Scribd Logo
Upload

Welcome to Scribd!

  • HOUCHIN Operation Maintenance and Parts Manual - GPU-C690-140

    Uploaded by

    Izeddin Hussein Ibrahim
    3K views129 pages
    HOUCHIN C690 Ground Power unit

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document
    HOUCHIN C690 Ground Power unit

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    3K views129 pages

    HOUCHIN Operation Maintenance and Parts Manual - GPU-C690-140

    Uploaded by

    Izeddin Hussein Ibrahim
    HOUCHIN C690 Ground Power unit

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 129
    Technical Manual Ground Power Unit Model C690/140/DV/UNI vovenn seposence Ce er este ry mecamons ‘SAFETY PRECAUTIONS FOR HOUCHIN EQUIPMENT ‘To be read attentively and acted on accordingly betore towing, iting, opeating, performing maintenance of repairing the equipment itmooucrion. ‘Tha poy f Houetin Revspace to provide the uses ol ha equipment wih ste, reliable and ctclent proguct, Favors taken ino acount are among ors (@)_Therntonded and predictable tute use of the products, and the environs in which they re expects io operat, (©) Applicable nes, coses an regulations. (©The expected ust product te, assuming rope saree and maintenance, (@)_Protiding a manus wth uptodate intra. Belore hang any produc take tie to read he relevant insructon manual Besides glng detated operating mstuctions, alco ves space nfomaton about salty, preventive maintenance, ec: his suggested nat the manual is kept at the unt lato, e porsonel ty accesible to he operating Seo the salt precautions forthe equipment, which are mentioned on the equipment r pats of the Uni. Those saely procaine are goneral and some satements wil neteore nt sways apply 10 & patieuar unt COniy peopl hat have the right ils shoul be alowed o operate, at, petam maintenance or ‘epai Houcin Aerospace equipment. Is he responsiy of management to appt operators wih the appre aiing ara hls or each ealegory ole. ‘Aso someone who rane inal aspects of operating he unit ans aio to know the satety ‘spect \winen handing, operating, overhauling andr porting mantonane or ep on Houchin ‘Aerospace equipment uso sale enghering practices and abuerve a eleva cel safely ‘ectarements he allowing let isa reminder o speci salty Scocives snd precaons mainly ‘ppicabl to Houein erogpace eaupmen Noglocting the sey precautions may (a) Endanger peopl as welas envronmont and machinery (0) Endangor people de o etc, mechanical or chemical ences (©) Endanger he envronment de o leakage fol solvents oor substances. () _Endanger he machinery duet uncon fares. Responsibly er any damage or ij resting rom neglecting these precatons or by non ‘observance of easonable caution and due car requred in handing. operating, maiionanco ‘ear ao not express} menioned inthis atrucion manual, le dislaimes ty Houshn Aerospace, NOVEMBER 2008 PAGE 1 eee ‘The manufacturer doos not accept ary ably er ny damage sing rom he use of ron-crignal pare andlor modiietons,addtons or conversions made wihout tne mansaclwre’s wpprvelin ‘ring. Hany statement inthis manual oos nt comply wih local lela, tho stile of he wo shal be apple’ ‘Stalemonts these salt procauton shuld not be inerpeted as suggestions, ‘ecommendatlons or inducement at tay shoul be used volation any apptcabe awe or ‘equatlons GENERAL SAFETY PRECAUTIONS. 1 The osmorisosponsiblformaintining he wnt in 2 sate operating conden. Uni pats and accessories most be replaced missing o” Unease oporaion 2 Tho suponisor, or the responsible parse, shal a al ios mako cur that allinstuctons regarding machinery and equpmentoperaton and ainenance ar sicly fotower and al te mactines wit ll accescois and safety dave, 25 we a he consuming davies, aren good repr, ree of tora wea or abuse. 3 Whonover har is an indeaton or ay suspicion tha an intel part of a Machine s overheated, te machine call be stopped but no nspecton covers shall bo opened bear suicent cooing te Nas elzgsed Ds 0 avo the ik of spontaneous ignitor of vapour whon ais admitod. 4 Operate he unt ony for the tends purpose and within A aed nts (Pressure, temperate, spoods et) 5 Themachinory and equipment shal be kept clean, Leas too as possible from of ua reher amt depot, 8 Areguatng and satety doves shal bo maintained wh duo care o ensure ha hy ‘unten propery. They must net be peut of acon, 7 Safety devices shal bo tasted as desorbed in he maintenance schedule of ‘he nctuction manual determine hal hey are good operating conn, 8 Payattention tothe markings and information labels on he nit 9 nthe event he safety abels ae damaged or destoyed, toy must be reptaced fo ensure ‘pera sally. 10 When working on the uni. wea safty cating, Dopanding onthe king of ‘etvtios those ate sally glasos, ear protect, salty Paet(ncudng vie), safoly ‘loves, potecive ceting, sally shows 11 Take precautons agains! tre. Handle ful land ant-teeze with care ‘because they ae ammadie eustances.Oo'not smoke or approach wih naked fame when Iancing Such substances, NOVEMBER 2008 PAGE 2 GROUND POWER UNIT MODEL C690 RECORD OF REVISION Rev. | Insertion | By | Rev. | Insertion | By | Rev. | Incortion | By No. | Date No. | Date No. | Date 1 | 220506 | BER 2 | (anos | BER 3 | zeros [DAW Retain this recordin the front of manual On receipt of revisions, insert revised pages in the manual and enter revision number, date inserted and initials. GROUND POWER UNIT MODEL C590 REVISION No.3 This revision covers the following: (1) Output voltage error quoted in manual from governor controller GAC 5111 (12 to 15 volts should have read 9V). Flamove the folowing documents: Section 4 Pages7&8 1 leaf ‘Add the following documents: Revision No.3 highlight leat Section 4 Pages7&8 1 leat Please revise your manual and enter Revision No.3 dated 24 October 2006 in the record of revisions at the front ofthe manual GROUND POWER UNIT MODEL C690 REVISION No.2 “This revision covers the following: (1) Modification to engine sump drain to allow more gap between engine ‘sump drain and chassis. Remove the following documents: Section 8 Pages 23 -26 2loaves |Add the following documents: Revision No.2 highlight 1 Neat Section 8 Pages 23 - 26 2ieaves Please revise your manual and enter Revision No.2 dated 12 October 2006 in the record of revisions at the front of the manual ‘SUPPLEMENT GROUND POWER UNIT MODEL C600 1. General HOUCHIN SUPPLEMENT No.284 “The ground power unt supplied ails from the stancard unit, Medal C880, as described in the Technical Manual as follows: - @ Flashing beacon kit fited 2. Special Parts: ‘A list of sparo parts special to the modified ground power units tached. This ist ‘ust be used in conjunction with Chapter 8 of the basic technical manual. Only ‘those parts considered to be wearing parts or consumable items ar listed. item | PartNo. Description nits |e. por Assy [7 Pem0-714 | FLASHING BEACON KIT TA | 0900-819 | BEACON i 18 | 755-0060 |. TOGGLE SWITCH 1P ON/OFF 108 + iC | 752-4968 |" TERMINAL 0115 116.07 2 ‘SUPPLEMENT TOVENBER 2005 PAGE 1 SUPPLEMENT eee End of Supplement GSU geet we OER coe PAGE 2 GROUND POWER UNIT MODEL C690 HOUCHI ‘TABLE OF CONTENTS ‘SECTION 1: INTRODUCTION PAGE INTRODUCTION 1 ENGINE 2 ALTERNATOR, 2 CONTROL PANEL 2 TRANSFORMER RECTIFIER UNIT (OPTIONAL) 2 (CURRENT LIMIT CONTROL 3 OUTPUT CABLES. 