ITW GSE 6400 Tier 4 Operation Manual Download Page 10

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Operation Manual – ITW GSE 6400 Tier 4

Appendix A – Options
Appendix B – Operating in Unusual Service Conditions
Appendix C – Initial Software Installation Procedure
Appendix D – Schematics

3-A/95
3-B/97
3-C/98
3-D/101

Chapter 3

Manufacturer’s Literature

Chapter-Section/Page#

OM2248 Rev B

Page 9 of 104

Summary of Contents for 6400 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 DCE6400 28 5 VDC Tier 4 Type OM2248 Manual 6400 Tier 4 28 5 VDC 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: ...fore starting the 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...

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: ...ponents of Generator Set Bottom 1 1 14 4 Specifications 1 1 15 5 Special Features 1 1 16 6 Canopy 1 1 17 7 Engine and Generator 1 1 17 8 Operator Controls 1 1 20 9 Power Module Assembly 1 1 25 10 Cold Weather Starting System 1 1 25 Section 2 Preparation for Use Storage Shipment 1 2 26 1 Preparation for Use 1 2 26 2 Preparation for Storage 1 2 28 3 Preparation for Shipment 1 2 29 Section 3 Operatio...

Page 8: ... Hours 2 1 64 k Seasonal Maintenance Checks Spring Fall E i 2 1 64 l Lamps and Fuses 2 1 64 Figure 2 1 4 Fuse Identification Chart 2 1 64 Section 2 Maintenance Procedures 2 2 65 1 General 2 2 65 Figure 2 2 1 Lubrication and Maintenance Chart 2 2 65 2 Lubrication 2 2 66 a General 2 2 66 b Lubrication Schedule 2 2 66 c Oil Specification 2 2 66 Figure 2 2 2 Lubrication Specifications 2 2 66 d Changin...

Page 9: ...diator Core 2 2 78 g Filling the Cooling System 2 2 78 h Thermostat 2 2 78 7 Engine Drive Belt 2 2 79 8 Generator Maintenance 2 2 79 9 Replacing the Control Board Battery 2 2 80 Section 3 Troubleshooting Procedures 2 3 82 1 General 2 3 82 2 Equipment for Troubleshooting 2 3 82 3 Parts Replacement 2 3 82 4 Normal Operational Parameters 2 3 82 5 Check Connections and Leads 2 3 83 6 Engine Troublesho...

Page 10: ... A Options Appendix B Operating in Unusual Service Conditions Appendix C Initial Software Installation Procedure Appendix D Schematics 3 A 95 3 B 97 3 C 98 3 D 101 Chapter 3 Manufacturer s Literature Chapter Section Page OM2248 Rev B Page 9 of 104 ...

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 DCE6400CUTT4 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: ...le Assembly 3 Battery inside tray pocket 4 Battery Disconnect 5 Output Connections 6 Output Contactor mounted under output table 7 Coolant fill access cover 8 Engine ECM Module Figure 1 1 2 Main Components of Generator Set Right Side 1 2 3 5 4 7 8 6 OM2248 Rev B Page 12 of 104 ...

Page 14: ...y Additive Fuel Pre Filter 2 Engine Oil Filter 3 Fuel Filter 4 Engine Oil Fill Tube 5 Generator 6 Air Filter Assembly 7 Tie Down Rings Location Option Figure 1 1 3 Main Components of Generator Set Left Side 1 3 2 4 5 6 7 OM2248 Rev B Page 13 of 104 ...

Page 15: ...Operation Manual ITW GSE 6400 Tier 4 1 Oil Drain Valve 2 Muffler Assembly 3 Fifth Wheel Figure 1 1 4 Main Components of Generator Set Bottom 3 1 4 OM2248 Rev B Page 14 of 104 ...

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: ...onitoring 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 automa...

Page 18: ...ngine is a fuel injection 4 cylinder electronically controlled engine rated at 171 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: ...nit finishes its self check after 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 During the engine start process the screen will be modified t...

Page 24: ...ssing the or navigation buttons to cycle through the display screens Pressing the navigation button will return 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...

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: ...ge 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 ...

