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Operation Manual – ITW GSE 4400 Tier 4

Load Contactor Operating Circuits

Output 1: Contactor K1

Output 2: Contactor K2

Trouble, Symptom, Condition

Probable Cause

Test, Check, and/or Remedy

1.

Load contactor will not close

when the corresponding

Output

pushbutton is pressed.

Generator is running at normal
voltage.

a.

Blown contactor fuse (F3) on

regulator board.

Check the fuse and replace if blown.
If it blows again, check the contactor.

b.

Defective display module

Check to make sure that the other
pushbuttons on the control panel
work. Replace the display board and
test all buttons again.

2.

Load contactor closes when

the

Output

pushbutton is

pressed, but opens within 10
seconds.

a.

The plug interlock EF circuit on

Interface board could be
defective.

Set 400 Hz Interlock to Bypassed. If
load contactor remains closed,
proceed to step

b.

b.

28.5 VDC is not reaching the plug

interlock EF circuit from aircraft
for following reasons:

Proceed as follows to find the cause
of this malfunction.

c.

Generator-to-aircraft cable

connector defective or not
plugged into aircraft receptacle
connector

Inspect cable connector plug
thoroughly for damaged E and F
terminals. Be sure plug is fully
mated with aircraft receptacle
connector and making good contact.

d.

Aircraft rejecting power.

Check aircraft on-board electrical
equipment and controls.

e.

Defective contacts in switch

mounted on side of contactor.

Connect a jumper lead between
terminals of the normally-open
auxiliary switch. If the contactor now
remains closed, replace the auxiliary
switch or the entire contactor.

OM2247 Rev B

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Summary of Contents for 4400 Tier 4

Page 1: ... B has become ITW GSE As simply ITW GSE we still offer the same premium products and service SAME PEOPLE SAME PRODUCTS SAME COMPANY Specification ACE4400 60 90 kVA Tier 4 Type OM2247 Manual 4400 Tier 4 400 Hz Generator Set Ground Power Unit ...

Page 2: ...and drawings are subject to change without prior notice Latest diagram versions can be found at www itwgse com IMPORTANT NOTICE We recommend that the battery that safeguards GPU settings etc is changed after 5 years of use in order not to lose data ...

Page 3: ...unit Learn to use the manual and to locate information contained in it Its style and arrangement are very similar to commercial aircraft manuals The manual is divided into three chapters plus appendices Each chapter is divided into as many sections as required Each page is identified by chapter section and page number which are located in the lower outside corner When information located in anothe...

Page 4: ...actions Safe practices have been developed from past experience in the use of power source equipment While certain practices below apply only to electrically powered equipment other practices apply to engine driven equipment and some practices to both 2 Shock Prevention Bare conductors terminals in the output circuit or ungrounded electrically live equipment can fatally shock a person Have a certi...

Page 5: ...n or by causing nearby combustibles to ignite b Batteries Batteries may explode and or give off flammable hydrogen gas Acid and arcing from a ruptured battery can cause fires and additional failures When servicing do not smoke cause sparking or use open flame near the battery c Engine Fuel Use only approved fuel container or fueling system Fires and explosions can occur if the fuel tank is not gro...

Page 6: ...IRST AID SEEK ADDITIONAL ASSISTANCE Use First Aid techniques recommended by American Red Cross until medical help arrives IF BREATHING IS DIFFICULT give oxygen if available and have victim lie down FOR ELECTRICAL SHOCK turn off power Remove victim if not breathing begin artificial respiration preferably mouth to mouth If no detectable pulse begin external heart massage 8 Equipment Precautionary La...

Page 7: ...1 1 4 Main Components of Generator Set Bottom 1 1 14 4 Specifications 1 1 15 5 Special Features 1 1 17 6 Canopy 1 1 18 7 Engine and Generator 1 1 19 8 Power Module Assembly 1 1 22 9 Operator Controls 1 1 23 10 Cold Weather Starting System 1 1 27 Section 2 1 Preparation for Shipment 1 2 28 2 Preparation for Storage 1 2 31 3 Preparation for Shipment 1 2 32 Section 3 1 General 1 3 33 2 400 Hz Operati...

Page 8: ...Operations 2 1 66 over 5000 Hours or 4 Years k Lamps and Fuses 2 1 66 Figure 2 1 4 Fuse Identification Chart 2 1 66 Section 2 Maintenance Procedures 2 2 67 1 General 2 2 67 Figure 2 2 1 Lubrication and Maintenance Chart 2 2 67 2 Lubrication 2 2 68 a General 2 2 68 b Lubrication Schedule 2 2 68 c Oil Specification 2 2 68 Figure 2 2 2 Lubrication Specifications 2 2 69 d Changing Engine Oil 2 2 69 Fi...

Page 9: ...2 80 h Thermostat 2 2 80 7 Engine Drive Belt 2 2 81 8 Generator Maintenance 2 2 81 9 Replacing the Control Board Battery 2 2 82 Section 3 Adjustments Tests 2 3 84 1 General 2 3 84 2 Testing the 400 Hz Generator Set 2 3 84 a Pre operational Test Procedures 2 3 84 b Engine Test Procedures 2 3 84 c 400Hz Initial Testing and Setup 2 3 85 d Output 1 Verification 2 3 85 e Output 2 Verification 2 3 85 f ...

Page 10: ...2 4 92 10 Troubleshooting Charts Error Codes 2 4 93 Engine Controls 2 4 97 Generator Excitation Circuits 2 4 100 Generator 2 4 101 Load Contactor Operating Circuits 2 4 102 Protective Circuit 2 4 103 Chapter 3 Manufacturer s Literature Chapter Section Page Vendor Literature 3 1 104 Appendix A Active Rectifier Unit ARU 3 A 106 Appendix B Options Appendix C Operating in Unusual Service Conditions Ap...

