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TLD GPU - 406 Manual

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GPU - 406
GPU - 409
CHAPTER 2
MAINTENANCE/MINOR REPAIR
Creation: 01.31 - 2014

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Tes
April 11, 2025

Hard starting

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1 comments:
Mr. Anderson
April 11, 2025

The causes of hard starting for the TLD GPU - 406 include:

1. Defective GCM – If the bar graph does not appear during engine cranking, the GCM may be faulty and should be replaced.
2. Defective starter relay (K4) – If the engine cranks when a jumper wire is connected across the relay terminals, the relay is defective and should be replaced.
3. Defective starter motor (M11) – If the starter motor does not operate during testing, it is defective and should be replaced.
4. Internal engine seizure – If all starting components function but the engine does not crank, internal seizure is likely. Contact the engine manufacturer.

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Tes
April 12, 2025

Engine cranke but not runnin

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1 comments:
Mr. Anderson
April 12, 2025

If the TLD GPU - 406 engine cranks but does not start, possible causes include:

1. Low fuel level – Add fuel.
2. Defective check valve (V1) on the fuel suction line – Remove and check the valve's operation.
3. Loose connections or damaged fuel lines between the tank and fuel pump – Check for fuel leaks, tighten fittings, and replace damaged lines.

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Summary of Contents for TLD GPU - 406

  • Page 1 GPU - 406 GPU - 409 CHAPTER 2 MAINTENANCE/MINOR REPAIR Creation: 01.31 - 2014...

  • Page 2: Table Of Contents

    GPU - 406 GPU - 409 Contents 1. Periodic Maintenance ..............2-1-1 A. Maintenance ..........................2-1-2 B. Filters and Lubricants ........................2-1-3 C. Air Cleaner Maintenance ....................... 2-1-4 D. Engine Fuel ........................... 2-1-7 E. Cooling System ..........................2-1-8 F. Belts ............................... 2-1-9 G.
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  • Page 5: Periodic Maintenance

    GPU - 406 GPU - 409 1. Periodic Maintenance In order to ensure a properly running unit, periodic maintenance and inspections are necessary. In addition to the pre-operational instructions given in Chapter 1 the unit must be maintained on a regular basis and any malfunctions or problems with the unit must be fixed at once.

  • Page 6: Maintenance

    GPU - 406 GPU - 409 Maintenance The following charts show the frequency of maintenance required on the listed components. Component Maintenance Required Engine air filter Check daily, replace when indicator turns red.* Engine oil and filter Check daily; change every 500 hours.

  • Page 7: Filters And Lubricants

    GPU - 406 GPU - 409 Filters and Lubricants Filters and lubricants for periodic maintenance are listed below. The chart includes the name, GPU part number, and description of the item needed to maintain this unit. TLD P/N TLD P/N...

  • Page 8: Air Cleaner Maintenance

    GPU - 406 GPU - 409 (1) Lubrication Schedule The time schedules indicated in Chart 1 are approximate. They are based on average operating conditions. It may be necessary to reduce the intervals shown when operating the GPU under harsh operating conditions, such as low engine temperatures, heavy loads, and high oil temperatures, intermittent operation, or operation in dusty environments.
  • Page 9 GPU - 406 GPU - 409 Tier 4 Final Engines The Tier 4 Final engine air cleaner assembly consists of replaceable primary and secondary air filter inside a plastic housing. It is designed to be maintained without tools. Refer to Table 2 to see the necessary parts for the maintenance of the air cleaner.
  • Page 10 GPU - 406 GPU - 409 END CAP FIGURE 1A TIER 3 AIR FILTER LATCHES FIGURE 1B TIER 4I AIR FILTER Creation: 01.31 - 2014 2-1-6...

  • Page 11: Engine Fuel

    GPU - 406 GPU - 409 Secondary Cyclonic Stage 4 Metal Latches Dust Evacuator FIGURE 1C TIER 4 FINAL AIR FILTER Engine Fuel (1) Quality Use of Grade 2 diesel fuel is recommended. The use of low sulfur diesel fuel allows for 500 hour oil change intervals.

