GPU - 406

GPU - 409

CHAPTER 1
General Information
and Operating Instructions

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Contents
INFORMATION ................................................................................... 1-1-1
1. Unit Description ............................................................................................................................. 1-1-1
A. GPU-406 and GPU-409 ........................................................................................................... 1-1-1
2. Major Component Description ....................................................................................................... 1-1-6
A. Engine ...................................................................................................................................... 1-1-6
B. Generator System .................................................................................................................... 1-1-7
3. Electrical Box Assembly ................................................................................................................. 1-1-9
A. Relay Panel Assembly ............................................................................................................ 1-1-10
B. Relay Panel Components ....................................................................................................... 1-1-11
C. Generator Control Module ...................................................................................................... 1-1-13
D. Instrument Panel .................................................................................................................... 1-1-15
E. Contactors .............................................................................................................................. 1-1-21
Operation ............................................................................................ 1-2-1
Specifications and Capabilities ........................................................ 1-3-1
Shipping ............................................................................................. 1-4-1
Storage ............................................................................................... 1-5-1

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INFORMATION
1. Unit Description

A. GPU-406 and GPU-409

The GPU-406 and GPU-409 are self-contained, diesel engine-driven, ground power units. The units
are designed to supply regulated 400 Hz electrical power to a parked aircraft for operation of the
aircraft's electrical equipment when the on-board generators are not running. The components of the
GPU-400 series are of a simple but rugged design with sufficient safety devices to ensure a long,
trouble-free service life. The illuminated control panel and backlit LCD display provide for easy night
operation.

The ground power units feature a brushless-revolving-field generator, rubber-torsion-axle-mounted

chassis of rugged galvanized steel construction with fifth-wheel steering, powder-coated sheet metal
panels, and fiberglass housings. TLD GPU’s can be equipped to meet Tier 3 (Stage IIIA) or Tier 4
Final (Stage IV) emissions standards.

Options available on the GPU-400 ground power units are listed below. Each piece of optional
equipment is covered by its own instructions and parts breakdown, and is located in Chapter 4.
Disregard the option if it is not applicable to your unit.

(1) Low fuel warning with shutdown or idle

(2) Low fuel warning
(3) Engine block heater (120 VAC or 240 VAC)
(4) Amber or red, flashing, non-flashing, or rotating warning beacon
(5) 28.5 VDC transformer-rectifier (TR) package with current limiting, rated at 600 amps continuous
and 2500 amps peak output
(6) 2nd 400 Hz output
(7) Fuel filter / water separator with heater
(8) Plastic rub rails

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1...Air filter
2...Exhaust silencer
3...Charge air cooler
4...Engine
5... Radiator
6...Generator

GPU-406 AND GPU 409

CUMMINS TIER 3 ENGINE CONFIGURATION
FIGURE 1

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4
1

1...Air filter
2...Charge air cooler
3...Engine
4... Radiator
5...Generator
6…Diesel Oxidation Catalyst

GPU-406 AND GPU 409

CUMMINS TIER 4 INTERIM ENGINE CONFIGURATION
FIGURE 2

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1
5
7

2
8

GPU-406 AND GPU 409

CUMMINS TIER 4 FINAL ENGINE CONFIGURATION
FIGURE 3

1…Air filter
2…Charge air cooler
3…Engine
4…Radiator
5…Generator
6…DOC (Diesel Oxidation Catalyst)
7…DRT (Decomposition Reactor Tube)
8…SCR (Selective Catalytic Reducer

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2
3

1...Fuel Overflow Vent

2...Fuel Tanks 1
3...Fuel Fill

GPU-406 AND GPU 409

FUEL SYSTEM
FIGURE 4

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2. Major Component Description

For the purposes of orientation and to familiarize operators and maintenance personnel with the location of
components, the radiator is considered to be at the front of the unit. The generator and controls are at the
rear. Right and left are determined by standing at the rear end facing the instrument panel.

FRONT REAR

A. Engine
The GPU-400 series is equipped with a 4-cylinder, in-Iine, turbocharged engine, certified to meet EPA
Tier 3 and Euro COM 3A emissions regulations. Tier 4 Final and Euro Stage IV compliant engines are
also available.

All engines used are equipped with electronic governors, which provide precise frequency regulation
and fast transient response. Engine protection such as low oil pressure, high coolant temperature, and
over speed protection are programmed into the engine electronic control module. An engine
diagnostic connector is provided for communicating with the engine. Full-flow fuel and lubrication oil
filters are utilized.

