information for daily, 250 hour, 500 hour, 1000 hour and 2000 hour intervals. See the Cummins Operation and Maintenance Manual sections 2 thru 7.

INSPECTION AND SERVICE SCHEDULE (HOURS)

COMPONENT DAILY 250 500

ENGINE OIL

Check Level X

Change Oil X X

Change Filter X X

Check Oil Pressure X

COOLANT

Inspect Hoses and Clamps X

Check Level (Cold) X

Inspect Fan Belt X

Check Coolant Concentration X

Flush and Change Coolant

FUEL

Change Lubricity Filter X X

Check Fuel Level X


Inspect for Leaks X

Drain Water Separator X

EXHAUST

Inspect X

Tighten Clamps X

AIR INTAKE


Check Clog Indicator X

New Filter (When Clogged) X

8.2 Short term preventive maintenance schedule continued on following page


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8.2 SHORT TERM PREVENTIVE MAINTENANCE SCHEDULE (continued)

INSPECTION AND SERVICE SCHEDULE (HOURS)

COMPONENT DAILY 250 500

24 VDC

Check Battery Fluid (If Applicable) X

Check Battery Terminals X

CHASSIS

Check for Loose Hardware X

Check Tow Bar Pin and Latch X

Check Tire Wear and Pressure X

Check Wheel Bearings X

Check Brake Function X

DC SYSTEM

Check Rectifier Connections X

Check DC Cable and Plug X

Check Terminals X X

Check Insulation X

Check Contactor X

ELECTRONICS

No Action

INSTRUMENT PANEL

Check Gauges X

Warning Lamps X

Inspect Switches X

Calibration X


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9.0 MAINTENANCE/ILLUSTRATED PARTS LISTS

9.1 GENERAL (Daily Checks)

1. Unit Visually inspect outside of GPU for loose hardware, loose parts, frayed wires/cables and general appearance.

2. Tow Bar Check for loose joints, hardware and other damage. Check tow bar latch. 3. Brakes Check brake operation. 4. Tires Check treads for wear and tires for pressure. 5. Radiator Open radiator access door and remove radiator cap (cold only). Ensure that




Check again once unit is running. 12. Doors Check that both doors are securely latched before towing or starting

Reference Sections 9.2 − 9.14 for Parts Lists, Descriptions and Illustrations

9.2 FILTERS

NOTE: The lubricity fuel filter plays a dual role in filtering the fuel and adding a lubricant. The lubricant is necessary when using Jet A fuel. Change the filter every 250 hours of running time.

ITEM PART NUMBER DESCRIPTION QTY

1.......................09286 ............................................... Lubricity Filter ..................................................................1 2.......................09289 ............................................... Fuel Strainer....................................................................1 3.......................09287 ............................................... Oil Filter ...........................................................................1 9.0 Maintenance/illustrated parts list continued on following page

1 2 3


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9.0 MAINTENANCE/ILLUSTRATED PARTS LISTS (continued)

9.3 ENGINE COOLING SYSTEM

NOTE: Use good quality ethylene glycol antifreeze mixed 50/50 or mixed for colder climate conditions using antifreeze manufacturers chart.


1................ G-1202-1100........................Stopnut, Elastic 5/8-11........................................................................2 2................ Call Tronair ..........................Washer, Cinch .66 I.D. x 2.75 O.D. x .19 thk......................................2 3................ Call Tronair ..........................Isolator (Large)....................................................................................2 4................ Call Tronair ..........................Guard, Fan..........................................................................................1 5................ Call Tronair ..........................Radiator Assembly..............................................................................1 6................ G-1100-10724 .....................Bolt, 3/8-16 x 2-1/2..............................................................................2 7................ G-1202-1070........................Stopnut, Elastic 3/8-16........................................................................2 8................ Call Tronair ..........................Washer, Cinch .39 in...........................................................................4 9................ Call Tronair ..........................Isolator (Small) ....................................................................................2 10................ Call Tronair ..........................Bracket, Radiator ................................................................................1 11................ N-2412-10............................Hose Barb, Brass ¼ in. .......................................................................1 12................ 09162...................................Hose Clamp ........................................................................................2 13................ TF-1145*24..........................Hose, ¼ in. Heater ..............................................................................1 14................ 09450...................................Radiator Hose (Upper)........................................................................1 15................ 09164...................................Hose Clamp ........................................................................................2 16................ Call Tronair ..........................Jiggle Pin valve ...................................................................................1 17................ TF-1154*34..........................Hose, ¾ in. Heater ..............................................................................1 18................ H-1426-03............................Hose Clamp ........................................................................................2 19................ N-2412-21............................Fitting, Brass Hose Barb.....................................................................1 20................ N-2200-10-B ........................Elbow, Brass Street ............................................................................1 21................ 09451...................................Radiator Hose (Lower)........................................................................2 22................ H-1426-10............................Hose Clamp ........................................................................................2


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9.4 ENGINE SENSORS


1.......................14110 ............................................... Water Temperature Switch..............................................1 2.......................09037 ............................................... Magnetic Pick Up ............................................................1 3.......................14109 ............................................... Water Temperature Sender.............................................1 4.......................09283 ............................................... Brass Nipple ....................................................................1 5.......................09282 ............................................... Brass Tee ........................................................................1 6.......................14102 ............................................... Oil Pressure Switch .........................................................1 7.......................14106 ............................................... Oil Pressure Sender ........................................................1 9.0 Maintenance/illustrated parts list continued on following page


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9.5 AIR INTAKE SYSTEM


1.......................H-2843 ............................................. Mounting band.................................................................1 2.......................H-2841 ............................................. Air Filter Assembly ..........................................................1 3.......................H-2864 ............................................. Clamp, 4 in. T-bolt ...........................................................1 4.......................09059*22.0....................................... Aluminum Tube 3” x 22” ..................................................1 5.......................09007 ............................................... Clamp, 3 in. T-Bolt..........................................................3 6.......................H-2881 ............................................. Elbow, 45 Degree Rubber ...............................................1 7.......................H-2885 ............................................. Reducer, Rubber Elbow ..................................................1 8.......................N-2203-02 ........................................ Fitting, Pipe Nipple 1/8 NPT............................................1 9.......................09003 ............................................... Clogged Filter Indicator ...................................................1 Not Shown ..............H-2842 ............................................. Replacement Air Filter Element ......................................1


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9.6 Exhaust System


1.......................18007 ............................................... Clamp, 3” Muffler.............................................................3 2.......................Z-6180-01......................................... Weldment, Exhaust Tube................................................1 3.......................18044 ............................................... rain Cap, 3 in. ..................................................................1 4.......................18046*14.00..................................... Tube, Exhaust .................................................................1 5.......................H-2883 ............................................. Muffler..............................................................................1 6.......................18057 ............................................... Muffler Mounting Band ....................................................2 9.0 Maintenance/illustrated parts list continued on following page