  • Page 12: Cooling System

    GPU - 406 GPU - 409 Cooling System WARNING: DO NOT USE METHYL ALCOHOL BASE ANTIFREEZE. DO NOT USE METHOXY PROPANOL ANTIFREEZE. DAMAGE MAY OCCUR TO THE RUBBER SEALS ON THE CYLINDER LINERS, WHICH ARE IN CONTACT WITH THE COOLANT.

  • Page 13: Belts

    GPU - 406 GPU - 409 Belts A single poly-V belt driven by the engine crankshaft pulley is used to drive the battery charging alternator, the radiator fan, and the engine coolant pump. The belt system is equipped with an automatic tensioner which eliminates the need for periodic tensioning.

  • Page 14: Battery

    GPU - 406 GPU - 409 (2) Adjustment The generator itself requires no adjustments. Battery Two 12 volt batteries wired in series produce a 24 VDC system which supplies power for operation of the engine electrical system and the clearance and panel lights.

  • Page 15: Cables And Cable Heads

    GPU - 406 GPU - 409 Battery Care (a) Maintain battery in fully charged condition. (b) Ensure battery is fastened securely to prevent damage. (c) Maintain battery fluid at the proper level. (d) Keep the battery terminal posts and clamps clean.
  • Page 16 GPU - 406 GPU - 409 J. Diesel Exhaust Fluid – Tier 4 Final Only 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.
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  • Page 19: Preventative Maintenance

    GPU - 406 GPU - 409 2. Preventative Maintenance Engine (1) Fuel (a) Check fuel level daily. (b) Check fuel filters and change elements in accordance with the instructions in the Manufacturer's Literature in Chapter 5. (c) Open the fuel tank drain every 500 hours to drain off water and sediment.

  • Page 20: Electrical System (Generator, 115 Vac)

    GPU - 406 GPU - 409 Electrical System (Generator, 115 VAC) The 400 Hz generator and controls are designed to be maintenance-free. No periodic maintenance adjustments are necessary. However, regular checks should be made to be sure all controls, instruments, etc. are working correctly.
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  • Page 23: Removal / Installation

    GPU - 406 GPU - 409 3. Removal / Installation This section explains the removal and installation of major components. Detailed instructions and diagrams help the mechanic, while cautions and warnings make the mechanic aware of potential hazards. WARNING: UNIT MUST BE DISCONNECTED AND SHUT-OFF BEFORE ATTEMPTING TO WORK ON OR REMOVE ANY COMPONENT.

  • Page 24: Engine/Generator Removal/Installation

    GPU - 406 GPU - 409 Engine/Generator Removal/Installation The engine and generator must be removed as an assembly. After the assembly is removed from the unit, the engine and generator may be separated. 1. Remove the exhaust system components. 2. Drain the coolant, unbolt the fan guard, and remove the radiator.

  • Page 25: Engine/Generator Coupling/Uncoupling

    Lift the generator up and out of the top of the unit. Engine and Generator Coupling Refer to Coupling Procedure TLD#101-03-0031 for coupling a generator to a Cummins engine (90 kVA). Creation: 01.31 - 2014...

  • Page 26: Electrical Box Removal/Installation

    GPU - 406 GPU - 409 Electrical Box Removal/Installation Unplug the electrical connector to the control box receptacle. Disconnect the generator wires from the contactor. Disconnect the output cable wires from the contactor. Disconnect the neutral wire from the distribution block.

  • Page 27: Cable Removal/Installation

    GPU - 406 GPU - 409 Cable Removal/Installation 1. Loosen the cord grip where the cable passes through the chassis of the unit. 2. Open the door to the electrical control box at the rear of the unit. 3. Remove the cover plate on the contactor that the cable is connected to.
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  • Page 29: Troubleshooting

    GPU - 406 GPU - 409 4. Troubleshooting General Practice Before troubleshooting the ACE Ground Power Unit and its associated components, the following areas of the unit should be checked: Engine Electrical System The engine's electrical system should be in proper working order. Check the unit batteries, engine sensors, and ECM (electronic control module) connections.

