ITW GSE 6400 JetEx Tier 3 Page 11 Manual Download | Manualshive

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Operation Manual - ITW GSE 6400 Tier 3

Chapter 1 Description/Operation

1) General

This manual describes a 28.5 V generator set manufactured by ITW GSE, Palmetto, FL 34221. This
generator system is designed to provide ground power for maintenance and startup of aircraft or other
loads.

2) Optional Equipment - Appendix A

Chapters 1 through 3 of this Operation and Maintenance Manual identify only the basic version of the
ITW GSE 6400 Tier 4 generator set. Appendix A contains a list of the rest of the optional equipment
that can be ordered with the unit. Each item has a brief description of the optional equipment.

Section 1

Description

Part Number

Mounting

Cable

Management

Model

Description

Power Rating

DCE6400CUTT3

Trailer

Cable Trays

Standard

Unit rated

28.5 VDC,

600 A continuous (17 kW),

2000 A peak (56 kW),

single output

Table 1: ITW GSE 6400 Series Generator Set Part Number Descriptions

OM2254 Rev A

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Summary of Contents for 6400 JetEx Tier 3

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 DCE6400 28 5 VDC Tier 3 Type OM2254 Manual 6400 Tier 3 28 5 VDC Generator Set Ground Power Unit ...

Page 2: ...re 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 OM2254 Rev A Page 1 of 103 ...

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 18 8 Power Module Assembly 1 1 20 9 Operator Controls 1 1 22 10 Cold Weather Starting System 1 1 26 Section 2 1 Preparation for Shipment 1 2 27 2 Preparation for Storage 1 2 30 3 Preparation for Shipment 1 2 31 Section 3 1 General 1 3 32 2 400 Hz Operati...

Page 8: ...tenance Checks Spring Fall E i 2 1 66 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 68 d Changing Engine Oil 2 2 69 Figure 2 ...

Page 9: ...tat 2 2 80 7 Engine Drive Belt 2 2 81 8 Generator Maintenance 2 2 81 9 Replacing the Control Board Battery 2 2 81 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 Sensor Testing...

Page 10: ...4 92 9 Troubleshooting Charts Error Codes 2 4 92 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 Appen...

Page 11: ... Maintenance Manual identify only the basic version of the ITW GSE 6400 Tier 4 generator set Appendix A contains a list of the rest of the optional equipment that can be ordered with the unit Each item has a brief description of the optional equipment Section 1 Description Part Number Mounting Cable Management Model Description Power Rating DCE6400CUTT3 Trailer Cable Trays Standard Unit rated 28 5...

Page 12: ...ing the machine As an example 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 Emergency Stop Switch 5 Sliding Removable Canopy 6 Clearance Lights Option 7 Radiator End 8 Generator End 9 Forklift Pockets 10 Low Fuel Beacon Option 11 Operating Beacon Option 12 Canopy Locking Latch Figure 1 1 1 ...

Page 13: ...ns QSB4 8 5 Engine 2 Control Module Assembly 3 Battery inside tray pocket 4 Battery Disconnect 5 Coolant fill access cover 6 Output Cable Connection Figure 1 1 2 Main Components of Generator Set Right Side 1 2 3 5 4 6 OM2254 Rev A Page 12 of 103 ...

Page 14: ...Fuel Pre Filter 2 Engine Oil Filter 3 Fuel Filter 4 Engine Oil Fill Tube 5 Generator 6 Air Filter Assembly 7 Engine ECM Module 8 Tie Down Rings Location Option Figure 1 1 3 Main Components of Generator Set Left Side 1 2 3 4 5 6 7 8 OM2254 Rev A Page 13 of 103 ...

Page 15: ...l Drain Valve 2 Muffler Assembly 3 Fifth Wheel Figure 1 1 4 Main Components of Generator Set Bottom 1 Oil Drain Valve 2 Muffler Assembly 3 Fifth Wheel Figure 1 1 4 Main Components of Generator Set Bottom 3 1 4 1 2 3 OM2254 Rev A Page 14 of 103 ...

Page 16: ... A continuous at 28 5 VDC Starting current capacity 2000 A maximum Current limiting capability 300 to 2000 A continuously adjustable d DC Protective System Specifications Condition Trip Point Over voltage 32 to 34 volts High engine coolant temperature 225º F 107º C Low Idle oil pressure 10 PSI 69 kPa e Generator Set Specifications Output power rating 22 8 kW continuous Rated load capacity 800 A co...

