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1 OPERATION & MAINTENANCE MANUAL AND PARTS LIST FOR GPU 400Hz GA90V120 GROUND POWER UNIT CHAPTER 3 OVERHAUL/MAJOR REPAIR 03/12/09 -Page 1 -

2 CHAPTER 3 TABLE OF CONTENTS Overhauls/Major repair Chapter/Section Page TROUBLE SHOOTING... 4 CLEANING Cleaning engine Cleaning GPU (Ground Power Unit)...15 ENGINE ALTERNATOR /12/09 -Page 2 -

3 COMPONENT OVERHAULS This section deals with the overhaul/repair of components within the GPU Ground Power Unit. The majority of repairs to the ground power unit are carried out by the replacement of defective parts. This section details the procedures recommended for the overhaul of the components after the removal from the Ground Power unit as detailed in Chapter 2 Section 3, Removal / Installation. There are specific overhaul periods recommended. The engine should run for many thousands of hours without requiring major attention, but should the engine be removed for a major repair after a considerable period of service, it is advisable to overhaul the unit or fit a factory reconditioned replacement. With the engine removed for overhaul or repair it may be found convenient to overhaul the generator and/or other major components at the same time. PAOS La Saussaye BP 29 Rue du Rond d eau SAINT CYR EN VAL FRANCE Tel: (33) Fax: (33) info@guinault.com Web site: 03/12/09 -Page 3 -

4 TROUBLE SHOOTING ASSISTANCE DIAGRAMS 8 situations of possible malfunction are explained hereafter : SITUATION 1: Ignition switch on position 1 : thing happens. SITUATION 2: Ignition switch on position 1 : Only the fuel gauge, the ignition pilot light and the hour meter are supplied. Nothing else happens ( lamp test). SITUATION 3: Ignition switch on position 1 : The lamp test is carried out. At the end of the lamp test, the FAULT pilot light lights up. It is t possible to start or reset the fault. SITUATION 4: After the lamp test and after pressing on START push button, the engine doesn t start. SITUATION 5: Ground Power Unit is in operation. GPU stops, the FAULT pilot light turns on. SITUATION 6: Ground power unit is in operation: the "FAULT" pilot light lights up and the 400Hz pilot light blinks. The ground power unit stops : Do t reset. 03/12/09 -Page 4 -

5 RECOMMENDATIONS In case an action has to be carried out on the thermal engine, it can be necessary to act on the gain and stability engine controls in order to erase the instability of the transient performances. For any action, please contact the GUINAULT after sales department. Make sure that these problems do t come from an engine fault (please refer to the engine operator handbook supplied with the ground power unit.) In case some boards have to be changed, please contact GUINAULT after sales department in order to test or to repair them. In case of an engine problem (power loss, functioning fault), please refer to the CUMMINS engine operator handbook). Whatever the problem is, it must be solved by a highly qualified technician. ANY WORK on the engine, opened capy, engine in rotation, is forbidden to any unqualified person. Required test materials : * Mechanical engineer's tools set * Universal multimeter (ex. Fluke 8060A) * Electric tools kit. Take all necessary precautions and locate the different parts before carrying out any maintenance on the ground power unit. BEFORE ANY WORK ON THE GPU, DISCONNECT THE BATTERIES. 03/12/09 -Page 5 -

6 REMINDER OF THE CONSEQUENCES OF THE FAULTS ON THE GROUND POWER UNIT ENGINE FAULT: Engine stop + lightening of the FAULT pilot light + display of the corresponding fault code on LEDs DISPLAY board RS669V2. VOLTAGE / FREQUENCY FAULT: Engine stop + lightening of the FAULT pilot light + blinking of the 400Hz pilot light. 400Hz INTENSITY FAULT: Opening of the 400Hz contactor + lightening of the FAULT pilot light and blinking of the 400Hz pilot light ( engine stop in order to ensure unit cooling). Please refer to the electronic boards documentation for more information 03/12/09 -Page 6 -