Page 11: ...Trailer Tier 4 US Labeled Single 400Hz No ACE44xxS28TT4 US xx Trailer Tier 4 US Labeled Single 400Hz Yes ACE44xxDTT4 US xx Trailer Tier 4 US Labeled Dual 400Hz No ACE44xxD28TT4 US xx Trailer Tier 4 US Labeled Dual 400Hz Yes xx 60 or 90 i e ACE4460T4 US is rated for 60 kVA full load output Table 1 1 1 ITW GSE 4400 Series Generator Set Part Number Descriptions 2 Optional Equipment Appendix A and B C...

Page 12: ...ple the control panel is mounted on the RIGHT FRONT side of the unit 1 Fuel Filler Neck Manual Gauge 2 Operator Control Panel 3 Composite Output Cable Trays 4 Fifth Wheel Assembly 5 Rear Axle Assembly 6 Emergency Stop Switch 7 Sliding Removable Canopy 8 Clearance Lights Option 9 Radiator End 10 Generator End 11 Forklift Pockets 12 Low Fuel Beacon Option 13 Operating Beacon Option 14 Canopy Locking...

Page 13: ...ne 2 Control Module Assembly 3 Batteries inside tray pockets 4 Battery Disconnect 5 N A 6 Generator 7 28 5 VDC ARU Option 8 Engine Alternator 9 Output Contactors Figure 1 1 2 Main Components of Generator Set Right Side 1 2 3 6 8 7 9 4 OM2247 Rev B Page 12 of 125 ...

Page 14: ...r 3 Fuel Filter 4 Engine Oil Filter 5 Engine Control Module ECM 6 Engine Dip Stick 7 Air Intake Tube 8 Engine Air Filter 9 Tow Bar Brake Release Lever 10 DEF Tank Fill Tube 11 5th Wheel Assembly Figure 1 1 3 Main Components of Generator Set Left Side 1 2 3 4 5 7 8 9 6 10 11 OM2247 Rev B Page 13 of 125 ...

Page 15: ...re 1 1 4 Main Components of Generator Set Bottom 1 2 3 4 1 Oil Drain Valve 2 Tie Down Rings Option 3 DOC Diesel Oxidation Catalyst 4 SRC Selective Catalytic Reduction 5 DEF Fluid Holding Tank 6 DEF Dosing Module 5 6 OM2247 Rev B Page 14 of 125 ...

Page 16: ...g Weight with 28 5 VDC ARU 4300 lb 1950 kg Operating temperatures 25 F to 125 F 32 C to 52 C Low temperature option Battery blanket Block Heater 40 F C c AC Output Specifications Output Power Rating 60 kVA 48 kW 90 kVA 72 kW Output Voltage 115 200 VAC 115 200 VAC Rated Load Capacity 173 Amps 260 Amps Frequency 400 Hz 400 Hz Power Factor 0 8 0 8 Duty Cycle 100 100 Operating Speed 2000 RPM 2000 RPM ...

Page 17: ...ad 10 minutes 125 to 150 load 10 seconds 150 to 175 load 2 seconds e DC Output Specifications with optional TR unit Output Power Rating 17 1 kW Output Voltage 28 5 VDC Load Capacity Continuous 600 A Current Limiting Capability 300 to 2400 A in selectable steps 50 100 200 300A Peak Starting Load Capacity 2400 A for 5 seconds Output Cable Size 4 0 for continuous loads up to 400A 2x 4 0 for continuou...

Page 18: ...hey appear a Protective Monitoring The protective monitoring system receives signals from the fault sensing components in the generator output circuit and functions to cause the load to disconnect from the generator if an abnormal condition of voltage frequency or load develops The nature of that abnormal condition is then presented on the graphical display b Voltage Regulator A microprocessor typ...

Page 19: ...trol Module ECM controls the amount of DEF that is sprayed into the exhaust It also controls the DEF tank heater and DEF line heaters Even though the DEF freezes at approximately 12 C 11 F the SCR system is designed to be frozen and thawed The DEF tank is heated by engine coolant and the DEF lines and dosing unit are electrically heated No operator interaction is needed when operating in cold temp...

Page 20: ...r with solenoid switch 2 Lubricity Additive Fuel Filter The fuel filter is a spin on disposable type located on the inside of the canopy near the engine s fuel pump The fuel filter s primary function other than removing contaminants from fuel is to automatically add a lubricity additive to the fuel Although the engine manufacturer does not recommend low lubricity fuels this additive can extend the...

Page 21: ...gine fan is designed to blow air outward through the radiator rather than pulling air inward like a conventional fan 4 Master Battery Disconnect Switch The master disconnect switch is designed to isolate the batteries from the entire electrical system to eliminate the possibility of battery current draw by the engine ECM or any other components during long periods of no operation The switch can al...

Page 22: ...ired on the unit before it is returned to operation Engine generated warnings and faults are also monitored and their respective Cummins fault numbers are shown on the display e Generator The 400 Hz generator is a brushless dual bearing revolving field three phase alternating current type unit The front end of the rotor shaft extends forward beyond the front bearing and is coupled to the engine fl...

Page 23: ...ation The current transformers detect the magnitude and power factor of current flowing from generator to load They feed a signal to the voltage regulator that interprets the signal and alters the exciter field current as required to maintain a constant predetermined voltage at the load These values are accessible on the color display 2 Ammeter The current transformers convert a current signal to ...