Page 17: ... monitoring system receives signals from the fault sensing components in the generator output circuit and functions to cause the load to be disconnected 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 type adjustable voltage regulator provides auto...

Page 18: ...ngine is a fuel injection 4 cylinder electronically controlled engine rated at 110 horsepower b Engine Manufacturer s Components As received from the engine manufacturer the engine includes some of the following components which are more fully described in the engine manufacturer s manual 1 Electrical System The 12 VDC electrical generating and starting system includes an alternator and starter wi...

Page 19: ...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 20: ...ase AC generator whose output is rectified The generator consists of the generator housing assembly which holds the stator windings and a rotor which holds the control winding The generator housing assembly bolts to the engine flywheel housing A flexible coupling assembly connects the front end of the rotor to the engine flywheel At the rear of the generator a bearing supports the rotor and brushe...

Page 21: ...ntrols Screen icon s The table below shows the different icons used in the display and what they mean ICON Description ICON Description Check Engine Fuel level is below 10 refuel as soon as possible Fuel level is below 10 Fault engine won t start until more fuel is added Fuel level is acceptable Critical fault the engine is stopping Exit Icon screen and return to the Default screen Access the Info...

Page 22: ...criptions of any potential issues 2 The Navigation Keypad is used to navigate through the simple menu systems 3 The Blue LED indicates that power is ON It is off 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 ...

Page 23: ...fter first being powered up the display will show the number of hours the engine has been operating After a short delay the engine hours are replaced with the current time This then becomes the default display when engine is off The engine operating hours are always available on the Engine information screen 11 27 47 28 06 2013 READY FOR USE PRESS TO START ENGINE 48 During the engine start process...

Page 24: ... the screen to the default menu screen Unit information is displayed using the Parameter Information icon To access the information icon press the from the default menu and hold it down for approximately 5 seconds Note Access to the ICON screen might be restricted If this is the case then the message DISABLED is displayed Paragraph 4 17 describes how to enable and disable access to the ICON screen...

Page 25: ...Standby operating load profile etc 28 V Voltage 28 0 V Current 600 A Power 16 8 kW Back Next Prev ENGINE Status Running RPM 2000 Oil Pressure 54 psi Temperature 180 F Back Next Prev ENGINE Engine Load 49 Engine Hours 4122 FUEL 85 Baro Pressure 101 kPa Back Next Prev SYSTEM Battl Voltage 28 1 V Hour Meter 14 57 07 Consumption 4527 kWh PWM Duty Cycle 0 UNIT INFORMATION Display FW 075100 F Control FW...

Page 26: ...ting the engine at very cold temperatures and reduces the white smoke associated with a cold start The intake air heater or grid heater is energized or de energized 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 temper...

Page 27: ...e Correct any leaks by tightening hose clamps tube fitting etc as required 6 Check tightness of generator set retaining components 7 Check fuel level 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...

Page 28: ...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 10 Check batteries located inside the right side cable tray Inspect batteries for proper connection of terminals Service or replace if necessary O...

Page 29: ...ected during storage period Be sure solution is thoroughly mixed 4 Clean exterior of engine Dry with clean rags and compressed air 5 Seal all engine openings Use water proof vapor proof material strong enough to resist puncture damage from air pressure changes c Long Term Storage Over 30 Days To protect the generator and other electrical components the complete unit should be packaged using moistu...

Page 30: ...wn and storage If weekly operation is not possible contact nearest engine manufacturer distributor for instructions 3 Preparation for Shipment a Disconnect battery negative terminal before shipping b During long shipments vibration jolting etc may loosen the generator set retaining hardware CAUTION When shipping unit provide sufficient retaining materials to ensure generator set cannot roll out or...

Page 31: ...ided with the unit when starting engine for the first time 1 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 begins processing and the engi...

Page 32: ...of the unit The displayed 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 Diag...

Page 33: ...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 34: ...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 35: ...lied with cable 28 V Current Limit A 800 A Output Mode Simultaneous Fan Control Normal Plug Temperature Normally Open b Adjusting the Current Limit 1 The unit remembers the last current limit that was selected This value will be used whenever the 28VDC output is turned on If the current limit is set too high the aircraft engine could snap the propeller shaft If the current limit is set too low the...