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9.7 ENGINE/ALTERNATOR/ENGINE MOUNTING


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9.7 ENGINE/ALTERNATOR/ENGINE MOUNTING (continued)


1.......................Call Tronair....................................... Fan, 20 in. Blower ...........................................................1 2.......................G-1114-100100................................ Bolt, M10 x 100MM Hex Head ........................................4 3.......................G-1514-M100R ................................ Lock Washer M10 ...........................................................4 4.......................Call Tronair....................................... Fan Spacer......................................................................2 5.......................69039 ............................................... Cummins B4.5 Engine Assembly ...................................1

with Mounts and Radiator 6.......................69024 ............................................... Alternator, 23KW .............................................................1 7.......................G-1420-110034................................ Bolt, 5/8-11x 3-1/2” Gr. 8.................................................4 8.......................G-1202-1100 .................................... Sopnut, Elastic. ...............................................................4 9.......................Call Tronair....................................... Washer, Cinch .66 I.D. x 2.75 O.D. x .19 thk ..................7 10.......................Call Tronair....................................... Isolator, Large .................................................................5 11.......................Call Tronair....................................... Bracket, Engine Mount. ...................................................2 12.......................G-1114-120030................................ BOLT, M12 x 30MM Hex Head .......................................8 13.......................G-1514-M120R ................................ Lock Washer M12 ...........................................................8 14.......................TS-2125-01 ...................................... Support, Engine...............................................................1 15.......................Call Tronair....................................... Bolt, M16 x 75MM Hex Head W/ Flange.........................1 16.......................G-1420-107010................................ Bolt, 3/8-16 x 1 in. Hex Head Gr. 8 .................................8 17.......................G-1513-1070N ................................. 3/8 Hardened Flat washer ...............................................8 18.......................G-1533-100035................................ Bolt, M10 x 35MM Hex Head ........................................10 19.......................G-1514-M100R ................................ Lock Washer, M10 ........................................................19 20.......................G-1533-100040................................ Bolt, M10 x 40MM Hex Head ..........................................2 21.......................Z-6122-01......................................... Weldment, Filter Bracket .................................................1 9.0 Maintenance/illustrated parts list continued on following page


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9.8 BATTERIES


1.......................S-2044-01 ....................................... Battery Tray.....................................................................2 2.......................19807 ............................................... Battery Box......................................................................2 3.......................09032 ............................................... Battery, 12 volt Group 24 ................................................2 Not Shown ..............EC-1928-05...................................... Battery 1 neg. (-) to engine block ....................................1 Not Shown ............EC-1928-06...................................... Battery 1 pos. (+) to battery 2 neg. (-) .............................1 Not Shown ..............EC-1928-06...................................... Battery 1 pos. (+) to battery 2 neg. (-) .............................1 Not Shown .............EC-1928-07...................................... Battery 2 pos. (+) to battery switch..................................1 Not Shown .............EC-1928-08...................................... Battery switch to starter ..................................................1 Not Shown .............EC-1928-09...................................... Starter frame (ground) to engine block ...........................1 Not Shown .............EC-1928-10...................................... Engine block to GPU frame.............................................1


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9.9 FUEL TANK


1.......................S-2045.............................................. Fuel Tank.........................................................................1 2.......................14146 ............................................... Fuel Sender.....................................................................1 3.......................TF-1152-03*33.0 .............................. Fuel Hose, 3/8 I.D. ..........................................................1 4.......................H-1426-22 ........................................ Hose Clamp.....................................................................4 5.......................N-2410-04 ........................................ Fitting, 3//8 Barb to ¼ NPT Brass ..................................1 6.......................S-2069-01 ........................................ Pad ..................................................................................1 7.......................S-2069-02 ........................................ Pad ..................................................................................2 8.......................A076-03*035.75 ............................... Angle, UHMW 2 X 2 X 1/4...............................................1 9.......................15253 ............................................... Fuel Cap..........................................................................1 10.......................TF-1152-02*96.0 .............................. Fuel Hose, 5/16 I.D. ........................................................1 11.......................N-2410-13 ........................................ Fitting, 5/16 Barb to 3/8 NPT Brass. ...............................2 12.......................S-2069-03 ........................................ Pad ..................................................................................2 9.0 Maintenance/illustrated parts list continued on following page


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9.10 ACTUATOR


1.......................09011-1 ............................................ Actuator ...........................................................................1 2.......................Call Tronair....................................... Actuator Arm....................................................................1 3.......................J-3684 .............................................. Throttle Strap...................................................................1 4.......................09011-5 ............................................ Actuator Rod Spacer .......................................................2 5.......................09011-4 ............................................ Actuator Rod End ...........................................................2 6.......................R015-24*003.00 ............................... Rod, Threaded ¼-28 .......................................................1 7.......................Z-6076-01......................................... Weldment, Actuator Bracket............................................1


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This page left blank intentionally.


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9.11 ELECRICAL ASSEMBLIES

9.11.1 Rectifier/Contactor/Battery Switch/Output cable


1.......................13072*007.00................................... Din Rail ............................................................................1 2.......................13070 ............................................... Din Rail Anchor ...............................................................2 3.......................13075 ............................................... Din Rail End Barrier.........................................................1 4.......................13068 ............................................... Terminal Block (Black 4 Place) .......................................2 5.......................13090 ............................................... Terminal Block (Black 2 Place) .......................................6 6.......................13082 ............................................... Terminal Block (Gray 2 Place) ........................................3 7.......................13089 ............................................... Terminal Block (Red 3 Place)..........................................1 8.......................13067 ............................................... Terminal Block (Green 3 Place). .....................................9 9.......................EC-1932 ........................................... Harness, Wiring P16 .......................................................1 10.......................EC-1933 ........................................... Harness, Wiring P17 .......................................................1 11.......................13016 ............................................... Rectifier Assembly...........................................................1


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9.11.1 Rectifier/Contactor/Battery Switch/Output cable (continued)


12.......................J-3693 .............................................. Buss Bar ..........................................................................3 13.......................13002 ............................................... Shunt, 2500 Amp.............................................................1 14.......................EC-1934 ........................................... Cable, DC Output, 32 ft. ..................................................1 15.......................EC-1928-01...................................... Cable, Power T3..............................................................1 16.......................EC-1928-02...................................... Cable, Power T2..............................................................1 17.......................EC-1928-03...................................... Cable, Power T1..............................................................1 18.......................13015 ............................................... Isolator.............................................................................6 19.......................EC-1928-04...................................... Cable, Power ..................................................................1 20.......................H-2840 ............................................. Lock Out, Switch .............................................................3 21.......................EC-1901 ........................................... Switch, battery Disconnect ..............................................1 22.......................H-1901-23 ........................................ Grommet..........................................................................2 23.......................EC-1935 ........................................... Contactor .........................................................................1 24.......................S-2050-01 ........................................ Box, Rectifier (Sheet Metal Only) ....................................1 25.......................EC-1175-24-A .................................. Strain Relief .....................................................................2 26.......................EC-1175-13-A .................................. Strain Relief .....................................................................1 27.......................EC-1176-03...................................... Nut ...................................................................................1 28.......................EC-1176-05...................................... Nut ...................................................................................2 9.11 Electrical assemblies continued on following page