3 TRAILER AND CANOPY 3 GENERAL DIMENSIONS, 4 OVERALL DIMENSIONS 4 weichT 4 TyAES 4 ENGINE a ‘CAPACITIES 4 RECOMMENDED FLUIDS AND LUBRICANTS: 5 pata 5 GPU MODEL 690190 (WITH CUMMINS ENGINE TYPE 68TS 90-152) 5 GPU MODEL 690/100 (WITH CUMMINS ENGINE TYPE 6875.90-152) 6 GPU MODEL 6901140 (WITH CUMMINS ENGINE TYPE 6BTAE.9C200) 7 ALTERNATOR CHECK DATA, 7 ALTERNATOR ASSEMBLY DETAILS 7 Way 2006 ‘CONTENTS PAGE 1 GROUND POWER UNIT MODEL C690 SECTION 2: OPERATION GENERAL PARKING AND TOWING PRE-START CHECKS FNGINE STARTING - NORMAL USE OF COLD START AID ENGINE WARM-UP AND IDLING USING THE 200V AC OUTPUT OBTAINING A 200V AC OUTPUT DISCONNECTING THE 200V AC OUTPUT STOPPING THE ENGINE USING THE 28V DC OUTPUT (WHEN FITTED) OBTAINING A 28V DC OUTPUT DISCONNECTING THE 28V DC OUTPUT ‘SPEED ADJUST CONTROL VOLTS ADJUST CONTROL \VOLTSIAMPS SELECTOR SWITCH EMERGENCY STOP PUSHBUTTON CONTENTS PAGE2 way 2006 GROUND POWER UNIT ‘MODEL C80 HOUCHINI ‘SECTION 3: ROUTINE MAINTENANCE PAGE. SAFETY PRECAUTIONS 1 GENERAL 1 SERVICING NOTES 1 SERVICING RECORD 1 FLUIDS AND LUBRICANTS 2 ENGINE SERVICING 2 ENGINE COOLANT 2 ENGINE O1L CHANGES 2 FUEL REPLENISHMENT 2 BATTERY CHARGING SYSTEM 2 SERVICING ACCESS 3 SERVICING SCHEDULES 3 ‘SUMMARY OF SERVICING ATTENTION 3 DAILY INSPECTION 4 [EVERY 250 RUNNING HOURS OR MONTHLY (B CHECKS) 4 EVERY 500 RUNNING HOURS OR BLMONTHLY (C CHECKS) 5 EVERY 1000 RUNNING HOURS OR 3-MONTHLY (0 CHECKS) 5 ENGINE COOLANT REFILL PROCEDURE 6 SHIPPING 7 ‘TIE DOWN POINTS 7 PACKING PRECAUTIONS 7 STORAGE 8 May 2006 ‘CONTENTS PAGES GROUND POWER UNIT aRDiAS ‘MODEL C590 HOUCHIN ‘SECTION 4: ADJUSTMENTS ‘ADJUSTING THE BRAKES BRAKE SHOE CLEARANCE ADJUSTMENT ‘ADJUSTING THE AUTOMATIC BRAKE MECHANISM ADUUSTING THE OVERRUN BRAKE CABLE [ADJUSTING THE CROSS: CABLES ADJUSTMENT OF WHEEL HUB BEARINGS ADJUSTING THE THROTTLE LINKAGE POSITIONING THE GOVERNOR MAGNETIC PICK-UP ENGINE SPEED (FREQUENCY) COARSE ADJUSTMENT FINE ADJUSTMENT OVERSPEED TRIP ADJUSTMENT ENGINE PROTECTION START DELAY ADJUSTMENT ADJUSTMENT OF AG PROTECTION UNIT ADJUSTMENT OF OC PROTECTION UNIT (WHEN FITTED) 40H OUTPUT VOLTAGE ADJUSTMENT DC OUTPUT VOLTAGE ADJUSTMENT (CURRENT LIMIT ADJUSTMENT CONTENTS PAGE 4 ‘MAY 2006 sono sown [SECTION 5: FAULT DIAGNOSIS: PAGE GENERAL 1 FAULT NO. 1 - BATTERY CHARGE LAMP FAILS TO ILLUMINATE WHEN THE ENGINE START SWITCH IS ON 3 FAULT NO. 2- ENGINE FAILS TO CRANK WHEN THE START SWITCH IS OPERATED TO THE HS POSITION 4 FAULT NO. 3 ENGINE CRANKS BUT FAILS TO START AND IDLE AT ANY SPEED 5 FAULT NO. 4 MALFUNCTION OF ENGINE PROTECTION SYSTEM 6 FAULT NO. 6 - ENGINE WILL NOT FUN UP TO SERVICE SPEED 7 FAULT NO. 6 ALTERNATOR FAILS TO EXCITE WHEN EXCITE SWITCH IS OPERATED 8 FAULT NO. 7- ALTERNATOR GIVES INCORRECT OUTPUT 9 FAULT NO. 8 - A.C, OUTPUT CONTACTOR FAILS TO CLOSE AND, RETAIN WHEN BYPASS IS SELECTED 10 FAULT NO. 9- A.C. OUTPUT CONTACTOR FAILS TO RETAIN WHEN IN| INTERLOCK " FAULT NO. 10 - A, PROTECTION SYSTEM IS FAULTY 2 FAULT NO. 11 -T:A.U. CONTACTOR FAILS TO CLOSE WHEN THE D.C. ON SWITCH IS PRESSED 13 FAULT NO. 12 -T.R.U. GONTAGTOR DOES NOT RETAIN WHEN THE D.C. ON SWITCHIS RELEASED. VOLTS CORRECT 4 FAULT NO, 13 -T.R.U, PROTECTION SYSTEM IS FAULTY 16 way 2006 ‘CONTENTS PAGES GROUND POWER UNIT ‘MODEL C890 HOUCHIN ‘SECTION 6: ASSOCIATED DRAWINGS DRAWING No. CONTENTS may 2008 PAGES GROUND POWER UNIT ‘MODEL C890 HOUCHING ‘SECTION 7: GAC ENGINE GOVERNING EQUIPMENT ESDS111 Speed Control Unit 225 Seties Electric Actuator Magnetic Speed Sensors ‘May 2006 ‘CONTENTS PAGE7 ‘GROUND POWER UNIT MODEL C590 HOUCHIN ‘SECTION 8: SPARE PARTS LIST INTRODUCTION ORDERING GENERAL ASSEMBLY CHASSIS ASSEMBLY TURNTABLE AND TOWBAR ASSEMBLY RADIATOR INSTALLATION FUEL TANK ASSEMBLY FUEL LINE INSTALLATION ENGINE EXHAUST INSTALLATION REAR AXLE ASSEMBLY ENGINE/ALTERNATOR ASSEMBLY AIR FILTER INSTALLATION ENGINE SUMP DRAIN ASSEMBLY ALTERNATOR ASSEMBLY ‘CONTROL PANEL ASSEMBLY (External Components) (CONTROL PANEL ASSEMBLY (Internal Components) [AG CONTAGTOR PANEL ASSEMBLY ‘TRANSFORMER RECTIFIER UNIT ASSEMBLY (WHEN FITTED) CONTENTS PAGE@ " 13 15 WAY 2006 GROUND POWER UNIT ‘MODEL. C890 HOUCHING ‘SECTION 1: INTRODUCTION The Hovchin 690 range of ground power units is designed to provide ground power servicing factity for tho AC and DC systems of al types of aircraft, ‘The untis powered by a Cummins “B" series 6-ylinder water-cooled dese, criving a Houchin brushless S-phase alternator through a steel drive disc coupling ‘Tho unt protected by a weatherproof canopy designed for maximum access and noise attenuator way 2006 SECTION 1 PAGE 1 GROUND POWER UNIT ‘MODEL Ca90 HOUCHIN ENGINE ‘The Cummins B series engine i ited with elactical starting, a speed contol system and a battery charge atlemator. Automate shutdown devi protect the engine inne event of low al pressure, high water tomporature or overspeed. ‘A dotaled description wil be found in the accompanying Cummins Publication. ALTERNATOR (Retr to Section 1 page 7) ‘The altomator isa staic-armature brushless machine, wound to give an ouput of 200V ne, 400H2, S-phase, 4a, when running at 2400 rpm. “The rotor crive end is cecty coupled tothe engine tiwhee! through a steel dsc coupling, The slator is boted othe tlywheet housing. The non-drve end ofthe rotor is supported by a single spherical olr bearing, which is ibreated traugh a grease nipple fited with an ‘extension tube Intay the alternator is excted by the starter battery, which