ITW GSE 6400 Tier 4, 6400 JetEx Tier 3 Operation Manual

28.5 VDC Generator Set Ground Power Unit

Manual

6400 Tier 4



Specification.: DCE6400 28.5 VDC Tier 4 Type: OM2248

AXA Power, Hobart, Houchin, Military and J&B has become ITW GSE. As simply ITW GSE, we still offer the same premium products and service.

SAME PEOPLE - SAME PRODUCTS - SAME COMPANY

Operation Manual - ITW GSE 6400 Tier 4

We recommend that the battery that

is changed after 5 years of use in

IMPORTANT NOTICE

safeguards GPU settings etc.

order not to lose data.

Diagrams and drawings are subject to change without prior notice.

Latest diagram versions can be found at www.itwgse.com

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Operation Manual – ITW GSE 6400 Tier 4

Introduction

This manual contains operation and maintenance information for a diesel engine-generator manufactured by ITW GSE, Palmetto, Florida 34221

This manual, including all information contained therein, is exclusive and confidential property of ITW GSE. This manual is not to be copied, reproduced, or delivered or disclosed to others, in whole or in part, except with express written permission of ITW GSE.

This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide information and instructions to experienced operators, electricians, and mechanics that have never operated this equipment. It is the intent of this manual to guide and assist operators and maintenance personnel in the proper use and care of the equipment.

Use of the manual should not be put off until trouble or a need for help develops. Read the instructions before 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 se ctions as required. Each page is identified by chapter, section and page number, which are located in the lower, outside corner.

When information located in another portion of the manual is referred to, a chapter, section, and paragraph or figure number identify its location. For example: “(see Section 2-3, Paragraph 1.a.)” refers to information located in Chapter 2, Section 3, Paragraph 1.a. If a chapter and section are not indicated in a reference, the referenced material is located in the same section as the reference, for example: “(see Paragraph 1.a.).”

Contents of the manual are arranged as follows:

Chapter 1 Description/Operation Chapter 2 Servicing/Troubleshooting Chapter 3 Manufacturer’s Literature Appendix A Options Appendix B Operation in Unusual Service Conditions Appendix C Software Installation Procedures Appendix D Schematics

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Safety Warnings and Cautions.

WARNING

IMPORTANT

WARNING

ELECTRIC SHOCK can KILL. Do not touch live electrical parts. ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and

ignite combustible material. DO NOT use power cables to break load. Prevent tools from causing short circuits.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached equipment.

Protect all operating personnel. Read, understand, and follow all instructions in the Operating/Instruction Manual before installing, operating, or servicing the equipment. Keep the manual available for future use by all operators.

CALIFORNIA PROPOSITION 65 - DIESEL ENGINES. Diesel engine exhaust and some of its constituents are known to cause cancer, birth defects and other illnesses.

1) General

Equipment that supplies electrical power can cause serious injury or death, damage to other equipment or property. The operator must strictly observe all safety rules and take precautionary 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 enginedriven 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 certified electrician verify that the equipment is adequately grounded and learn what terminals and parts are electrically HOT. Avoid hot spots on machine. Use prop er safety clothing, procedures and test equipment.

The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow through it. When inspecting or servicing the equipment, do not work in damp areas. Stand on a dry rubber mat or dry wood, and use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry, and never work alone.

a) Output Cables and Terminals

Inspect cables frequently for damage to the insulation and the connectors. Replace or repair cracked or worn cables immediately. Do not overload cables. Do not touch output terminal while equipment is energized.

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3) Service and Maintenance

This equipment must be maintained in good electrical condition to avoid hazards stemming from disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of the equipment until its safety has been assured. Repairs should be made by qualified personnel only. Before inspecting or servicing this equipment, take the following precautions:

a) Shut off all power at the battery disconnect before inspecting or servicing the equipment. b) Lockout the equipment at the battery discon nect switch if it is out of service. c) If troubleshooting must be done with the unit energized, have another person present who is

trained in turning off the equipment and providing or calling for first aid.

4) Fire and Explosion Prevention.

Fire and explosion are caused by electrical short circuits, combustible material near engine ex haust pipes, misuse of batteries and fuel, or unsafe operating or fueling conditions.

a) Electrical Short Circuits and Overloads.

Overloaded or shorted equipment can become hot enough to cause fires by self-destruction 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 grounded prior to or during fuel transfer. Shut unit DOWN before opening fuel tank cap. DO NOT completely fill tank, because heat from the equipment may cause fuel expansion overflow. Remove all spilled fuel IMMEDIATELY, including any that penetrates the unit. After clean-up, open equipment doors and blow fumes away with compressed air.

5) Toxic Fume Prevention.

Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air conditioners.

6) Bodily Injury Prevention.

Serious injury can result from contact with fans or hot spots inside some equipment. Shut DOWN such equipment for inspection and routine maintenance. When equipment is in operation, use extreme care in doing necessary troubleshooting and adjustment. Do not remove guards while equipment is operating.

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7) Medical and First Aid Treatment.

First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of all injury victims. Electric shock victims should be checked by a physician and taken to a hospital immediately if any abnormal signs are observed.

EMERGENCY

FIRST AID

8) Equipment Precautionary Labels

Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot be easily read.

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 massa

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Table of Contents

Chapter 1 Description/Operation Chapter-Section/Page#

Section 1 Description 1-1/10

1) General 1-1/10

2) Optional Equipment - Appendix A 1-1/10

3) Component Locations 1-1/11 Figure 1-1-1: General Assembly of Generator Set 1-1/11 Figure 1-1-2: Main Components of Generator Set (Right Side) 1-1/12 Figure 1-1-3: Main Components of Generator Set (Left Side) 1-1/13 Figure 1-1-4: Main Components 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 Operation 1-3/30

1) General 1-3/30

2) 28 VDC Operating Procedure 1-3/30

3) Icon Menu 1-3/37

a) View Parameters Menu 1-3/38 b) Setup Menu 1-3/39 c) Black Box 1-3/48 d) Power Log 1-3/49

e) Update/Save Log Menu 1-3/50

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Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#

Maintenance Inspection/Check 2-1/53

1) General 2-1/53

2) Maintenance Schedule 2-1/53 Figure 2-1-1 Maintenance Schedule Check Sheet 2-1/54

3) Inspection / Checks 2-1/55

a) General 2-1/55

b) “AR” Checks and Operations (As Required) 2-1/55 c) “BR” Checks and Operations (Break-In Period) 2-1/56 d) “A” Checks and Operations (10 Hours or Daily) 2-1/57 e) “B” Checks and Operations (250 Hour or 3 Months) 2-1/59 f) “C” Checks and Operations (500 Hour or 6 Months) 2-1/60 g) “D” Checks and Operations (1000 Hours or 1 Year) 2-1/61 h) “E” Checks and Operations (1500 Hrs or 1.5 Year) 2-1/62 i) “F” Checks and Operations (2000 Hour or 2 Years) 2-1/63 j) “G” Checks and Operations (Over 10,000 Hours) 2-1/64 k) Seasonal Maintenance Checks Spring/Fall 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) Changing Engine Oil 2-2/67

Figure 2-2-3 Oil Fill and Check Locations 2-2/67

e) Engine Accessories Lubrication 2-2/69 f) Trailer Lubrication 2-2/69

3) Servicing the Air Cleaner 2-2/70 a) Inspecting the Air Cleaner 2-2/70

Figure 2-2-4 Air Cleaner Assembly 2-2/70

b) Changing the Air Filter 2-2/70 c) Disposal 2-2/70

4) Engine Fuel 2-2/71 a) How to Select Fuel - Quality 2-2/71 b) Cold Weather Operation 2-2/71

2-1/64

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Chapter 2 Servicing / Troubleshootin

Figure 2-2-5 Lubricity Filter 2-2/72

Figure 2-2-6 Primary Fuel Filter 2-2/73

Section 3 Troubleshooting Procedures 2-3/82

…Engine Controls 2-3/87 …Generator 2-3/90 …Load Contactor Operating Circuits 2-3/91 …Protective Circuit 2-3/92

5) Engine Fuel System 2-2/72 a) Fuel Tank 2-2/72 b) Fuel Water Separator or Lubricity Additive Filter 2-2/72

c) Primary Fuel Filter 2-2/73

d) Fuel Pump 2-2/74 e) Fuel Return 2-2/74 f) Fuel Level Indicators 2-2/74 g) Draining the Fuel Tank 2-2/75

6) Engine Cooling System 2-2/76 a) General 2-2/76 b) Radiator Cap 2-2/76 c) Coolant 2-2/76 d) Draining the Cooling System 2-2/77 e) Flushing the Cooling System 2-2/77 f) Cleaning the Radiator 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

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 Troubleshooting 2-3/83

7) GPU Control Monitoring 2-3/83

8) Cummins Engine Fault Codes & Troubleshooting 2-3/84

9) Troubleshooting Charts/Error Codes 2-3/85

Chapter-Section/Page#

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Operation Manual – ITW GSE 6400 Tier 4

Chapter 3 Manufacturer’s Literature

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

hapter-Section/Page#

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

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Chapter 1 Description/Operation

Section 1 Description

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.

