Operation & Maintenance Manual

for
GPU-4060-T-CUP
(& GPU-4060-T-CUP-28)

Ground Power Unit

 CHAPTER 1

INFORMATION & OPERATION

Ground Power Unit

GPU-4060-CUP
(Version: 200903)
 Chapter 1
Table of Contents
INFORMATION & OPERATION Chapter/Section Page
Description ....................................................................................1-1 ..............................1
1. Unit Description .................................................................................................................... 1
A. GPU-4060 ......................................................................................................................... 1
2. Major Component Description.............................................................................................. 3
A. CUMMINS ENGINE:........................................................................................................ 3
B. Generator System............................................................................................................. 5
C. Control Box ....................................................................................................................... 7
D. GENERATOR CONTROL MODULE.............................................................................. 11
E. Instrument Panel............................................................................................................. 13
F. Contactors ...................................................................................................................... 16
Operation.......................................................................................1-2 ..............................1
1. Preparation for Use .............................................................................................................. 1
A. Inspection/Check .............................................................................................................. 1
B. Installing Output Cables.................................................................................................... 2
2. Unit Operation ...................................................................................................................... 3
A. Prestart Inspection............................................................................................................ 3
B. Engine Starting Procedures.............................................................................................. 3
C. Starting Engine in Cold Weather ...................................................................................... 3
D. Delivering Power to the Aircraft ........................................................................................ 3
E. Removing Power from the Aircraft................................................................................... 4
F. Shutting Down the Engine ............................................................................................... 4
Specifications and Capabilities...................................................1-3 ..............................1
1. GPU-4060 SERIES .............................................................................................................. 1
A. Generator Specifications .................................................................................................. 1
B. TLD Generator.................................................................................................................. 1
C. Generator Protective System ........................................................................................... 1
D. Engines: ............................................................................................................................ 2
2. CUMMINS ENGINE SPECIFICATION:................................................................................ 2
Shipping ........................................................................................1-4 ..............................1
1. Shipping the Unit .................................................................................................................. 1
A. Secure the unit.................................................................................................................. 1
B. Lifting Arrangements......................................................................................................... 1
Storage ..........................................................................................1-5 ..............................1
1. Storing the Unit..................................................................................................................... 1
2. Removing the Unit From Storage......................................................................................... 1

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Contents
 Description
1. Unit Description
A. GPU-4060

The GPU-4060 is a self contained, diesel engine driven, ground power unit. The unit is
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-4060 are of a simple but rugged design with sufficient safety
devices to ensure a long, trouble free service life. The illuminated control panel provides for
easy night operation.

The unit features a brush-less revolving field generator, rubber torsion axle-mounted chassis
of rugged galvanized steel construction with fifth wheel steering and powder-coated sheet
metal panels. The unit meets U.S. and EURO emission standards, Tier3 and Com 3.

Options available on the GPU-4060 Ground Power Unit are listed below. Each piece of
optional equipment is covered by it's own instructions and parts breakdown and is located in
Chapter 4. Disregard the option if 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 package with current limiting, rated at 1000 amps
continuous, 2500 amps peak

(6) Fuel filter / water separator with heater

(7) Hush kit

(8) Forklift safety pockets

(9) Plastic rub rails

Creation:03.09 — 2009 1-1-1

Description
 1
6
9
4

8
7

2 3

1. Air filter 6. Generator

2. Exhaust silencer 7. Radiator
3. Instrument panel 8. Charge air cooler
4. Engine 9. Electrical Box
5. Fuel Tank

GPU-4060 SERIES GROUND POWER UNIT

CUMMINS ENGINE CONFIGURATION
FIGURE 1

Creation:03.09 — 2009 1-1-2

Description
 2. Major Component Description
The unit is equipped with 4 cylinders, in-Line, and turbo-charged engine, certified to meet EPA
Tier 3 and Euro COM 3 emissions regulations. Since various engines are offered to power the
generator, refer to the section that is applicable to your unit.

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 rear, above the generator, and pushes it across the radiator and turbocharger air
cooler.

A. CUMMINS ENGINE:

(1) Engine Control Module (ECM):

Refer also to the Engine Manufacturer’s Literature for more detailed information.