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9.11 ELECRICAL ASSEMBLIES (continued)

9.11.2 Instrument Panel Drawer (Outside)


1.......................14130 ............................................... Switch, Power on/off........................................................1 .......................14142 ............................................... Flange Latch....................................................................1 .......................14143 ............................................... Block, Contact (Green)....................................................3 .......................14144 ............................................... Block, Contact (Red) .......................................................1 2.......................14141 ............................................... Switch, Start ....................................................................1 .......................14142 ............................................... Flange Latch....................................................................1 .......................14143 ............................................... Block, Contact (Green)....................................................1 3.......................14133 ............................................... Switch, Idle / Run ............................................................1 .......................14142 ............................................... Flange Latch....................................................................1 .......................14143 ............................................... Block, Contact (Green)....................................................1 .......................14144 ............................................... Block, Contact (Red) .......................................................3 4.......................14131 ............................................... Switch, DC On / Off .........................................................1 .......................14142 ............................................... Flange Latch....................................................................1 .......................14143 ............................................... Block, Contact (Green)....................................................1 .......................14144 ............................................... Block, Contact (Red) .......................................................1 5.......................14132 ............................................... Switch, Emergency Stop .................................................1 .......................14142 ............................................... Flange Latch....................................................................1 .......................14144 ............................................... Block, Contact (Red) .......................................................1 6.......................12084 ............................................... Potentiometer, Current Limit ...........................................1


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9.11.2 Instrument Panel Drawer (Outside) (continued)


7.......................14065 ............................................... Voltmeter, 24V Digital......................................................1 8.......................14066 ............................................... Ammeter, DC Digital........................................................1 9.......................14105 ............................................... Gauge, Oil Pressure (24 Volt) .........................................1 .......................14138 ............................................... Bulb, Gauge ....................................................................1 10.......................14108 ............................................... Gauge, Coolant temp (24 Volt) .......................................1 .......................14138 ............................................... Bulb, Gauge ...................................................................1 11.......................14145 ............................................... Switch Gauge, Fuel (Murphy)..........................................1 12.......................14115 ............................................... Gauge, Battery Voltage (24 Volt) ....................................1 .......................14138 ............................................... Bulb, Gauge ....................................................................1 13.......................14117 ............................................... Tachometer, (24 Volt)......................................................1 .......................14139 ............................................... Bulb, Tachometer ............................................................1 14.......................14116 ............................................... Hour Meter, (24 Volt).......................................................1 15.......................12022 ............................................... Breaker, Circuit (5 Amp)..................................................5 16.......................12001 ............................................... Breaker, Circuit (10 Amp)................................................1 17.......................14128 ............................................... Lamp Assembly (Green) .................................................2 .......................14137 ............................................... Bulb, Replacement ..........................................................1 18.......................14126 ............................................... Lamp Assembly (Red).....................................................4 .......................14137 ............................................... Bulb, Replacement ..........................................................1 19.......................14127 ............................................... Lamp Assembly (Amber).................................................1 .......................14137 ............................................... Bulb, Replacement ..........................................................1 20.......................14129 ............................................... Lamp Assembly (Blue) ....................................................1 .......................14137 ............................................... Bulb, Replacement ..........................................................1 9.11 Electrical assemblies continued on following page


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9.11 ELECRICAL ASSEMBLIES (continued)

9.11.3 Instrument Panel Drawer (Inside)


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9.11.3 Instrument Panel Drawer (Inside) (continued)


1.......................13072*018.00................................... Rail, Din (18 in.)...............................................................1 2.......................13093 ............................................... Relay, SPSD W/ Led (50A) .............................................1 3.......................13073 ............................................... Socket, Relay (8 Pin).......................................................3 4.......................13063 ............................................... Relay, Compact Spade (DPDT) ......................................2 5.......................13071 ............................................... Relay, Compact Spade (SPDT) ......................................1 6.......................13074 ............................................... Socket, Relay (11 Pin).....................................................1 7.......................13064 ............................................... Relay, Compact Spade (TPDT).......................................1 8.......................13066 ............................................... Terminal Block, Three Pole White...................................1 9.......................13065 ............................................... Terminal Block, Three Pole Blue.....................................1 10.......................13069 ............................................... Terminal Block, Four Pole Yellow ...................................1 11.......................13608 ............................................... Terminal Block, Four Pole Black .....................................9 12.......................13067 ............................................... Terminal Block, Three Pole Green................................13 13.......................Call Tronair....................................... J-16 Receptacle ..............................................................1 14.......................12061 ............................................... Transformer, 28 VDC Excitation......................................1 15.......................13011 ............................................... Barrier, Eight Position......................................................1 16.......................13008 ............................................... Terminal Strip, Eight Position..........................................1 17.......................12005 ............................................... Governor, Engine ............................................................1 18.......................13053 ............................................... Solenoid, 24 VDC (K-3 Start) ..........................................1 19.......................12010 ............................................... Switch, Momentary (Small) .............................................3 20.......................12011 ............................................... Switch, Momentary (Large) .............................................2 21.......................12009 ............................................... Switch, Toggle (2 Position)..............................................1 22.......................12001 ............................................... Breaker, Circuit (10A)......................................................1 23.......................12015 ............................................... Breaker, Circuit (50A)......................................................1 24.......................13094 ............................................... Heat Sink (50A Relay).....................................................1 9.11 Electrical assemblies continued on following page


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9.12 SHEET METAL COMPONENTS

9.12.1 Instrument Panel Mounting


1.......................S-2054.............................................. Drawer, Electrical (Sheet Metal Only) .............................1 .......................EC-1929 ........................................... Drawer, Complete Without Module ........................... REF 2.......................S-2038-01 ........................................ Sheet Metal, Instrument Louver ......................................1 3.......................K-3906.............................................. Sound Proofing (Complete Kit).................................. REF 4.......................S-2066-01 ........................................ Support, Drawer ..............................................................1 5.......................S-2065.............................................. Box, Control Cover ..........................................................1 6.......................H-2813 ............................................. Drawer Slide (Complete Set)...........................................1 7.......................S-2055-01 ........................................ Angle, Drawer Mounting..................................................2 8.......................09042 ............................................... Vibration Mount ...............................................................8 9.......................H-1547-08 ........................................ Bumper, Rubber (Recess)...............................................2


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9.12 SHEET METAL COMPONENTS (continued)