Part Number Mounting

DCE6400CUTT4

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

Cable

Management

Trailer Cable Trays Standard

Model

Description

Power Rating

Unit rated

28.5 VDC,

600 A continuous (17 kW),

2000 A peak (56 kW),

single output

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.

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3) Component Locations

For purpose of orientation when designating RIGHT and LEFT throughout this manual, the radiator is considered to be at the FRONT of the unit and the generator is at the REAR. RIGHT and LEFT are determined by standing at the REAR facing 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)

Figure 1-1-1: General Assembly of Generator Set

7. Radiator End

8. Generator End

9. Forklift Pockets

10. Low Fuel Beacon (Option)

11. Operating Beacon (Option)

12. Canopy Locking Latch

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1. Cummins QSF2.8 Engine

2. Control Module Assembly

3. Battery (inside tray pocket)

4. Battery Disconnect

Figure 1-1-2: Main Components of Generator Set (Right Side)

5. Output Connections

6. Output Contactor (mounted under output table)

7. Coolant fill access cover

8. Engine ECM Module

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1. Lubricity Additive Fuel Pre-Filter

2. Engine Oil Filter

3. Fuel Filter

Figure 1-1-3: Main Components of Generator Set (Left Side)

132

4. Engine Oil Fill Tube

5. Generator

6. Air Filter Assembly

7. Tie Down Rings Location (Option)

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1. Oil Drain Valve

2. Muffler Assembly

3. Fifth Wheel

Figure 1-1-4: Main Components of Generator Set (Bottom)

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4) Specifications

a) Standards

This unit has been designed to be in compliance with the following standards:

US EPA Tier 4F/CARB Tier 4F EU Stage IV US MIL-STD-704F, SAE ARP5015

b) Physical Specifications

Physical

includes trailer)

Length 103 in.

Width 66.2 in.

Height 63.9 in.

Weight (dry fuel tank) 2800 lbs.

Ground Clearance 9 in. (22.86 cm

c) DC Output Specifications

Output power ratin

Output voltage 28.5 VDC

Rated load capacity 600 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

17.1 kW continuous

2615 mm) (w/ towbar up

1682 mm

1622 mm

1814 kg.

e) Generator Set Specifications

Output power ratin

Rated load capacity 800 A continuous at 28.5 VDC*

Operating speed 1600, 2000, 2400 RPM**

Idle speed 1000 RPM

* The generator rating is limited to 600 A by the current carrying capacity of the output cable. ** The Operating Speed is based on the Current Limit setting:

22.8 kW continuous

300A to 1100A –- 1600 RPM 1150A to 1400A –- 2000 RPM 1450A to 2000A –- 2400 RPM

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f) Engine Specifications

Manufacturer Cummins, Inc.

Model No. QSF2.8

Type

Bore and Stroke 3.7 in x 3.94 in (94 mm x 100mm)

Displacement 171 in

Horsepower 74 hp/55 kw

Low Idle speed 1000 rpm

Electrical system 12 VDC

Ground Negative

Lubricating oil capacity (w/ filter

Coolant capacity system 5.3 Quarts

Fuel tank capacity 53

g) Normal Operating Characteristics

4 cylinder, 4 cycle diesel with turbocharger and fuel in

8.66 Quarts (w/filter) (8.2L

ection

2.8 L

2400 RPM

5 liters

allons (200 L

Engine oil pressure (warm and at rated speeds 1600 - 2400 RPM

Engine coolant temperature

normal operation)

45 - 55 PSI

310 - 379 kPa

180 ºF - 230º F (82ºC to 95ºC)

5) Special Features

The generator set has special features that are described more fully under the assemblies in which they 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 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 automatic voltage regulation at the aircraft. The regulated output is also adjustable for a variety of output cable sizes and lengths.

c) Engine Electronic Control Module (ECM)

The engine is equipped with an electronic control module (ECM) that monitors, records, and controls engine performance.

d) Battery System Disconnect Switch

The generator set is equipped with a battery disconnect switch outside the unit on the RIGHT side. The disconnect switch should be placed in the OFF position for long periods of shutdown.

NOTE: DO NOT disconnect the batteries when the engine is running or within two (2) minutes after the engine stops.

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6) Canopy

A composite enclosure, identified as a canopy, provides protection for the engine, generator and electrical controls. The canopy is also designed to reduce the operational noise level in the immediate area of the machine. The canopy is equipped with a bolted latch on the back left corner, which will require the use of a wrench to remove the canopy. Once the bolt is loosened the canopy can be slid to the rear and removed by two people for easy access to all engine and generator components.

We recommend using Simple Green® Industrial Cleaner & Degreaser or an equivalent to clean the canopy and cable trays.

7) Engine and Generator

The engine and generator comprise the principal components of the generator set. They are mounted on a galvanized, welded steel frame chassis. The following figures show the locations of all major components and sub-assemblies.

a) Diesel Engine

The diesel engine 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 with solenoid switch.

2) Fuel/Water Filter

The fuel/Water filter is a spin-on disposable type located on the inside of the canopy, near the engine’s fuel pump. Water that has been removed from the fuel should be removed daily. (See Chapter 2-1)

The use of low lubricity fuels can shorten life and/or damage the engine’s fuel pump.

CAUTION

3) Oil Filter

The engine oil filter is a spin-on, full-flow type, located on the left side of the engine near the front.

4) Pre-programmed Electronic Control Module (ECM)

The ECM is a pre-programmed engine control module, mounted directly to the engine block.

Only diesel fuel is recommended by the engine manufacturer. Refer to engine manufacturer’s manual for approved fuels.

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c) Factory Installed Components and Protective Systems

This generator set is assembled with the following components and protective systems:

1) Shutdown/Reset Systems

 Emergency Shutdown

The emergency shutdown switch is to provide instant manual shut off of the generator set by disconnecting power to the ECM through the control box. It is located on the FRONT RIGHT of the generator set next to the control box.

To operate the EMERGENCY SHUTDOWN

 Push button in until engine stops or until button travel stops

 Pull the button back out to reset

CAUTION

 Low Fuel Warning System

Do not 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 push-button for all normal engine shutdowns.

The low fuel warning system monitors the fuel level in the fuel tank. When the fuel tank level reaches approximately 10%, a warning is generated signifying it is time to put fuel in the tank. Once the engine is not running, a low fuel fault is generated and the engine is not allowed to start.

2) Radiator and Charge-Air-Cooler (CAC)

The radiator and charge-air-cooler is a two-piece type designed for long periods of operation without servicing.

3) Engine-Cooling Fan

The engine 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 also be used to lock-out the starting circuit of the equipment for maintenance safety purposes.

5) Air Cleaner

The diesel engine air cleaner is constructed so that air enters through its cylindrical body, and then is filtered before being passed into the engine turbo-charger assembly. An air cleaner service indicator device is mounted on the air cleaner assembly to monitor the airflow into the air cleaner. As the air cleaner becomes filled with dust, dirt, and carbon, the intake system airflow becomes increasingly restricted. This restriction causes a diaphragm inside the indicator to move toward an electrical contact. When the maximum allowable restriction level is reached, the circuit closes and the air cleaner indicator fault appears on the control panel fault display to warn the operator that the air cleaner must be changed. The electrical indicator automatically resets when the restriction level drops sufficiently. Note: This function should not be used as a replacement indicator. Follow recommended replacement schedule as specified in this manual.