A 24-volt starting motor and alternator are used, as well as a heavy duty spark arresting exhaust
silencer and dry-type air cleaner. The fan is a pusher type, which sucks the air into the unit through
the bottom, underneath the generator, and pushes it across the radiator and turbocharger air cooler,
and finally out the roof of the unit.

REFER TO CHAPTER 5, CUMMINS QSB OPERATION AND MAINTENANCE MANUAL FOR MORE
INFORMATION ON THE ENGINE.
B. Aftertreatment System
The Tier 4 Final engine is equipped with a special exhaust system that treats the emitted exhaust gas
from the diesel engine to reduce harmful emissions. The exhaust system processes the exhaust gas
by first passing it through a Diesel Oxidation Catalyst (DOC) to reduce unburnt hydrocarbon and CO
emissions. Then, the exhaust gas passes through a Selective Catalytic Reactor (SCR) which, along
with the Diesel Exhaust Fluid (DEF), reduces NOX emissions.

The parts that support the SCR include the DEF supply module, heater lines, and DEF tank. These
parts aim to regulate the temperature and delivery of DEF to the exhaust system. Refer to Error!
Reference source not found.9 for more detail.

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C. Generator System

The generator system is a simple system which contains few components. The unit utilizes a TLD
brand generator. The other major assembly of the generator system is the electrical box assembly,
which contains the generator control module, instrument panel controls, and a relay panel.

Generator:

The 400 Hz generator is a brushless, revolving-field, three-phase, synchronous, alternating-current

generator of single-bearing construction. Generator excitation current is supplied from a directly-
connected brushless rotating D.C. exciter. The generator stator core is constructed of one-piece steel
laminations. The steel laminations are assembled under pressure to form the stator core. The
assembled core is rigidly welded to the frame ribs, and heavily-insulated stator coils of the highest-
quality magnetic copper are then inserted in the stator slots. The stator core slots are insulated with
the highest-quality insulating material.
The generator field poles are mounted on a large-diameter shaft. Field coils of heavily insulated wire
are wound directly onto the poles. The coils are blocked and braced for physical strength and rigidity.
The exciter armature and rotating rectifier bridge assembly are sleeve-mounted on the shaft of the
synchronous generator. The rotating rectifier assembly consists of a full-wave rectifier bridge made up
of six semiconductor devices in a potted enclosure.
The generator‘s brushless exciter is an inverted synchronous AC generator with the field winding
stationary and the three-phase armature windings rotating with the generator rotor. The stationary
exciter field (stator) is designed to be the primary source of the generator’s residual magnetism. This
residual magnetism allows the exciter armature (rotor) to produce AC voltage even when the exciter
field (stator) is not powered. This AC voltage is rectified to DC by the rotating rectifier assembly and
fed directly to the main field (rotor). As the generator shaft continues to rotate, the main field (rotor)
induces a voltage into the generator’s main armature (stator).
The voltage regulator is powered by the GPU diesel engine’s charging system. This system of using
an external voltage source to provide the excitation current for the generator eliminates the need for a
special field flashing circuit in the regulator.
The generator is designed with a self-contained cooling system which circulates cool air through the
machine. Ambient air is drawn into the machine through louvered openings at the exciter end of the
machine by a large capacity blower. The warm air is exhausted to the atmosphere through the
screened opening enclosing the blower assembly. The complete generator is bolted to the engine
flywheel housing.

Generator electrical characteristics:

- Phase imbalance: Not to exceed 1% at balanced 3- phase load. Not to exceed 4% at 1/3
load on 1 phase and no-load on the other 2 phases.
- Harmonic content: Total harmonic distortion not to exceed 2%. Any single phase
harmonic not to exceed 1.5% at 0.8 P.F. linear load.
- Crest factor: 1.414 +/- 0.007
- Frequency regulation: +/- 0.1% no-load to full-load and overload.
- Frequency transient: +/- 2.5% no-load to full load
- Frequency transient recovery time: +/- 0.5% of nominal frequency within 1.5 seconds.
- Overload rating: 125% for 5 minutes.