The ECM manages fuel delivery rate to ensure optimum engine performance under
various load conditions. Increased fuel economy results from precise drive-train and
application matching. The ECM uses the engine speed and correction variables in
conjunction with stored performances mapping to calculate control rod position and
volume of fuel injected. The ECM also stores diagnostic messages. The data storage
and retrieval bank consists of a re-programmable read only nonvolatile (EEPROM)
memory module. The module is initially pre-programmable with general engine
characteristics. After initial testing, the module receives a set of data specific to the
engine application through the diagnostic connector. The ECM microprocessor is an
interface device connected between engine sensors, unit controls, and indicators. On the
unit side, primary components are the battery (power supply), diagnostic connector, and
fault indicator lamp. On the engine side, are the oil pressure sensor, coolant temperature
sensor, camshaft speed sensor, control rod position/actuator, wire harness and shutdown
solenoid. The ECM incorporates logic that regulates engine start up speed depending on
current engine temperature to minimize smoke emissions from over fueling.

(a) Control Rod Position Sensor Actuator

The position sensor/actuator performs two functions: it actuates the fuel injection
pump control rod to meter the correct volume of fuel injected for the load and signals
control rod position to the ECM through an integral travel sensor installed in the
actuator housing. A rotary solenoid incorporated in the actuator positions the control
rod against return spring tension using a variable strength electromagnetic current.
The ECM regulates the strength of the output signal, determining the correct
excitation current to send the actuator by comparing engine sensor input to pre-
programmed values and performance maps stored in memory. The differences
between the dynamic and static values comprise the input variable. The actuator
supplies the force needed to move and position the fuel control rod as required to
maintain steady state equilibrium. At equilibrium, the control rod fuel supply position
corresponds to the engine power requirement and the current operating conditions. If
engine speed drops under increased load, the ECM sends a current signal to the
actuator that moves the control rod in the direction of increased fuel delivery until
equilibrium is again established. An internal spring returns the control rod to the fuel
shut off position when the actuator is de-energized. An external shutdown solenoid
assures that engine shut down occurs when the power supply is switched off.

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Description
 (b) Engine Sensors

The engine sensors transmit data to the ECM describing engine dynamic
performance. The sensors allow comparison of current engine operating conditions
with specific parameters to determine the correct fuel delivery rate. Sensor inputs are
supplied for control rod position, speed, coolant temperature, and oil pressure. The
data received is used by the ECM to monitor and regulate engine performance, to
provide diagnostic information, and to activate the engine protection system.

(c) Speed Sensor.

The engine speed sensor reads a pulse wheel on the camshaft to calculate engine
speed. The ECM system provides over speed protection which retracts the control
rod to the stop position and initiates a fault indication condition.

(d) Engine Protection Sensors.

The ECM records and displays engine fault conditions. The ECM continuously
monitors input data received from the engine sensors and illuminates the engine fault,
high coolant temperature, or low oil pressure light if a fault is detected. Automatic
engine shutdown is programmed for low oil pressure and high coolant temperature
conditions. Indicator lights on the instrument panel identify the specific fault condition.
Transient overrun conditions will not cause engine shutdown. Active and inactive
fault codes stores in the ECM’s memory can be accessed via the interface connector
on the panel using a PC loaded with factory diagnosis software. Displayed
information identifies the fault location; type of fault, engine speed and condition,
number of fault locations, frequency and fault active or passive status.

Creation:03.09 — 2009 1-1-4

Description
 B. Generator System

The GPU-4060 Series generator system is an extremely simple system which contains very
few components. It can utilize either the TLD, Kato, or Marathon brand generators. All are
direct drop-in replacements. 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.

1. Generator:

The 400 Hz generator is a brush-less, revolving field, three phase, synchronous,

alternating current generator of single bearing construction. Generator excitation
current is supplied from a direct connected brush-less 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 complete assembly is vacuum pressure impregnated with epoxy resin and
thermally cured to ensure excellent bonding qualities, high dielectric strength and
maximum moisture resistance. The generator field poles are mounted on a large
diameter shaft. Field coils of heavily insulated wire are machine wound directly onto the
poles. The coils are blocked and braced for physical strength and rigidity. The entire
rotor is vacuum pressure impregnated with 100% epoxy resin to form one complete,
homogeneous mass. 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
mounted on aluminum heat sink.