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d) Warnings/Faults

The control system reacts appropriately to different detected issues. These types can be generalized between warnings and faults. Warnings are given when the system is able to function but requires servicing/user interaction. Faults are generated when the unit cannot or should not supply regulated power to the aircraft.

All faults prevent the engine from starting. However, they react differently to an operating unit. Faults can be categorized into three subcategories as defined by the fault number.

 Fault numbers less than 6000

o Minor faults: Will disconnect power to the aircraft but not affect engine and generator

 Fault numbers between 6000 and 8000

o Mid-level faults: Will disconnect power to the aircraft, turn off the generator and shut

 Fault numbers greater than 8000

o Major faults: Result in immediate shutdown of all system components including the

Engine generated warnings and faults are also monitored and their respective Cummins fault numbers are shown on the display.

functions.

down the engine after the required 30 second cool down.

engine. Service is required on the unit before it is returned to operation.

e) Generator

The generator is a 3-phase 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 brushes and slip rings provide the electrical connection to the exciter winding.

The generator consists of six windings, which result in 12 numbered output leads. When connected at the rectifier assembly, these windings form two three-phase delta connections. The rectifier assembly, described later in this section, converts the three-phase AC to the DC for the generator set output.

The generator is self-excited. Part of the generator’s output powers the rotating control winding. One positive and one negative brush in contact with slip rings supply controlled excitation current. The voltage regulator controls the excitation current and maintains a constant output voltage. Access to the brushes is through holes in the rear end bracket.

A radial-blade fan behind the coupling hub draws cooling air over the generator windings. Air flows over the rectifier assembly and then enters through the rear end of the generator and is discharged through openings in the flywheel housing at the drive end.

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8) Operator Controls

The control box is a protected enclosure on the right front panel of the GPU that has a modern graphical display 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.

ICON Description ICON Description

Check Engine

Fuel level is below 10% Fault, engine

won’t start until more fuel is added

Critical fault, the engine is stopping

Access the Information screens

Access the Black Box logs

Access the firmware upgrade screens and

the data save screen

Fuel level is below 10%, refuel as soon as

possible

Fuel level is acceptable

Exit Icon screen and return to the Default

screen

Access the Setup screens

Access the Power logs

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1) LED Graphical Display

2) Navigation Keypad

3) Power ON "Blue" LED

4) Warning "Amber" LED

5) Alert/Failure "Red" LED

6) Output ON "Green" LEDs

7) Current Limit Increase/Decrease

8) Power ON & Engine Start/Stop (Reset)

Figure 1-1-5 Control Panel

1: The color LED Graphical Display and easy to use menu system places all required operational information at the fingertips of the operator/maintenance personnel. Its color presentation accents critical data and simplifies the troubleshooting process by giving textual descriptions 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 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 current limit buttons increase or decrease the maximum amount of current the unit will provide to the connected aircraft. The step size is selected in the SETUP menu.

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8: The power ON & Engine Start/Stop button will wake the unit from low-power sleep mode. Pressing it again will begin the start-up sequence for the diesel engine. Pressing it again will shut down the engine. If the engine is already running, it will begin the manufacturer required 30 second cool down. If the unit has a fault, this button will reset the fault.

NOTE! – The screens shown in this manual reflect the current software version at the time of publication. The screens on your unit might differ slightly based on the software version running on your unit. Any changes will be described in a Service Bulletin which should be placed in the back of this manual.

Default Screen:

There are two default displays depending on whether the engine is running or not. When the unit 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 to show 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 the output is activated, it will still say it is ready for use. However, the engine will have to ramp up to its normal running speed (1600, 2000 or 2400 RPM) and the voltage stabilized before the output contactor will close. The running speed is determined by the current limit setting which is shown in the lower right corner of the display.

Current Limit Setting RPM 300 A to 1100 A 1600 1150 A to 1400 A 2000 1450 A to 2000 A 2400

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When output power is being provided, the screen will appear as follows:

29.5 V: 94% 560 A

28 VDC

Output Activated

40%

1500

The selected current limit is changed by using the up and down arrow keys that are located just below the navigation buttons. The amount the current limit value changes per button push is selected in the SETUP menu. The values are 50 A, 100 A, 200 A or 300 A.

Both default screens enable the user to quickly have access to other pertinent information by pressing 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 the message ”DISABLED” is displayed. Paragraph 4.17 describes how to enable and disable access to the ICON screen.

To Select a submenu, simply use the navigation keys ◄▼▲► to highlight the icon and then press the ● to enter the sub-menu.

To leave the Icon Menu highlight the ”Home” icon and press ●

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Parameters – Menu structure

ENGINE

Status: Running

RPM: 2000

Oil Pressure: 54 psi

Temperature: 180 °F

◄ Back ▼/▲ Next/Prev

Highlight the by using the navigation

◄▼▲► keys.

● to select ”View parameters” sub-menu.

Press

Use the the ▼/▲ to browse through the various screens.

Use ◄ to leave the sub-menu and return to basic Icon Menu.

Notice! Parameters may vary depending on the mode of the unit Standby / operating / load profile etc.

UNIT INFORMATION

Display FW: 075100 F

Control FW: 075100 F

Unit Serial: 215PS00000

Unit Rating: 90 kVA

MAC: C8:02:58:00:00:00

◄ Back ▼/▲ Next/Prev

SYSTEM

Battl Voltage: 28.1 V

Hour Meter: 14:57:07

Consumption: 4527 kWh

PWM Duty Cycle: 0 %

28 V

Voltage 28.0 V

Current 600 A

Power 16.8 kW

◄ Back ▼/▲ Next/Prev

ENGINE

Engine Load:: 49 %

Engine Hours: 4122

FUEL: 85%

Baro. Pressure: 101 kPa

◄ Back ▼/▲ Next/Prev

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9) Power Module Assembly

The power module assembly is mounted under the output table which is located at the rear of the machine over the generator. The assembly consists of the rectifier, a current transformer and an output contactor. The rectifier converts the generator AC output to DC

10) Cold Weather Starting System (BH1)

The intake air heater, located on the intake manifold, is used for starting 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 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.

ir Intake Heater

Figure 1-1-6: Air Intake Heater

)

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Operation Manual ITW GSE 6400 Tier 4

Section 2 Preparation for Use, Storage, or Shipping

1) Preparation for use after receipt of unit

a) Inspection/Check

Inspect unit thoroughly prior to operation.

1) Remove blocking, banding, ties, and other securing material.

2) If Tie Down Rings are present, make sure they are secured with both bolts. (Typically one bolt is used to secure middle blocks to unit during shipping.)

3) Inspect exterior for shipping damage such as broken lights, damaged sheet metal, etc.

4) Slide the canopy open and inspect the interior for foreign material such as rags, tools, shipping papers, etc.

5) Check fuel, coolant, oil hoses and connections for visible leaks. Visually inspect compartment floor and ground surface under unit for signs of leakage. 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) 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 neck.

CAUTION

NOTE: For antifreeze protection, use a solution of 50% permanent antifreeze (Ethylene

Lubricatin Coolant capacity system 5 gallons(18.9 liters

Be sure cooling system antifreeze solution is adequate to protect below lowest temperature expected.

glycol) and 50% clean water.

oil capacity (w/ filter

Figure 1-2-1: Engine Oil and Coolant Capacities

2.9 gallons(11 liters

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Operation Manual ITW GSE 6400 Tier 4

9) Check engine lubricating oil level. The oil gauge rod has “H” high-level and “L” low-level marks to indicate operating lubrication oil supply. Oil level should be kept as near the high mark as possible, without going over. See Figure 1-2-1 for capacity.

CAUTION

NOTE: See Engine Manufacturer’s Operation Maintenance Manual for oil recommendations.

NEVER operate engine with oil level below “L” level or above “H” level mark.

Dipstick

Oil Fill Cap

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.

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Operation Manual ITW GSE 6400 Tier 4

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 disconnect battery negative terminal at battery.

1) The unit should be prepared for storage as soon as possible after being removed from service.

2) The unit should be stored in a building that is dry and can be heated during winter months.

3) Moisture-absorbing chemicals should be used where excessive dampness is a problem; however, the unit must be completely packaged and sealed if moisture-absorbing 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 seconds in cool down mode after stop button is pressed.)

NOTE: Do not drain fuel system or crankcase after this run.