energses the stor exiter field windings. This induces a current in the auxiliary windings on the rotor. This is rected by the rotating diode assembly and fed tothe stator fed windings, art the alternator begins to praduce an output The APU swiices ofl ho ballory excter supply ‘whon the exctaton s sel-sustainng. The exctation current is controled by te automatic voltage regulator AVR. ‘A centitugal fan mounted on a carer rng atthe bearing and ofthe rotor cools the allemator. Airfow is trough the endshiol, over the altemator windings and ut through the stator atthe couping end ofthe altemato. ‘CONTROL PANEL “The contol pane, including the output switchgear, s mounted on a hinged support at the ‘ront end ofthe unis, protected by a hinged Perspex cover. The compte cairo pane! {and support can belted ona hinge to expose the (optional) 28V DC Transtorner Rectifier Unit ‘AC CABLE(S) AG output cabo(s), 7.6m eft ong, 4-core, 7omme, terminating ina standard 6pin irra Connector, i ited as standara ‘OPTIONAL AC CABLE(S) LENGTHS ‘AC output cabe(s), 10m eff long, 4-core, Zone, terminating ina standard 6 pin ara Connector. ‘AC output cabo(s), 15m eff long, 4-core, 7omme, terminating na standard pin alrrat connector SECTION 1 way 2006 PAGE 2 TRANSFORMER RECTIFIER UNIT (Optional) ‘Tho 28V DC transformer rectfir unit (TRU) assembly i, wien ited, bolted directly to the chassis flor beneath the hinged control panel support..‘The TRU operates from the 200V 440042 output from the alternator. The power rect and output switcing contact are located in the enclosure below the contol panel. The contol cculs,seftches and indicator amps are added toa secton ofthe control panel facia, ‘The output is regulated by adjusting the 400Hz AC input. If the 28V OC supply isin use the 400H2/200V AC supp 6 unavalabe Tor external use OPTIONS (tt Fitted) CURRENT LIMIT CONTROL, ity tis device fited, the output curont ofthe TAU can be limi within the range 500A 1500A. A Swiich fitted to allow the current limiting to be selected ON oF OFF as requ. Dc OUTPUT CABLE ‘A 26V DC output cable, OMS long, 4-core, 7mm, texminaing in a standard 3 pin connector may be ited ‘TRAILER AND CANOPY “The equipment is mounted ona four-whee! taller vithin a weatherprocl canopy, with ‘integral cable stowage compariments on either side. The ali ited with semi-liptical leat spring suspension, umtable steoring and pneumatic tyres. The fue tank is mounted transversely, underneath the talr, between the wheels ‘The front whee! brakes are automatically actuatod when the towbar is in ether the lowored position or the raised stowed poston. ‘The towbar has an overrun brace mechanism and ‘rose-cable operated drum brakes fited to the font wheels “The equipment is enclosed by a canopy wich sin two sections which run on nylon wheels in tracks. The contol panel (ont) section sides boneath tho rear (angine) section to allow ‘access tothe elctrizal swicngear. The engine section slides forward lor access to the fengine. Tho Sections are secured in their normally closed postions by toggle fasteners. ‘The canopy soctons are lined with acoustically absorbent material anda noise-reducing air dallector sited at he rear (radiator ond) ofthe tral. May 2006 ‘SECTION 1 PAGES GROUND POWER UNIT MODEL C590 GENERAL DIMENSIONS OVERALL DIMENSIONS: Length towbar up) Length towbar down) with Height Whestbaee Track (ron) “Track (eat) WEIGHT ual Votage Unit RI Typarsize Pressure “Maxamum Towing Speed ENGINE alos Spoed il Pressure Low Oil Pressure Protection Coating System High Temporature Protection lectronie Speed Governor ‘Cold Start Aid (en fited) ‘overspeed Protection 606mm “450mm 755mm 680mm s97mm 4015mm 470mm -2480Kg (approx) 18x7x8 ph, 7 bar (100K8n2) ‘2k (15 mph) 2400 rpm > 20bbin2 (22kg/em2) at 2400 rpm ‘Automatic shutdown at 10 lone (0,7kglem2) Reciculating type with thermostatic contol, preseurised to Mibin2 (0 Skglem2) ‘Automate Shutdown at 99 degC Gacsint Ether ijoction with electric contro valve ‘Automate shutdown at 2640 rom CAPACITIES Engine Lubricating Oi System 20 tres Coating Syetom 33 Moe Fuol Tank Capacity 275 tre SECTION T May 2006 PAGE 4 eer RECOMMENDED FLUIDS AND LUBRICANTS. Fuel Oi Spectcation ‘See the Cummins Operation and Maintenance Mana Engine Coolant (all seasons): ‘above “37 deg ‘A mixtuce of 50% water and 50% ethylene ‘lyeorbased antireez below -37 degC ‘Armixuce of 40% water and 60% ethylene ‘yeorbased antroeze Stooring Turtable ‘Sprint EP2 grease Brake Cable ‘Sprint EP2 grease Leat Spring shackles, ‘Sprint EP2 grease Wheel Hub Bearings ‘Sprint EP2 grease ‘Alternator Endshield Bearing ‘Shel Alida F2 grease ‘Mechanical Control Linkages Engine Oi Cold Start Fis Flestguard GWA Part No, 258345 DATA GPU MODEL 690/00 (with Cummins engine type 6BTS.9C-152) ouput 200V AC 400H2, Phase Avie Continuous AC rating: SORVA at a power factor of 0.8 - 1.0 lagging Intermitient AC rating 103KVA at 08 pf lagging, fr 1 nour in 12 at ‘normal iemperature pressire Reserve rated ouput avaiable +44 deg C ambient at up to 8000 1¥1000" ‘tua Noise reduced to: SABA 41-348 at 4 mee ‘28 DC Output (when fitted) ‘Continuous Rating 8008 Intermittent Rating 25008 MAY 2006 ‘SECTION + PAGES Ground MODEL C690 Output Continuous AC rating Intermittent AC rating: Rosorve rated output available Noise reduced to 28V DC Output (when ited) Continuous Rating Intermittent Rating ‘GPU Model 690/100 (with Cummins engine type 6BTS.9C-152) 200V AC 400Hz, 8-Phase 4 wire 5dBA 4/9484 at 4 meties 2008 25008 ‘GPU Model 690/140 (with Cummins engine type 6BTAS.6¢200) output Continuous AC rating Inormitont AC rating: Reserve rated output avaliable Noise reduced to: 28V DC Output (when fitted) Continuous Rating Intermittent Rating ‘SECTION PAGES 10OKVA at a power factor 0.8 - 1.0 lagging 1 15RVA at 0.8 pf lagging for 1 hour in 12 at normal temperature pressure +444 dog C ambiontat up to 3000 f1/1000m altitude 200 AG 400H2, Phase 4 wire 140KVA at a power factor 0.8 1.0 againg 161KYA at 08 pf lagging for 1 hour 12 at roemal femporatire pressure +44 dog C ambiont at upto 3000 f/100¢m attude SABA +/-34BA at 4 metres 25008 MAY 2006 GROUND POWER UNIT mMobeL cos0 HOUCHINI Alternator check data: 1G resistance of windings. The resistance values of the windings at 201C are as follows: Modo! 90/100KVA Exciter ld winding 0.96 ohms Main stator windings 0.0044 