9.12.2 Outer Sheet Metal

PARTS LIST


1.......................S-2059-01 ........................................ Top Panel ........................................................................1 2.......................S-2076-01 ........................................ Top Panel ........................................................................1 3.......................S-2049-01 ........................................ Hinge (Mount)..................................................................1 4.......................J-3775 .............................................. Cover (Lexan)..................................................................1 5.......................H-2912 ............................................. Knob, 10-32 x ¾ in. Stud.................................................2 6.......................H-2913 ............................................. Stud retainer....................................................................2 7.......................S-2041-01 ........................................ Side Tray .........................................................................1 8.......................15109 ............................................... Rubber Bumper. ..............................................................2 9.......................S-2046-01 ........................................ Rear Cross Member ........................................................1 10.......................S-2042-01 ........................................ Side Tray .........................................................................1 11.......................A-1218-01 ........................................ Brace, Tray......................................................................2 12.......................H-2827 ............................................. Hinge ...............................................................................4 13.......................H-2884 ............................................. Latch, Door......................................................................2 14.......................H-2915 ............................................. Pull-Tab. ..........................................................................2 15.......................S-2035-01 ........................................ Door.................................................................................2 16.......................H-2882 ............................................. Magnet, Encased Ceramic ..............................................4 17.......................S-2036-01 ........................................ Corner, Opposite Muffler .................................................1 18.......................S-2037-01 ........................................ Corner, Near Muffler (Not Shown) ..................................1 19.......................S-2039-01 ........................................ Rear Louver ....................................................................1 20.......................Z-6168-01......................................... Lid, Radiator Access .......................................................1 9.0 Maintenance/illustrated parts list continued on following page


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9.13 Replacement Labels


1.......................H-2807 ............................................. Reflective Tape, Red..................................4 at 5 in. each 2.......................V-2099.............................................. Label, Warning Noise Hazard .........................................1 3.......................V-1896.............................................. Label, Read Manual ........................................................1 4.......................V-2097.............................................. Label, Warning Voltage Hazard ......................................1 5.......................V-1050.............................................. Label, ISO Electric...........................................................2 6.......................V-2118.............................................. Label, Serial No. CE........................................................1 7.......................V-2124.............................................. Label, 28 VDC Operating instructions.............................1 8.......................V-2111.............................................. Label, Diesel or Jet A ......................................................1 9.......................V-2096.............................................. Label, Danger (Harmonized) ...........................................2 10.......................V-1340-01 ........................................ Label, Tronair ..................................................................2 11.......................V-1814.............................................. Label, Warning Keep 5 Ft................................................2 12.......................V-2083.............................................. Label, 28.5 VDC ..............................................................2 13.......................H-2806 ............................................. Reflective Tape, Yellow..............................8 at 5 in. each 14.......................V-2109 ............................................. Label, Fill Rate ................................................................1 Not Shown ..............H-2899 ............................................. Reflective Tape, White ...............................4 at 5 in. each Not Shown ..............V-2114.............................................. Label, Oil Filter Replacement..........................................1 Not Shown ..............V-2115.............................................. Label, Air Filter Replacement..........................................1 Not Shown ..............V-2116.............................................. Label, Lubricity Filter .......................................................1


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10.0 TROUBLE SHOOTING

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 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 • The instrument panel and switches • The 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.

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.

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 protection 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.

10.1 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 quite easy to determine what has actually happened to which component. The charts list information under three headings:

• Fault • Cause • Correction

2.1 Use of the troubleshooting chart continued on following page.


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10.1 Use Of The Troubleshooting Chart (continued)

P8 HARNESS

WIRE WIRE SIZE WIRE LETTER PIN (AWG) COLOR FROM TO

A ............12 ........... 20............. Green............ DC Plug Minus.................................. TB2, TB1, J16/12 DC Volt Meter, DC Lamp B ............40 ........... 20..............Black ............ Rectifier Plus ....................................TB2, J16/40 F ............41 ........... 20..............Black ............ Shunt Plus ........................................ D, J16/41 Ammeter Plus L ............42 ........... 20............. Green............ Rec Thermal Switch ......................... J16/42 Z .............8 ............ 20..............Violet ............ Fuel Sender ...................................... J16/8, Fuel Gauge BB ............4 ............ 20............. Green............ Low Oil Pressure Switch .................. JK, J16/14 CC............5 ............ 20............. Green............ High Coolant Temp Switch............... J16/5 TT ............6 ............ 20..............Violet ............ Coolant Temp Sender ...................... J16/6, Coolant Temp Gauge UU............1 ............ 20..............Violet ............ Engine Alternator A .......................... J16/1, Tachometer VV ............3 ............ 20..............Violet ............ Oil Pressure Sender ......................... J16/3, Oil Pressure Gauge XX ...........43 ........... 20............ Orange........... DC Plug Green Wire......................... J16/43, Inter-Lock Switch YY ............. ............. 20............ Orange........... K15/1 Contaqct (3) ........................... Inter-Lock Switch AB ............. ............. 20............ Orange........... K15/1 Contaqct (5) ........................... DC Off Switch (21) AE ...........46 ........... 20............. Green............ Rec Thermal Switch ......................... J16/46, K9 Coil (10) AK ...........15 ........... 16..............Black ............ CB-1 ................................................. K18 Coil, J16/15, Engine Fuel Solenoid AP ............. ............. 20............... Red ............. CB-4 ................................................. TB-3 AQ............. ............. 20............... Red ............. CB-5 ................................................. TB-3 AR............. ............. 20............... Red ............. CB-6 ................................................. TB-3 W............47 ........... 20............. Green............ Shunt Minus...................................... J16/47, Ammeter Minus AS ............. ............. 20..............Black ............ .......................................................... DC Volt Meter, K9/3 (6) BC...........29 ........... 20............. Green............ K14/1 Contact (5) ............................. J16/29, F-2 Excitation BD...........30 ........... 20..............Black ............ K14/2 Contact (6) ............................. J16/30, F-1 Excitation BN............. ............. 16..............Black ............ 12VDC Battery.................................. CB-8, K-14/2

(NOTE: Keep plug orientation standard) Twisted pair to magnetic pick up

WIRE WIRE SIZE WIRE LETTER PIN (AWG) COLOR TO

AF .............. 22..................Yellow .............................. 12.....................................Battery Plus JJ............... 17.................. Green............................... 12.....................................TB2 (Ground) AG.............. 16...................Black ............................... 12.....................................Starter Solenoid (`S' Terminal) AH.............. 23 ..................Black ............................... 16.....................................K2 Coil AI............... 13 ..................Black ............................... 16.....................................Actuator AJ .............. 14 ..................Black ............................... 16.....................................Actuator AL .............. 21 ..................Black ............................... 12.....................................Engine Alternator


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CHASSIS FAULT - Excessive towing force Possible Cause Solution 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

FAULT - Excessive steering force Possible Cause Solution Turntable bearing (if installed) ................ Check grease in upper and lower roller bearing. Repack if

required Seized towbar ......................................... Lubricate joints and brake actuator pins

CANOPY/HOUSING

FAULT - Door stiff to open Possible Cause Solution Dry hinge pin........................................... Lubricate with light graphite based oil

FAULT - Door difficult to latch Possible Cause Solution Latch out of adjustment .......................... Close door against rubber extrusion on the hoop. Adjust latch so

that door just compresses the rubber



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24 VDC POWER FAULT - No power when "power-on" switch is selected Possible Cause Solution Main breaker off...................................... Reset CB-7 Main battery switch off ............................ Check, turn on Loose battery terminals .......................... Check, clean and tighten terminals Low electrolyte........................................ Check fluid and top-up if required System leakage-battery discharged ....... Check power input via P16 connector to the panel, if current flow

ceases with P16 disconnected, check leakage to all systems fed by P16 plug. Isolate failed component and rectify. If all P16 fed components okay then inspect the relays for failure-replace

Power-ON select switch inoperative....... 24 VDC should be available at the switch. Test switch for correct operation

Power circuit contactor off ...................... Reset CB7. Refer to schematic of other possible component failures in the power-on circuit

FAULT - Power-OFF select switch does not remove power.