3) Cooling system antifreeze solution must be adequate to protect below lowest temperatures expected 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.

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c) Long-Term Storage (Over 30 Days)

To protect the generator and other electrical components, the complete unit sh ould be packaged using moisture proof packaging and sealing material. Place containers of moisture-absorbing chemicals in unit before packaging.

From the Cummins 4BT shop manual: long term storage is up to 24 months. Change the oil and fill with 30W Preservative oil. Then start the engine with clean diesel fuel (the units needs to be filled with at least 10% or more of fuel in order to start) 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 on cylinder 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 b e operated once a week.

When operating once a week:

1) Make certain the cooling system is adequately protected.

WARNING

2) Start engine and operate under full load (using a resistive load bank or aircraft) until coolant temperature has reached a minimum 176ºF (80ºC).

3) While engine is running, ensure normal operating controls are in good working condition before shutdown and storage. If weekly operation is not possible, contact nearest engine manufacturer distributor for instructions.

ENSURE adequate ventilation before starting the engine.

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

NOTE: It is suggested strong banding is used to secure generator set.

When shipping unit, provide sufficient retaining materials to ensure generator set cannot roll out or off the vehicle in which it is being transported.

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Section 3 Operation

1) General

This section contains information and instructions for safe and efficient operation of the equipment. Operating instructions are presented in systematic sequence of procedures to be followed in supplying 28.5 VDC power.

NOTE: Read ALL operating instructions before attempting operation of equipment.

WARNING

2) 28 VDC Operating Procedure

a) Pre-start Inspection

1) Check engine and generator compartments to make certain they are free of rags or other foreign materials.

2) Make certain sufficient lubricating oil and coolant is in the engine.

3) Be sure that the battery isolation switch is closed, ensuring that 12 VDC power is available to the engine starting and control systems.

Ear protection equipment may be necessary when working close to this equipment.

4) Make certain the control panel is on. If not, press the Power ON/Engine Start-Stop button to wake the unit.

b) Engine Starting Procedures

CAUTION

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 and warmup procedures. When finished, the starter will begin to crank.

2) If the Idle Mode is active (default), once the engine starts it will quickly ramp to idle speed of 1,000 RPM and hold until an output pushbutton is pressed or the unit runs out of fuel.

3) If the Idle Mode is inactive, the engine starts and ramps up to its idle speed of 1,000 RPM pauses for a moment and then continues to ramp up to its running speed of 1600 to 2400 RPM (the actual running speed is determined by the current limit setting) and stays there until an output pushbutton is pressed or the unit runs out of fuel.

4) Once the engine is running at idle or rated speed, check the oil pressure to make certain it is normal and observe all other engine values on the display screen for normal operation.

CAUTION

Refer to operating instructions in the engine manufacturer’s operation manual (provided with the unit), when starting engine for the first time.

Never use an ether start system in conjunction with the air intake heater.

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1. LED Graphical Display

2. Navigation Keypad

3. Power ON "Blue" LED

4. Warning "Amber" LED

5. Alert/Failure "Red" LED

6. Current Limit Adjustment Buttons

7. Output ON "Green" LEDs

8. Output ON/OFF (Reset) *

9. Power ON & Engine Start/Stop (Reset) *

* All output and engine buttons are multitasking buttons dependent on the status of the unit. The displayed screen is NOT important. These buttons are always active.

CAUTION

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 the reason for the fault, clear the fault, and press the engine start button again.

To eliminate the possibility of wet stacking (See Appendix B), DO NOT allow the engine to idle for long periods.

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d) Power Delivery

After the engine has started and the display has changed to the output status default screen, insert the aircraft cable into the aircraft. Make sure the cable is inserted until you feel a natural resistance. The plug may be equipped with a 90% insertion switch (split “C” pin). In this case, the unit will not function if the plug is not fully inserted. Press the output ON/OFF button. If the unit is already at rated speed, the contactor will immediately close. If at idle speed the engine will ramp up to rated speed, the generator will set output voltage and the contactor will close. The green LED will turn ON next to the active output. In addition, current power status information will appear on the output status default screen.

WARNING

1) Early in the power delivery run it is recommended that the operator check output voltage and current in each of the three phases. Use ▼ ▲ pushbuttons to view voltage. If the load is changing, observe the display until load conditions stabilize.

2) 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 output pushbutton to reset the system. Proceed with power delivery by pressing the same switch.

Operation Manual – ITW GSE 6400 Tier 4

All output ON/OFF buttons are active regardless of the displayed screen.

WARNING

CAUTION

e) Failed Power Delivery

If the contactor indicator light goes out and EF fault is shown on the display, this indicates that the aircraft plug interlock circuit is no longer receiving 28.5 VDC from the aircraft power connector. Correct the condition and press the output pushbutton to reset the fault. Press the button again to close the output contactor and provide 28.5 VDC to the aircraft/load bank.

1) If the aircraft cable does not have the Split-C wire, set the 28V Interlock to Bypassed through the Setup icon menu using the following steps:

2) Press and hold “DISABLED” appears in the display screen, contact the Maintenance department for access to the

SETUP menu to unlock.)

3) Use the navigation keys (

4) Set EF interlock to bypass.

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.

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.

● for approximately 5 seconds. (If the ICON screen doesn’t appear and

◄▼▲►) to highlight the setup icon. Press ● to select.

5) Press

6) Use the

● to accept the change.

◄ navigation key to go back to the Icon screen. The display will return to the default

screen after a period of inactivity.

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f) Discontinue Power Delivery with Unit Shutdown

1) Normal conditions

Push the Output ON/OFF pushbutton next to the lit green LED indicator to open the output load contactor. The indicator light next to the button will go OFF, indicating the load contactor has opened and power is no longer being delivered to the aircraft.

Once all contactors are opened:

a) If Idle Mode option is active (default), the generator will turn off and the engine will return to

idle speed after a 5 second delay.

b) If Idle Mode is inactive, the generator will turn off and the engine will remain at rated speed.

c) Pushing the engine Start/Stop pushbutton once while the engine is running begins the

automatic shutdown sequence which will shut off the engine after 30 seconds.

d) If the Engine Shutdown option is active, ten minutes after all outputs are opened (OFF) the

engine will slow to idle speed and 30 seconds later it will shut down.

2) Emergency conditions

a) Depress the “EMERGENCY STOP BUTTON” located on front of the unit to the right of the

control panel. When pushed, this button shuts the generator set off. Pull the button back out to reset it before restarting the generator set.

CAUTION

g) Low Fuel Warning and Fault

1) A Low Fuel Warning occurs when the unit is running and fuel levels drops below 10% in the fuel tank. The unit will continue to operate until it is out of fuel or the operator shuts off the engine.

2) A Low Fuel Fault will display if the fuel level is below 10% and the engine is off. The engine can’t be started until the fuel level is above 10%.

h) Display

1) The display will automatically turn off if the engine has been off at least 10 minutes. Pushing any button will return the display to full brightness. However, if there is a warning or fault message on the display, it will not turn off.

2) If the display is off, and the battery disconnect switch is closed, press the Engine pushbutton to return the display to full brightness.

i) Battery Disconnect Switch

Do not 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 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 with power delivery by pressing the same switch.

If the unit is not going to be used for a long period of time, open the battery disconnect switch to remove 12 VDC power to the control board and Cummins ECM controller. DO NOT open the battery disconnect switch while the engine is running or within two minutes after the engine has shut down.

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3) Starting the 28.5 VDC generator set

CAUTION

The unit can deliver up to 2000 amps of current during the starting of an aircraft engine. This much current will shear the propeller shaft of some aircraft. Therefore,

1) Default setup values

28 V Voltage (V): 28.5 VDC

28 V Compensation (V/600A): 0.0 (Set if GPU supplied with cable)

28 V Current Limit (A): 800 A

Output Mode: Simultaneous

Fan Control: Normal

Plug Temperature: Normally Open

2) Adjusting the Current Limit

make sure that the current limit is correctly set for the aircraft that is being powered.

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 limit section can be used to change the current limit value. The step size used for changing the current limit is set in the Current Limit Step Size setup menu screen.

ii. Once the correct value is selected, use the below procedure to start the unit.

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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.