ohms por phase Exciter roto windings (0.28 ohms per pase Main rotor windings 3.1 ohms Model 140KVA Exciter ld winging 1.25 ohme Main stator windings 0.002 ohms per phase Exeitor rotor windings (0.322 ohms per phase Main rotor windings 3.7 ohms. Alternator assembly detail Drive diss to engine flywheel serow torque seting: 25041 (35Nm) (Gecure using Loctte 270 tneaclocker) Drive diss to alternator rotor shaft screw torque setting 12511165 5m) tometer diodes to rotor torque setting 3b in 58m) MAY 2006 SECTION 1 PAGE Figure 1: Typical View with Control Canopy Retracted (Fuol Tank Guards Not Shown) CContral Panel Contral Panel Support Hinge Bar Control Panel Support Canopy Section - Gontol Panel Ena Engine Ar Fier ‘40042 Alternator Location for Fastening Canopy Tie Down Points for fe Grouns Power Unit Stooring Turtable Brake Compensator and Cross-Cables Towing Eye Tonbar ‘Towbar Catch Fuel Filler Cap Fuel Contents Gauge SECTION 1 MAY 2006 PAGE 8 GROUND POWER UNIT MODEL C690 HOUCHING Figure 2: Typical View with Engine Canopy Retracied {Fuel Tank Guards Not Shown) Air Delletor Fadiator Cow Fan Guard Cummins 8 Series Engine Batteries Engine Canopy Section Locations for Fastening Canopy Ouiput Gable Stowage Compartments Engine Exhaust Outlet (0. Fuel Tank Way 2006 ‘SECTION T PAGES GROUND POWER UNIT moDeL C890 HOUCHIM End of Section 1 SECTION MAY 2006 PAGE 10 GROUND POWER UNIT MODEL C690 ‘SECTION 2: OPERATION GENERAL, It is recommended that, before operating the equipment, personnel become thoroughly familar with th location and function of al the controls an incicators It the units notin regular use, the engine should be run fora least halfan hour each wook to lubricate the engine niemal paris and reduce the risk of intemal corrosion It is recommended tha the engine be run on ful load fr 10 minutes at hiervals of 50 hours, {in order to clear carbon deposits from the engine PARKING AND TOWING “The ground power unit must be postioned on fim, level ground. The font wheel brakes \wilbe automatically actuated with the towbar in either the lowered poston, or raised to the stowed positon “The overrun brake mechanism incorporates a reversing catch onthe tonbar which must be engaged when reversing the uni, to prevent brake application. In pregaring to tow the uni, the reversing catch must be released to allow the overun brake to operate PRE-START CHECKS 8, tits the fist star ofthe day cary out the dally maintenance checks on the ‘engin, refering fo the Cummins Operation and Maintenance anual Check the gauge onthe uel tank and replenish as necessary ©. Ifthe engine is naw or has been standing ile for more than two months, prime the ‘gine uel system before starting. Ref to the engine manufacturer's service ‘manual for dataled information and method. 4, Ensure that the manually operated circult breaker, lated under the canopy behind the mstrumern pare, fn the ON positon The ckeultreakor should Femain in the ON positon except when the equipment is laid up for any length of time. &. Tum the battery isolator switch (hen fited) to ON. This swt is local close to the batteries, MAY 2006 ‘SECTION 2 PAGE1 ‘GROUND POWER UNIT ‘MODEL ce%0 HOUCHING ENGINE STARTING - NORMAL ‘Turn the IDLE/SERVICE switch to the IDLE postion. . Insert the key nt the stat svitch and tum clockwise to the 'F’ postior. The ‘battery charge lamp wil luminate. Turn the key further clocknise, against spring pressure othe HS" postion to ancrgioe tha startar mator Wien the engine ties and begins to accent, folease the Koyswich, which wil return to tho postion. NOTE - If THE ENGINE FAILS TO START WITHIN 10-20 SECONDS OF FIRST ‘TURNING THE START SWITCH TO THE 'R’ POSITION, A LOW OIL PRESSURE FAULT WARNING WILL BE INITIATED. IF THIS OCCURS, TURN THE START KEYSWITCH TO ‘OFF, WAIT 2 MINUTES, THEN REPEAT THE START ATTEMPT & When the engine has started, check thatthe battery charge waming lamp has been extinguished, USE OF COLD START AID (i Fited) 8. Prepare engine for stating inthe normal way. Start ranking the engine and press the cold start swith, ©. Whilst cranking the engine, olease the col start svc fo inject statrg fd into the engine. necessary, press and release the cold stat switch agair unt the engine reaches a sel sustaining speed, ‘SECTION? May 2006 PAGE2 GROUND POWER UNIT MODEL C690 IY he engine fails to stadt, vite off and repeat the staring cycle ENGINE WARN-UP AND IDLING + AVOID IDLING THE ENGINE FOR MORE THAN 10 MINUTES Long periods of ising cause damage tothe combustion chambers, injectors, valves and piston rings. ‘Allow the engine to warm up betore apptying a lad. USING THE 200v AC OUTPUT OBTAINING A200V Ac OUTPUT 1a. Start the engine as described b, Check he BYPASS ON lamp. ‘This should normally be extinguished as the accralt interlock systom is pre-set to INTERLOCK. If he arratt being serviced does not have a 28V DC feedback supply through pole F ofthe output cable socket, then i ‘wilbe necessary o reset the system to BYPASS, ‘To reset to BYPASS: ‘Shut down the engine. Release the fastonors which socure the engine/AC instrument panel.” Open the hinged panel, locate the system svitch onthe inside ofthe panel and Select BYPASS. Close and relasten the panel then restart the engine as previously described, © Operate the IDLE/SERVICE switch o tho SERVICE positon. ‘The engine spead wal inrease tothe servicing speed of 2400 mpm, 4. Chock thatthe AC digital meter reads Channel 1 - zero volts way 2006 ‘SECTION 2 PAGE 3 GROUND POWER UNIT ‘MODEL C590 HOUCHIN ©. Press the excite switch and hold unt the AC votage rises to between 113V and nv. * NOTE IF THE AC OUTPUT CONTACTOR OPEN LAMPS ARE FITTED, THESE WILL ILLUMINATE WHEN THE ALTERNATOR IS EXCITED AND REMAIN ILLUMINATED UNTIL THE CORRESPONDING OUTPUT CONTACTOR CLOSES 1. Select the meter to Channel 7 - Frequency. The frequency should be between 396 9. Connect the output cabo(s) tthe areratt h. Press the OUTPUT (No. 1 andlor OUTPUT No.2, fitted) pushbutton switches). ‘The POWER ON lamps) wil ight upto indicate thatthe output contacts) hhasthave closed and connacted the power tothe output cable sockets). The indicated voltage onload should be between 118 and 117V and the traquancy bbetwoen 305 and 406i DISCONNECTING THE 200V AC OUTPUT ‘8. Press the appropriate OUTPUT OFF pushbutton switch, The POWER ON lamp vil be extinguished