NOTE: Upon engine shut down the GPU will continue to run at idle for approximately one minute before stopping

Possible Cause Solution Power-OFF select switch inoperative..... Check switch for correct operation if okay delay timing circuit on

PCB within panel

FAULT - Power switch locks in and power ON lamp (amber) is on, but engine starter motor will not turn

Possible Cause Solution Main breaker out..................................... Reset Idle/run switch......................................... Check, reset to idle J16 feed to starter disconnected ............ Reconnect. If starter still does not turn jumper battery + to

solenoid, if motor turns, check 30 amp pilot relay in panel and replace if required

FAULT - 24 VDC power gradually fades, voltage below 18 VDC Possible Cause Solution Charging alternator inoperative .............. Check P16 to alternator cable if okay. Check 50 amp pilot charge

relay in panel if required. If relay wiring okay. Check alternator output current, if zero replace


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ENGINE FAULT - Engine will not start, 24 VDC power okay, starter turns engine okay Possible Cause Solution Fuel......................................................... Check contact breaker 1. Check power 24 VDC to fuel solenoid.

Listen to click when "POWER ON" Select switch is selected. No click, check power available with meter, if "yes" replace solenoid. If "no" 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 & replace. Check lift pump by loosening outlet fitting, replace, if faulty

Electrical ................................................. Check contact breaker 2. 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

FAULT - Engine starts and stops within 10-20 seconds Possible Cause Solution Low oil pressure or empty oil gallery ...... Restart. Check oil pressure, if normal engine will continue to run after oil change Electrical ................................................. Check oil pressure gauge, if no indication, change oil pressure

sender

FAULT - High coolant temperature Possible Cause Solution Low coolant............................................. Let engine cool down, check coolant level Broken fan belt........................................ Replace FAULT - Excessive engine vibration at steady state 2000 rpm Possible Cause Solution Injector or engine valve out of ................ Check engine manual in Appendices adjustment or worn All other engine faults consult engine manual in Appendices

ALTERNATOR FAULT - High frequency vibration or sound, metal particles in base of alternator Possible Cause Solution Ingress or digress ................................... Check intake air filter is fitted, if not fit a spare. With battery

disconnected, remove any foreign objects Bearing overheat .................................... Check bearing housing, if hot, allow GPU to cool, inspect and

replace bearing, according to manual

FAULT - Any one phase not producing rated voltage or current (phase balance) Possible Cause Solution Broken or frayed connections................. Check alternator output cables and connections to contactors Electrical ................................................. Test diodes in the non-driven end of the alternator. Consult

manual in Appendices 10.1 Use of the troubleshooting chart continued on following page.


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EXHAUST SYSTEM FAULT - Cooling air outlet louver blackened with soot Possible Cause Solution Leakage within the exhaust .................... Check all joints, adjust tubes and secure clamps. Any tubes that plenum chamber have corroded should be replaced

FAULT - Blackened components around exhaust on the engine side of the radiator Possible Cause Solution Leakage, failure or loose tubes .............. Ensure all tubes are fully inserted into the mating "bell" ends and

reclamp. Replace corroded or broken tubes

28 VDC DC POWER SYSTEM FAULT - No volts or amps shown on operators panel Possible Cause Solution Sensing wires disconnected from........... Check wires are connected on P16 harness TB2 and 50 MV shunt

FAULT - No power output, but AC system working Possible Cause Solution Rectifier diode heat sink, overheat ......... Let GPU cool down and re-test. Check continuity of thermostat

on rectifier at TB2 Blown diodes on rectifier ........................ Disconnect flexible cables and check “Blocking” with meter

FAULT - No power at aircraft plug (assuming all control electronics are operating correctly) Possible Cause Solution Disconnected/broken power cables ....... Check continuity of positive and negative cables from GPU to

plug Sensing lines disconnected with............. Check sensing and interlock continuity between GPU TB2 and sensing switch in “remote” and return to plus and minus power points and TB2 interlock in “remote” Contactor inoperative ............................. Disconnect contactor supplying power transformer. Operate from

external 24 VDC 30 amp source. Replace if faulty


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28 VDC CONTROL SYSTEM FAULT - Engine running correctly. Select DC ON - contactor does not pull in Possible Cause Solution 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 P16 with meter between this pin and ground, if

no signal when DC “ON” button is pressed, check switch and wiring in operators panel

Pilot relay inoperative ............................. Look for LED on K-9 relay in control drawer, if none change relay

FAULT - Power will not switch on Possible Cause Solution DC interlock faulty................................... Check interlock at cable head and TB2 for continuity

FAULT - Over volt light 'on' contactor drops out Possible Cause Solution DC cable too long 30 ft/8m maximum .... DC controller within the DCM set to provide 22-32 VDC at GPU

based of cable head sensing of 28VDC on 25ft. or 8 meters of cable

FAULT - Overload light 'on' contactor drops out Possible Cause Solution Exceedance of rating.............................. Consult Tronair

FAULT - 28 VDC 'no load' available on remote sensing, zero volts indicated, low volts warning

lamp on Possible Cause Solution Wiring fault.............................................. If meter indicates 28 VDC check remote sense wiring to cable

head via TB2 Voltmeter ................................................ Check operation and replace if failed

FAULT - 28 VDC 'no load' available on remote sensing load is increased but ammeter shows zero

amps Possible Cause Solution Shunt ...................................................... 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

FAULT - GPU continually shuts down when all faults have been corrected Possible Cause Solution Failure in DCM........................................ Replace unit and return to Tronair for analysis



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INSTRUMENT PANEL FAULT - Contact breaker keeps popping out, AFTER correction of all discernable faults Possible Cause Solution Weakened CB......................................... Replace

FAULT - Erratic Engine Idle Possible Cause Solution Faulty idle circuit in governor.................. Replace and return unit to Tronair, provided replacement

corrects the fault

FAULT - Transient engine performance not to specification Possible Cause Solution Gain and stability adjustment ................. Adjust to specification per manual