Page 28: ...oing 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 battery located inside the right side cable tray Inspect battery for proper connection of terminals Service or replace if necessary Oil...

Page 29: ...sorbing chemicals are to be effective b Temporary Storage 30 days or less 1 Lubricate unit completely in accordance with instructions in Chapter 2 2 Page 2 This will include changing engine oil and all filter elements 2 Start engine and operate a minimum of two minutes so all internal engine components are coated with new oil Note if unit is operated outside of diagnostic mode it will run for 30 s...

Page 30: ...r head and under rocker housing covers Cover all openings Do not rotate crankshaft Drain the fuel tank The unit can be stored for long periods without the above preparation if engine can be operated once a week When operating once a week 1 Make certain the cooling system is adequately protected WARNING ENSURE adequate ventilation before starting the engine 2 Start engine and operate under full loa...

Page 31: ...ngine 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 engine will start its initialization a...

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 B 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: ...em to operate After the fault has been corrected press the output pushbutton to reset the system Proceed 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 diagn...

Page 34: ...gine ON OFF pushbutton for all normal engine shutdowns b A condition of over voltage under voltage or overload in the output circuit will automatically open the load contactor and display a fault code to signal the operator which of the above faults caused the protective monitor system to operate After the fault has been corrected press the respective output pushbutton to reset the system Proceed ...

Page 35: ... Output Mode Simultaneous Fan Control Normal Plug Temperature Normally Open 2 Adjusting the Current Limit a The unit remembers the last current limit that was selected This value will be used whenever the 28VDC output is turned on b If the current limit needs to be changed use the following procedure i With the unit s engine running and the 28 VDC power is off the up or down arrows in the current ...

Page 36: ...o start providing 28 5 VDC power to the aircraft b During operation various parameters can be viewed via the display Use the navigation keys to browse through the available screens 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 OM2248 Rev B Page 35 of 104 ...

Page 37: ...he 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 personnel If the fault is no longer active press the Start Stop Reset to ...

Page 38: ... while in the default menu and hold it down for approximately 5 seconds If access to the Icon menu has been locked out the word DISABLED will be displayed when the center button is pressed Enter the correct unlock pattern and then press and hold the center button for approximately 5 seconds Center Navigation Button OM2248 Rev B Page 37 of 104 ...

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 OM2248 Rev B Page 38 of 104 ...

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 OM2248 Rev B Page 39 of 104 ...

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: ... the various set up lines parameters The 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 En...

Page 44: ...set 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 ...

Page 45: ...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 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 ...

Page 46: ... value to be changed Press the up or down arrow buttons to change 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 sub menu allows the user to enter the slave addr...

Page 47: ...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 The default is set to disabled b Go into the Setup Menu and then scroll up or down to the Menu Lock Bypass submenu Press the center button t...

Page 48: ...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 comes w...

Page 49: ...Operation Manual ITW GSE 6400 Tier 4 c Black Box OM2248 Rev B Page 48 of 104 ...

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 OM2248 Rev B Page 49 of 104 ...

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 4 OM2248 Rev B Page 52 of 104 ...

Page 54: ...e as a guide for establishment 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...

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: ...Wiring and Connections X Check All Engine Meters X Note G service 10 000 hours items are covered in section j below Figure 2 1 1 Maintenance Schedule Sheet 2 of 2 3 Inspection Checks a General 1 See Chapter 2 2 for detailed maintenance procedures 2 See Chapter 2 3 for adjustment and test procedures b AR Checks and Operations As Required 1 Engine a Change Air Cleaner i Replace the air filter when t...

Page 57: ...ll 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 clog the filter c Change crankcase oil New engines often release metal shavings more frequently Therefore the crankcase oil must be changed as a precautionary measure d Change ...

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: ...a fire 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 t...

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: ...gine 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 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...

Page 62: ...or assistance and the most update to date information b Check Hose Clamps on Air Intake Side Be sure that all clamps are properly secured to prevent leaks and all hose are in good condition c Check Belt 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 th...

Page 63: ...be observed WARNING Exercise care to avoid injury and damage to eyes and skin CAUTION 1 If a cleaning compound is used select one that is free from acid and will not remove paint 2 Protect or remove all electrical accessories such 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 Remov...