During operation, the three-phase power generated in the exciter armature is applied
directly to the rotating rectifier assembly. The forward polarity rectifiers mounted on one
heat sink and the reverse polarity rectifiers on the other heat sink are connected to form
a three phase full wave rectifier bridge. The rotating rectifier bridge assembly rectifies
the alternating current supplied by the exciter armature. The direct current output of the
rotating rectifier bridge assembly is in turn applied to the rotating field of the generator
via lead wires routed through a key way shaped slot on the rotor shaft. Excitation
current for the stationary field coils is supplied by the synchronous generator through
the Generator Control Module.

A heavy duty "greaseable" bearing is used to support the generator rotor for prolonged
operating life. Grease fitting and grease relief are installed on the generator housing for
easy lubrication of the bearing.

The generator is designed with a self-contained cooling system which circulates coolant
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.

In order to absorb the counter EMF which is present during NO BREAK POWER
TRANSFER, a ring resistor (field discharge resistor) has been added across the main
rotor windings, and over-sized diodes have also been added in the rotating rectifier
assembly.

Creation:03.09 — 2009 1-1-5

Description
 1
2 3 4
5
6
7

16

15
8
9

11
10 12
13
14

1. Drive plate assembly 9. Endbell

2. Coupling hub 10. Exciter field
3. Screen cover 11. Bearing
4. Adapter 12. Exciter armature
5. Fan assembly 13. Rotating rectifier assembly
6. Aluminum baffle 14. Ring Resistor
7. Generator frame and stator assembly 15. Exciter cover
8. Generator rotor assembly 16. Drip proof shield

TYPICAL GENERATOR BREAKDOWN

FIGURE 5

Creation:03.09 — 2009 1-1-6

Description
 C. Control Box

1. 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. It also provides a place for the engine’s electronic
control module (ECM) to mount to. This is located on the outside of the electrical box
back wall and accessed from inside the GPU.

1. Electrical Box
2. Instrument Panel Assembly
3. Relay Panel Assembly

ELECTRICAL BOX ASSEMBLY

FIGURE 6

Creation:03.09 — 2009 1-1-7

Description
 2. 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).

2) Relay Panel with Spare Relay

1) Relay Panel without Spare Relay

1. Current Transformers, T4, T5, T6 5. Output Test Bank Switch, S11

2. Contactor, K10 6. Frequency Simulator Switch, S4
3. Engine Cooldown Timer Module, K7 7. Spare Relay (for K4, K5, K6, K8 & K11)
4. Relays, K4, K5, K6, K8, K11

RELAY PANEL
FIGURE 12

Creation:03.09 — 2009 1-1-8

Description
 The relay panel contains the following.

(1) Current Transformers, T4, T5, T6

The relay panel assembly contains 3 current transformers which are used to transform current
measurements to mili-volt signals to the Generator Control Module (GCM) for load sensing and
line drop compensation, for instrument panel indication, and for over-current protection.
(2) Contactor(s), K10

The function of the contactors is to allow, or not allow, 400 Hz output power from the generator
to the aircraft. The contacts state, open or closed, is controlled by the 28 VDC contactor coil.
(3) Output Plug Interlock Relay(s) and Circuit Description, K11

The function of the plug interlock relay(s) is to cause the output load contactor to open, via the
generator control module (GCM) in the event the cable plug connector becomes accidentally
disconnected from the aircraft during power delivery, or if an attempt is made to deliver power
when the output cable is not connected to the aircraft, or if the aircraft should reject the GPU’s
400 Hz power for any reason. 28 VDC for operation of the relay is supplied from the aircraft
either through an on-board transformer-rectifier or from a 28 VDC electrical system.
Connection from the aircraft to the interlock relay is made through terminals E and F on the
output cable plug connector.
(4) Output Test Bank Switch(es), S11

A SPST, toggle switch provides a means of bypassing the plug interlock relay when supplying
power to a load bank or to an aircraft not equipped with 28 VDC feedback.
(5) Starter Lockout Relay, K8

The function of the starter lockout relay is to not allow the engine’s starter motor to crank when
it is already running.
(6) Idle / Rated Speed Relay, K5

The function of the idle/rated speed relay is to allow the engine to run either at idle speed or
rated speed. When the idle/rated speed relay is de-energized, the engine is running at idle
speed. When the idle/rated speed relay is energized, it sends a signal to the speed control
unit, allowing the governor actuator to bring the shut off lever to the rated speed position.
(7) Engine Fault Relay, K4