to indicate thatthe output contactor has opened to cisconnect Power from the output cable socket '. Disconnect the AC output cable from th arrat, ‘STOPPING THE ENGINE Ensure that e POWER ON lamp() isfare extinguished and dsconnect the output table trom the aircraft b. Select the IDLE/SEAVICE evich to IDLE, ‘Allow the engine toile for 3-§ minutes, then tum the start Keyswitch to the CFF positon, USING THE 28V D¢ OUTPUT (WHEN FITTED) + NOTE THE AC OUTPUT CANNOT BE USED AT THE SAME TIME AS THE 28V Dc ourPur. SECTION 2 WAY 2006 PAGE 4 GROUND POWER UNIT MODEL. C690 HOUCHIN' OBTAINING A 28v Dc OUTPUT Start the engine as described eater ad plugin the 28Vdc cabo tothe aicat. Press the 28V DC ON snitch, The POWER ON lamp vl luminate to inca that power has been connected tothe aircraft b. Select the DC meter to Channel 1. Check that the DC wotage is between 26 and 29 vot. €. Select the meter to Channel 2 to monitor the output curont + NOTE- THE TRU MAY HAVE THE OPTIONAL CURRENT LIMT FACILITY. THIS WILL AUTOMATICALLY LIMIT THE MAXIMUM OUTPUT CURRENT BY REDUCING THE AC ALTERNATOR VOLTAGE ‘Current limit selection is by means of a switch located inside the DC sexton of the contol panel.” potentiometer, also inside the contol panel, allows acjustmert ofthe maximum feurrent evel, although this is normaly pre-set and labelled DISCONNECTING THE 28V DC OUTPUT ‘2. ross the 28V_DG OFF swilch. ‘The POWER ON lamp wil extrguish to indicate iat the powor has been disconnected fom the aircrat. b. Disconnect the 28V DC autput cable ftom the aircraft ‘c. _ Shut down the engine as previously described ‘SPEED ADJUST CONTROL “The speed adjust potentiometer on the control pana provides fine conta of engine speed Itis normally pre-set and locked bus, adjustment is necessary, shout be caried ut with ‘he allematar excited and unt running without load, ‘2. Loosen the spindle locking nu and adjust the spoed until the feaueney moter ‘ads 400H2 b. After agjustment, hold the spindle ints set postion wth sorewdver whilst tightening the spina locking ut ‘way 2006 ‘SECTION 2 PAGES oe sane VOLTS ADJUST CONTROL “The voltage adjustment potentiometer on the control panel allows the AC output votlage to be times. 4, Adjustment must be carried out whist running of oad. Select the interock/Bypass sich to Bypass and press the Output ON pushbutton to clase the outst Contactor. ‘Loosen the potentiometer spindle locking nut b. With a test meter, measure the cable end voltage and tun the adjuster until the Indicated phase-neutral voltage for each phase is 115V, ‘& After adjustment, hold the spindle ints set postion wth a screwehiver whilst tightening the spinel locking nut \VOLTS/AMPS SELECTOR SWITCH “The Phase Voltage and Line Current can be monitored by selection ofthe aperopiate Meter Channel EMERGENCY STOP PUSHBUTTON “To shut down the ground power unit in an emergency, press the EMERGENCY STOP pushbutton. The engine wil shut down and faut code No.? wil be iuminated onthe onl panel (On operation, the EMERGENCY STOP pushbutton latches mechanically so ta it mains closed. To reset the pushbuton, turn the knurled ing, situated under the operating head, Cockise unt the button is released and returns tots former postion. End of Section 2 SECTION? May 2006 PAGES a seas ‘SECTION 3: ROUTINE MAINTENANCE ‘SAFETY PRECAUTIONS. DANGER Con ae em Deusen ance + THIS EQUIPMENT GENERATES 200V AC - DUE CARE IS TOBE TAKEN WHILST SERVICING. * CARE IS TO BE TAKEN TO AVOID SCALDING BY ESCAPING VAPOUR WHEN [REMOVING THE FILLER CAP FROM THE PRESSURISED RADIATOR ON A HOT ENGINE * THE COLD START SYSTEM USES A VOLATILE FLAMMABLE LIQUID. WHEN. SERVICING: 1. ENSURE THAT YOU ARE IN A WELL-VENTILATED AREA AWAY FROM HEAT, OPEN FLAMES OR SPARKS 2, WEAR GOGGLES WHILST TESTING TO AVOID EVE INJURY 8. MAKE SURE THAT THE OPENINGS OF THE TUBE OR ATOMISER ARE POINTED AWAY FROM YOURSELF WHEN SERVICING + THE ETHYL ETHER-BASED COLD START FLUID IS EXTRENELY FLAMMABLE AND IS TOXIC, HARMFUL OR FATAL IF SWALLOWED. AVOID CONTACT WITH SKIN OF EYES - AVOID BREATHING THE FUMES. IF SWALLOWED, DO NOTINDUCE VONITING. CALL PHYSICIAN IMMEDIATELY. IF COLD START FLUID ENTERS OR IRRITATES EVES, IRRIGATE WITH LARGE QUANTITIES OF CLEAR WATER FOR 15 MINUTES. CONSULT AN EVE SPECIALIST GENERAL, ‘The following inspection periods suggest the maximum intorvals for inspecting and servicing the Houchin C690 range of ground power unis. Ihmay be necessary fp adjust the sevice intervals o compensate for extreme envicnmental conditions. SERVICING NOTES: SERVICING RECORD ‘The hours at which replacement parts have been filed, and at which servicing has been Carried out are tobe entered on a Servicing Record Form, This form shouldbe examined before using the GPU to ensure that tems prevcusly reported detective have been repaited lor passed ifr service. May 2008 ‘SECTIONS PAGE 1 mene FLUIDS AND LUBRICANTS ‘The recommended grades of fds and lubricants are listed in Section 1 (Or Cummins ‘Operations and Maintenance Handook) ENGINE SERVI ING ‘The servicing schedule in this manual does not include tems of attention on tke Cummins ‘engine. ‘The engine must be sorviced as defined in the Cummins Operation and Maintenance Manual accompanying this mana. It the GPU is not in regular use, the engine shouldbe run for atleast half an Maur per Wek, to lubricate the iternal parts and to reduce the risk of infernal corosion. It is also recommended thatthe engine run an fl load fora 10-minute period, at 50-hour interval, In ordoro clear carbon deposits tram the combustion chamber. ENGINE COOLANT Use antireeze during all seasons to protect the cooing system from cortosion as well as freezing damage. Hofer to Engine Coolant Rell Procedure on page 8 ENGINE OIL. CHANGES ‘Alter changing the engine ol run the engine for afew minutes, then recheck te ol level and replenish if necessary. FUEL REPLENISHMENT ‘The fuel must be replenished before the contents gauge registers emply. The engine noed ‘not be stopped during fuel replenishment BATTERY CHARGING SYSTEM Iti essential, when servicing the battery charging system, to avoid damage tothe semiconductors by taking he folowing precautions: ‘Observe correct polarity when making connections. Do not run engine wit the batteries deconnocted - Belore disconnecting the Datlones, ensure thal the START switch i slocted to