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1…Louvered panel 13...Shim Plates

2…Screen Cover 14...Drive Plates
3...Exciter Stator 15...Ring
4...End Bell 16...Ring
5…Main Stator 17...Screen Cover
6...Cover Plate 18...Key
7…Bridge Rectifier 19...Key
8…Exciter Rotor 20...Transition Segment
9…Bearing 22...Cover Plate, Exciter
10…Main Rotor 23...Screw
11...Cooling Fan 24...Cover, End Bell
12...Fan Seat 25…Screen

GENERATOR BREAKDOWN
FIGURE 5

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3. Electrical Box Assembly
The electrical box assembly is located at the extreme rear of the unit and houses the instrument panel
and the relay panel.

3 1

4 FIGURE 6

1…Electrical Box
2…View Screen
3…Select Buttons
4…Control Knob
5…Emergency Stop (E-Stop)
6…Electrical Panel
7…GCM2 Control Box
7

FIGURE 7

ELECTRICAL BOX ASSEMBLY

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A. Relay Panel Assembly
The relay panel assembly is mounted inside the electrical box on the back wall. The relay panel
provides mounting facilities for engine and generator control and protection relays, 3 current
transformers, and output load contactor(s).

5
1 6
11

T1 T3
10

2 K3 K10 K5
T2

TB2 K17
K16 (OPTIONAL)
8

3
7

1…Current Transformers – T1, T2, T3 8…Engine Running Relay – K3

2…Contactor(s) – K16 (K17 is optional) 9…Key Switch Power Relay – K10
3…Generator Neutral Distribution Block – TB2 10…Low Fuel Relay – K5
4…400Hz Control Signal Terminal Blocks – TB8 (TB10 11…J1939 Data Link Connector – P11
is optional and not shown)
5…Battery Ground Terminal Block – TB5
6…Switched +24V Terminal Block – TB3
7…Battery Power Terminal Block – TB7

RELAY PANEL
FIGURE 8

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B. Relay Panel Components

(1) Current Transformers – T1, T2, T3

The relay panel assembly contains 3 current transformers which send current signals from the
three phases to the Generator Control Module (GCM) for load sensing and line drop
compensation, for instrument panel indication, and for over-current protection. The transformer
converts current readings at a ratio of 400:5; that is, for every 80A of output current, 1A of
sensing current flows through the GCM. For 180 KVA units, this ratio is 600:5.
(2) Contactor(s) – K16, K17
The function of the contactors is to allow, or not allow, 400 Hz output power from the generator to
the aircraft. The contactor states, open or closed, is controlled by the 24 VDC contactor coil.
GPU-406 and GPU-409 have (1) contactor as standard and a 2nd is included with the optional
2nd 400 Hz output.

(3) Generator Neutral Distribution Block – TB2

The purpose of the neutral distribution block is to provide a means to connect the generator
neutral to the aircraft neutral through a cable. TB2 is for connecting the 400 Hz output cable(s)
Neutral wire “N” to the Generator “N” cable.

(4) 400Hz Control Signal Terminal Blocks – TB8, TB10

TB8 and TB10 connect the E and F pins of the 400Hz AC output cable to the generator
controller module (GCM). This provides the GCM with a 28 Volt Signal once the aircraft has
accepted power from the GPU. TB10 provides the signal for AC Output #1, while TB8 (optional)
provides the signal for AC Output #2.

(5) Battery Ground Terminal Block – TB5

TB5 provides the ground connection for all components inside the electrical box. It is connected
directly to the battery negative terminal.

(6) Switched +24V Terminal Block – TB3

TB3 provides 24V power when the GPU is turned on for all components inside the electrical
box. It is connected to a relay that is active after the GPU is turned on with the green power
button, or after it wakes up when the battery switch is engaged.

(7) Battery Power Terminal Block – TB7

TB7 provides battery power to components inside the electrical box. It is directly connected to
the battery positive terminal.

(8) Engine Running Relay – K3

The purpose of a relay is to provide a controlled connection. A relay is also used to connect a
high-power circuit by using a low-power circuit to control the connection. K3 is the engine

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running relay. Its function is to provide a 24V signal when the engine is running above 600 RPM.
This signal is used to power an analog engine hourmeter.

(9) Key Switch Power Relay – K10

K10 is the key switch power relay. This relay provides 24V power to all the components
connected to TB3 (switched +24V terminal block). It is only active after the GPU has turned on.
The engine control module (ECM) requires the 24V signal that this relay provides to allow the
engine to run.