Page 24: ...ay and easy to understand controls The display allows the user to easily have access to all critical operational information as well as providing textual descriptions of all warnings and failures a Operator Controls Screen icon s The table below shows the different icons used in the display and what they mean Figure 1 1 5 Control Panel OM2247 Rev B Page 23 of 125 ...

Page 25: ... in sleep mode 4 The Amber LED indicates a warning The details of that warning are available on the display Up to five warnings can be displayed at one time 5 The Red LED indicates a fault The details of this fault are also visible on the graphics display Only one fault can be displayed at one time 6 The Green LED s indicate that the respective output is ON 7 The ON OFF buttons are used to turn on...

Page 26: ...ow the current status until the engine is running and the unit is ready to output power Note If the engine is configured to go to idle until an output is activated it will still say it is ready for use However the engine will have to ramp up to 2000 RPM and the voltage stabilized before the output contactor will close When output power is ready the screen will appear as follows showing all availab...

Page 27: ...Operation Manual ITW GSE 4400 Tier 4 OM2247 Rev B Page 26 of 125 ...

Page 28: ...from a power relay controlled by the ECM The amount of time the air intake heater stays on in the preheat phase is a function of the intake manifold temperature at start up The pre heat time increases with colder intake manifold temperatures The maximum duration of the pre heat phase is around 30 seconds CAUTION Never use an ether start system in conjunction with the air intake heater Figure 1 1 7...

Page 29: ...l A manual quick reference fuel gauge is located at back of unit This gauge is accurate only when fuel level is above 50 NOTE For recommended fuel specifications refer to Engine Manufacturers Operation and Maintenance Manual provided with this manual 8 Check engine coolant Remove radiator cap under hatch on top of operator section to check coolant level Coolant level should be at bottom of filler ...

Page 30: ...ng over See Figure 1 2 1 for capacity CAUTION NEVER operate engine with oil level below L level or above H level mark NOTE See Engine Manufacturer s Operation Maintenance Manual for oil recommendations Figure 1 2 2 Oil Fill and Oil Level Check Locations 11 Check batteries located inside the right side cable tray Inspect batteries for proper connection of terminals Service or replace if necessary O...

Page 31: ... normally open auxiliary contact block attached to the side of the output contactor See Figure 1 2 5 AC output cables installation 1 Remove canopy While not necessary it greatly simplifies the process 2 Loosen screws on cable clamps 3 Route cables through hole in cable tray through cable clamps up to load side of load contactor s 4 Connect phase cable terminal lugs to appropriate terminal studs on...

Page 32: ... are not stored and will prevent the GPU from delivering power to the Aircraft unless the Tow bar is in the upright position 2 Preparation for Storage A generator set in storage or removed from operation has special precautions that should be taken to protect internal and external parts from rust corrosion and gumming in the engine fuel system a General Open battery disconnect switch and disconnec...

Page 33: ...and then switch fuel lines to a can of preservative oil Cummins specifies Dauber Chemical NoxRust 518 When the preservative oil is running out the injector return tube turn off the motor and cap ends of fuel return and supply tubes Drain 30W preservative oil from crankcase Add rust inhibitor to the coolant and make sure that the radiator is full Spray preservative oil into intake and exhaust ports...

Page 34: ...rer s operation manual provided with the unit when starting engine for the first time i Press and release engine Start button The remaining portion of the startup procedure is automated Startup status is shown on the display The procedure will begin by providing power to the engine and other vital components Next it will check the engine to insure proper operation Once verified the engine data beg...

Page 35: ...isplayed screen is NOT important These buttons are always active CAUTION To eliminate the possibility of wet stacking See Appendix C DO NOT allow the engine to idle for long periods c Failed Starting Procedure If an error during initialization occurs the engine fails to start after 3 automatic attempts 15 seconds crank 15 seconds wait per attempt the display will show a fault Diagnose and treat th...

Page 36: ...ceed with power delivery by pressing the same switch WARNING NEVER disconnect the output cable while power is being delivered Output contactor s must be open prior to removal of the cable from the aircraft CAUTION The generator set must be shut down so the failed power delivery problems can be diagnosed Only personnel who are trained or qualified on this type of equipment should work on this GPU e...

Page 37: ...t use the EMERGENCY STOP BUTTON as a normal shutdown device Damage to the engine turbo charger may result without proper cooling time Use the Engine ON OFF pushbutton for all normal engine shutdowns b A condition of over voltage under voltage under frequency over frequency or overload in the output circuit will automatically open the load contactor and display a fault code to signal the operator w...

Page 38: ...ct switch while the engine is running or within two minutes after the engine has shut down 3 Active Rectifier Unit ARU 28 5 VDC Power Supply a See Appendix A for ARU Operation CAUTION The ARU can deliver up to 2 400 amps of current during the starting of an aircraft engine This much current will shear the propeller shaft of some aircraft Therefore make sure that the current limit is correctly set ...

Page 39: ...he default screen Press the center navigation button while in the default menu and hold it down for approximately 5 seconds If the Icon menu doesn t appear after 5 seconds see paragraph 4 23 below to unlock access to the Icon menu Center Navigation Button OM2247 Rev B Page 38 of 125 ...

Page 40: ... View Parameters Menu is accessed from the Icon screen Press the center navigation button while in default menu and hold down for approximately 5 seconds The Icon menu is displayed press the right navigation button to highlight the icon OM2247 Rev B Page 39 of 125 ...

Page 41: ...p Menu is accessed from the Icon screen Press the center navigation button while in the default menu and hold down for approximately 5 seconds The Icon menu is displayed press the right navigation button to highlight the Setup icon OM2247 Rev B Page 40 of 125 ...

Page 42: ...Operation Manual ITW GSE 4400 Tier 4 OM2247 Rev B Page 41 of 125 ...