3) Providing 28.5 VDC power.

a) With the engine running and the output cable securely inserted into

the aircraft power receptacle, press the ON/OFF/Reset button to 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:

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c) Turn off the unit by pressing the 28VDC Start/Stop button. The engine will slow down to 1000 rpm

and the display will show the amount of time left in the 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 personnel. If the fault is no longer active, press the Start/Stop/Reset to reset the alarm and the unit.

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3) Icon Menu

The Icon Menu can only be accessed from the Default screen. Press the center navigation button ● 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

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a) View Parameters Menu

The 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.

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b) Setup Menu

The Setup 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.

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Setup (continued) – Menu structure

11:27:47 Setup Menu 28/06/2013

Cable Temperature

Normally Open

◄ Back ● Modify

Settings:

Normally Open Normally Closed

Refer to Section 3 – 4.7

11:27:47 Setup Menu 28/06/2013

Cable Temperature Allow Engine Idle Automatic Engine Shutdown Real Time Clock Setup Date / Time Format Ethernet Configuration

◄ Back ● Select Parameter.

Highlight the by using the navigation ◄▼▲► keys.

Press

● to select ”Setup” sub-menu.

Use the the ▼/▲ to browse through the various set-up lines / parameters. The selectable line will be highlighed in green.

Press

● to select the parameter you

want to change.

● to Modify the parameter.

Press 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 The basic Icon Menu.

Notice! Availability of parameters 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

11:27:47 Setup Menu 28/06/2013

Automatic Engine Shutdown

Bypassed

◄ Back ● Modify

11:27:47 Setup Menu 28/06/2013

Real Time Clock Setup

◄ Back ● Modify

11:27:47 Setup Menu 28/06/2013

Date / Time Format

HH:MM:SS I DD:MM:YYYY

◄ Back ● Modify

11:27:47 Setup Menu 28/06/2013

Ethernet Configuration

◄ Back ● Modify

Settings:

Enabled Disabled

Refer to Section 3 – 4.8

Settings:

Bypassed Active

Refer to Section 3 – 4.9

Settings in additional sub-menu:

Month , Day, Year, Hour, Minute, Second

Refer to Section 3 – 4.10

Settings:

HH:MM:SS I DD:MM:YYYY HH:MM:SS AM I MM:DD:YYYY

Refer to Section 3 – 4.11

Settings in additional sub-menu: Ethernet Mode IP Address, Subnet Mask, Gateway, DNS1

Format: 000.000.000.000

Refer to Section 3 – 4.12

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Setup (continued) – Menu structure

11:27:47 Setup Menu 28/06/2013

Modbus Slave Address

◄ Back ● Modify

Settings:

1 – 247

Refer to Section 3 – 4.13

11:27:47 Setup Menu 28/06/2013

Modbus Slave Address LED Brightness Unit of Measure Diagnostic Mode Menu Lock Bypass Battery Replaced

◄ B ack ● Se lect Parameter.

Highlight the by using the navigation ◄▼▲► keys.

Press ● to select ”Setup” sub-menu.

Use the the ▼/▲ to browse through the various set-up lines / parameters. The selectable line will be highlighed in green.

Press

● to select the parameter you

want to change.

● to Modify the parameter.

Press Parameter will now be highlighted in green.

Use the the ▼/▲ to adjust parameter.

● to save changes.

Press

Use ◄ to leave the sub-menu and return to The basic Icon Menu.

Notice! Availability of parameters may vary depending on the mode of the unit Standby / Engine Running etc.

11:27:47 Setup Menu 28/06/2013

LED Brightness

Low

◄ Back ● Modify

11:27:47 Setup Menu 28/06/2013

Unit of Measure

Imperial

◄ Back ● Modify

11:27:47 Setup Menu 28/06/2013

Diagnostic Mode

Disabled

◄ Back ● Modify

11:27:47 Setup Menu 28/06/2013

Menu Lock Bypass

Disabled

◄ Back ● Modify

11:27:47 Setup Menu 2 8/06/2013

Warning: Do not confirm unless the Control Board battery has been replaced.

Confirm Battery Replaced

◄ B ack ● Modify

Settings:

Low Medium High

Refer to Section 3 – 4.14

Settings:

Metric Imperial

Refer to Section 3 – 4.15

Settings: Disabled Engine Only AVR Battery Only Engine Interface

Refer to Section 3 – 4.16

Settings:

Disabled Enabled

Refer to Section 3 – 4.17

Settings:

Yes No

Refer to Section 3 – 4.18

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Setup (continued) – Menu structure

11:27:47 Setup Menu 28/06/2013

Language

◄ Ba ck ● Select Parameter.

Use the the ▼/▲ to browse through the

various set-up lines / parameters. The selectable line will be highlighed in green.

● to select the parameter you

Press

want to change.

11:27:47 Setup Menu 28/06/2013

Language

English

◄ Ba ck ● Mod ify

Settings:

English, French, German, Italian, Polish, Portuguese, etc.

Refer to Section 3 – 4.19

● to Modify parameter.

Press 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.

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1) 28V Voltage

This Setup submenu allows the 28 volt 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 28V 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 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.

2) 28V Compensation

a) DC voltage drops quickly as the current increases over a given length of cable. This Setup

submenu allows the 28 volt output to be automatically adjusted as the load increases. The allowed setting is between 0.0 and 3.0 VDC per 600 amps. Note that the maximum output voltage of the unit is 33 VDC.

b) Enter the Setup Menu and then scroll up or down to the 28V Compensation 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 to exit the submenu and return to the submenu list.

3) Current Limit Step Size

a) If too much current is supplied to an aircraft engine, it is possible for the engine to shear the

propeller shaft. The Current Limit should be set to the maximum current the aircraft to be powered can take (per the aircraft manufacturers recommendations). The Current Limit is 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.

b) 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 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.

4) 28V Interlock

a) The 28V interlock is a personnel and equipment safety feature. This 28VDC signal will not be

present until the GPU closes its output contactor and provides power to the aircraft connector. The connector typically has a split “C” socket with +28VDC on one side and a jumper to the return wire on the other side of the socket. The GPU will not keep the output contactor closed if this voltage is not detected on the return wire in the cable. (This option requires a special cable such as the JB2840-30CS, JB2840-40CS or JB2840-50CS.)

Note! The value will be automatically reset to Active if the unit detects 28 volts on the "F" pin input of the I/O board.

b) Go into the Setup Menu and then scroll up or down to the 28V Interlock 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 to exit the submenu and return to the submenu list.

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5) 28V Interlock Delay

a) The default value is 3.5 seconds. For safety, it is recommended to remain at this value or less.

b) Go into the Setup Menu and then scroll up or down to the 28V Interlock Delay submenu. Press the

6) Aircraft Connector Insertion

a) Some aircraft power cables are equipped with a split "C" socket in the connector. This device sends

a 28 VDC signal to the unit when the connector is inserted at least 90% of the way into the aircraft power receptacle. Set this sub-menu value to Enable when such a cable is connected to the unit. The default value is set to Disable.

b) Go into the Setup Menu and then scroll up or down to the Aircraft Connector Insertion 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 to exit the submenu and return to the submenu list.

7) Cable Temperature

a) Some aircraft cables have temperature sensors installed in the connector body and/or replaceable

nose. This sub-menu allows the unit to accept Normally Opened or Normally Closed temperature sensor switches to be used.

b) Go into the Setup Menu and then scroll up or down to the Plug Temperature submenu. Press the

8) Allow Engine Idle

a) When this option is set to Enable, the engine will ramp up to its idle speed (1,000 RPM) and wait for

an output to be turned on. Once an output is turned on, the unit will ramp up to its running speed (1,600, 2,000 or 2,400 RPM) and energize the generator and close the selected output contactor when the generator is stabilised. The unit will return to idle speed five seconds after all outputs are turned off.

b) Enter the Setup Menu and scroll up or down to the Allow Engine Idle submenu. Press the center ●

button to enter the submenu, and press the ● button again to allow the 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.