(10) Low Fuel Relay – K5

K5 is the low fuel relay, and it is only present when the GPU has been optioned with a low fuel
warning beacon. This relay provides power to the low fuel warning beacon when the fuel level
has reached its low limit.

(11) J1939 Data Link Connector – P11

P11 is the Data Link Connector. Its purpose is to provide a way to communicate with the engine
control module (ECM) for diagnostic purposes.

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C. Generator Control Module

The generator control module is mounted inside the door of the GPU’s electrical box. Its display
is read without opening up the electrical box.

GENERATOR CONTROL MODULE

FIGURE 9

The Generator Control Module (GCM) is the brain of the GPU-400. It is a fully-automatic voltage
regulator that not only provides voltage and frequency regulation, but also generator fault protection
and generator power output display. The GCM also functions as an engine instrument panel that can
display engine fault codes, and other useful information such as charging voltage and engine RPM. On-
screen directions in multiple available languages guide the operator on how to properly operate the
GPU.

The GCM monitors the 400 Hz output when 400 Hz is in use and automatically switches over to
monitor the 28.5 VDC output when the optional 28.5 VDC transformer-rectifier is in use. The GCM
provides line drop compensation on 400 Hz as well as line drop compensation and current limiting on
the 28.5 VDC transformer-rectifier. The GCM displays the generator output voltage, current, and
frequency on a backlit LCD. The voltage regulator is programmed to protect against the following
generator fault conditions:

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- Over-frequency: AC Output is over 420 Hz for 5 seconds
- Under-frequency: AC Output is under 380 Hz for 7 seconds
- Over voltage: AC Output is over 130 volts for 2 seconds
- Under voltage: AC Output is under 100 volts in 7 seconds
- Overload: Output is over 125% of rated capacity for 5 minutes

The voltage regulator displays and latches the fault if any of the above should occur.
Power is automatically disengaged from the aircraft.

Generator Control Module Characteristics:

The following are the electrical characteristics of the Generator Control Module:

- Voltage regulation: +/- 1% maximum over full range of generator loading.

- Voltage transient: 13.8% no load to full load.
- Voltage transient recovery time: +/- 1% of nominal voltage within 100 milliseconds.
- Voltage modulation: 0.5% at steady state.
- Line drop compensation: Provides a voltage increase of up to 10 volts, line to neutral, to
compensate for voltage drop in the aircraft cable assembly.

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D. Instrument Panel
The GPU’s instrument panel is located at the rear extreme of the unit. It provides the operator with controls and
displays for generator and engine functioning. 2 3

1
4

INSTRUMENT PANEL
FIGURE 10
7
1…Blue Button
2…Red Button
3…Yellow Button
4…Green Button
5…Dial with Pushbutton
6…LCD Screen
7…Emergency Stop

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The instrument panel contains the following buttons and switches:

(1) Blue Button

The four colored pushbuttons are the main method to control the GPU. The function of the button
changes, depending on the GPU’s current operating condition. The current function of each
button is always displayed on the screen directly above the button. The icon will be color-coded
the same color as the button it represents.

The blue button is used to crank and start the engine. It is also used to stop the engine.

Press and release the blue button to start the engine.

Press and release the blue button to stop the engine.

(2) Red Button

The red button is used to enter maintenance mode or control the #1 400 Hz output.

Press and release the red button to enter maintenance mode.

This mode is available only with the engine off.

The blinking airliner icon means the output is available for use.
Press and release the red button to activate the #1 400 Hz Output.

The solid airliner icon means the output is being used. Press and
release the red button to deactivate the #1 400 Hz Output.

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(3) Yellow Button
The yellow button is used to control the #2 400 Hz output.

The blinking airliner icon means the output is available for use. Press
and release the yellow button to activate the #2 400 Hz Output.

(The solid airliner icon means the output is being used. Press and
release the yellow button to deactivate the #2 400 Hz Output.

(4) Green Button

The green button is used to turn the GCM on or off. It also controls the 28VDC output.

Press and release the green button to turn off the GCM. When
the GCM is off, this button can be used to turn it on.

The blinking small aircraft icon means that the output is available for
use. Press and release the green button to activate the 28VDC output

The solid small aircraft icon means that the output is being used. Press
and release the green button to deactivate the 28VDC output.

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(5) Dial with Pushbutton

The dial with a built-in push button is used for making on-screen selections and GPU servicing.
When the 28VDC output is active, the push button of the dial toggles between adjusting the DC
output current limit and scrolling the engine information display.