Page 43: ...nit Standby Engine Running etc Settings Low Medium High Refer to Section 3 4 17 11 27 47 Setup Menu 28 06 2013 LED Brightness Low Back Modify Settings 1 247 Refer to Section 3 4 16 11 27 47 Setup Menu 28 06 2013 Date Time Format HH MM SS I DD MM YYYY Back Modify Settings Metric Imperial Refer to Section 3 4 18 11 27 47 Setup Menu 28 06 2013 Unit of Measure Imperial Back Modify 11 27 47 Setup Menu ...

Page 44: ...Operation Manual ITW GSE 4400 Tier 4 OM2247 Rev B Page 43 of 125 ...

Page 45: ... selectable line will be highlighed in green Press to select the parameter you want to change Press to Modify parameter Parameter will now be highlighted in green Use the the to adjust parameter Press to save changes Use to leave the sub menu and return to basic Icon Menu Notice Availability of parameters may vary depending on the mode of the unit Standby Engine Running etc Settings Enabled Disabl...

Page 46: ...r button to accept and record this value Press the LEFT arrow button to exit the submenu and return to the submenu list 4 Output Mode a When the unit has 2 outputs the Output Mode submenu is used to set either Individual or Simultaneous mode of operation b If the output mode has been set to Individual the outputs can be used individually If the output mode has been set to Simultaneous both outputs...

Page 47: ...ed onto the EF DC signal b This sub menu sets the trip level for the AC ripple on the DC EF interlock signal The default value is 7 0 volts and a setting of 0 0 volts disables the function c Go into the Setup Menu and then scroll up or down to the EF Interlock Ripple Level submenu Press the center button to enter the submenu and then press the button again to allow the value to be changed Press th...

Page 48: ... The Setup submenu allows this option to be activated or bypassed Enter the Setup Menu and then scroll up or down to the Automatic Engine Shutdown submenu Press the center button to enter the submenu and then press the button again to allow the value to be changed Press the up or down arrow buttons to change the selection Press the center button to record the new value Press the LEFT arrow button ...

Page 49: ...t output to be adjusted between 19 0 VDC and 33 0 VDC using the UP and DOWN navigation buttons Please note that the acceptable voltage range for all commercial DC powered aircraft is 26V to 29V Enter the Setup Menu and then scroll up or down to the ARU Voltage submenu Press the center button to enter the submenu and then press the button again to allow the value to be changed Press the up or down ...

Page 50: ...Icon screen when the center button is pressed for 5 seconds Enabled locks out the center button When the center button is pressed the screen will display DISABLED Technicians can gain temporary access to the Icon menu by performing the following sequence of button presses Right Arrow Up Arrow Down Arrow Down Arrow Holding the center button again approx 5 seconds will take you to the main Icon menu...

Page 51: ...is strongly recommended that the unit is kept in this mode The Disabled option should only be selected for short periods of time Disabling the regeneration process for long periods of time 50 hours will lead to engine faults that will de rate the engine per EPA requirements and prevent it from running at operational speeds The Do it now option forces the unit to run the regeneration process when s...

Page 52: ...Operation Manual ITW GSE 4400 Tier 4 c Black Box OM2247 Rev B Page 51 of 125 ...

Page 53: ...Menu is accessed from the Icon screen Press the center navigation button while in the default menu and hold it down for approximately 5 seconds The Icon menu is displayed press the right navigation button to highlight the Power Log icon OM2247 Rev B Page 52 of 125 ...

Page 54: ...highlighted If another function is wanted use the the to highlight the function Before pressing to select Update Display Software please remember to insert a USB stick into the USB port on the Display located on the side of the Display enclosure inside the unit Press to select the function Press to confirm update firmware The firmware is now being uploaded to the display card Upload is counting fr...

Page 55: ...o the USB port on the control card located on the interface board Press to select function Press to confirm update firmware The firmware is now being uploaded to the display card Upload is counting from 0 to 100 The system automatically reboots if the update is successful Otherwise an Update has failed Message is displayed 10 30 00 USB MENU 28 06 2013 Updating Control Card 8 10 30 00 USB MENU 28 0...

Page 56: ...Operation Manual ITW GSE 4400 Tier 4 OM2247 Rev B Page 55 of 125 ...

Page 57: ...ablishment of a schedule to meet the customer s maintenance requirements for his specific operation c Time Intervals The schedule is based on both hours of operation and calendar intervals These two intervals are not necessarily the same For example in normal operation the oil change period based on hours of operation will be reached long before the three months calendar period The calendar period...

Page 58: ...X Check Air Intake Piping X X Check After treatment Exhaust System X Check Dust Ejection Valve X Inspect Cooling Fan Guard X Charge Air Cooler CAC and Piping X Check Radiator Core and Hoses X Check Oil Pressure X Change Lubricity Fuel Filter Element X X Change Crankcase Oil X X Change Oil Filter Element X X Check Engine and Generator Mounts X X Check Coolant Additive Concentration X X Check Radiat...

Page 59: ...nections Spring Fall Check Thermostats and Seals Fall Change DEF Dosing Filter X Overhead Set X Electrical 24 VDC System Check All Lights X Check Alternator Charging Rate X Check Battery X Clean Battery Terminals X X Check Wiring and Connections X Check All Engine Screens when running X Electrical 400 Hz System Check E F By Pass Operation X Check Output Cable and Connectors X Check Volt Amp Freque...

Page 60: ...riod Once After 50 150 hrs The following procedures are precautionary measures taken on most new engines If a problem occurs with any of the following issues be sure to recheck it after the next 50 150 hours 1 Engine a Check for leaks and correct This involves an overall inspection of the engine and may require some maintenance if leaks are found Refer to the engine manufacturer s operations manua...