7 SITUATION 1 : Ignition switch on position «1» : thing happens Batteries fitted? Fit batteries Connect batteries Close Batteries connected? Manual battery disconnector closed? FCB (RS678) Correct? Does switch 1 work properly? Check wiring, connections, call GUINAULT technical support 03/12/09 -Page 7 -

8 SITUATION 2 : Ignition switch on position 1 Only the fuel gauge, the ignition pilot light and the hour meter are supplied. Nothing else happens. (No lamps test). Unlock the emergency stop Check the connections RS769 if necessary Emergency stop unlocked? FG fuse (RS678) OK? FRS fuse (RS678) OK? KCB relay (RS678) supplied? Open the electrical cabinet Led DV 10 on RS769 lit? F1 on RS769 RS678 Principal pole KCB closed? Check wiring RS769 03/12/09 -Page 8 -

9 SITUATION 3 : Ignition switch on position 1 : the lamp test is carried out. At the end of lamp test, the "FAULT" pilot light lights up It is t possible to start or reset the fault. On Off Check the connections and the wiring RS769 Fault code on RS769 Display of the high water temperature fault (HTE) on the led display board Fault code (RS679 red LEDs) DV6 DV5 DV4 DV3 DV2 DV1 Does the HTE sensor work correctly? Unit having worked? - let the unit cool down - check the cooling circuit - check the engine fan - complete the cooling circuit if necessary (See on the following page) 03/12/09 -Page 9 -

10 SITUATION 3 Continuation : (From the previous page) On Off Display of the low water level fault on the led display board Fault code (RS769 red LEDs) DV6 DV5 DV4 DV3 DV2 DV1 Complete the coolant level Unit under operation? Is the coolant level OK? Let cool down (the engine water circuit is under pressure) - Check the sensor supply - Check the connections between the sensor and the RS769 board. - Check the sensor functioning - Check the RS769 functioning Display of the water presence in fuel fault on the led display board Fault code (RS536 red LEDs) DV6 DV5 DV4 DV3 DV2 DV1 Drain the water in the fuel primary filter, then press the fault reset push button Does the fault can be resetted? The GPU can be started. End of troubleshooting - Check the sensor supply - Check the connections between the sensor and the RS769 board. - Check the sensor functioning - Check the RS769 functioning 03/12/09 -Page 10 -

11 SITUATION 4: After the lamp test and after pressing on "START" push button, the engine does t start. Does the starter run? Check the wiring FD fuse (RS678) Ok? Is the starter s coil properly supplied? Starter out of order «+» of the battery present on the «+» terminal of starter? Connectors on RS769 and RS678 well connected? Connect properly Does RD relay (RS678) work properly? (to be checked separately) relay - Check the batteries - Check the starter - if necessary - Check the engine flywheel Repair conection Check the fuel pump and the fuel circuit. Is the engine correctly driven by the starter? Is the engine controller supplied? Connection to speed sensor Check the CUMMINS ECM FRN fuse (RS678) and F2 fuse ( RS769) Does the RRN relay (RS678) work correctly? RS769 Does the START Push button work properly? RS769 03/12/09 -Page 11 -

12 SITUATION 5 : Ground power unit is in operation The ground power unit stops, the "FAULT" pilot light turns on. (See on following page) On Off Display of the oil pressure fault" on the Oil LEDs pressure display fault board DV6 DV5 DV4 DV3 DV2 DV1 Display of the battery charge fault" on the Battery LEDs load display fault board DV6 DV5 DV4 DV3 DV2 DV1 Display of the aif filter clogged fault" on Air the filter LEDs clogged display up fault board DV6 DV5 DV4 DV3 DV2 DV1 Oil drain and fill up with recommanded oil Check the oil pressure pump if necessary Is oil level SAE oil category respected? Does the oil pump work correctly? Does the oil pressure sensor work correctly? Does the RPH relay work properly? Check the alternator / batteries connection (wire B+) Check the battery charge alternator Put back into operation and check the current supplied by the battery load alternator. Put back Intensity > 4 A? Is D+ terminal of alternator properly connected? Does the clogging-up microswitch operates correctly? Air filter clogged up? air filter according to maintenance manual Check the wiring Check the board RS769 Check the ECM Check the wiring between the D+ and the RS769. Check the board RS769 Check the wiring between the sensor and the RS769. Check the board RS769 03/12/09 -Page 12 -