GENERAL FAULT - All action taken per this chart for any specific fault - still not rectified Possible Cause Solution Electronic microprocessor failure ........... Replace complete. If fault is cleared return failed module to

Tronair for analysis DO NOT OPEN THE MODULE CASE THIS VOIDS WARRANTY. If fault not cleared replace original module

FAULT - Electronic module okay but specific fault still not rectified Possible Cause Solution Indeterminate.......................................... Replace instrument panel complete, if fault clears, then

troubleshoot the panel on the bench, returning GPU to service. If fault persists check P16 and P17 harness and operators panel

CIRCUIT BREAKER FAULT - CB-1 POPS Possible Cause Solution Fuel solenoid or relay shorted. ............... Replace solenoid or relay Engine will not start, or stops without apparent reason

FAULT - CB-2 POPS Possible Cause Solution Control Circuit Short. .............................. Check control circuit and remedy fault

FAULT - CB-3 POPS Possible Cause Solution Governor fault. ........................................ Replace governor

FAULT - CB-4, -5, -6 POPS Possible Cause Solution Excitation transformer short.................... Change excitation transformer


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ERRATIC ENGINE RPM FAULT - Engine Control Erratic Possible Cause Solution Loose linkage to injector pump............... Reset and tighten linkage Actuator arm will not spring return.......... Reset. If not possible, replace actuator to left Linkage sticking ...................................... Reset linkage Faulty fuel solenoid................................. Replace solenoid Magnetic pickup collected metal dirt....... Replace magnetic pickup or is faulty Loose electrical connection .................... Fix loose connection Bad governor .......................................... Replace Governor

10.2 ENGINE SPEED

Engine RPM is controlled by three components: 1. The fuel actuator which is a servo device to control fuel flow to the engine. 2. The Governor, located in the Instrument panel, which monitors the engine RPM and

governs the fuel actuator to maintain the set RPM. 3. 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 IDLE 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.

10.3 GAIN/STABILITY ADJUSTMENTS

1. Start GPU and allow unit to warm up. 2. Select RUN 3. Locate GAIN and STABILITY adjusting screws on the electronic governor in the Control Drawer. 4. Turn the GAIN adjustment slowly clockwise until engine starts to search. 5. Turn adjustment slowly counterclockwise until engine smooths out and continue adjustment an

additional 1/8th turn. 6. Turn stability adjustment slowly clockwise until engine starts to search. 7. Turn adjustment slowly counter clockwise until engine smooths out and continue adjustment an

additional 1/8th turn. 8. A slight additional counter clock wise adjustment may be required if, when a load is applied, the

engine starts to search again.

10.4 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.


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11.0 PROVISION OF SPARES

11.1 SOURCE OF SPARE PARTS

TRONAIR, Inc. Telephone: (419) 866-6301 or 800-426-6301 1740 Eber Road Fax: (419) 867-0634 Holland, Ohio 43528-9794 USA E-mail: [email protected] Website: www.tronair.com

11.2 RECOMMENDED SPARE PARTS LISTS

It is recommended that the following spare parts be kept on hand and available for immediate use during maintenance. 1.2.1 Spare Electrical Parts

Part Number Description Qty

H-2842 ................................................................. Air Filter element ..........................................................................1 09287................................................................... Oil Filter ........................................................................................1 09286................................................................... Lubricity Fuel Filter .......................................................................1 09289................................................................... In Line Fuel Strainer .....................................................................1 14110................................................................... Water Temp Switch ......................................................................1 14109................................................................... Water Temp Sender .....................................................................1 14102................................................................... Oil Pressure Switch ......................................................................1 14106................................................................... Oil Pressure Sender .....................................................................1 09037................................................................... Magnetic Pick Up .........................................................................1 14139................................................................... Tachometer Bulb Replacement....................................................1 14138................................................................... Gauge Bulb Replacement ............................................................1 14137................................................................... Panel Bulb Replacement..............................................................1 12.0 IN SERVICE SUPPORT

Contact Tronair, Inc. for technical services and information. See Section 1.3 − Manufacturer. 13.0 WARRANTY

Tronair products are warranted to be free of manufacturing or material defects for a period of one year after shipment to the original customer. This is solely limited to the repair or replacement of defective components. This warranty does not cover the following items:

a) Parts required for normal maintenance b) Parts covered by a component manufacturers warranty c) Replacement parts have a 90-day warranty from date of shipment

If you have a problem that may require service, contact Tronair immediately. Do not attempt to repair or disassemble a product without first contacting Tronair, any action may affect warranty coverage. When you contact Tronair be prepared to provide the following information:

a) Product Model Number b) Product Serial Number c) Description of the problem

If warranty coverage is approved, either replacement parts will be sent or the product will have to be returned to Tronair for repairs. If the product is to be returned, a Return Material Authorization (RMA) number will be issued for reference purposes on any shipping documents. Failure to obtain a RMA in advance of returning an item will result in a service fee. A decision on the extent of warranty coverage on returned products is reserved pending inspection at Tronair. Any shipments to Tronair must be shipped freight prepaid. Freight costs on shipments to customers will be paid by Tronair on any warranty claims only.

APPENDIX I

WIRING SCHEDULE 28.5 VDC 4.5 CUMMINS ENGINE

ASSEMBLY WIRING SCHEDULE PAGE 1 OF 6

DOCUMENT NUMBER: INS-1830

Model: 112820C DATE: 06/2006 REV: 01

WIRE

LETTER WIRE SIZE

COLOR FROM TO

A 20/GREEN D.C. PLUG (MINUS) (J17) GREEN T/B2 (J14) P16/J16 (12) GREEN T/B1 P15 (45) D.C. VOLT METER (LO), DC ON LAMP (LO)

B 20/BLACK RECTIFIER (PLUS) BLACK T/B2 P16/J16 (40) BLACK TB/1 P15 (35) K15/2 CONTACT (4

C 20/GREEN HI VOLT TEST SWITCH P15 (1)

D 20/GREEN LOW VOLT TEST SWITCH P15 (2)

E 16/BLUE 24 VOLT RUN P15 (29) BLUE T/B1 INTERLOCK SWITCH DC ON SWITCH (4) EXCITATION

TEST SWITCH

F 20/BLACK SHUNT (PLUS) P16/J16 (41) BLACK T/B1 AMMETER (PLUS) P15 (4)

G 20/GREEN OVER LOAD TEST SWITCH P15 (5)

H 20/GREEN HI VOLT LAMP (MINUS) P15 (6)

I 20/GREEN LOW VOLT LAMP (MINUS) P15 (7)

J 20/GREEN OVER LOAD LAMP (MINUS) P15 (8)

K 20/GREEN LAMP TEST SWITCH (3) P15 (9) IDLE/RUN SWITCH# 3 (2) (OPT) D11 DIODE (CATHODE)

L 20/GREEN THERMAL SWITCH GREEN T/B2 P16/J16 (42) GREEN T/B1 P15 (10)