DC OUTPUT DISPLAY WITH LIMIT AT 1500 AMPS

FIGURE 11

With the 28VDC output on, press the dial push button to enter the output current limit adjustment.
Rotate the dial left or right to increase or decrease the DC output current limit. Push the dial again
to exit this adjustment.

When the 28VDC output is off, rotating the dial only scrolls the engine information display. See
the following section for more information on the engine information display.

(6) LCD Display

The GCM is equipped with a 5.7” high-contrast LCD display that can be visible even in direct
sunlight. It displays all of the operating information to the operator. This information includes
output voltage, output current, output power, and any information related to an output power
fault. It also functions as basic engine instrumentation by providing useful information such as
engine speed, engine temperature, charging voltage, and diagnostic trouble codes.

Diesel Engine Charging Voltage

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Check Engine

Engine Hours

Engine Oil Pressure

Engine RPM

Water in Fuel

Diesel Exhaust Fluid Level – Tier 4 Final Only

Exhaust System Cleaning (E.S.C) in Progress – Tier 4 Final Only

High Exhaust Temperature – Tier 4 Final Only

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(7) Emergency Stop
The large red button located on the control panel provides a means to stop the engine and disable
power delivery when catastrophic failure and damage to either the GPU or aircraft is imminent. It
is not meant to be used to shut the engine off in routine GPU operation.

Tier 4 Final Engine Operation Example Screens

Built-In Diesel Exhaust Fluid (DEF) Gauge

On GPU’s equipped with a Tier 4 Final engine, a DEF gauge will automatically appear to the right of the fuel
gauge. This gauge alerts the operator when the DEF is running low, and when it should be filled. Refer to page
2-1-10 for instructions on how to fill the DEF tank.

The generator controller screen will also indicate when an exhaust system cleaning is taking place if the engine
is idling. The cleaning process occurs automatically through the control of the engine computer, and it maintains

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the efficiency of the emissions reduction system. Exhaust temperature will increase as a part of the cleaning
process, and the “HIGH” Exhaust Temperature icon will appear. The “E.S.C.” icon will replace the water
temperature icon to show that exhaust system cleaning is taking place. The GPU operator will only receive this
notification if the engine is idling at the time of the exhaust system cleaning. If the cleaning process starts when
the GPU is delivering power, no notification will appear.

The GPU should not be shut down until the E.S.C. icon disappears.

E. Contactors
The GPU’s contactors are mounted on the relay panel, which is on the rear wall of the control
box. The contactors use a 24V control voltage, and they are driven directly by the GCM. The
GCM provides the logic for closing the contactors after the engine has ramped up. The GCM also
controls when the contactors need to open in the case of an aircraft rejecting the power delivered
by the GPU or when the delivered power enters a fault condition. The GCM can detect a stuck
contactor. If a contractor is determined to be stuck, either open or closed, voltage regulation will
stop and the engine will return to idle speed.

Note that for 90 KVA GPU’s, the 2nd contactor and output cable are optional.

(1) Load Contactor

When 400 Hz power is supplied to the aircraft, the aircraft returns a voltage signal to the GPU
through the E & F pins of the output cable and terminal block. This return signal is used to provide
a logical interlock for the GCM. Without this signal from the aircraft, the GCM does not allow the
contactor to stay closed. If the aircraft decides 400 Hz power is not within specification, it will cut
the return signal through the E and F pins, causing the GPU’s contactor(s) to open.

The output load contactor contains three main contact sets. The three main contacts conduct
three-phase AC generator output. Three-phase, 400 Hz generator output cables are connected
from the generator to the line side of the load contactor by passing through a set of current
transformers. From the contactor, power is brought to the aircraft via 400 Hz output cables (in
various lengths) and plugs.

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Operation
1. Preparation for Use

WARNING:
IMPROPER OPERATION CAN KILL! READ AND UNDERSTAND
ALL OF THE OPERATING INSTRUCTIONS BEFORE
ATTEMPTING TO OPERATE THE UNIT.

A. Inspection/Check
Inspect the unit thoroughly prior to operation.

(1) Remove the blocking, banding, ties, and other securing material.

(2) Inspect for shipping damage.

(3) Inspect the interior for foreign material such as rags, shipping papers, etc.

(4) Check the fuel, coolant and oil hoses and connections for visible leaks. For Tier 4 Final engines,
check the DEF fluid lines.