  • Page 30: Engine And Controls

    GPU - 406 GPU - 409 Engine and Controls PROBLEM CAUSE REMEDY 1. Engine will not start. A. Battery disconnect switch (S6) A. Check for proper operation of Starter will not crank engine. or emergency stop switch (S22) is S6 and S22. 24VDC should be open or defective.
  • Page 31 GPU - 406 GPU - 409 Engine and Controls (cont.) PROBLEM CAUSE REMEDY 2. Engine will not start. Cranking A. Low battery output A. Check for 24VDC across the speed is low. battery (BT1/BT2). Charge or replace the battery if necessary.
  • Page 32 The oil pressure sensor low oil pressure. may be fault and require replacement. Contact the engine manufacturer or TLD if necessary. 5. Engine will not come up to rated A. The screen displays “Aircraft A. The GCM is not getting the EF...
  • Page 33 H. The engine may require diagnostic fault codes. maintenance or repair. Refer to chapter 5 to troubleshoot engine performance problems. Contact the engine manufacturer or TLD if necessary. I. Defective Fuel Pump I. Replace the pump. Contact the engine manufacturer.
  • Page 34 7. Engine lacks power D. The GCM is reporting D. The engine may require diagnostic trouble codes. maintenance or repair. Refer to chapter 5 to troubleshoot engine performance problems. Contact the engine manufacturer or TLD if necessary. Creation: 01.31 - 2014 2-4-6...

  • Page 35: Generator And Controls

    Refer to displaying diagnostic trouble chapter 5 to troubleshoot engine codes. performance problems. Contact the engine manufacturer or TLD if necessary. E. The GCM is faulty E. Replace the GCM. Replacing the GCM will require calibration. Contact TLD for the required document 102-00688.
  • Page 36 GCM. C. Voltage display is inaccurate C. Correct the wiring to the regulator. The GCM may require calibration. Refer to the TLD document 102-00688. D. The voltage adjustment on the D. Calibrate the GCM. GCM is incorrect.
  • Page 37 B. Replace the GCM. GCM are defective. C. The engine is overloaded. C. Reduce the load at the aircraft to the rating of the TLD generator. Overloading can also occur for a short period when the aircraft first requests power.

  • Page 38: Output Load Contactor Operating Circuit

    GPU - 406 GPU - 409 #1 Output Load Contactor Operating Circuit PROBLEM CAUSE REMEDY 1. The #1 400Hz contactor does A. Faulty wiring to the contactor A. Ensure that 24 VDC is present not close after the RED button is...
  • Page 39 Correct the engine fault. Refer to chapter 5 to troubleshoot engine problems. Contact the engine manufacturer or TLD if necessary. B. Low fuel shut down has B. This is a normal operation for occurred. units equipped with a low fuel shutdown.

  • Page 40: Output Load Contactor Operating Circuit (Optional)

    GPU - 406 GPU - 409 #2 Output Load Contactor Operating Circuit (Optional) PROBLEM CAUSE REMEDY 1. The #2 400Hz contactor does A. Faulty wiring to the contactor A. Ensure that 24 VDC is present not close after the YELLOW...
  • Page 41 Correct the engine fault. Refer to chapter 5 to troubleshoot engine problems. Contact the engine manufacturer or TLD if necessary. B. Low fuel shut down has B. This is a normal operation for occurred. units equipped with a low fuel shutdown.

  • Page 42: Generator Protective Circuit

    GPU - 406 GPU - 409 Generator Protective Circuit PROBLEM CAUSE REMEDY 1. The output contactor opens A. A faulty connection exists A. Correct the wiring. during power delivery, and the between the voltage sensing wire GCM displays on the contactor terminal and the “FAULT LATCHED,...
  • Page 43 GPU - 406 GPU - 409 Generator Protective Circuit (cont.) PROBLEM CAUSE REMEDY 5. The output contactor opens A. There is too much load on the A. Reduce the load at the aircraft. during power delivery, and the GPU. GCM displays “FAULT LATCHED,...