M 20/GREEN (INSIDE DCM) GROUND (38) (INSIDE DCM) (13)

N 20/GREEN FAULT RESET P15 (12)

O 20/BLACK CURRENT LIMIT POTENTIOMETER (RIGHT TERMINAL) P15 (37)

P 20/BLACK CURRENT LIMIT POTENTIOMETER (MID TERMINAL) P15 (38)

Q 16/BLACK POWER ON SWITCH #1 AND #2 (4) BLACK T/B1 POWER ON LAMP (PLUS)

IDLE/RUN COMMON (1/3) P15 (13) POWER ON

SYSTEM F1 FUSE

R 20/YELLOW POWER ON SWITCH #1 (NO) (3) P15 (14)

S 20/GREEN POWER OFF SWITCH (1) P15 (39)

T 20/YELLOW CIRCUIT BREAKER# 2 P15 (15) E-STOP SWITCH (1)

U 20/BLACK K 13 COIL (A1) P15 (40) D6 DIODE (CATHODE)

INS-1830 Assembly Wiring Schedule

112820C

03/2006 - Rev. 01 - 1 -

WIRE

LETTER WIRE SIZE

COLOR FROM TO

V 16/BLACK P15 (18) CB1

W 20/GREEN SHUNT (MINUS) GREEN T/B2 P16/J16 (47) GREEN T/B1 P15 (41) AMMETER (LO INPUT)

X 16/BLACK DC CONTROL MODULE P15 (19) K-14/2 CONTACT (4)

Y 16/GREEN DC CONTROL MODULE P15 (20) K-14/1 CONTACT (1)

Z 20/VIOLET FUEL SENDER (S) P16/J16 (8) CONNECTOR (J4) FUEL GAUGE BLUE WIRE (J9)

AA (OPT) 20/BLACK ENGINE ALTERNATOR (B) PIN (OPT) INLINE FUSE# 2 (OPT) J16/J16 (7) (OPT) K-22 COIL (8) (OPT) D13 DIODE

(CATHODE)

BB 20/GREEN LOW OIL PRESS SWITCH P16/J16 (4) P15 (44)

CC 20/GREEN HI COOLANT TEMPERATURE SWITCH P16/J16 (5) P15 (3)

DD 20/GREEN FUEL SWITCH GAGE (BROWN WIRE) GREEN T/B1 NO FUEL LAMP (MINUS) (OPT) K23 COIL (13) A1 (OPT) D12 DIODE (ANODE)

EE (OPT) 20/GREEN (OPT) P15 (31) (OPT) ALT/FAN BELT LAMP (MINUS)

FF 20/GREEN LOW OIL PRESS LAMP (MINUS) P15 (34)

GG 20/GREEN HI COOLANT TEMP LAMP (MINUS) P15 (46)

HH 20/YELLOW EMERGENCY STOP (2) P15 (36)

I I 16/BLUE RUN SWITCH# 1 (4) P15 (17)

GREEN T/B2 P16/J16 (17) (12 AWG) GREENT/B1 P15 (16) (16 AWG) P16/J16 (20)

D.C. SHUNT (MINUS) POWER OFF SWITCH #1 (2) K3 COIL

LAMP TEST SWITCH GOVERNOR (E) DC AMMETER (GND)

OIL PRESSURE GAUGE/LAMP

WATER TEMPERATURE GAUGE/LAMP FUEL GAUGE J15 CONNECTOR TO (BLACK WIRE)

TACHOMETER/LAMP (BLACK WIRE) RESET BUTTON ENGINE VOLTMETER (GND)

K2 COIL (X1) HI VOLT TEST BUTTON K 18 RELAY COIL (13)

LOW VOLT TEST BUTTON OVERLOAD TEST BUTTON K14/1 CONTACT (5)

JJ 12/16/20/ GREEN

GROUND/FRAME (ALL OTHERS 20AWG)

(OPT) K22 RELAY COIL (13) (OPT) K22/1 CONTACT (9) (OPT) 21/2 CONTACT (10)

KK 20/BLUE GOVERNOR (L) P15 (47)

LL 20/BLUE GOVERNOR (M) P15 (48)


112820C

03/2006 - Rev. 01 - 2 -

WIRE

LETTER WIRE SIZE

COLOR FROM TO

MM 20/RED EXCITATION TRANSFORMER PHASE (T-1) P15 (24) T/B3 (1)

NN 20/RED EXCITATION TRANSFORMER PHASE (T-2) P15 (25) T/B3 (2)

OO 20/RED EXCITATION TRANSFORMER PHASE (T-3) P15 (26) T/B3 (3)

PP 16/BLACK OIL PRESSURE GAUGE (I) P15 (27) R-80 (INSIDE DCM)

QQ 16/BLACK WATER TEMPERATURE GAUGE (I) P15 (28) R-81 (INSIDE DCM)

RR 20/BLACK (J6) CONNECTOR T/B2 (BLACK) P16/J16 (48) K15/2 RELAY CONTACT (8)

SS 16/BLACK START SWITCH (4) BLACK T/B1 K3 COIL P15 (33) D7 DIODE (CATHODE)

TT 16/VIOLET COOLANT SENDER P16/J16 (6) WATER TEMPERATURE GAUGE (S)

UU 20/VIOLET ENGINE ALTERNATOR (A) P16/J16 (1) J-27 CONNECTOR TACHOMETER GRAY WIRE/J-28

VV 20/VIOLET OIL PRESS SENDER P16/J16 (3) OIL PRESSURE GAUGE (S)

WW 16/BLACK GOVERNOR (B) K18 CONTACT (9)

XX 20/ORANGE ACFT. PLUG SPLIT PIN (J18) CONNECTOR (J8) BLACK T/B2 P16/J16 (43) INTERLOCK SWITCH

YY 20/ORANGE INNER-LOCK SWITCH (COMMON) K15/1 CONTACT (5)

ZZ 20/ORANGE DC ON/OFF DIODES 1&2 (CATHODES) WHITE T/B1 K9 COIL (14) D 8 DIODE (CATHODE) K15 COIL (14) D 14 DIODE (CATHODE)


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WIRE

LETTER WIRE SIZE

COLOR FROM TO

AB 20/ORANGE K15/1 CONTACT (9) DC OFF SWITCH (2)

AC 12/16 BLACK (12AWG) CB7 BLACK T/B1 (12AWG) K13 CONTACT (L1)

(12AWG) K3 CONTACT (12AWG) CB3 (16AWG) K9/1

CONTACT(9)

AD 16/BLACK GOVERNOR (F) CB3

AE 20/GREEN THERMAL SWITCH GREEN T/B2 P16/J16 (46) K9 COIL (13) K15 COIL (13) D 8 DIODE

(ANODE) D 14 DIODE

(ANODE)