The function of the engine fault relay is to make the engine go back to idle should an engine
fault, such as low oil pressure or high coolant temperature occur. When any of the above
conditions develop, the engine fault relay is de-energized by the Deutz ECM, which opens the
K4 engine fault relay contact, cutting power to the K5 rated speed relay. This causes 2 things
to happen. First, it tells the Deutz ECM to go to idle engine speed. Second, it cuts power to
the Generator Control Module (GCM), which cuts the signal to the generator field and causes
400 Hz output power to stop.
(8) Engine Cooldown Relay, K6

The purpose of the Engine Cooldown Idle Relay is to ensure the engine goes to idle for a
period of 1 minute prior to shutting down. This is a standard feature of the GPU-4060 series
Ground Power Units designed to protect the engine’s turbo from rapid temperature changes. It
will greatly improve the longevity of the engine and it’s logic must not be defeated, Nor should
the emergency stop switch be used to shutdown the engine under normal operation.

Creation:03.09 — 2009 1-1-9

Description
 (9) Engine Cooldown Timer Module, K7

The purpose of the Engine Cooldown Timer Module is to perform the acutal timing of the
Engine Cooldown Circuit. When the engine is running and the ignition switch is moved to the
off position, power is cut ot the “initiate” contact of this relay. One minute after, this relay will
go back to it’s original state and cut power to the 24 VDC run circuit, cutting power to the
engine’s ECM and shutting off the unit.

On startup, there is no timing feature.

(10) Frequency Simulator Switch, S4

The frequency Simulator Switch is a single-pole, double-throw, switch with momentary

contacts used for maintenance purposes only. It functions to increase or decrease the
engine’s speed by sending a signal to the appropriate contact on the engine’s ECM. When the
engine’s speed is increased, the generator’s output frequency is also increased, and visa versa.
This switch is used to ensure the generator control module (GCM) causes the output
contactor(s) to open anytime the frequency goes over 420 Hz or falls under 380 Hz.
(11) Bridge Rectifier, CR1

The function of the bridge rectifier(s) is to convert a 115 VAC signal to 28 VDC to energize the
unit’s main output load contactor(s).
(12) Terminal Boards, TB1, TB2, TB3, TB4, TB5

The purpose of the terminal boards is to provide a means to interconnect power from 1 wire or
cable to another. TB5 is for connecting the 400 Hz output cable(s) Neutral wire “N” to the
Generator “N” cable. TB6 connect the output cable(s) E and F pins to the K11 output plug
interlock relay coil. TB9 is to allow connecting of the optional 28.5 VDC circuit.

Note that there is no Terminal Board for connecting output cable(s) for lines A, B, or C. These
are connected directly into the output contactor(s) respective contact.
(13) Spare Relay

The purpose of the Spare Relay is disconnected and provides to replace any of the failure
relays (for K4, K5, K6, K8 & K11).

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Description
 D. GENERATOR CONTROL MODULE

The generator control module is mounted inside the door of the GPU’s electrical box. It’s
display is read without opening up the electrical box. The module the waterproof electrical
box. The regulator panel provides mounting facilities for the generator control components.

The Generator Control Module is designed to provide 1% of voltage regulation with 100
millisecond recovery time for all loads up to 100% of the rated load on all 3 three-phase, four-
wire, 115/200 volt, 400 Hz, brushless generators. It has a voltage regulator circuit which
controls the generator output voltage by regulating the amount of current to the exciter field.
The maximum continuous output rating of the regulator is 65 VDC, 5 amperes, with a one-
minute field forcing capacity of 90 VDC, 7 amperes.

The voltage regulator senses the generator voltage, compares a rectified sample of that
voltage with a reference voltage, and supplies the field current required to maintain the
predetermined ratio between the generator voltage and the reference voltage. The voltage at
which the generator is regulated may be adjusted with the voltage regulator. Refer to the
Manufacturer's Literature in Chapter 5 for more detailed information on the generator control
module.