Page 64: ...king 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 for assistance and the most update to date information b Check Charge Air Cooler and Radiator Systems i Check for damaged hoses and loose or damaged hose clamps ii Check the radiator for leaks damage and build up of dirt in the ...

Page 65: ...ons e Replace engine and generator shock mounts i Contact factory for detailed instructions k Seasonal Maintenance Checks Spring Fall Engine 3 Check Fan Mounting a Check fan to be sure it is securely mounted b Check for fan wobble and or broken cracked blades c Check fan hub and crankshaft pulley for secure mounting 2 Check cooling system each spring and fall Clean if necessary 3 Check All Hoses 4...

Page 66: ...nterface Board F2 5A AP SI2075 Exciter Circuit 12V Interface Board F3 5A AP SI2075 Contactors Interface Board F4 5A AP SI2075 Relays Interface Board F5 2A AP SI2076 Key Switch Ignition Interface Board F6 5A AP SI2075 ECM Dongle Interface Board F7 5A AP SI2075 Exciter Out Interface Board F8 10A 500V Cylindrical f AP SI2085 ECM Interface Board F9 30A AP SI2078 Engine Air Intake Heater Engine Electri...

Page 67: ...apacity is approximately 15 5 quarts 14 7 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 lu...

Page 68: ...il 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 ...

Page 69: ...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 70: ... 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 71: ... 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 72: ...ect 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 the Air Filter 1 Release 4 Clips 2 on each end of air filter housing 2 Remove the end cover...

Page 73: ...esult in damage to the engine and after treatment system within a short period of time 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 restrict flow and clog filters Fuel ...

Page 74: ... 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 Fleetguard FS9016...

Page 75: ...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 76: ...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 77: ... 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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...erforming 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 requi...

Page 85: ...layed 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 ...

Page 86: ...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 87: ...id 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 Battery Replace Battery 2400 28V PLUG TEMPERATURE TOO HIGH The temperature sensor in output 2 plug has tripped Press ARU button to reset Remove loa...

Page 88: ...attery Reset Date Replace Control Board A1 For faults in this section Disconnect from aircraft Shut down engine after cooldown 6000 CONTROL BOARD FAILURE Watchdog Timeout Press Engine Button to reset Replace Control Board A1 6100 AVR SOFTSTART ERROR AVR Soft start Error Press Engine Button to reset Check Excitation Wiring Fuse Replace Control Board A1 Replace Interface Board A2 6600 ECM ERROR CODE...

Page 89: ...ide 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 12 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 the...

Page 90: ...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 91: ...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 92: ...lder mounting bracket Check it with an ohmmeter to see if 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 generator stat...

Page 93: ...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 94: ...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 95: ...l Cummins Bulletin 4358561 Not Included purchased separately from Cummins Diagram Number Diagram Description 293194 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 A for specific information on the ITW GSE 6400 28 5 VDC Generator Set optional equipment OM2248 Rev B Page 94 of 104 ...

Page 96: ...Operation Manual ITW GSE 6400 Tier 4 This page is intentionally left blank OM2248 Rev B Page 95 of 104 ...

Page 97: ...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 98: ...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 99: ...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 100: ... 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 101: ... 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 102: ...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 OM2248 Rev B Page 101 of 104 ...

Page 103: ...eld 7 NOT USED 3 NOT USED 5 NOT USED 1 pin 5 6 Air Filter 4 NOT USED 6 PLUG TEMP 2 pin 4 3 KeySwitch Ignition 5 Current Sense X14 1 Stator A 3 pin3 1 Alternator S 6 NOT USED 2 Stator B 4 pin 2 5 Engine Crank 1 Run Beacon 3 Stator C 5 pin 1 4 Engine Crank 2 Low Fuel Beacon 4 Not Used 6 pin 9 2 NOT USED 3 Running Lights Front X15 1 Exciter 7 pin 8 8 Air Filter 4 Running Lights Rear 2 Exciter 8 pin 7...

Page 104: ...OM2248 Rev B Page 103 of 104 ...

Page 105: ...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...

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