AF 12/YELLOW BATTERY-2 PLUS P16/J16 (22) YELLOW T/B1 K13 CONTACT (T1) CB2

AG 12/BLACK STARTER SOLENOID (S) TERMINAL P16/J16 (16) K3 CONTACT

AH 16/BLACK K-2 CONTACTOR COIL (X2) BLACK T/B2 P16/J16 (23) K9 CONTACT (5)

AI 16/BLACK ACTUATOR RED WIRE CONNECTOR (J3) SPLICE P16/J16 (13) GOVERNOR (A)

AJ 16/BLACK ACTUATOR WHITE WIRE (J2) SPLICE P16/J16 (14) K-18 CONTACT (5)

AK 16/BLACK CB1 OR (OPT) K-21 RELAY (1) BLACK T/B1 P16/J16 (15) ENGINE FUEL SOLENOID K18 COIL (14) D5 DIODE (CATHODE)

AL 12/BLACK ENGINE ALTERNATOR (B+) P16/J16 (21) CB7

AM 20/RED ALTERNATOR (T-1) RED T/B2 P16/J16 (11) CB4

AN 20/RED ALTERNATOR (T-2) RED T/B2 P16/J16 (10) CB5

AO 20/RED ALTERNATOR (T-3) RED T/B2 P16/J16 (9) CB6

AP 20/RED CB-4 T/B3 (6)

AQ 20/RED CB-5 T/B3 (7)

AR 20/RED CB-6 T/B3 (8)

AS 20/BLACK K15/2 CONTACT (12) BLACK T/B1 K-9/3 CONTACT (8) DC VOLT METER (PLUS)

AT 16/BLACK IDLE/RUN SWITCH# 1 (2) START SWITCH (3)

AV (OPT) 20/GREEN (OPT) LOW COOLANT SENSOR (BLUE WIRE) (OPT) P-16/J16 (2) (OPT)K-21 RELAY COIL (13) A1 (OPT) D10 DIODE (ANODE)

AW 20/GREEN IDLE/RUN CONTACT# 3 (1) D3 DIODE (CATHODE)

AX (OPT) 16/BLACK CB-1 OR (OPT) K23/2 CONTACT (12) (OPT) K-21/1 RELAY CONTACT (9)

AY 20/BLUE EXCITATION TEST SWITCH K-9/2 CONTACT (10)

AZ 20/BLUE K-9/2 CONTACT (2) K14 RELAY COIL (14) D 9 DIODE (CATHODE)


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LETTER WIRE SIZE

COLOR FROM TO

BA 20/BLACK K-9/3 CONTACT (12) DC ON LAMP (PLUS)

BC 16/GREEN K-14/1 COMMON CONTACT (9) D4 DIODE (ANODE) P16/J16 (29) GREEN T/B2 (J1/J3) CONNECTOR F-2

BD 16/BLACK K-14/2 COMMON CONTACT (12) D4 DIODE (CATHODE) P16/J16 (30) BLACK T/B2 (J2/J4) CONNECTOR F-1

BE 16/BLACK BATTERY SWITCH BLACK T/B2 P16/J16 (18) CB-8

BF 20/BLACK IDLE/RUN CONTACT 4 (1) DC ON LAMP (PLUS)

BG 20/BLACK POWER ON SWITCH 2 (3) IDLE/RUN SWITCH# 4 (2)

BH (OPT) 20/GREEN K-3 RELAY COIL (MINUS) (OPT) K-21/3 RELAY CONTACT (4) D 7 DIODE (ANODE)

BI (OPT) 20/GREEN (OPT) K-22 RELAY CONTACT (1) (OPT) P15/ (43)

BJ 16/BLACK (OPT) LOW COOLANT SENSOR (RED WIRE) P16/J16 (24) P15 (32)

BK (OPT) 20/GREEN (OPT) K-21/2 RELAY CONTACT (6) (OPT) D-6 DIODE (ANODE) (OPT) LOW COOLANT LAMP (MINUS)

BL 20/GREEN D3 DIODE (ANODE) DC ON LAMP (MINUS)

BM 16/YELLOW #2 BATTERY (NEGATIVE TERMINAL) BATTERY SWITCH

BN 16/BLACK CB-8 TB-1 BLACK (12 VDC) K14/2 CONTACT (8)

BO 16/BLACK INLINE FUSE# 1 BLACK T/B1 J16/P16 (31) BLACK T/B2 (OPT) CORNER LAMPS

BP 16/BLACK (OPT) INLINE FUSE #2 P16/J16/ (25) BLACK T/B1 J16/P16/ (19) (OPT) K-22 COIL (14) A2

(OPT) D13 DIODE (CATHODE)

BQ NOT USED

BR (OPT) 16/BLACK CB-1 (OPT) K23/2 CONTACT (4)

BS (OPT) 20/GREEN (OPT) K21/3 CONTACT (12) (OPT) K23/1 CONTACT (9)

BT NOT USED

BU (OPT) 20/GREEN K23/1 CONTACT (1) K22/3 CONTACT (4)


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WIRE LETTER WIRE SIZE COLOR FROM TO

MAG WIRE 20/WHITE MAG PICK-UP P16/J16 (34) ENGINE GOVERNOR (C)

MAG WIRE 20/SHEILD END OF CABLE P16/J16 (35) ENGINE GOVERNOR (D)

MAG WIRE 20/BLUE MAG PICK-UP P16/J16 (36) ENGINE GOVERNOR (D)

DC CABLE (PLUS) 16/BLACK DC CABLE END J-16CONNECTOR J-6 CONNECTOR/WIRE [RR] TB-2 (BLACK)

DC CABLE (MINUS) 16/WHITE DC CABLE END J-16CONNECTOR J-14 CONNECTOR/WIRE [A] TB-2 (GREEN)

DC CABLE (INTER-LOCK) 16/GREEN DC CABLE END J-16CONNECTOR J-8 CONNECTOR/WIRE [XX] TB-2 (WHITE)

APPENDIX II

28.5 VDC ELECTRICAL SCHEMATICS (pages 1 – 5)

APPENDIX III

SPEED CONTROL UNIT

APPENDIX IV

ELECTRIC ACTUATOR

APPENDIX V

ALTERNATOR OPERATION AND

MAINTENANCE MANUAL

APPENDIX VI

Declaration of

Conformity

Declaration of Conformity

Ground Power Unit (Electric Motor Driven)

Relevant draft complied with by the machinery:

prEN 1915-1:1995

Relevant standards complied with by the machinery:

prEN 982:1996 prEN 60204-1:1997

HFPA/JIC T2.24.1-1990 ISO 4021:1997

ARP 1247B NFPA 70/NEC 1999

Identification of person empowered to sign on behalf of the Manufacturer:

Quality Assurance Representative

Tronair, Inc. 1740 Eber Road

Holland, Ohio 43528-9794 USA

Telephone: (419) 866-6301 • 800-426-6301 Fax: (419) 867-0634

Web Site: www.tronair.com E-mail: [email protected]

112820c technical revor 06-06 - tronair

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