OFF. Never run the battery charge alternator with the output lead clsconnectad Bo not boost charge the batleres when they are connected to the elec ‘ofthe ground power unt ‘When making test connections to the batery charge allemator or regulator, avid fouling adjacent terminals or accidental earthing, 6. _Donot use electrical welding equipment onthe ground power unt with the batteries {and alemator output wires connected 3 system SECTIONS MAY 2006 PAGE2 GROUND POWER UNIT MODEL C690 ‘SERVICING ACCESS ‘Access tothe ground power uit interiors gained by releasing toggle fasteners at ethor ‘end of he canopy sects, then sliding the canopy sectons to expose the internal equipment Fr access tothe instruments and contol, the Perspox intrumont cover is hinged. Upwards. To expose the intemal svitchgear, the fasteners al the top ot the control section {are released and the panel lowered on ts hinges. ‘Access foto TU (when tea) s by releasing the fasteners whicn secure the contol pane! ‘support tothe chassis, then iting tha complete control panel and support to expase the ‘TRU beneath. Tho assombiy is held open by a suppot stay. [SERVICING SCHEDULES [SUMMARY OF SERVICING ATTENTION ‘ATTENTIONS Dally] Every 280 | Every500 | Every 1000 (When | running | running | running in hours hours’ hours service) | or monthly | or bimonthly | or 8-monthiy ‘Check engine ol evel x x A * ‘Chackfuel level x x x x (Check radiator water ove) x x x x ‘Check lamps and indicators | x x x x Drain fuel secimenter x x x ‘Serie batteries x x x Check wheel nuts and ie x x x pressures. ‘Check engine air itor x z x Lubieae the 400H2 x x aternator bearing (lean al electrical equipment : Examine al electrical cabies x Check security of electical x ‘connections Examine engine/atomator x mountings Lubricate tote inkage x Inspect cooling system hoses, x Service Cola Start ai x site | Renew grease at chassis x Iubecation points | Lubricate automatic brake : mechanism Renew grease in whoo! hubs zi ‘Adjust whee brakes x Examine lyre x May 2006 ‘SECTIONS PAGE 3 ee DAILY INSPECTION 1 \witn the GPU parked on a love surface, check the ol ave nthe engine sump. Replenish, i necessary, tothe “ult mark onthe dipstick, Check the fuel gauge, whic is located onthe end of he tank, and replenish i necessary {Check the ove of coolantin the radiator. Top up as required, using an antiweze ‘misuro as spacties in the Cummins manual Examine the GPU for damage, leakages, insecure parts and unserviceable lamps and indeatos EVERY 250 RUNNING HOURS OR MONTHLY (B Checks) 2 Carry out ‘Dally Inspection’ Checks. Feemove the battery terminals, clean and ref. It the batery s sealed, maintenance-tree uni, check is state of charge, following the instructions in he manulacturers late te batlory is nota maintenance-free unit, then, using a hydrometer, check tho specific gravity ofthe elecrlyt in each col ofthe batteries. The cali uly Charged f the spectic gravy indicated is between 1.270 and 1.290 at 15 dogC. It any Calis found tbe discharged, remove the battery and fia fly charged replacement. (On completion of he specie gray checks, ensure thatthe electrolyte level in each cols just above the plates. I the levels lo, top up, using distil water only. NOTE - IF ITIS FOUND NECESSARY TO REPLACE THE BATTERIES, ENSURE ‘THAT, WHEN FITTING NEW DRY CHARGE BATTERIES, THEY ARE ‘COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER'S: INSTRUCTION LEAFLET ISSUED WITH EACH NEW BATTERY ‘Check tighten road wheel nuts, (Check he tyre pressures (100 vin2(7 bar) ‘Check tho engine air iter restrition incicator and empy the dust bow on the end of the air cleaner. If reds showing in the indicator window, then remove the air leaner element and clean or roplaca it. To reset the indicator, depress the pushbuton at te conte, Check the fuel sedimenter and drain any sediment and water by removag the dain plugins base, DO NOT alow the waterlsedkment level to ise above the top atthe transparent bow. SECTIONS WAY 2006 PAGE 4 ‘GROUND POWER UNIT ‘MODEL C890 HOUCHING Clean the flter element using compressed air at no more than 80 Ibin2(5.5 bar), from the lean air sido, or by washing in a non-foaming detergent. Alow the element to Soak fr at least 10 minuies and then genty agitate. Rinse with clean water and allow fo dry - do not tise oven heat. When ary, inspact the element by placing @ Bright igh ats cane. Ary piavoles, thin spots or ruptures render the fier unt for use. + NOTE. THE DRY ELEMENT MUST BE RENEWED AFTER SIK CLEANINGS OR ANNUALLY EVERY 500 RUNNING HOURS OF BIMONTHLY (C Checks) 1. Repeat the 250 hour ‘8 Checks: 2. Remove, clean and refit he grease trap forthe 400Hz alternator endshield bearing 3. Lubricate the 400H2 alternator endshila bearing tough the grease nipple Provides. 4. Stop the engine. Remove grease trap and chock that new groase has exudod from the bearing int the trap. Ino, repeat the greasing operation. Fnaly clean all ‘exuded grea from the trap and roi EVERY 1000 RUNNING HOURS OR 3-MONTHLY (D Checks) 1. Repeat the 500 hour 'G Checks 2. Rlemove all dust and dit trom electrical equipment wth a vacuum cleaner. Examine the GPU for damaged or perished cables, paying particular attetion to the flexible output cables 3. Check securiy of al electrical connections. 4. Examine the engineratenator mountings for secur and sign of deterioration 5. Clean and lubricate engine throttle linkage 6, Service the cold star system (when fited); Refer tothe safety precautions inthe ‘senvicing notes betore carving aul sorvicing, 7. Clean al dirt from the cylinder and from the exterior of the valve 8, Check the ud supply - empty cylinder weight is about 160214609, a ful eyinder about 38 029359" I the oyinders emply, replace i + NOTE FIT A NEW VALVE GASKET WHEN REPLACING THE CYLINDER. THE CYLINDER MUST BE SCREWED ALL THE WAY DOWN, HAND TIGHT May 2006 SECTION 3 PAGES eouere ‘Check operation ofthe cold stat system by removing the atomise fron the engine and activating the systom. Ino id sprays out, disconnect tho atomisor from the {bing and re-activate the systom. It ui flows out of he tube, the aemiser must bbe renewed. Do not activate for more than & seconds ata ins. Renew the grease at the folowing grease points: “Turntable (8 grease nipples) Leaf Spring Shackles (3 grease nipples per spring) ‘Overrun brake Cable (one grease nips) Lubricate the automatic brake lover and brake compensator mechanisms with engine ot Remove whee! hubs and repack bearings wih grease. Consult the relevant section, ‘Adjust fron whee! brakes by means of he adjuster which is accessible through th brake drum on removal ofthe road wheels. Consul he relevant section ofthe manual Engine Coolant Refill Procedure GPU Model 690/140 (wth Cummins engine type 6BTAS.90200)._ For ngine Coolant Refi Procedure refer tothe Cummins engine randbook for specie deta. ‘GPU model 680/80KVA or 680/100KVA (wth Cummins engine ype 6B5. 