  • Page 44: 28Vdc Operating Circuit (Optional)

    GPU - 406 GPU - 409 28VDC Operating Circuit (Optional) PROBLEM CAUSE REMEDY 1. The GCM displays A. A faulty connection to the coil A. Correct the wiring. “FAULT LATCHED, of the input contactor (terminals VOLTS LOW”. X+ and Y- on K19) to the TR.
  • Page 45 GPU - 406 GPU - 409 28VDC Operating Circuit (cont.) PROBLEM CAUSE REMEDY 3. The GCM displays A. There is too much load on the A. Reduce the load at the aircraft. “FAULT LATCHED, 28VDC circuit. OVERLOAD”. B. A faulty connection exists B.
  • Page 46 C. The line drop compensation C. Increase the setting. Contact lower than expected. setting within the GCM is set too TLD, as this changes the GCM low. calibration. D. The GCM is limiting current. D. Increase the limit if necessary.
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  • Page 49: Repairs

    GPU - 406 GPU - 409 5. Repairs Torque Charts When working on the equipment it is important to follow general mechanic guidelines. Charts 5 and 6 show the proper torque required on several different types of bolts. These charts should be used when any repairs are made to the unit or its components.
  • Page 50 GPU - 406 GPU - 409 RECOMMENDED ASSEMBLY TORQUE VALUES – METRIC BOLTS CHART 6 Creation: 17.10.2013 2-5-2...

  • Page 51: Adjustments

    GPU - 409 Adjustments The GPU-409 ground power unit uses the TLD-designed Generator Control Module which eliminates the need for periodic switch and relay setting adjustments. The following is a list of adjustments that are available to maintenance and operations personnel, depending on different airline requirements.
  • Page 52 GPU - 406 GPU - 409 1. Follow the steps in the adjusting the 400 Hz AC voltage setting to access the adjustments menu. 2. Scroll to the setting named “AC Line Drop” 3. Rotate the dial left or right to decrease or increase the setting. Adjust this until 115VAC is present at the load bank with a 90 kVA load.
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  • Page 55: Using The Schematics And Connection Diagrams

    Included with this manual are the pages that are the exact diagrams used to construct your GPU. When discussing with TLD field technicians, be sure to reference the 7 digit drawing number located in the lower right corner of each drawing and have the unit’s 6 character serial number available.
  • Page 56 GPU - 406 GPU - 409 This page intentionally left blank. Creation: 1.31 – 2014 2-6-2 |...