Generator Control Module

(GCM)

The Generator Control Module is the brain of the GPU-4060. It is a fully-automatic Voltage
Regulator that not only provides voltage regulation, but also generator fault protection as well
as generator operating parameter display. The voltage regulator monitors the 400 Hz output
when 400 Hz is in use and automatically switches over to monitor 28.5 VDC output when
optional 28.5 VDC transformer rectifier is in use. The voltage regulator provides line drop
compensation on 400 Hz as well as line drop compensation and current limiting on 28.5 VDC
transformer rectifier. The voltage regulator displays the generator output operating parameters
such as voltage, current, and frequency, digitally on a backlit LCD. The voltage regulator is
programmed to provide generator output fault protection in the following settings:
- Over frequency: 420 Hz in 5 seconds
- Under frequency: 380 Hz in 7 seconds
- Over voltage: 130 volts in 2 seconds
- Under voltage: 100 volts in 7 seconds
- Overload: 125% of rated load for 5 minutes
The voltage regulator displays and latches the fault if any of the above should occur.

Creation:03.09 — 2009 1-1-11

Description
 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.
- Phase balance: 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.
- Line drop compensation: Provides a voltage increase of 10 volts,
line to neutral, to compensate for
voltage drop in the aircraft cable
assembly.

Creation:03.09 — 2009 1-1-12

Description
 E. Instrument Panel

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

1. Idle / Rated Speed Switch, S6 15. Spare

2. #1 Output Contactor Switch, S10 16. Low Fuel Level Light, DS101
3. Spare 17. Generator “No-Go” Light (Red)
4. 28.5 VDC Contactor Switch, S14 18. Generator “Go” Light (Green)
5. Ignition Switch, S3 19. Generator Control Module Scroll Left Button
6. Emergency Stop Switch, S2 20. Generator Control Module Scroll Right Button
7. #1 Output Light, DS10 21. Generator Control Module Scroll Down Button
8. Spare 22. Generator Control Module Scroll Up Button
9. 28.5 VDC Output Light, DS12 23. Engine Function Display Gage, G2
10. Engine Cool Down Light, DS9 24. Engine Diagnostic Switch, S5
11. Engine Fault Light, DS7 25. Engine Diagnostic Connector, P1
12. Engine Stop Light, (Cummins only) 26. Fuel Level Gage, G3
13. Engine Maintenance Light (Cummins) 27. Panel light, DS2
14. Intake Heater Light, DS8 28. Panel light, DS

INSTRUMENT PANEL - FIGURE 14

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Description
 The following instruments and control switches are mounted on the instrument panel.

(1) Idle / Rated Speed Switch

The engine idle / rated speed switch is a three position toggle switch identical to the
output contactor switches. The lower position of the switch is for idle engine speed and
the center position of the switch is for full engine speed. Both of these positions are
maintained contacts.

The top position of the switch is a momentary contact and is used to turn on the
generator control module which then allows the generator to build up voltage. At this
point, 400 Hz power is available at the generator side of the output load contactor(s),
but no further. When the switch is released, it will automatically return to the rated
speed position.

In the OFF position, the switch opens the AC circuit to the rectifier bridge, thereby
cutting the DC power to the contactor coil. This causes the output load contactor to
open.

(2, 3) Output Contactor Switches

The output contactor switches are three position toggle switch identical to the idle/rated
speed switch. When held in the momentary CLOSE position, it provides 400 Hz power
directly to a rectifier bridge, which supplies DC power to the respective contactor coils
for closing the output contactors. When released, it returns to the normal ON position
and continues to allow power to go to the rectifier bridge, but in this switch position, AC
power must pass through the plug interlock relay contacts, K11 & K13, and the
generator control module, VR1.

(4) 28.5 VDC Contactor Switch (optional)

The 28.5 VDC contactor switch functions the same way as the 400 Hz output contactor
switches except it controls the 28.5 VDC output load contactor.

(5) Ignition Switch

The ignition switch is used to turn the GPU on and off by controlling power to the
engine’s Electronic Control Module (ECM).

(6) Emergency Stop Switch

The emergency stop switch cuts battery power to the engine ECM and the Generator
Control Module, and will shut the GPU off.

THE EMERGENCY STOP SWITCH MUST ONLY BE USED IN AN EMERGENCY

SITUATION AND NOT FOR NORMAL GPU USE.

(7) #1 Output Light

The #1 output light will illuminate whenever 400 Hz power is traveling accross the #1
output load contactor.

(8) Spare

(9) 28.5 VDC Output Light (optional)

The 28.5 VDC output light will illuminate whenever 28.5 VDC travels accross the 28.5
VDC output load contactor.