Page 36: ...nto the aircraft power receptacle press the ON OFF Reset button to start providing 28 5 VDC power to the aircraft With the engine running and DC power OFF press the Up arrow to increase the DC current limit With the engine running and DC power OFF press the Down arrow to decrease the DC current limit OM2254 Rev A Page 35 of 103 ...

Page 37: ...he engine cool down period Once the cool down period is finished the engine will turn off Always ensure that the output is off before removing the aircraft plug Note Please note that the 28 VDC Start Stop button also functions as a Reset push button If for some reason the unit stops due to an error failure record the fault number and message and forward this information to your maintenance personn...

Page 38: ...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 OM2254 Rev A Page 37 of 103 ...

Page 39: ... 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 OM2254 Rev A Page 38 of 103 ...

Page 40: ...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 OM2254 Rev A Page 39 of 103 ...

Page 41: ...eters may vary depending on the mode of the unit Standby Engine Running etc 11 27 47 Setup Menu 28 06 2013 Allow Engine Idle Enabled Back Modify Settings Normally Open Normally Closed Refer to Section 3 4 7 11 27 47 Setup Menu 28 06 2013 Cable Temperature Normally Open Back Modify 11 27 47 Setup Menu 28 06 2013 Automatic Engine Shutdown Bypassed Back Modify Settings Bypassed Active Refer to Sectio...

Page 42: ...vary depending on the mode of the unit Standby Engine Running etc Settings Low Medium High Refer to Section 3 4 14 11 27 47 Setup Menu 28 06 2013 LED Brightness Low Back Modify Settings 1 247 Refer to Section 3 4 13 Settings Metric Imperial Refer to Section 3 4 15 11 27 47 Setup Menu 28 06 2013 Unit of Measure Imperial Back Modify 11 27 47 Setup Menu 28 06 2013 Modbus Slave Address 1 Back Modify S...

Page 43: ...Operation Manual ITW GSE 6400 Tier 3 OM2254 Rev A Page 42 of 103 ...

Page 44: ... using the UP and Down arrows on the Operators Panel This submenu is used to set the step size the current limit is changed by every time the UP or Down button is pressed The current limit settings are from 300 amps to 2000 amps in steps 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 Ent...

Page 45: ...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 to exit the submenu and return to the submenu list 8 Allow Engine Idle a When this option is set to Enable the engine will ramp up to its idle speed 1 000 RPM an...

Page 46: ...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 to exit the submenu and return to the submenu list 13 Modbus Slave Address a If the unit will be part of an RS 485 Modbus RTU BMS RMS monitoring system it must be assigned a Modbus Slave Address This ...

Page 47: ...ss a This submenu is used to lock out the center button on the navigation keypad which will prevent access to the ICON screen Disabled allows access to the 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 followin...

Page 48: ...menu 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 to exit the submenu and return to the submenu list 19 Language This submenu is used to change the language that all of the display screens messages alarms and reports are displayed in The unit co...

Page 49: ...Operation Manual ITW GSE 6400 Tier 3 c Black Box OM2254 Rev A Page 48 of 103 ...

Page 50: ...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 OM2254 Rev A Page 49 of 103 ...

Page 51: ...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 52: ...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 53: ...Operation Manual ITW GSE 6400 Tier 3 OM2254 Rev A Page 52 of 103 ...

Page 54: ...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 55: ...nd Piping X Change Lubricity Fuel Filter Element X X Check Radiator Core and Hoses X Check Oil Pressure and Record 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 Fan Hub and Drive Pulley X Check Hose Clamps on Air Intake Side X X Check Belt Conditions and Tensioner X X Check and or Adjust Valve Clearance...

Page 56: ...ck Thermostats and Seals Fall 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 Meters X Electrical 400 Hz System Check E F By Pass Operation X Check Output Cable and Connectors X Check Volt Amp Frequency Displays X Check and or Adjust Output Voltage X X Inspect Wiring and Connect...

Page 57: ...ew 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 manual for assistance b Change all fuel filter elements Metal shavings from the new fuel tank can c...