(5) Check the following for sufficient quantity.

(a) Fuel
The level gauge should be at or near full.

CAUTION:
BEFORE FUELING WITH ANY TYPE OF JET FUEL, CONTACT
TLD. DAMAGE TO THE FUEL INJECTION SYSTEM COULD
RESULT. NEVER USE JET FUEL WITH A TIER 4 ENGINE. ONLY
ULTRA LOW (<15PPM) SULPHUR DIESEL CAN BE USED WITH
(b) Engine Coolant

CAUTION:
BE SURE THE COOLANT SYSTEM ANTI-FREEZE SOLUTION IS
ADEQUATE TO PROTECT BELOW THE LOWEST
TEMPERATURE EXPECTED.

Coolant level should be approximately one inch below the radiator filler neck. The expansion
tank should be approximately half full. See engine manufacturer’s manual (Chapter 5) for
recommended coolant type.

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NOTE:
For antifreeze protection, use a solution of 50% long life
antifreeze (ethylene glycol) and 50% distilled water.

(c) Engine Lubricating Oil

The oil level should be at the full mark on the dipstick. See the engine manufacturer’s
manual (Chapter 5) for oil recommendations.

(d) Air Cleaner

The air cleaner is a permanent dry type with a replaceable filter element. Check to ensure
there are no papers, tape, or other material covering the air inlet.
(e) Diesel Exhaust Fluid (DEF) – Tier 4 Final Engine Only
The DEF level should be near 100% as indicated on the generator controller DEF Level
gauge. If it is necessary to replenish the DEF, refer to page 2-1-10 for instructions.

NOTE:
When DEF level falls below 2.5% of the maximum capacity,
engine power output will be reduced to comply with emission
regulations. This may cause an interruption in power delivery to
attached aircraft.

B. Installing Output Cables

Units are generally shipped with an aircraft cable assembly. Follow the instructions below if the GPU
does not have factory-installed cables.

(1) Three-phase AC Aircraft Cable Assembly Installation (#1 Output)

The #1 output contactor is located at the left rear of the electrical box.
(a) Loosen the cable clamp and connect the loose ends of the cable assembly to the #1 output
contactor.

NOTE:
The AC aircraft cable assembly recommended shall consist of
four single conductor #2/0 cables with two #12 control leads
connected to an AN3430 plug.
The #2/0 cables must be equipped with terminals having a 3/8
Inch diameter mounting hole. The mounting hole in the #12
leads must be 1/4 Inch.

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(b) Each contactor is identified by a nameplate. Each cable should be identified by a band-type
marker. Connect cable "A" to terminal "A", "B” to "B", etc. Tighten the terminal nuts
securely. Connect the "E" lead to the "E" terminal and the "F" lead to the "F" terminal on the
distribution block below the contactor.
(c) Tighten the cable clamps securely, but avoid damage to the cable insulation.

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2. Unit Operation

WARNING:
IMPROPER OPERATION CAN KILL! READ AND UNDERSTAND
ALL OF THE OPERATING INSTRUCTIONS BEFORE
ATTEMPTING TO OPERATE THE UNIT.

This section contains information and instructions for the safe and efficient operation of the unit.

A. Prestart Inspection

(1) Check the engine oil level.s

(2) Check the coolant level.

(3) Check the DEF Level (Tier 4 Final Engine Only)

(3) Make a visual check of the unit for conditions which could affect serviceability.

B. Engine Starting Procedures

The engine and generator operating controls and monitoring equipment are mounted on the
instrument panel as illustrated in Figure 10.

(1) Ensure that the battery disconnect switch (S6) is in the ON position.

(2) Press the GREEN button to turn on the GCM.

(3) Wait 5 seconds for the GCM to reach the blue start screen.

(4) Press and release the BLUE button to start the engine. Allow the engine warm-up sequence to
run for the 60 second count down. If the engine is already warm the GCM2 will skip the warm-up
sequence.

(5) The generator is now ready to provide power.

C. Starting Engine in Cold Weather

This engine is equipped with an automatic intake manifold heater. Pre-heating the intake takes place
automatically when the engine ambient temperature reaches a predetermined low temperature limit.

The heater icon illustrates when pre-heating is taking place. Wait until the heater icon disappears,
then follow the normal starting procedure.

NOTE:
Always wait until the heater light goes out then start the engine
to ensure a successful and clean start.