Page 61: ...ound clean the tube with detergent and warm water or a solvent Dry tube with compressed air d Drain Fuel Lubricity Filter Pre Filter Element The life of the fuel pump and injectors can be extended if the operator drains about a cup of fuel from the fuel pre filter element to remove water and sediment before starting the engine each day CAUTION BE SURE to prime and bleed the fuel system after drain...

Page 62: ...ections etc for signs of leakage Correct as required g Check Fault Code Screen for Air Filter Clogged warning At each daily start up observe the fault screen on the display of the control panel If the display shows AIR FILTER CLOGGED change the air filter See Chapter 2 4 for other fault codes h Check Air Intake Piping Visually inspect the intake piping daily for wear points and damage to piping lo...

Page 63: ...ed to as wet stacking This condition results from the accumulation of unburned fuel in the exhaust system It is recognizable by fuel oil wetness around the exhaust manifold pipes and muffler along with an excessive amount of soot Wet stacking is common and can be expected in diesel engines operated under light loads Light loads do not allow the engine to reach the most efficient operating temperat...

Page 64: ...nerator set is MAINTENANCE FREE Check battery terminals and clean if necessary 2 Electrical 400 Hz System a Check the operation of the E F bypass system f C Checks and Operations 500 Hours or 6 Months 1 Engine a Check Engine and Generator Mounts CAUTION An unstable or loosely mounted engine can create hazardous environment and may damage equipment i Engine mount bolts must be torqued to 100 N m 73...

Page 65: ...t Condition and Tensioner Refer to the engine manufacturer s operations and maintenance manual for assistance and the most update to date information d Check and or Adjust Valve Clearance Refer to the engine manufacturer s operations and maintenance manual for assistance and the most update to date information e Check Air Compressor Discharge Line All air compressors have a small amount of lubrica...

Page 66: ...as voltage regulator alternator and electrical wiring 3 Seal all openings DO NOT use a flammable solvent 4 DO NOT use mineral spirits or solvents on a hot engine 5 Remove or protect bottom panel of unit belly pan to protect insulation b Check the Crankcase Breather External See engine manufacturer s operation manual for instructions Pages 7 1 to 7 5 c Flush and Change the Coolant See engine manufa...

Page 67: ...ar e Replace Rotor Assembly if required f Replace engine and generator shock mounts k Lamps and Fuses 1 Check all lamps daily 2 Check fuses as required 3 The fuse chart lists all fuses with their location size and type Fuse Protects rating type PN F1 Display 2 amp ATO AP SI2076 F2 Control Board 5 amp ATO AP SI2075 F3 Exciter 24V 5 amp ATO AP SI2075 F4 Contactor 5 amp ATO AP SI2075 F5 Relays 15 amp...

Page 68: ...capacity is approximately 20 quarts 18 9 liters Coolant hoses and connections Check coolant hoses and connections daily for leaks Air Cleaner Change air cleaner filter as required when the fault code display on engine control panel shows the Air code Fan Belt Check fan belt condition and tension every 1000 hours or 1 year of use Alternator Alternator bearings are sealed and require no periodic lub...

Page 69: ...s recommended by the engine manufacturer is identified by an API American Petroleum Institute classification designation The manufacturer does not recommend any specific brand of lubricating oil The use of quality lubricating oil combined with appropriate lubricating oil drain and filter change intervals are important factors in extending engine life Oil Type Use oil specification API CF 4 HT HS V...

Page 70: ...un when the engine is at operating temperature If lubricating oil is drained immediately after the unit has been run for some time most of the sediment will be in suspension and will drain readily Change the oil filter element each time the oil is changed CAUTION High ash oils may produce harmful deposits on valves that can cause valve burning Do not use solvents as flushing oils in running engine...

Page 71: ... to the gasket sealing surface and install the filter DO NOT over tighten the filter 10 Clean the drain cap and install when engine oil has completely drained or close the drain valve 11 Refill the engine with new clean oil that meets engine manufacturer s recommendations Use the oil fill tube by the filter or the oil fill opening at the top of the engine CAUTION Remember to close the drain cap an...

Page 72: ... and requires no periodic lubrication Replace pump if signs of lubricant leakage are found 4 Fan Pulley The fan hub is also lubricated at assembly and requires no periodic lubrication Replace hub if lubricant is leaking f Trailer Lubrication 1 Wheel bearings Inspect each wheel bearing annually to ensure that there is sufficient grease in the assembly 2 Fifth Wheel Hub Bearings Inspect the Fifth Wh...

Page 73: ...pect regularly Replace when the Air Filter Clogged warning appears on the display Figure 2 2 4 Air Cleaner Assembly a Inspecting the Air Cleaner 1 Make periodic checks of air cleaner inlet screen for obstructions If any obstructions are present remove them 2 Check outlet connection for proper seal b Changing Air Filters 1 To change primary air filter open 4 metal latches and remove cover Slide old...

Page 74: ...See engine manufacturer s operation manual In general fuels meeting the properties of ASTM designation D 975 grades 1 D and 2 D have provided satisfactory performance For more information regarding the selection of fuel to use refer to publication Engine Requirements Lubricating Oil Fuel and Filters available from authorized engine maker s service outlets b Cold Weather Operation In cold weather d...

Page 75: ...utlet The filter s function is to add a lubricant to the fuel to help prolong the engine seals and fuel pump life when fuels other than diesel are used i e jet fuel The filter also removes foreign material and removes both free and emulsified water from the fuel before it enters the fuel lift pump Daily draining of the filter is required Replacement Filter Element Fleetguard FS1098 Drain the water...