90-152), Fill empty systoms using the folowing procedure: 1, Remove radiator ier cap, 2. Slacken one of he Ar bled off serows indicated on igure 1, 3. Slow fil radiator using 50:50 mix of water and anti-freeze (Mix befor filing radiator unt coolant escapes though blood of sctow. Rostighten bleed of ‘serew and continue to fil radiator. 4. Raft aditor iter cap, 5. Start the GPU and run inthe ‘le’ condition unt normal engine operating Temporaturo is obtained, 6 Stop the GPU and when safe to do 0 re-check coolant lev 7. Top up coolant i necessary. SECTION 3 May 2006 PAGES GROUND POWER UNIT MoDeL C890 HOUCHING Figure 1, Air Bleed Off Screws ‘SHIPPING ‘TIE DOWN POINTS Four eyes are welded tothe chassis, two at each end. These ar usod fo ying the trolley down. Each canopy section has a locaton fora ifting eye which must be Used Tor canopy removal only. The thread size forthe canopy Hing aye is M12 PACKING PRECAUTIONS ‘when packing he trolley for shipment, cover all apertures with mouldable wax paper.” Contols, indicators and Perspox covers should also be covered with ouldable wax paper. Cable end terminations should be wrapped in waterprof packaging and rubber ‘covered cables treated with a dusting powdor Permanent of temporary storage procedures should be carries ut on the ene as defined inthe engine manufacture's Shop Manual Batteries should be disconnected and spilage protection caps fitted to each cel, “The fel tank should be ary May 2006 ‘SECTION 3 PAGE seouees STORAGE “The ground power unit and its associated parts and sub-assembkes should be stored ina clean dry atmosphere ata room temperature of normally 16 deg C. Al disconnected plugs and sockets must be fited with protective caps and the ends ‘fall disconnected pipes sealed wih suitable blenking medi. \Where possible, protect all parts and sub-assembles from corrosion and contamination by lacing them in sealed plastic bags wih silica gl crystals. electronic unit printed circuit cards ae to be stored then these shoulcbe stood on ledge n a grooved rack to prevent mechanical damage. When storing an alternator assembly fr any length of time, itis advised to pertodially lubricate the endshield bearing wih Shell Albida 2 grease. Do not subject the atemator assembly to any prolonged vibration during storage as ths may damage the bearing {All uber parts such as tyes, inner tubes, seals etc, must not be exposed to strong ‘sunight during siorage._ Is preterable o store such items in a dark, coo, well ventilated pace. For storage instructions relating to the engine, refer tothe engine manufacturer's Shop Manual End of Section 3 SECTIONS Way 2006 PAGES mooe.ca0 HOUCHIN' ‘SECTION 4: ADJUSTMENTS ADJUSTING THE BRAKES ‘Before adjusting the brakes, lower the towbar to apply the front wheel brakes, and examine the compensator plato to which the overrun brake cable Is afached. Tre compensator ‘slate pivots about the point at which the overrun brake cable and automatic brake rod is Bttached, i urn brake eross-cables are connected from ths compenssior pate tothe front ‘whee! Brake mechanisms via‘ bracket attached to the front axle beam. This arrangement Constitutes a mechanical compensator which equalses the brake cross cable forces within ‘wie limits of componont mavement. I the compensator mechanism ic ree and in good ‘order, the braking torques of he front wheels are balanced, “The adjustment ofthe brake shoe clearance and the length of the crost- cables should bo ‘such tha, ith the towbar fly lowered, the compensator plate of the compensator is ‘approximately parallel wih he front axle beam. itis at an angle of mare than 20 dogreos to he axle beam, it is probable that now brake linings are required. Figure 1: Brake Compensator way 2006 ‘SECTION 4 PAGE (GROUND PoweR UNIT aay ‘MODEL C800 HOUCHING [BRAKE SHOE CLEARANCE ADJUSTMENT ‘Park the GPU on firm level ground withthe towbar in tne with the chassis. Chock the rear wheo's to prevent movement in ether crection, . Jack up the GPU front unt wheels are clear ofthe ground and supper! the GPU on axle stands, © Support the taubar 20 that he llr on the automate parking brake mechanism is at ‘the mid positon of the towbar cam. Once the towbars supported, spn the brake ‘drums to contiem that both are re, Figure 2: Wheel Hub and Brake ‘SECTION 4 ‘WAY 2006 PAGE2 GROUND POWER UNIT MODEL C690 HOUCHINI 4. Turmthe adjuster nut clockwise unl the brakes just grip on each brake drum, then tum each aduster one eek’ counter ockwise. Check that bath drums spin realy ‘wihout binding, I @ satisactory agjustment cannot be cblained, check that the hub ‘bearing is cocrectyinstaled and adjusted, and that the brake drum i ful located on the hub, fe, Remove the fowar support and check tha the wheel brakes are fully appli wien {ne towbar is lowored o te ground and also when setin the sowed postion. ‘proper braking nat achieved, adjust the automatic brake mectanism, f. Jack up the GPU tron, remove axle stands, lower the GPU ontc the ground. Check lighten the wheel nuts and romove the jack. + NOTE THERE ARE 4 RED-PAINTED HEXAGON NUTS IN CLOSE PROXIMITY ‘TO THE FOUR WHEEL NUTS ON EACH WHEEL. THESE SECURE THE TWO HALVES OF THE SPLIT WHEEL AND 00 NOT FORM PART OF THE WHEEL HUB ATTACHMENT DANGER Ca en Re mR eens Sa [ADJUSTING THE AUTOMATIC BRAKE MECHANISM (Refer to Figure 3) a. Adjust the brake shoe clearance as described, b. _Sotthe towbarto the neutal postion (brakes tre) for this chock. Ensure that ‘pring (1) s compressed by 28mm and is secured with locknut @). © Lower towbar (2) until he toning eye i 500mm from the ground (minimum tow height). Adjust rod (2) s0 that rl (5) fs just touching the towbar cam (6). Check ‘tha the brakes are just OFF. 6. Raise the towbar until the toning eye i 800mm from the