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D. Delivering Power to the Aircraft

WARNING:
REMOVE THE AC PLUG FROM THE AIRCRAFT WHEN USING THE DC
OUTPUT TO START AN AIRCRAFT.

HAVING BOTH PLUGGED IN MAY RESULT IN BURNING THE GROUND

WIRE AND GCM BECAUSE OF OVERCURRENT IN THE GROUND WIRE.

(1) Connect the power cable to the external power receptacle on the aircraft.

(2) If the engine has completed its warm-up, the power outputs will be available for use.

a. Press and release the RED button to turn on the #1 400 Hz power

b. Press and release the YELLOW button to turn on the #2 400 Hz power

(only models with 2 AC cables)

c. Press and release the GREEN button to turn on the 28VDC power

(only if model is equipped with a DC cable)

(3) The engine ramps up automatically. Once the GCM has detected that the power quality is good,
the output contactor will close to allow power to the aircraft. The icon text above the output
symbol will turn green to show that the contactor has closed.

(4) External power is now being supplied to the aircraft.

E. Removing Power from the Aircraft

WARNING:
DO NOT UNPLUG CABLE FROM AIRCRAFT BY PULLING ON THE CABLE.

PULL ONLY ON THE CABLE HEAD. INCORRECT REMOVAL OF THE CABLE

PLUG FROM THE AIRCRAFT MAY CAUSE INTERNAL PLUG DAMAGE,
INCREASING RISK OF SHORT CIRCUIT OR OTHER DAMAGE.

(1) Press and release the button below the screen symbol to the output that should be turned off.

a. Press and release the RED button to turn off the #1 400 Hz power

b. Press and release the YELLOW button to turn off the #2 400 Hz power

(only models with 2 AC cables)

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c. Press and release the GREEN button to turn off the 28VDC power

(only if model is equipped with a DC cable)

(2) Disconnect the power cable from the aircraft.

(3) Stow the power cable on the generator in the proper location.

F. Shutting Down the Engine

(1) Press and release the BLUE button. If any outputs are being used, they will automatically shut off.
The engine will cool down for 60 seconds before shutting down.

The operator can cancel the shutdown at any time of the cool-down by pressing and releasing the
blue button.

When the engine is shut-down, battery power to the engine computer must be maintained for a
minimum of 120 seconds. This allows existing engine faults to be registered by the ECM. On a
Tier 4 Final Engine, this allows the DEF injection system to be purged. Do not turn off the main
battery disconnect switch during this time.

Failure to maintain battery power to the ECM will result in diagnostic trouble codes upon the next
start-up.

CAUTION:
FAILURE TO ALLOW THE ENGINE TO IDLE AFTER OPERATING
UNDER LOAD MAY LEAD TO TURBOCHARGER BEARING
DAMAGE.

DO NOT USE THE EMERGENCY STOP SWITCH TO SHUT DOWN

THE UNIT DURING NORMAL OPERATION.

Tier 4 Final Engine Operation Notes

In order to meet cleaner emissions standards, TLD ground power units can be equipped with a diesel engine
that is compliant with U.S. Tier 4 Final/E.U Stage IV regulations. The effect of these regulations is that off-road
diesel engines must emit less harmful emissions than ever before. Engine manufacturers have employed new
technology to accomplish the goals set forth by governing bodies.

The Tier 4 Final engine equipped on a TLD ground power unit has an exhaust system fitted with a diesel
oxidation catalyst (DOC) which reduces emitted hydrocarbons and carbon monoxide. The exhaust system also
contains a selective catalytic reducer (SCR) which, when used with DEF, reduces emitted NOX.

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TLD ground power units have been designed to reduce overall maintenance, but some steps are required to be
taken for the continued reliability of the Tier 4 Final engine and to prevent unexpected interruption in power
delivery to aircraft.

- Maintain a DEF level of greater than 10% as indicated on the generator controller screen

- Only fill the DEF tank with ISO – compliant DEF or ADBLUE.

- Only use diesel engine motor oil that meets the CJ-4 standard in North America or the ACEA E9
standard in Europe.

- Only use ultra low-sulpher diesel fuel with less than 15 PPM of sulphur.

- Never attempt to deliver power to an aircraft while engine diagnostic trouble codes are present.