Creation:03.09 — 2009 1-1-14

Description
 (10) Engine Cool Down Light

The engine cool down light will illuminate whenever the engine cooldown relay, K6, is
de-energized. This relay is engergized during normal engine running operation and no
power is allowed to the light. When the ignition switch is moved to the off position,
power is cut from the cooldown timer module, at which time, it’s contacts open after a
predetermined time, removeing power to the engine’s ECM and shutting down the
engine. THIS CIRCUIT WILL INCREASE THE LIFE OF THE ENGINE AND TURBO.

(11) Engine Fault Light

The engine fault light is controlled by the engine’s electronic control module
(ECM) and it will illuminate anytime a fault is detected via the engine’s safety
sensors. It is also used to flash diagnostic codes.

(12) Engine Stop Light (Cummins Only)

The engine stop light is used to notify the operator of a critical engine condition
and the engine should be shut down immediately. The cause of the fault must be
determined and fixed prior to the unit being put back into service.

(13) Engine Maintenance Light (Cummins Only)

The engine maintenance light signals to the operator that the engine is due for
routine maintenance.

(14) Engine Intake Heater Light

When the ignition switch is turned to the "run” position, the intake manifold heater will
turn on until the temperature rises above the required temperature.

The illumination of the intake heater light indicates that the pre-heating is taking place.
Wait until the light goes out, then follow the normal starting procedure.

(15) Spare

(16) Low Fuel Level Light

The low fuel level light will illuminate when the level of fuel in the tank falls below
approximately ¼ full which causes

(18) Fuel Level Gage

The fuel level gage is an electrical type. It receives signals from the fuel level sender
mounted in the fuel tank. The gauge indicates the fuel level in the fuel tank.

(21) Ignition Switch

The ignition switch serves to connect power to the auxiliary starter relay, K2, which then
allows power to go to the starter relay, K1. Battery voltage is then applied to the starter
motor which engages the starter gear with the flywheel ring gear and cranks the engine.

(27,28) Panel Lights

The panel lights provided illumination to the instrument panel for night time operation.

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Description
 F. Contactors

The GPU’s contactors are mounted on the inside bottom surface of the electrical box. The
contactor is wired to it’s own bridge rectifier. These components, together with interlock relays)
and Note that for 60 KVA GPU’s.

(1) Load Contactor and Bridge Rectifier

The bridge rectifier receives 400 Hz AC from phase C of the generator output and
converts it to a pulsating direct current for energization of the output load contactor
holding coil, K10. This DC coil holding circuit is controlled indirectly by controlling the 400
Hz A.C. to the rectifier. The hot line for the rectifier AC supply must pass through the
generator control module’s protective circuit, therefore any time a generator protective
device functions to trigger the relays, the rectifiers AC circuit is interrupted. No DC power
is then available for the load contactor holding coil, K10, hence, the load contactor opens.

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 energize either of the interlock relays (K11), which allow power to go to the
generator control module, then through either of the output contactor switches (S10),
through the bridge rectifiers (CR1), and finally to the output contactor coils (K10). If the
aircraft decides 400 Hz power is no longer required, it will cut the return signal through the
E and F pins causing the GPU’s contactor(s) top 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
output terminal block(s) and 400 Hz output cables (in varous lengths) and plugs.

(2) Voltage Adjustment Rheostat

The voltage adjustment rheostat provides adjustment of the regulated generator output
voltage plus or minus 10% of the nominal.

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Description
 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.

(5) Check the following for sufficient quantity.

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

(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.

NOTE:
For antifreeze protection use a solution of 50% permanent
antifreeze (ethylene glycol) and 50% clean water.

(c) Engine Lubricating Oil

The oil level should be at the full mark on the dipstick. See the “Cummins Engine”
manual for oil recommendations.

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Operation
 (d) Air Cleaner
The air cleaner is a disposable dry type with an integral filter element. Check to
ensure there are no papers, tape, or other material covering the air inlet.

B. Installing Output Cables

Units are generally shipped without aircraft cable assembly.

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

The output terminal 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
output terminal.

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.

(b) Each terminal stud 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 "E" lead to "E" terminal and "F" lead
to "F" terminal.

(c) Tighten the cable clamps securely but avoid damage to the cable insulation.

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Operation
 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.

(2) Check the coolant level.