  • Page 57: Gmc2 Setup

    GPU - 406 GPU - 409 7. GMC2 Setup A. Software Install Required Equipment -USB Flash Drive -A Computer 1. Obtain a USB flash drive with at least 2 MB of available memory. 2. Obtain a copy of the latest firmware through E-Mail or download it from the unit CBOM. The firmware file will always be named “GCM2VXXX.hex”, where XXX is the version number.
  • Page 58 GPU - 406 GPU - 409 Figure 4: Accessing the Root Folder from the AutoPlay Menu 4. Drag the update file from its original location into the window of the root folder of the flash drive accessed in the previous step. The file is successfully copied when it appears in the root folder. Ensure that this is the only GCM2 update file on the flash drive.
  • Page 59 GPU - 406 GPU - 409 Figure 5: Copying the Update File into the Root Folder Now, safely remove the flash drive from the computer using the “Eject” command. The way this is accomplished on different versions of Windows can vary. After the computer indicates that it is safe to remove hardware, unplug the USB flash drive from the computer.
  • Page 60 GCM2 is in its off state. The GCM2 will display the TLD logo and firmware version for 5 seconds before transitioning to the blue start up screen. At this point, insert the USB flash drive with the update file into the USB port on the right side of the GCM2.
  • Page 61 GPU - 406 GPU - 409 Figure 7: USB Port on the GCM2 Creation: 1.31 – 2014 2-7-5...
  • Page 62 7, Press the red button the front of the GCM2 to start the update process. The GCM2 will load in the new file, and automatically restart. This process can take up to one minute. 8. When the GCM2 restarts, the firmware version will be displayed below the TLD logo. Verify that this is the latest version.
  • Page 63 2. Connect the battery by using the battery switch mounted to the right of the control box. The GCM2 screen should turn on after a short delay, and the TLD logo will be displayed along with the firmware version number. After five seconds, the start screen should be displayed.
  • Page 64 GPU - 406 GPU - 409 Figure 9: Rotary Dial with Built-In Pushbutton Creation: 1.31 – 2014 2-7-8...
  • Page 65 GPU - 406 GPU - 409 Figure 10: Magnetic Switch Location Figure 11: Adjustment Menu Creation: 1.31 – 2014 2-7-9...
  • Page 66 // 1021 = TLD GPU 60kVA w/28VDC // 1030 = TLD GPU 75kVA // 1031 = TLD GPU 75kVA w/28VDC // 1040 = TLD GPU 90kVA // 1041 = TLD GPU 90kVA w/2 Outputs // 1042 = TLD GPU 90kVA w/28VDC Creation: 1.31 – 2014 2-7-10...
  • Page 67 GPU - 406 GPU - 409 // 1043 = TLD GPU 90kVA w/2 Outputs & 28VDC // 0144 = TLD GPU 90kVA G-DRIVE Fixed RPM // 0145 = TLD GPU 90kVA G-DRIVE Fixed RPM w/28VDC // 1050 = TLD GPU 120kVA...
  • Page 68 GPU - 406 GPU - 409 User Preferences These parameters are adjustable and are intended to be set to match the customer preferences. If customer preference is not specified then the default settings may be left as-is. Show Metric – Change this according to customer preference (1 = Metric Units Display, 0 = Imperial Units Display).
  • Page 69 GPU - 406 GPU - 409 90KVA ACOP Limit – Set to Off or On, on GPU with 2 AC Outputs, Limit the overload to 90KVA when only one OP is switched ON. Default = On. DC Microswitch Enable – Set to Off or On, on GPU with 28.5VDC TR option, if optional DC Cable Micro-switch is fitted change this to ON.
  • Page 70 GPU - 406 GPU - 409 Run RPM – Change this to the appropriate engine RPM for output operation. Default = 1846 Warm-Up Seconds – Sets the warm-up timer in seconds. Default = 0060 Cool-Down Seconds – Sets the cool-down timer in seconds. Default = 0060 Hz Max Limit –...
  • Page 71 GPU - 406 GPU - 409 AC Diff Rate – Set the Rate (Incremental Update time) for AC Volts Differential Regulation. Default = 0 (For Build B) or Default = 0 (For Build A) ACV Int Gain – Set the level of Integral Gain in the AC Voltage Regulation.
  • Page 72 Plug the output cable(s) into the appropriate load bank. The GCM2 is now ready to be calibrated. Engage the output under calibration using one of the colored buttons corresponding to the desired output. Refer to TLD 102-00570, GPU-4000 Performance Test, for the correct settings. ACV Target Cts –...
  • Page 73 GPU - 406 GPU - 409 DC Volts Scale – This setting calibrates the 28VDC output voltage that the GCM2 indicates on the LCD. It should be calibrated against a calibrated AC Amp meter. This setting is pre-adjusted on each specific GCM2 at factory calibration and should rarely need...
  • Page 74 GPU - 406 GPU - 409 Idle RPM Run RPM Language CAL: Volts A CAL: Volts B CAL: Volts C CAL: Amps A CAL: Amps B CAL: Amps C CAL: Watts Warm-Up Seconds Cool-Down Seconds Idle Timer Seconds Lowload Timer Secs...

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