9) Automatic Engine Shutdown

a) If the engine is running at its rated speed and all outputs are off for ten (10) minutes or the total load

is less than 5 amps, the engine will automatically go into its 30 second shutdown mode when this function is active. The Setup submenu allows this option to be activated or bypassed.

b) 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 arro the submenu list.

w button to exit the submenu and return to

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10) Real Time Clock Setup

a) This set of sub-menu s allows the user to adjust the internal clock to the correct local time.

b) Go into the Setup Menu and then scroll up or down to the Real-Time Clock Setup submenu. Press

11) Date/Time Format

a) The date and time format that is displayed on all the screens and reports can be adjusted using this

submenu. The selection is a 24 hour clock and DD:MM:YYYY date format or a 12 hour clock with the MM:DD:YYYY date format.

b) Go into the Setup Menu and then scroll up or down to the Date/Time Format submenu. Press the

12) Ethernet Configuration

a) The sub-menu s allows the user to enter the Ethernet IP address, Subnet Mask, Gateway address

and DNS1 values for TCP/IP communications with a BMS or RMS central monitoring system.

b) Go into the Setup Menu and then scroll up or down to the Ethernet Configuration 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 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 address.

b) Go into the Setup Menu and scroll up or down to the Modbus Slave Address submenu. Press

center ● button to enter the submenu, and press the ● button again to allow the value to 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.

14) LED Brightness

a) The unit status LED’s have three brightness levels. The default is set to medium.

b) Go into the Setup Menu and then scroll up or down to the LED Brightness submenu. Press the

15) Unit of Measure

a) This submenu is used to set the unit of measurements to Metric or Imperial.

b) Go into the Setup Menu and then scroll up or down to the Unit of Measure submenu. Press the

w value. Press the LEFT arrow button to exit the submenu and return to the submenu

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16) Diagnostic Mode Disabled

a) This setup submenu is used to assist in the troubleshooting procedure. The default setting is

“Disabled”; use the “Engine Only” to verify engine performance. The “Engine Interface” allows read only access to the engine ECM module. In the “Engine Interface” mode, the engine ECM will perform a self-test and then enter its Run mode. (The display will indicate running in the engine screen). In this mode the output contactor can be toggled on and off to verify that is functioning correctly.

b) The engine must be stopped before any of these modes can be changed.

c) Enter the Setup Menu and then scroll up or down to the Diagnostic Mode submenu. Press the

17) Menu Lock Bypass

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 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

18) Confirm Battery Replaced

Situated on the back of the control board, is a coin type lithium battery which ensures that Firmware / Set-up data etc. are not lost during utility drop-outs. The expected life of the battery is approximately 7 years. Note, a low battery voltage does not affect the internal safety system of the GPU that monitors the output voltage, among others. Thus, aircraft connected to the GPU are not exposed to any danger. However, to avoid loss of data and Control Board lock up *, we recommend changing the battery after 5

years of use.

Note!

A time stamp is stored in the ID chip (A6) upon production and after 5 years a warning occurs at the display, telling the user/operator to replace the Control Board battery. It is strongly recommended to change the battery when this message is shown:

Fig. 8.2.1

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To allow the user/operator to use the converter, it is possible to postpone the battery change, by pressing the ◄ (left arrow) push button. The warning message occurs 90 seconds after the unit is powered on or the output contactor(s) are opened (the unit is in Standby Mode). If this message is ignored for 6 months, the controls will be locked out and the below failure message will be displayed.

Fig. 8.2.2

The battery must be changed before the unit can be operated again.

To ensure high reliability of the back-up battery, the only type of battery that can be used on the Control Board is the Panasonic BR-2032

Go into the Setup Menu and then scroll up or down to the Confirm Battery Replaced 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 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 with English, French, German, Italian, Polish, Portuguese, Czech, Russian, Turkish and Spanish already installed. Other languages can be added as required. The default is set to English.

Go into the Setup Menu and then scroll up or down to the Language 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 to exit the submenu and return to the submenu list.

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c) Black Box

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d) Power Log

The Power Log 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.

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e) Update/Save Log Menu

The Update/Save Log 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 then the down button to highlight the Update/Save Log icon.

Update/Save Log – Menu structure

10:30:00 USB MENU 28/06/2013

USB Firmware Update Detected

Do you wish to update?

Press ● to update firmware

10:30:00 USB MENU 28/06/2013

Update Display Software

Update Control Card Software Save Logs

◄ Back ● Select

Highlight the by using the navigation ◄▼▲► keys.

● to select ”Update/Save Log Menu” sub-menu.

Press

The default function ”Update Display Software”

is green highlighted. If another function is wanted, use

the the ▼/▲ to highlight the function.

Before pressing 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).

● to select the function.

Press

● to confirm update firmware.

Press

● to select ”Update Display Software”,

10:30:00 USB MENU 28/06/2013

Update in Progress

Do not turn off or reset during update

18%

10:30:00 USB MENU 28/06/2013

Updating Display

Update Succesful! Please Reboot!

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.

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Update/Save Log (continued) – Menu structure

10:30:00 USB MENU 28/06/2013

USB Firmware Update Detected

Do you wish to update?

0.0%

Press ● to update firmware

10:30:00 USB MENU 28/06/2013

Update Display Software

Update Control Card Software

Save Logs

◄ Back ● Select

Highlight the by using the navigation ◄▼▲► keys.

Press

● to select ”USB Menu” sub-menu.

Use the the ▼/▲ to highlight the function ”Update Control Card software”.

Before pressing

● to select ”Update control card

software”, please remember to insert an USB stick into the USB port on the control card (located on the interface board).

● to select function.

Press

● to confirm update firmware.

10:30:00 USB MENU 28/06/2013

Updating Control Card

10:30:00 USB MENU 28/06/2013

Updating Control Card

Update Succesful! Please Reboot!

USB connection

Control card

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Chapter 2 Service and Troubleshooting

Section 1 Maintenance Inspection/Check

1) General

To make certain the generator set is always ready for operation, it must be inspected and maintained regularly and systematically so that defects may be discovered and corrected before they result in serious damage to components, or failure of the equipment.

Warning

STOP operations at once if a serious or possibly dangerous fault is discovered

2) Maintenance Schedule

a) General

A periodic maintenance schedule should be established and maintained. A suggested schedule is provided in Figure 2-1-1 on the following pages. It may be modified, as required to meet varying operating and environmental conditions. It is suggested that generator set and vehicle inspections be coordinated as much as possible.

b) Maintenance Schedule Check Sheet

It is strongly recommended that the customer use a maintenance schedule check sheet such as the one in the engine manufacture’s operation manual. The check sheet will provide a record and serve 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. The calendar period is included to make certain services are performed regularly when the equipment is stored, or being operated infrequently. Lubricating oil standing in engines that are stored, or used very little, may tend to oxidize and may require changing although it is not dirty. Perform all services on a whichever- comes-first basis.

d) Identification o f Interval Periods.

Each interval period is identified by a letter A, B, C, etc. For example, services under B schedule should be performed at the end of each 250 hours of operation, or every three months, BR service is performed during the BREAK IN period (first 50-150 hours) and AR service is performed AS REQUIRED.

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WARNNGHourly Interval AR 50-150

Calendar Interval Symbol AR Engine

Change Air Cleaner Cartridge Check Coolant Hose and Clamps Check Crankcase Oil Level Drain Fuel PreFilter Elements Check Coolant Level Check for Leaks and Correct Check Air Cleaner Indicator Check Exhaust System Charge-Air-Cooler (CAC) and Piping Change Lubricity Fuel Filter Element Check Radiator Core and Hoses Check Oil Pressure and Record Change Crankcase Oil Change Oil Filter Element Check Engine and Generator Mounts Check Coolant, Additive-Concentration Check Fan Hub and Drive Pulley Check Hose Clamps on Air Intake Side Check Belt Conditions and Tensioner Check and/or Adjust Valve Clearance Check Water Pump Steam Clean Engine Clean Fuel System Check Alternator Check Starter Motor Check Vibration Damper Check Cooling and CAC systems

X X

Once Daily 3 Mo. 6 Mo. 1 Yr. 1.5 Yr. 2 Yr.

Figure 2-1-1 Maintenan ce

(Sheet 1 of

250 500 1000 1500 2000

X X X X

X X

X X X X X X

X X

Schedule

X X X X

X X X X X

X X X X

X X

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Hourly Interval AR 50-150 Calendar Interval Symbol AR Engine (continued )

Flush and Change Coolant Drain & Inspect Fuel Tank Check Fan Mounting Clean Cooling System Check Hoses Clean Electrical Connections Check Thermostats and Seals

Electrical (12 VDC System)

Check All Lights Check Alternator Charging Rate Check Battery Clean Battery Terminals Check Wiring and Connections Check All Engine Meters

Once Daily 3 Mo. 6 Mo. 1 Yr. 1.5 Yr. 2 Yr.