(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 14.

(1) Turn the ignition switch to the "START" position.

(2) Release the ignition switch when the engine starts.

(3) The engine is now running at idle speed. Let the engine warm up to the operating
temperature.

(4) Hold the engine switch in the “"UP" position momentarily to bring the engine to
operating speed abd to build up generator voltage.
C. Starting Engine in Cold Weather
This engine is equipped with an automatic intake manifold heater. Pre-heating to the heater
takes place automatically when the engine ambient temperature reaches a predetermined
value.
The heater light illustrates when pre-heating is taking place. Wait until the heater light goes
out 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.

D. Delivering Power to the Aircraft

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

(2) Hold the contactor switch (#1 output) in the "CLOSE" position.

(3) When the output lamp (#1) lights, release the contactor switch.

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

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Operation
 E. Removing Power from the Aircraft

(1) Place the contactor switch in the "OFF" position.

(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) Turn the ignition switch to “OFF” position. The engine will ramp down to idle and remain
in idle for approximately one (1) minute to cool down. It will then shut down
automatically.

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.

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Operation
 Specifications and Capabilities
1. GPU-4060 SERIES
A. Generator Specifications

RATED LENGTH
MODEL KVA P.F. KW WIDTH HEIGHT
AMPS (TOWBAR UP)

With beacon
65.35"
92.36” 57.09” 1650 mm
GPU-4060 60 0.8 48 174
2346 mm 1450 mm W/O beacon
59.05”
1500 mm

B. TLD Generator
TLD generator is used in the GPU-4060 Series ground power unit. It is rated at 115/200
Volts nominal, 400 Hz, and 125% of rated load for 5 minutes. It’s 3 phase, 4 wire wye
connected, grounded neutral. It’s brushless, self-cooling, single bearing generator directly
coupled to the engine. Refer to the chart above for power and current rating.
Based on the number of poles in the TLD generator, the engine must turn at the speed to
obtain the 400 Hz output. The Operating Speed is:
2000 rpm

C. Generator Protective System

Over voltage relay .......................................................Trips @ 130 Volts, resets @ 125 Volts

Under voltage relay .....................................................Trips @ 100 Volts, resets @ 110 Volts

Over frequency relay ...................................................Trips @ 420 Hz, resets @ 417 Hz

Under frequency relay ..................................................Trips @ 380 Hz, resets @ 383 Hz

Overload relay ..............................................................Trips @ 125%, 5 minutes

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Specifications & Capabilities
 D. Engines:
All engines used are fully-electronic diesel engines with electronic engine governors 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. Engine operating parameters are displayed with electronic
gages via SAE J1939 Controller Area Network, which include:

- Engine Hours
- Engine RPM
- System Voltage
- Oil Pressure
- Coolant Temperature
- % Engine Load at the current RPM
- Active and stored Service Codes
- View Engine Configuration Parameters

A separate analog fuel gage is provided automatic engine cool down and emergency
shutdown are standard engine controls.

2. CUMMINS ENGINE SPECIFICATION:

Manufacturer ..................................................................Cummins

Model .............................................................................QSB4.5

Type ...............................................................................Turbocharged, in-line,

4 Cylinder 4-cycle diesel
Gross Rated Horsepower @ governed speed...............130HP/97KW

Governed speed.............................................................2000 RPM

Firing order.....................................................................1-3-4-2

Electrical system ............................................................24 Volt, negative ground

Refer to chapter 5 (manufacturer’s literature) for details of Cummins QSB4.5

engine.

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Specifications & Capabilities
 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 axels. 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, certain precautions are necessary to prevent
damage to the unit. The forks must be positioned so that they extend far enough under the
unit to provide a stable lift. The bottom of the unit is flat across the bottom of the cable tray
and fuel tank and no blocking or spacers are required.

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Shipping
 Storage
1. Storing the Unit
A. When storing the unit in cold ambient temperatures be sure that the proper glycol
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.

(2) Remove most of the weight from the tires using blocks under the frame.

Remove all fuel from the fuel tank and add a desiccant to absorb condensation.

Cover the air screens on the generator with tape to prevent the access of freign material.

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.

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

C. Remove the tape on the generator air screens.

D. Remove the tape on the generator air screens.

E. Make a visual check of the unit as birds and small rodents may build nests or chew on
wires and hoses.

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

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Storage