Page 76: ...h a final half turn j Make sure that all rags or absorbent sheets are clear of moving engine parts and cannot be drawn in to the radiator fan k Open fuel valve l Start the engine and check for leaks Correct as necessary with the engine off c Primary Fuel Filter A primary fuel filter is mounted above the engine starter in the engine compartment The filter s function is to remove foreign material fr...

Page 77: ...pen fuel valve d Fuel Pump The fuel pump supplies high pressure to the fuel system so the diesel fuel can circulate freely This engine is equipped with a common rail fuel system that is under very high pressure DO NOT attempt to crack fuel lines WARNING DO NOT attempt to crack fuel lines This engine is equipped with a common rail fuel system that is under very high pressure Failure to follow this ...

Page 78: ... threads and sealing surfaces are free of burrs nicks and scratches or any foreign material ii Apply sealant lubricant to male pipe threads if not pre applied b With any sealant the first one to two threads should be left uncovered to avoid system contamination If PTFE tape is used it should be wrapped 1 1 2 to 2 turns in clockwise direction when viewed from the pipe thread end Caution More than t...

Page 79: ...a WARNING When removing cap from a very hot radiator DO NOT turn cap past safety stop until the pressure or steam has escaped 2 Removal To remove turn the cap to the left counterclockwise to the safety stop When all pressure is released press down on the cap and continue to turn until the cap is free to be removed CAUTION Allow engine to cool before adding coolant CAUTION Do not attempt to repair ...

Page 80: ...reliable tester when in doubt about antifreeze protection d Draining the Cooling System To completely empty the cooling system requires draining the radiator assembly Follow these steps to drain the cooling system 1 Remove radiator cap 2 Place a drain pan with at least a 40 quarts 28 4 liters capacity under radiator to catch coolant 3 Remove the front grill to access the hose valve Place the drain...

Page 81: ...ocation b Pour coolant into radiator very slowly until it reaches the bottom of fill neck Allow time for trapped air to escape from the system then continue filling until the coolant level remains at the bottom of the fill neck c Start the engine and bring up to rated speed and allow the thermostat to open Add coolant as trapped air escapes from the system and the coolant level falls d Continue to...

Page 82: ...ssing the belt with an index finger to determine the amount of belt deflection obtained When a force is applied at a point halfway between pulleys on the longest span of a belt there should be no more than 1 2 inch of deflection attained Refer to the engine manufacturer s operation manual for checking belt tension and changing worn belts 8 Generator Maintenance The 400 Hz generator requires no mai...

Page 83: ...ke sure that the replacement battery is within reach as the Control Board must not be without battery power for more than 30 seconds Otherwise all software and the setup data will be erased Fig 8 2 3 Control Board front view To replace the battery Switch OFF the unit by means of Q1 Remove the Control Board from its 4 posts marked with a in Figure 8 2 3 Place the PCB on an insulated surface with th...

Page 84: ...he unit via the input switch Q1 and close the door The unit now passes through the initialization test and goes into standby mode Enter the setup menu and select menu item Battery Replaced to confirm new battery installation Important Note If the blue LED on the Control Board location can be found on the Fig 8 2 3 flashes with approximate 2 flashes per second and the display reports Communication ...

Page 85: ... of drive belt 4 Verify that there is at least a 1 4 tank of diesel fuel 5 Make a general inspection of all wiring and terminals Inspect the equipment to be certain no damage will result from starting the engine 6 Turn on battery disconnect switch 7 Place unit in Engine Only Diagnostic Mode See Menu Operating Instructions Chapter 1 3 Paragraph 4 19 Return to home screen to view status Screen will ...

Page 86: ...al operation with no faults 5 If Output 2 is not available skip to g below e Output 2 Verification 1 Make sure that the EF switch is in the ON position on the load bank and turn on Output 2 Contactor must close and indicator on the display illuminate 2 Verify ABC phase rotation at the load bank 3 Turn the EF switch OFF on the load bank and verify that contactor opens and fault is displayed Red lam...

Page 87: ...ent manufacturer if in doubt of bearing serviceability 3 Generator Set Adjustment a Generator Adjustment The 400 Hz generator is a brushless type requiring no adjustments of any kind For the following adjustment the generator set must be running at rated speed 2000 RPM under no load conditions Adjust the regulator as follows 1 Output Voltage Adjustment a Adjust Voltage Control The output voltage a...

Page 88: ...l 4 Generator and Exciter Test The generator fields and exciter stator may be tested with a Kelvin bridge This is a double bridge type instrument required for the very low resistances encountered in this test It is understood that zero 0 resistance indicates a SHORTCIRCUITED condition An infinite resistance reading indicates an OPEN CIRCUITED condition a Disconnect generator stator leads at the ba...

Page 89: ... the threaded end of the diode Hold the other lead point on the wire terminal end Observe and note the indicated resistance Now reverse the lead connection on the diode Observe and note the ohmmeter indicated resistance If an infinite or very high resistance was indicated with the leads connected one way and a low readable resistance was indicated with the leads connected the opposite way the diod...

Page 90: ...icating that DC power has been removed from the load bank 3 Current Limiting Soft Start Control The Current Limit default value is set using the 28V Current Limit screen in the Setup Menu See Chapter 1 3 Paragraph 4 19 To change the value for the current aircraft and this test use the RIGHT and LEFT navigation buttons when the diesel is running the 28VDC ARU is NOT on and the default operator scre...

Page 91: ...when performing terminal to terminal checks to be certain the proper terminals are being used especially when using jumper leads Damage to electrical components may result from the application of improper voltage and current 2 Equipment for Troubleshooting A good quality multimeter is the only instrument required for troubleshooting At least two jumper leads with alligator or similar clips will be...