Page 58: ...er draining the filters replacing filter element or if the fuel tank has run empty Failure to do so can cause engine starting problems i Provide a container for catching drained fuel ii Open the drain valve on the fuel water filter by turning it counterclockwise iii Drain the filter until clear fuel is visible iv Tighten the drain valve v Safely dispose of drained fuel vi Purge air from fuel syste...

Page 59: ...re hazard 2 Electrical System 12 VDC a Check All Lights Check all indicating lights to be sure they operate when they should If any light fails to operate check the indicator and insure proper power is being given If power is present and the light does not activate replace the light fixture b Check Engine Battery Voltage Observe the engine voltmeter each time the engine is started to be sure the a...

Page 60: ...lso increase the fuel consumption rate The unburned fuel collects in the exhaust system to create the wet condition known as wet stacking To alleviate wet stacking in lightly loaded engines it is recommended that the machine be connected to a load bank after each 250 hours of use and operated under full rated load for one hour This will burn away and evaporate the accumulation of fuel and soot in ...

Page 61: ...Engine mount bolts must be torqued to 100 N m 73 7 ft lb ii Generator mount bolts must be torqued to 100 N m 73 7 ft lb b Change oil and oil filters c Change all fuel filters d Check Coolant Additive Concentration The cooling system protective liquid nitrite amine and phosphate free provides effective protection against corrosion cavitation and freezing See engine manufacturer s operation manual f...

Page 62: ...turer s operations and maintenance manual for assistance and the most update to date information e Check Water Pump Inspect the water pump weep hole for indication of a steady leak If a steady flow of coolant or oil is observed replace the water pump with a new or rebuilt unit Refer to the engine manufacturer s operations manual for assistance f Drain and Inspect Fuel Tank Annually drain the fuel ...

Page 63: ...Cranking Motor The alternator and cranking motor on this engine require no periodic lubrication i F Checks and Operations 2000 Hours or 2 Years 1 Engine a Check Vibration Damper Check vibration damper for looseness wobble chunking and streaking Also verify the hub bolts are tightened to the engine manufacturer s specifications Refer to the engine manufacturer s operations and maintenance manual fo...

Page 64: ...r 10 000 Hours 1 Engine a Refer to Engine OEM Service Center for recommended testing and maintenance 2 Engine Generator Assembly Note All Generator Overhaul items to be performed by a qualified generator motor facility a Replace Generator Bearings b Inspect Front and Rear Bearing Housings c Inspect Generator Shaft for Wear i Replace Rotor Assembly if required d Replace engine and generator shock m...

Page 65: ... Replace hoses as required 5 Check thermostat and seals each fall when cooling system is serviced l 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 Item Protected Location Schematic Type ITW PART NO Identifier Display Board Interface Board F1 2A AP SI2076 Control Board Interface Board F2 5A AP SI2075 Exciter Circu...

Page 66: ...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 67: ...l that is 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...

Page 68: ...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 69: ... 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 70: ... 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 71: ...mbly 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 the Air Filter 1 Pull out the latch and rotate the back cover to the unlocked position counterclockwise as viewed from the rear The cover has padlock symbols to show the locked and unlocked positions 2...

Page 72: ...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 diesel fuel will form wax crystals which can re...

Page 73: ... above the fuel tank outlet 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 FS9924 Drai...

Page 74: ...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 75: ...Open 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 76: ... 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 77: ...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 78: ...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 30 quarts 28 4 liters capacity under radiator to catch coolant 3 Remove the front grill to access the hose valve Place the drain...

Page 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...n starter was activated Press Engine button to Reset 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 ...

Page 87: ... Soft start Error Press Engine Button to reset Check Excitation Wiring Fuse Replace Control Board A1 Replace Interface Board A2 6600 ECM ERROR CODE RECEIVED Engine Error Code Received from ECM Service Engine 6900 AVR FAILURE 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...

Page 88: ...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 89: ...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 90: ...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 91: ...h holder mounting bracket Check it with an ohmmeter to see if it is good Defective voltage regulator on interface board Replace interface board Defective generator control winding Measure resistance between two yellow wires coming from generator It should be around 13 ohms It is defective if shorted or open Defective generator armature G402 If no problem was found with the control winding the gene...

Page 92: ...ushbutton is pressed but opens within 10 seconds a 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 b 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 wit...