250

X X

Spring & Fall Spring & Fall Spring & Fall Spring & Fall

Fall

X X

Note: “G” service (10,000+ hours) items are covered in section j) below.

500 1000 1500 2000

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 the “Air Filter Clogged” warning is displayed. These filters

ii. Check and tighten, as required, all coolant hose clamps, air intake hose clamps and

Figure 2-1-1 Maintenan ce

(Sheet 2 of 2

should not be washed because washing breaks down the material inside the filters.

exhaust clamps. Check all coolant hoses, air intake hoses and exhaust pipes for leaks.

Schedule

)

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b) Electrical System (12 VDC) – Check Battery Terminals

i. Periodically, open the battery compartment panel in the right cable tray and visually

check the battery cable connectors and battery posts. If corrosion is observed, disconnect the cables and clean battery posts and connectors with a wire brush or special battery post-cleaning tool. Coat the posts and connectors with a light film of petroleum lubricant before reconnecting the cables.

c) Electrical (28.5 VDC System) -- Check Output Voltage

i. Check the output voltage and be sure it is set for 28.5 VDC System. Adjustment can be

made using the Setup menu. (See Chapter 1-3, paragraph 3.a.)

c) “BR” Checks and Operations (Break-In Period, 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 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 oil filter element. The oil filter should be changed with the oil. e) Check engine and generator mounts to ensure they are properly installed and they have not

worked loose. (Torque i s set at 100 N-m, 73.7 ft-lb.). f) Check coolant additive concentration. Refer to the engine manufacturer’s o perations

manual for assistance. g) Steam clean the engine to free it of oil and dirt to prevent uneven engine cooling “hot

spots”. The oil and dirt can also fall into the engine and fuel system when covers are

removed during repair work. h) 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.

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d) “A” Checks and Operations (10 Hours or Daily).

1) Engine.

CAUTION

Check Crankcase Oil Level.

DO NOT overfill. DO NOT operate the engine with oil level below the lower bar or above the upper bar on the dipstick.

i. Check oil level daily with oil gauge dipstick.

ii. Oil level should not be checked until 3 to 5 minutes after engine shutdown. Keep oil level

as near the upper bar as possible. b) 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.

BE SURE to prime and bleed the fuel system after 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.)

WARNING

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 system if necessary.

c) Check Coolant Level

Check coolant level daily or at each fuel fill interval. Investigate for cause of any coolant

loss.

Cooling system is pressurized. To avoid personal injury, DO NOT remove radiator cap when engine is hot.

d) Check for Leaks and Correct At each daily start-up, check for coolant, fuel, and oil leaks. Coolant leaks may be more

noticeable when components are cold. Observe pumps, hoses, fittings, gasket connections, etc., for signs of leakage. Correct as required.

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Water Drain

WARNING

Figure 2-1-2 Fuel Lubrici ty

Drain

r Drain

e) Check Fault Code Meter. 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. f) Check Exhaust System. Visually inspect muffler and exhaust pipes for rust and signs of approaching failure.

Listen for any gasket or joint leaks.

A leaking and defective exhaust system could be a fire hazard.

2) Electrical System (12 VDC) a) Check All Lights. Check all indicating l igh ts 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 alternator is

functioning correctly and charging the batteries. If the batteries need to be replaced, be sure

the replacements meet the specifications for Cold Cranking Amps (CCA) and Reserve

Capacity. c) Check the operation of all the engine indicators.

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3) Electrical (28.5 VDC System). a) Check Output Cables and Connector. Check the output cable and plug connection for damaged insulation and contacts each time

the connector is detached from the aircraft. b) Monitoring sensors. Verify that the voltage, amps and frequency readings are di splaying correctly (use up and

down arrows) each time the unit is started.

e) “B” Check and Operations (250 Hours or 3

1) Engine. a) Prevent Diesel Engines Wet Stacking. All diesel engines operated for extended periods under light load may develop a condition

commonly referred 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 temperature for complete combustion of fuel and will also 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 the exhaust system. This clean-out procedure should be considered as a regular maintenance operation for machines operated under light loads.

b) Charge-Air-Cooler and Piping.

i. Inspect the charge-air-cooler for dirt and debris blocking the fins. Check for cracks,

holes, or other damage.

ii. Inspect the pipes and hoses for leaks, holes, cracks, or loose connections. Tighten

the hose clamps if necessary.

Months).

c) Check and record oil pressure. After each oil change, check and record oil pressure at operating speed after oil has

warmed to approximately 140º F. Record oil pressure under identical conditions at each oil change interval. A comparison of pressure at idle speed with previous readings will give an indication of progressive wear of oil pump, bearings, shafts, etc. Investigate any abnormal change in pressure readings.

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d) Check Radiator Core and Hoses.

i. Inspect the radiator core for dirt and debris blocking the fins. Clean as necessary.

Check for cracks, holes, or other damage.

ii. Check Fuel Pump.

iii. Inspect the fuel injection pump mounting nuts for loose or damaged hardware.

2) Electrical (12 VDC System).

NOTE: The battery furnished with this generator set is MAINTENANCE FREE. Check battery terminals and clean if necessary.

a) Check the battery terminals and clean if necessary.

f) “C” Checks and Operations (500 Hours or 6 Months)

1) Engine.

CAUTION

Check Engine and Generator Mounts

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-, am ine- an d phosphate free) provides

effective protection against corrosion, cavitation, and freezing. See engine manufacturer’s operation manual for ordering and mixture details.

2) Electrical (12 VDC sy st em).

3) Wiring. a) Inspect all cables and leads for worn or damaged insulation. b) Connections.

i. Inspect connectors for damaged or corroded condition.

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1) Electrical (28.5 VDC System).

a) Protective Monitoring Circuits. Check operation of all protective monitoring circuits to make certain they will function if a

fault occurs in the output circuit. Procedures for testing these circuits are contained in the

Adjustment/Test section of this manual. b) Inspect Wiring and Connections. Check all cables, leads, and wiring for broken, worn and damaged insulation. Check all

connections for tightness. c) Clean and inspect generally.

g) “D” Checks and Operations (1000 Hours or 1

1) Engine. a) Check Fan Hub and Drive Pulley. Inspect for loose bolts or worn features. Tighten bolts and replace parts if necessary. Refer

to the engine manufacturer’s operations and maintenance manual for 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 l eaks 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 the engine manufacturer’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.

Year)

f) Drain and Inspect Fuel Tank Annually drain the fuel tank and inspect it for dirt, debris or Diesel fuel “algae”. Clean the

tank if necessary. (See Chapter 2-2)

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h) “E” Checks and Operations (1500 Hours or 1.5 Years)

1) Engine. a) Steam Clean Engine. There are several reasons why the engine exterior should be kept clean. Dirt on the outside

will enter fuel and oil filter cases and rocker housings when covers are removed, unless dirt is removed first. A clean engine will run cooler and develop fewer hot-spots. Steam cleaning is one of the most satisfactory methods of cleaning and engine; however, there are some CAUTIONS to be observ e d.

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. Remove or protect bottom panel of unit (belly pan) to protect insulation.

b) Clean Fuel System.

See engine manufacturer’s operation manual for instructions. c) Check Alternator and Cranking Motor. The alternator and cranking motor on this engine require no periodic lubrication.

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i) “F” Checks and Operations (2000 Hours or 2 Years).

1) Engine. a)

Check Vibration Damper.

2 3

1 4

1. Fan

2. Exhaust Outlet

3. Alternator

Pulley

Figure 2-1-3 Engine

4. Belt Tensioner

5. Fuel Pump

6. Vibration Damper

Accessories

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 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 fins. Clean or

replace as necessary.

c) Flush cooling system and change coolant.

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j) “G” Checks and Operations (Over 10,000 Hours).

1) Engine.

a. Refer to Cummins Engine Manual for recommended maintenance and overhaul.

2) Engine/ Generator Assembly

a. Note: All Generator Overhaul items to be performed by a qualified generator/ motor

facility

b. Replace Generator Bearings

i. Contact Factory for Detailed Instructions

c. Inspect Front and Rear Bearing Housings

i. Bearing is a press fit, contact the factory for detailed instructions

d. Inspect Generator Shaft for Wear

i. Replace Rotor Assembly if required. Contact the factory for detailed

instructions.