Page 92: ...yed on the LED display 2 Engine Run Mode When the ENGINE pushbutton is pressed the blue power indicator LED and the Operating Beacon will start flashing The starter will engage when the engine is ready After the engine reaches its idle speed 1000 rpm the GPU is ready to supply power to the aircraft Note that the engine will make three 15 second attempts to start the engine If the engine doesn t su...

Page 93: ...s down the Alert Failure LED is lit and the fault text appears display Pressing the Engine pushbutton or shutting down the GPU resets the fault 8 Cummins Engine Fault Codes Trouble Shooting The best source of information to aid in trouble shooting Cummins engine issues is at the quickserve cummins com website Go to this website and register up to five engine serial numbers for free It is recommend...

Page 94: ...et Check starter circuit to ensure that it is properly energized Replace Starter Solenoid Replace Starter 600 UNABLE TO START ENGINE Engine did not start after 3 tries Press Engine button to Reset Check fuel valve to ensure it is open Service Engine 700 BATTERY LEVEL TOO LOW Battery voltage level is too low to attempt startup sequence Press Engine button to Reset Check battery cables Charge Batter...

Page 95: ...ensor in output 1 plug has tripped Press Output 1 button to reset Remove load and let plug cool down Check connector output cabling for any malfunction Replace Control Boards A1 A2 2300 PLUG 2 TEMPERATURES TOO HIGH The temperature sensor in output 2 plug has tripped Press Output 2 button to reset Remove load and let plug cool down Check connector output cabling for any malfunction Replace Control ...

Page 96: ...r at rectifier heat sink 3600 28V TRANSFORMER TEMP TOO HIGH ARU Transformer Temperature is too high Press ARU button to reset Let the unit cool down and reset Check airflow air filters fan Check temp sensor at Transformer 3800 28V INTERLOCK LEVEL TOO LOW 28V F Level too low Press ARU button to reset Verify that output cable is correct inserted Check correct installation Replace Control Board A1 Re...

Page 97: ...E The duty cycle for the Exciter is too high Inspect the generator and the exciter circuit for damage or bad connections Check fuses F8 and F3 Replace Interface Board A2 Replace Control Board A1 8000 CONTROL VOLTAGE LOW Control Voltage 20V Running Press Engine button to reset Check Alternator Check Battery 8200 EMERGENCY STOP ACTIVATED Release emergency stop and press Engine button to reset Check ...

Page 98: ...ot side of the starter solenoid and the starter input terminal If starter does not crank engine the starter may be defective e No voltage at starter solenoid coil Check connector X5 on the PC1 Interface board Verify that there is 24 VDC across the starter solenoid and terminals when the engine start pushbutton is pressed Check and replace if necessary the Interface board f Defective starter Remove...

Page 99: ...ngine cranks but will not start Over temperature indication appears immediately a Defective engine temperature switch Check wiring to engine high temperature switch S49 on schematic which is located on top of the engine block If wiring is correct remove wires and check resistance between terminals C and N O A resistance of less than 10 ohms indicates a defective switch Replace switch if defective ...

Page 100: ...l fittings to be sure they are tight and the thread sealant is still present Tighten the fittings and add new thread sealant as required 11 Engine lacks power a Improper engine adjustments and gear train timing Tune up engine in accordance with engine manufacturer s operation manual b Insufficient fuel Check low fuel level in accordance with engine manufacturer s operation manual Repair or replace...

Page 101: ...ttery to the exciter field which should produce an indicated output voltage of 100 20 VAC line to neutral b Verify 24 VDC across connector J6 terminals A B Check X20 on the Interface board and connector J6 at the generator c Defective connector at voltage regulator or defective wiring from regulator to exciter field Disconnect the exciter wires at the terminal strip J6 Using jumper leads with clip...

Page 102: ...r stator G1 Check stator winding resistances See Chapter 2 3 Section 4 for normal values 3 Generator overheats a Loose connection causing high resistance Check all output connections Look for discoloration caused by heat Tighten or replace as required b Improper or blocked ventilation Check for foreign material rags etc blocking airflow Provide adequate ventilation c Generator stator windings shor...

Page 103: ...ock EF circuit on Interface board could be defective Set 400 Hz Interlock to Bypassed If load contactor remains closed proceed to step b b 28 5 VDC is not reaching the plug interlock EF circuit from aircraft for following reasons Proceed as follows to find the cause of this malfunction c Generator to aircraft cable connector defective or not plugged into aircraft receptacle connector Inspect cable...

Page 104: ...ad bank at no load use the Output Voltage screen in the Setup menu Chapter 1 3 Paragraph 4 1 to reduce the voltage to 110 VAC Observe the voltmeter on the load bank and gradually increase voltage If the load contactor opens at any value less than 125 VAC replace the interface and processor board 2 Load contactor opens during power delivery Under voltage fault indicated a Under voltage condition ma...

Page 105: ...g Cummins Bulletin 4056563 Not Included purchased separately from Cummins Diagram Number Diagram Description 293197 Diagram Schematic Connection Contact ITW GSE if copies of these drawings or manuals are not delivered with the unit unless otherwise noted above Refer to Appendix B for specific information on the ITW GSE 4400 400 Hz Generator Set optional equipment OM2247 Rev B Page 104 of 125 ...

Page 106: ...Operation Manual ITW GSE 4400 Tier 4 This page is intentionally left blank OM2247 Rev B Page 105 of 125 ...

Page 107: ...s supplied from the 400 Hz generator where the 28 VDC output voltage is controlled regardless of the 400 Hz output voltage The DC output current is calculated very precisely on the basis of the 400 Hz parameters using the current transformer T20 located on phase A at the power input Input Contactor Q3 The 400 Hz input power to the ARU is supplied and controlled via Q3 When this contactor is closed...