ground (maximum towing height). Brakos shouldbe just OFF Check thatthe brakes fully engage when the toning eye is below 500mm from the ‘ground ang above 800mm trom the ground, ‘May 2006 ‘SECTION 4 PAGE 3 GROUND POWER UNIT ‘MODEL cs90 HOUCHIN' Figure 8: Automatic Brake Mechanism [ADJUSTING THE OVERRUN BRAKE CABLE itis ft the overrun brake cable i not operating etfecvely then an adjustment may be ‘made by slackening the brake cable aster locknuts and serawing out the acjuster unt the brakes begin fo grip. Faly, tighten the brake cable adjuster locknuts [ADJUSTING THE CROSS- CABLES To rostore correct adjustment tothe cross- cables aftr replacing components oF lsmanting, proceed as folows: + NOTE- THE GEOMETRY OF THE BRAKE COMPENSATOR REQUIRES THAT ‘THIS ADJUSTMENT POSITIONS THE COMPENSATOR PLATE SO THAT IT 1S APPROXIMATELY PARALLEL TO THE AXLE BEAM. (SEE ILLUSTRATION) SECTION 4 May 2006 PAGE 4 ee Aalst the brake shoe clearance as described. '. Adjust the automatic brake mechanism, it necessary {& _Laosen the locknuts on one or both cross- cables attached tothe compensator plate ‘and adjust cable(s) uni coract geometry is achive. Re-tghten locknuts 1d. Check that with operation of the automatic brake mechanism, both front wheetsidrums spn tthe whoets ae removed: (When dismanting a whoo! assembly, the tyre must be completely deflated and the valve cote removed before attempting to remove the whee! from the hub and slackening the clamping bolts (i) Tho wheel assembly should be re-fitad to the hub ofthe vehicleftraler and the stud nuts tightened to the recommended, torque salting before inflating to the recommended tyrotwhoal assembly inflation pressure 1. Jack up the GPU front, remove axe stands, ower the GPU onte the ground. Check tighten the wheo! nuts and remove the jack ADJUSTMENT OF WHEEL HUB BEARINGS ‘when retting whee hus, the hub nuts must be fully tightened and then backed off one third ofa tum belore securing wih a spit pin. This ensures correct bearing end Hot ADJUSTING THE THROTTLE LINKAGE ‘a. Locate the engine throttle rod and disconnect it rom the actuate lover. 1b. Check that the actuator lever i positioned on the splined spindle so that tis at 90 eg 10 the tote rod, as shown. Push the fuel pump arm tots fully closed positon. 4. Adjust he throttle rod length until the fing bolt lines up with the actuator love xing hole. 12. _Lengthon the thot rod by five compote tune and fix to the actuator lover. ‘May 2006 ‘SECTION 4 PAGES GROUND POWER UNIT mmoDeL co MAXIMUM STOP THROTILE ROD FUEL PUMP ACTUATOR — Figure 44 Trt Linkage (OKVA, 00K¥4) WAXIMUM STOP THROTTLE ROD ACTUATOR ARM FUEL PUMP ial ‘6 actuator Figure 45: Tre Linkage (40KVA) Sections wav 2008 PAGES GROUND POWER UNIT moDEL ce00 HOUCHING POSITIONING THE GOVERNOR MAGNETIC PICK-UP the magnetic pick-up forthe electronic thatle contol has been disturbed rom its location inthe engine flywheel housing, then its ip clearance from the fywheel ng oar must be set as follows: ‘a, With te pick-up removed, vew irough he exposed note in he tywneet nousing, b, Bar the engine over whist vowing the ring gear testh on the fee! unt one gear tooth is central inthe hole. ©. Screwin the magnets pick-up, by hand unt it touches the top ofthe gear tooth ©, Unsorew the magnetic plek-up by 78 01/2 a tum and lock itin-his postion vith its Took ENGINE SPEED (FREQUENCY) (COARSE ADJUSTMENT 8, Runthe engine upto service speed and check that the output vltage from the governor contrller (GAC 5111, terminal 2 and 3)'s 9 volts OC. Ino, re-agust the thatte rod length fo achieve tis. Reduce the throtle red lengh to reduce, anc increase tho length to increase, the governor output votage b, Check thatthe fuel pum arm, a is extremes of rave, makes contact wih he dle and maximum speed stops on the fuel pump. The stops on the uel pump must not be tampered with, ©. Ensure thatthe engine shuts dow when the stat switch is turned to OFF. not, decrease the tote rod length to achieve this. 1. With the engine tuning at servicing speed, excite the alomator 6 Check tha, altar exctation, the frequency meter reads 400H2 on no load - this represents speed of 2400 cpm. FINE ADJUSTMENT Fine adjustment is carried out using the engine speed adjust contol. This slated on the front of he contral panel. With the engine running and te aerator exerted on no 103d, adjust the control untl the frequency meter reads 400Hz.. Alter acjustment, lock the contol by holding itn ts set postion with a sorewdrver whilst ightening he spindle lock nut, May 2006 ‘SECTION 4 PAGE GROUND POWER UNIT ‘MODEL C690 (OVERSPEED TRIP ADJUSTMENT “The engine is protected against overspeed by the engine protection unit EPU. The trip HOUCHING levels normaly set toa frequency of #40Hz (2640 rpm) ENGINE PROTECTION START DELAY ADJUSTMENT ‘The engine protection unit (Part No.334 8855H) has an adjustable override timer to allow the engine al pressure to bul up during staring, thus preventing promalture faut indleation and shutdown ‘The time delay is adjusted by means of potentiometer RV2 on the engine protection unit PCB, and shouldbe set wihin the range of 15-20 seconds. ADJUSTMENT OF AC PROTECTION UNIT Protection Seling Tip point adjusted | ED Wuminates by ven trp points reached: ‘ver Votage 30 Phase neual ve OW ‘Under Volaga | 96V Phase-neutal va 09, ‘ver Frequency | 4aaHe ve ba Une Frequeney | 76H avi a ADJUSTMENT OF DC PROTECTION UNIT (when fited) Protection Beling ip pont ah TED Mmnatos when tp potnt is reached! Cree Vonage av. Hig oF Under Votage 2isv co DS: 400Hz OUTPUT VOLTAGE ADJUSTMENT Hany component in the 400Hs output votlage regulation circuits replaced it may be necessary to reset the output voltage 8 Select the Interlock/Bypass switch, located inside the conta panel to EYPASS and ‘lose the autbut contactor. , _Slackon the volts adjuster spindle lock nut ©. Measure the cable end voltage with an accurate test meter and operate the volts “aguster on the contol pana unl the Indicated phase-noutal voage is 115V in ‘each phase. SECTION 4 WAY 2006 PAGES GROUND POWER UNIT moDeL cs90 HOUCHINI 6. Alter adjustment, lock the contro! by holding it ints set postion vith a screwdriver ‘whist tightening tne spindle lack nut Dc OUTPUT VOLTAGE ADJUSTMENT ‘The DC output vottage from the 28V DC wanstoemer rectifier unit TRU ft fies) is

    You might also like