Page 93: ...be certain voltage is normal 28 5 VDC Adjust to normal if necessary If load contactor is opened again and the fault message indicates an over voltage condition proceed to step b b Defective Interface or control board Replace the control and or the interface board 2 Load contactor opens during power delivery Under voltage fault indicated a Under voltage condition may have been result of a sudden sh...

Page 94: ...og Cummins Bulletin 4056563 Not Included purchased separately from Cummins Diagram Number Diagram Description 293428 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 OM2254 Rev A Page 93 of 103 ...

Page 95: ...Operation Manual ITW GSE 6400 Tier 3 This page is intentionally left blank OM2254 Rev A Page 94 of 103 ...

Page 96: ...Heater 120 V 293503 XX Kit Block Heater 240V 293503 XX Tie Down Ring Option 293192 Kit 28VDC Only Towbar Interlock 293337 02 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 293099 001 Kit Beacon Unit Operating Amber 293099 002 Kit Beacon Unit Operating ...

Page 97: ...240 VAC powered battery blanket on top of the batteries in the right cable tray 293503 XX Kit Block Heater 120V This option adds an independently powered 120 VAC powered block heater to the engine 293503 XX Kit Block Heater 240V This option adds an independently powered 240 VAC powered block heater to the engine 293337 02 Kit 28VDC Only Tow Hitch Interlock This option adds a lock to the tow bar as...

Page 98: ...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 99: ... 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 100: ... 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 101: ...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 OM2254 Rev A Page 100 of 103 ...

Page 102: ...text 5 Press to view detailed Alarm Data 6 Use the to browse through the recorded data 7 Use to leave the submenu 8 Use to leave the submenu and return to basic Icon Menu 28VDC Output Voltage V Current A Battery Voltage V Hour Meter PWM DUTY CYCLE ENGINE Status RPM OIL Pressure Engine Temp Engine Load Hours FUEL WARNINGS Other indication lamps LED s damages of enclosure etc Forward to Americas ITW...

Page 103: ...ITW GSE DIV GSE HOLDINGS INC CAGE 12867 11001 US HIGHWAY 41 NORTH PALMETTO FL 34221 OM2254 Rev A Page 102 of 103 ...

Page 104: ...Y X ITW GSE DIV GSE HOLDINGS INC CAGE 12867 11001 US HIGHWAY 41 NORTH PALMETTO FL 34221 OM2254 Rev A Page 103 of 103 ...

Page 105: ...Illustrated Parts Breakdown 6400 Tier 3 28 5V DC Generator Set Ground Power Unit Specification ACE6400 28 5 V DC Type OM2254 ...

Page 106: ...Operation Manual ITW GSE 6400 Tier 3 Figure 3 1 Generator Set 6400 JetEx 8 T3 Sheet 1 of 3 Clearance Light Option Fire Extinguisher Option 1 2 Page 1 of 26 ...

Page 107: ...Operation Manual ITW GSE 6400 Tier 3 Figure 3 1 Generator Set 6400 JetEx 8 T3 Sheet 2 of 3 Display Controller Assembly Battery Blanket Option Block Heater Option 8 3 6 4 9 7 5 Page 2 of 26 ...

Page 108: ...e Light Option 1 2 293171 Fire Extinguisher Option 1 3 293503 XX Block Heater Option 1 4 293498 XX Battery Heater Blanket Option 1 5 293454 05 Display Controller Output Assembly 1 275194 Membrane 28V DC Output 1 AP 378807 Cover Display Assy 1 6 293084 Top Canopy Composite Assy 1 7 293291 Trailer Assembly 1 8 293073 Cable Tray 1 9 293192 Tie Down Ring Option 1 Item not illustrated Page 3 of 26 ...

Page 109: ...Operation Manual ITW GSE 6400 Tier 3 Figure 3 2 Assy Chassis Running Gear JetEx 8 T3 Sheet 1 of 2 Spindles should be packed and filled with wheel bearing grease 1 2 3 4 5 6 6 7 8 Page 4 of 26 ...