Page 108: ...tactor Q3 Interface for heatsink thermostat X5 Input for current transformer T20 X6 Resistor R20 The discharge resistor R20 is part of the output filter stage and discharges the capacitor C20 when the unit is turned off Filter Capacitors C20 The output filter capacitors are also part of the output filter stage and secures that the AC ripple is kept to a minimum less than 2 at the output Fan M20 Th...

Page 109: ...ty the converter automatically returns into normal mode once it receives a 28 VDC voltage at terminal TB3 5 e g when the plug is connected to an aircraft Note The interlock will not work correctly unless the negative busbar has a connection to the ground block The ARU comes equipped with this connection already made but it might have been removed to meet other requirements If the interlock is not ...

Page 110: ...eration various parameters can be viewed via the display Use the navigation keys to browse through the available screens After operation the unit has to be turned off before removing the aircraft plug Press the 28 VDC Start Stop button The aircraft cable can now be removed from the aircraft and placed at the cable rest position Note Please note that the 28 VDC Start Stop button also functions as a...

Page 111: ... 07 2014 Ready For Use Ready For Use 600 400 Hz I Default Display Screen Operating POWER P S Phase A 5 6 kW 5 6 kVA Phase B 5 6 kW 5 6 kVA Phase C 5 6 kW 5 6 kVA Sum 16 8 kW 16 8 kVA Back Next Prev Use the the to browse through the various screens Use to leave the sub menu and return to Default Screen Notice Parameters may vary depending on the mode of the unit Standby operating load profile etc 1...

Page 112: ...Operation Manual ITW GSE 4400 Tier 4 A 6 Additional menu items for ARU OM2247 Rev B Page 111 of 125 ...

Page 113: ...nged Press the up or down arrow buttons to change the selection Press the center button to record the new value Press the LEFT arrow button to exit the submenu and return to the submenu list A 9 28V Compensation DC voltage drops quickly as the current increases over a given length of cable This Setup submenu allows 28 volt output to be automatically adjusted as the load increases The allowed setti...

Page 114: ...of 50 100 200 300 amps This menu selects the size of the steps that the operator uses to adjust the current limit before turning on the 28 VDC to the aircraft Enter the Setup Menu and then scroll up or down to the Current Limit Step Size submenu Press the center button to enter the submenu and then press the button again to allow the value to be changed Press the up or down arrow buttons to change...

Page 115: ...Operation Manual ITW GSE 4400 Tier 4 Figure A13 1 Front View ARU Figure A13 2 Rear View ARU A20 ARU Board 6 x ARU Transformer PM20 Rectifier Output terminals OM2247 Rev B Page 114 of 125 ...

Page 116: ...4 Kit Battery Blanket 230 Volt 293498 06 Kit Block Heater 120 V 293503 02 Kit Block Heater 240V 293503 04 Kit Single Output Towbar Interlock 293485 01 Kit Dual Output with 28VDC Towbar Interlock 293485 03 293148 DIN40 Tow bar This option replaces the standard Towbar with a 40mm diameter eye version 293098 Kit Clearance Lights This option adds clearance lights to the four top corners of the canopy ...

Page 117: ...independently powered 120 VAC powered block heater to the engine 293503 04 Kit Block Heater 240V This option adds an independently powered 240 VAC powered block heater to the engine 293485 01 Kit Single Output Tow Hitch Interlock This option adds a lock to the tow bar assembly to prevent it from being lowered if the single 400 Hz cable isn t properly inserted into the receptacle at the front of th...

Page 118: ...ses d Nuclear radiation e Steam salt laden air or oil vapor f Damp or very dry locations radiant heat vermin infestation or atmospheres conducive to fungus growth g Abnormal shock vibration or mechanical loading from external sources during equipment operation h Abnormal axial or side thrust imposed on rotating equipment shafts i Low and or high ambient temperatures j High electromagnetic fields 2...

Page 119: ... program the Control Board The Display Board must be programmed first If the blue LED is flashing slowly in a sequence of one flash a pause one flash and so on the microcontroller on the Control Board has lost its internal programming most likely due to a faulty or missing battery Contact ITW GSE technical support and request a replacement control board First time programming of the Display Board ...

Page 120: ... 1 100 o Subnet Mask 255 255 255 0 o Gateway No significance o DNS 1 No significance The displays shows a COMMUNICATION ERROR screen This is caused by a failure in CAN bus communication between the Control Board and the Display Board usually because the Control Board is not programmed or has halted its execution Check for faulty un programmed Control Board flashing blue LED and replace or program ...

Page 121: ...and make sure that Quick Format is NOT clicked Press start The USB should function without issue after the format is complete This may take several minutes to complete on larger drives 5 Copy the files into the root drive and it is ready OM2247 Rev B Page 120 of 125 ...

Page 122: ...a 7 Use to leave the submenu 8 Use to leave the submenu and return to basic Icon Menu Output voltage A V B V C V Average V Output current A A B A C A Average A 28VDC Output option Voltage V Current A Ripple V Hour Meter Interlock 1 Level V Ripple V ENGINE STATUS Interlock 2 Level V Ripple V Control DC Voltage V Generator Duty Cycle Engine RPM Oil Pressure Engine Temp Engine Load Fuel Level DEF T4 ...

Page 123: ...OM2247 Rev B Page 122 of 125 ...

Page 124: ...OM2247 Rev B Page 123 of 125 ...

Page 125: ...OM2247 Rev B Page 124 of 125 ...

Page 126: ...OM2247 Rev B Page 125 of 125 ...

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