13 SITUATION 5 - Continuation: (See on previous page) On Off Check the board RS769 Display of the engine fault" on the LEDs display board Engine fault DV6 DV5 DV4 DV3 DV2 DV1 Are Warning or Fault lights on? Check the blinking code on CUMMINS diagsis device, then contact your CUMMINS dealer. 03/12/09 -Page 13 -

14 Carry out the test again. Check the connections Suspect RS532 SITUATION 6: Ground power unit is in operation: the "FAULT" pilot light lights up and the 400Hz pilot light blinks. The ground power unit stops : Do t reset. Led CR64 on RS532 lit? Check the CUMMINS ECM parameters Check the adjustment and the functioning of the voltage regulator. if necessary Check the connections on board RS532 Put back into operation Is frequency Open the electrical cabinet without neither switching off r resetting Check the displayed fault on board RS532 Is voltage Does the fault appear again? Check the connections board over voltage or over frequency Put back into operation under the same conditions and check the voltage and the frequency Led CR14 or RS532 lit? Check the fuel circuit. Check the CUMMINS ECM parameters Are Fu6, Fu7, Fu8 fuses Is FRV fuse (RS678) Under-voltage or under-frequency Put back into operation under the same conditions and check the voltage and the frequency Is frequency Is voltage Check the connections on board RS532 and put back into Is the problem fixed? RS525 Is functionning Does the fault appear again? RS532 End Check the alternator (Measurement of resistances isolating resistances. Test with separated excitation) End 03/12/09 -Page 14 -

15 CLEANING 1. Cleaning engine WARNING : DO NOT USE DIRECTLY ON HIGH PRESSURE SPRAY THE ENGINE - Degreaser mixt with water (mixture ratio according to the manufacturer s) - Spray the mixture on the sides to clean with the spray - Leave on for 5 to 10 minutes - Clean with a clean cloth or clean water (do t used pressurized water) - Expel moisture in compressed air - Start the engine and let rise in temperature gradually 2. Cleaning GPU (Ground Power Unit) The Ground Power Unit bodywork and chassis can be cleaned with high pressure spray warm water with additive (car shampoo for example). Caution : - Spray distance : minimum 12 in - Spray pressure : 30 bar - DO NOT SPRAY WATER ON THE CONTROL PANEL - REMOVE THE POWER CABLES FROM CABLE TRAY TO PREVENT INFILTRATION OF WATER INTO THE ELETRICAL OUTLETS - PROTECT THE CANOPY S HOLE LOCATED BEHIND THE PLUG BOX. - DO NOT ORIENTATE THE WATER FLOW IN DIRECTION OF THE TOWBAR POSITION SENSOR - DO NOT CLEAN THE ROLLER EXTREMITIES WITH A HIGH PRESSURE SPARY (ROLLERS LUBRICATION) 03/12/09 -Page 15 -

16 ENGINE If the engine needs to be overhauled, we recommended that a certified Cummins service station do the work. Special tools and fixtures are needed to overhaul this engine and the cost of having a service station do the work is well invested. Regular maintenance and tune-up information is located in Chapters 2. Follow the Removal and Installation instructions in Chapter 2 when removing the engine for overhaul. Adjustments and test procedures are most applicable to testing and adjusting the engine after a major repair, replacement of parts, or an overhaul. 03/12/09 -Page 16 -

17 ALTERNATOR If the generator needs to be overhauled, follow the Removal and Installation instructions in Chapter 2. Before attempting to overhaul the generator, be sure that all of the trouble shooting steps have been followed. Adjustments and test procedures are most applicable to testing and adjusting the generator set after a major repair, replacement of parts, or an overhaul. 03/12/09 -Page 17 -