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CHAPTER 3

OVERHAUL/MAJOR REPAIR

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Standard Procedures

WARNING:
THIS UNIT PRODUCES HIGH VOLTAGE ELECTRICITY.
ALWAYS DISCONNECT THE POWER CABLE AND BATTERY
BEFORE WORKING ON ANY COMPONENT.

1. Before any disassembly or removal of a component insure all troubleshooting procedures

have been used.

2. Special tools that are required to overhaul components are as follows:

A. Ohmmeter or multi-meter
B. 0 - 250 FT LB Torque wrench
C. Stroboscope

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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 no 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.

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1. Generator
Details on overhauling the generator are located in the Manufacturer's Literature section of this manual
(Chapter 5). 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.

2. Engine
If the engine needs to be overhauled, we recommend 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 and 5. 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.

1. Basic Engine Adjustment (CUMMINS):

Refer to chapter 4, 5, & the CUMMINS QSB engine manual for information.

2. Engine Accessories Adjustment

The engine accessory drive belt is self adjusting. Refer to Chapter 2 for replacement instructions.

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