Page 110: ...r Wall Guard 1 3 293401 5th Wheel Axle Assy 1 4 293402 Parking Brake Assy 1 5 84655UC1 EZ EZ Hub Hit Pivot Hub 5th Wheel Steel 1 6 84545UC1 EZ EZ Hub Hit Wheel Hub Rolling Steel 4 7 293399 Rear Axle Assy 1 8 293400 Towbar Assy 1 293290 Tow Bar Din 40 Option 1 Item not illustrated Figure 3 2 Assy Chassis Running Gear JetEx 8 T3 Sheet 2 of 2 Page 5 of 26 ...

Page 111: ...Operation Manual ITW GSE 6400 Tier 3 1 2 3 4 5 6 14 15 16 13 8 7 9 11 12 10 Figure 3 3 Genset Fuel Tank Installation JetEx 8 T3 Sheet 1 of 2 Page 6 of 26 ...

Page 112: ... Sender 1 7 293459 01 Fuel Hose Assembly Supply 1 8 293459 02 Fuel Hose Assembly Return 1 9 293459 03 Fuel Hose Assembly Engine 1 10 FF9674 Engine Primary Fuel Filter Element 1 11 LF9212 Oil Filter Element 1 12 FS9924 Lubricity Fuel Water Separator Element 1 13 293080 Oil Drain Hose Assembly 1 14 VA11479 Valve Oil Drain 1 15 TS11478 Adapter SAE 37 DEG Male Flare Bulkhead 1 16 FL11603 Adapter ST JI...

Page 113: ...Operation Manual ITW GSE 6400 Tier 3 Figure 3 4 Genset Assembly JetEx 8 T3 Sheet 1 of 2 1 2 3 6 5 4 7 8 9 Page 8 of 26 ...

Page 114: ...ins 28 5V DC QSB4 5 1 2 282918 Indicator Electrical Restriction 1 3 288985 Generator Assembly 1 4 FB11360 Fan Radiator 1 5 288003 Cover Fan Housing 1 6 VM11349 Mount Engine Generator 3 7 293457 Tube Air Intake Rubber Formed 1 8 EC11682 Motor Starter 1 9 3289941 Belt Serpentine 1 Figure 3 4 Genset Assembly JetEx 8 T3 Sheet 2 of 2 Page 9 of 26 ...

Page 115: ...Operation Manual ITW GSE 6400 Tier 3 CUMMINS SPARE ENGINE PARTS Visit http www quickserve cummins com To Setup Cummins Online Account Page 10 of 26 ...

Page 116: ...ation Manual ITW GSE 6400 Tier 3 Apply thread sealant before installing Apply thread sealant before installing 1 3 5 3 4 7 6 2 8 Figure 3 5 Fuel Tank Composite Assembly JetEx 8 T3 Sheet 1 of 2 Page 11 of 26 ...

Page 117: ... Internal 2 2 293093 Gasket Fuel Neck 2 3 293094 Fuel Filler Neck 2 1 2 NPT Weldment 1 4 293366 Fuel Sender Nipple 1 5 EB11439 Protectoseal Fuel Cap Green 1 6 IL11359 Mechanical Fuel Gauge 1 7 SR11536 Fuel Sender w Coupling Cap 1 8 HV11620 SAE 2 Plug 2 item not illustrated Figure 3 5 Fuel Tank Composite Assembly JetEx 8 T3 Sheet 2 of 2 Page 12 of 26 ...

Page 118: ...Operation Manual ITW GSE 6400 Tier 3 Figure 3 6 Radiator After Treatment Installation JetEx 8 T3 Sheet 1 of 2 1 2 3 4 5 6 7 Page 13 of 26 ...

Page 119: ...F 1 293069 Radiator Coolpack 1 2 AA6380 Sensor Coolant Level 3 Pin 1 3 293175 Muffler Assembly 1 4 293349 Assy Muffler Pipe w Thermo Jacket 1 5 293023 Muffler Pipe 1 6 EB11641 Thermo Jacket 30 Long 1 7 293272 Bracket DOC 2 Item Not Illustrated Figure 3 6 Radiator After Treatment Installation JetEx 8 T3 Sheet 2 of 2 Page 14 of 26 ...

Page 120: ...Operation Manual ITW GSE 6400 Tier 3 Figure 3 7 Coolpack Radiator Assy JetEx 8 T3 Sheet 1 of 2 1 2 Page 15 of 26 ...