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Specifications and Capabilities

1. GPU-400 SERIES

RATED LENGTH
KVA P.F. KW WIDTH HEIGHT
AMPS TOWBAR UP
MODEL
With beacon
64"
112" 68" 1630 mm
GPU-406 60 0.8 48 170
2845 mm 1728 mm W/O beacon
59”
1502 mm
With beacon
64"
112" 68" 1630 mm
GPU-409 90 0.8 72 260
2845 mm 1728 mm W/O beacon
59”
1502 mm

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Generator Specifications

The generator used in the ground power unit is rated at 115/200 Volts nominal, 400 Hz, and 125% of
rated power for 5 minutes. It is 3-phase, 4-wire wye connected, and with a grounded neutral. It is a
brushless, self-cooling, single-bearing generator directly coupled to the engine. Refer to the chart
above for power and current ratings. The operating speed is 1846 rpm.

C. Generator Control Module Protection System

Over voltage ................................................................. Trips @ 130 Volts

Under voltage ............................................................... Trips @ 100 Volts
Over frequency ............................................................. Trips @ 420 Hz
Under frequency ........................................................... Trips @ 380 Hz
Overload ....................................................................... Trips @ 125%, 5 minutes

All faults require a manual reset on the generator control module before any power can be delivered to
the aircraft again.

D. Engines:

All engines used are electronically-controlled diesel engines with electronic engine governors
providing precise frequency regulation and fast transient response. Engine protection such as low oil
pressure, high coolant temperature, and over speed protection are programmed into the engine
electronic control module (ECM). An engine diagnostic connector is provided for communicating with
the engine for diagnostic purposes. Engine operating parameters are displayed on the GCM display
via SAE J1939 Controller Area Network (CAN), which include:

- Engine hours
- Engine RPM
- System Voltage
- Oil Pressure
- Coolant temperature
- % Engine load at the current RPM
- Active and stored service codes
- Intake Heater Status
- Diesel Exhaust Fluid (DEF) Level (Tier 4 Final Only)

The fuel gauge is built into the GCM. Automatic engine cool down and emergency shutdown are
standard engine controls.

1. Cummins Engine Specification: Refer To Chapter 5 / Cummins Manual.

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Shipping
1. Shipping the Unit

CAUTION:
DO NOT SHIP THE UNIT BY RAIL. DAMAGE MAY OCCUR DUE
TO HIGH AND UNPREDICTABLE ACCELERATION WHEN
SHIPPING BY RAIL AND THE FACTORY SUGGESTS THAT
OTHER MODES OF TRANSPORTATION BE USED.

CAUTION:
DO NOT USE CHAINS OR STRAPS OVER FUEL LINES,
ELECTRICAL WIRES, OR COMPONENTS.

A. Secure the unit using straps or chains over the axles. Use wheel chocks in front of and behind
the tires to prevent movements.

NOTE:
If shipping the unit by boat it is advisable to keep the unit below
decks and away from salt water spray. If this is unavoidable,
cover the unit with plastic to keep salt water spray from coming
in contact with the unit.

B. Lifting Arrangements
If it is desired to lift the unit with a forklift, utilize the unit forklift pockets only to move the unit. Do not
hoist, lift or otherwise move the unit using the on frame tie down points, they are designed for stowage
only.

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Storage
1. Storing the Unit

A. When storing the unit in cold ambient temperatures, be sure that the proper antifreeze percentage
is present in the engine cooling system.

B. When storing the unit for extended periods of time, perform the following steps:

(1) Drain the cooling system completely from the engine and radiator. Drain the DEF tank if the
unit is equipped with a Tier 4 Final engine.

(2) Remove most of the weight from the tires using blocks under the frame.
(3) Remove all fuel from the fuel tank and add a desiccant to absorb condensation.
(4) Cover the air screens on the generator with tape to prevent the ingress of foreign material.
(5) Disconnect the battery with the battery switch.

NOTE:
Consult the manufacturer's literature in Chapter 5 for further
Information on storage.

2. Removing the Unit From Storage

A. Check and replenish the level of engine coolant. Replenish the DEF if the unit is equipped with a
Tier 4 Final engine.

B. Check and replenish the level of oil in the engine.

C. Remove the tape on the generator air screens.

D. Visually check of the unit for damage, as birds and small rodents may build nests or chew on wires
and hoses.

E. Connect the battery with the battery switch.

NOTE:
Consult the manufacturer's literature in Chapter 5 for further
Information on removing components from storage.

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