Page 121: ...er 3 FIGURE ITEM NO ITW GSE PART NO NOMENCLATURE QTY 3 7 293069 Coolpack Radiator Assy REF 1 892001025 Top Radiator Hose 1 2 892001126 Bottom Radiator Hose 1 Figure 3 7 6400 T3 Coolpack Radiator Assy JetEx 8 Sheet 2 of 2 Page 16 of 26 ...

Page 122: ...Operation Manual ITW GSE 6400 Tier 3 3 1 2 4 Figure 3 8 6400 T3 Electrical System Installation JetEx 8 Sheet 1 of 2 Page 17 of 26 ...

Page 123: ...put Table Assembly 4400 1 2 FH11369 Fuse Holder 1 3 FU11370 Fuse Fast Acting 1 4 RE11371 Relay Grid Power Heater 2 293054 Harness Exciter Display 1 293059 Harness Jumper Kit Power 1 293060 Harness Main Chassis 1 293145 Schematic Engine Drive 4400 REF Item not Illustrated Figure 3 8 6400 T3 Electrical System Installation JetEx 8 Sheet 2 of 2 Page 18 of 26 ...

Page 124: ...Operation Manual ITW GSE 6400 Tier 3 Figure 3 9 6400 T3 Output Table Assembly JetEx 8 Sheet 1 of 2 2 3 4 Page 19 of 26 ...

Page 125: ...sy 6400 T3 T4 REF 1 293132 Output Stand 1 293208 Harness Output Table 1 2 293273 Rectifier TRU Assembly 1 293203 Harness Kit Rectifier Assembly 1 3 286810 002 Contactor DC 800 AMP 12VDC 1 4 293303 Control Box Assembly 1 Item Not Illustrated Figure 3 9 6400 T3 Output Table Assembly JetEx 8 Sheet 2 of 2 Page 20 of 26 ...

Page 126: ...Operation Manual ITW GSE 6400 Tier 3 Enclosure is equipped with Snap On standoffs 6 PL to attach PCB 3 5 2 4 1 6 Figure 3 10 6400 T3 Control Module Box Assembly JetEx 8 Sheet 1 of 2 Page 21 of 26 ...

Page 127: ...cts Contactor 1 AP SI2076 Fuse F5 2 amp Protects Relay 1 AP SI2075 Fuse F6 5 amp Protects Ignition Key Switch 1 AP SI2075 Fuse F7 5 amp Protects ECM Dongle 1 AP SI2085 Fuse F8 10 amp Protects Exciter Out 1 AP SI2078 Fuse F9 30 amp Protects ECM Power 1 FU11370 Fuse F10 150 amp Protects Intake Air Heater Fuse 1 3 293026 Control Box Cover 1 4 293211 Cummins Dongle Harness 1 5 579526 J8 Control Board ...

Page 128: ...Operation Manual ITW GSE 6400 Tier 3 Figure 3 11 Cable Tray Assembly Right Side JetEx 8 T3 Sheet 1 of 2 1 3 2 Page 23 of 26 ...

Page 129: ...3 11 293086 Cable Tray Assembly Left Side REF 293087 Cable Tray Assembly Right Side REF 1 293085 Cable Tray Symmetrical 1 2 293193 Compression Latch Modified 1 3 293013 Battery Cover 1 Item Not Illustrated Figure 3 11 Cable Tray Assembly Right Side JetEx 8 T3 Sheet 2 of 2 Page 24 of 26 ...

Page 130: ...00 Tier 3 Figure 3 12 Top Canopy Composite Assembly JetEx 8 T3 Sheet 1 of 2 6 4 FASTEN WITH 4 55 SELF CUTTING SCREWS GR8 OR HIGHER 5 2 1 FASTEN WITH M6 1 SCREWS GR8 OR HIGHER 3 FASTEN WITH M6 1 SCREWS GR8 OR HIGHER Page 25 of 26 ...

Page 131: ...CLATURE QTY 3 12 1 293517 Top Canopy Composite Assembly REF 2 293020 Panel Top Grid 1 3 293078 Latch Assembly Top Canopy 1 4 293018 Hook Slide Main Canopy 4 5 293019 Heat Shield Side Top Canopy 1 Figure 3 12 Top Canopy Composite Assembly JetEx 8 T3 Sheet 2 of 2 Page 26 of 26 ...

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