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) In addition to daily checks of hoses for leaks, inspect hoses thoroughly each time the cooling

system is cleaned and serviced.

a) Inspect for signs of deterioration and collapse. Inspect for cracks and cuts. Inspect for

cutting and deformation caused by hose clamps. Replace hoses as required.

5) Check thermostat and seals each fall when cooling system is serviced.

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l) Lamps and Fuses:

1) Check all lamps daily.

2) Check fuses as required.

The fuse cha rt l i st s all fuses wi th th ei r l o cati on , siz e , and ty pe.

Item Protected

Display Board Interface Board Control Board Interface Board

Exciter Circuit (12V) Interface Board

Contactors Interface Board F4

Relays

Key Switch

ECM Dongle Interface Board

Exciter (Out) Interface Board

Engine Ai r

Heater

nition)

ECM

Interface Board F9

Intake

Location

Interface Board

Engine

Panel

Electrical

Schematic

Identifier

F1 F2 F3

F6 F7

F10

Type

2A 5A 5A 5A

5A 5A

10A 500V Cylindrical

30A

ANL-150

ITW PART NO.

AP-SI2076 AP-SI2075 AP-SI2075 AP-SI2075

AP-SI2076 AP-SI2075 AP-SI2075 AP-SI2085 AP-SI2078

FU11370

Figure 2-1-4 Fuse Identification Chart

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Section 2 Maintenance Procedures

1) General

A suggested maintenance schedule is provided in Section 1 of this Servicing Chapter. Each step of the schedule is also covered in general in Section 1. This Section covers maintenance in more detail, where necessary.

Item Maintenance Required

Check oil level daily or after every 10 hours of use. Change oil and the oil filter

Engine Oil

Fuel/water Pre-Filter Drain filters daily. Change the filter elements every 500 hours or after 6 months

Coolant

after the first 50 to 150 hours of use, then at 500 hours or 6 month intervals thereafter. En

of use, whichever comes first. Check coolant level daily. Service and maintain coolant system according to

Section 2-2, paragraph 6. Engine coolant capacity is approximately 15.5 quarts

14.7 liters

ine oil capacity is approximately 11.6 quarts (11 liters).

Coolant hoses and connections

Air Cleaner

Fan Belt Check fan belt condition and tension every 1000 hours or 1 year of use.

lternator Starter Starter motor bearings are sealed and require no periodic lubrication. Water Pump The water pump is packed at assembly and requires no periodic lubrication. Fan Hub The fan hub is lubricated at assembly and requires no periodic lubrication.

C Generator Periodic cleaning –no lubrication or adjustment required Generator Controls No periodic maintenance is required. Adjustments are covered in Section 2-3. Trailer

WARNING

STOP all operations at once if a serious or dangerous fault is discovered.

Check coolant hoses and connections daily for leaks.

Change air cleaner filter as required when the fault code display on engine control panel shows the “Air” code.

lternator bearings are sealed and require no periodic lubrication.

nnually grease the wheel bearings.

Figure 2-2-1: Lubrication and Maintenance Chart

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2) Lubrication

a) General

Proper lubrication is one of the most important steps in good maintenance procedure. Proper

lubrication means the use of correct lubricants and adherence to a proper time schedule.

Lubrication points, frequency of lubrication, recommended lubricants and filters are indicated in

Figures 2-2-1 and 2-2-2.

This section incorporates the engine maker’s, engine lubrication recommend atio ns from their

Operation and Maintenance Manual.

b) Lubrication schedule

Time schedules indicated on the Maintenance Schedule, Figure 2-2-1, are approximate and

based on average operating conditions. It may be necessary to lubricate more frequently under

severe operating conditions such as: low engine temperatures, high oil temperatures, or

intermittent operation. However, time intervals should not exceed those indicated in the chart

without careful evaluation.

c) Oil specification

The engine lubricating oil 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

Capacity Oil Filter

Replacement Part Number

Lube Oil Viscosity Required as per Ambient Temperatures

Synthetic Oils

Use oil specification API CF-4, HT/HS Viscosity 3.7cP minimum. Oil recommended for the diesel engines in this application is API Class CCMC. Refer to the manufacturer’s operation manual.

pproximately 10 quarts (9.5 liters

Cummins: LF9279

VISCOSITY

SAE 15W40 (Preferred) SAE 10W30 SAE 5W30 SAE 0W30

See the engine manufacturer’s operations manual for usable synthetic oils and instructions.

Figure 2-2-2: Lubrication Specifications

AMBIENT TEMPERATURE CONDITIONS

0ºF (-18ºC) and above for most climates

-10ºF to +50ºF (-23ºC to +10ºC) Winter conditions

-20ºF to +50ºF (-29ºC to +10ºC) Arctic Conditions

-20ºF and below to +50ºF

-29ºC and Below to +10ºC

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d) Changing engine oil

Change the oil once after the first 50 - 150 hours of use and then every 500 hours of engine

operation thereafter. The generator set is equipped with an hour meter to record actu al engine

operating time.

The ideal time to change engine oil is soon after a power delivery run, 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 engines.

lways use clean containers, funnels, etc.



Dipstick

ure 2-2-3: Oil Fill and Check Locations

Oil Fill

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Change oil as follows:

1) Provide an open container for catching the old oil below the oil drain plug. Container capacity must be greater than 20 quarts (18.9 liters).

2) The oil drain tube can be found by the muffler at the front of the unit.

3) Remove the drain cap (older models or turn the valve handle.

4) While oil is draining, change the oil filter element. See instructions below.

5) Provide a container for catching spilled oil from the filter.

6) Remove the oil filter by turning it counter-clockwise and inspecting it.

7) NOTE: The gasket can stick to the filter head. Make sure it is removed before installing a new filter.

8) Fill the new filter with clean lubricating oil before installation.

9) Apply a light coating of lubricating oil to the gasket-sealing surface and install the filter. DO NOT over tighten the filter.

CAUTION

WARNING

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.

Remember to close the drain cap and install the new oil before starting the engine.

12) Start engine and check oil pressure at once. Allow engine to run for 5 minutes, check for leaks then stop the engine.

13) After the engine has been stopped for about 5 minutes, recheck the oil level. Add oil, if required, to bring the level up to the high bar on the oil dipstick.

If bearing metal particles are found on the element or in the shell, the source should be determined before a failure.

STOP operations at once, if a serious or possibly dangerous fault is discovered.

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e) Engine Accessories Lubrication

1) Alternator

Most alternators contain sealed bearings and require no periodic lubrication, however, check to make certain there are no lubrication points on your particular alternator.

2) Starter

Most starting motors are lubricated at assembly and should be re-lubricated only when the starter is removed and disassembled, however, inspect the starter to make certain it has no lubrication points.

3) Water Pump

The water pump is packed at assembly 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 Wheel Hub bearing every three years to ensure that there is sufficient grease in the assembly.

Paragraph Name Specification Notes

d) Grease, General Purpose MIL-G-3545 e) Grease, Wheel Bearing ASTM D-4950

Excludes those of sodium or soda soap thickness. NLGI #2 Grade Lithium Complex EP Grease

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3) Servicing the Air Cleaner

A definite time schedule for cleaning or changing the air cleaner cannot be determined because of varying operating conditions. Pull the yellow tab out (about 1 inch) then rotate the hub counterclockwise about one inch and pull it off of the housing to access the air cleaner filter. It may be inspected either at prescribed service intervals or at any time deemed necessary.

Replacement air filter element ITW GSE part numbers: EB11485

Primary – AF55020 Secondary – AF55320

Inspect regularly. Replace when the “Air

Filter Clogged” warning appears on the display

Restriction Senso

Latches

Latches Hidden

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 of housing.

3) Pull out air filter elements and replace.

4) Replace end cover on housing, making certain that the filter is centered in the housing.

5) Snap (4) clips back into place.

c) Disposal

Normal trash pick-up should be acceptable. NEVER burn the air filter for disposal.

Figure 2-2-4: Air Cleaner Assembly

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4) Engine Fuel

a) How to select Fuel—Quality

The quality of fuel oil used in the diesel engine is a major factor in engine performance and life. Fuel oil must be clean, completely distilled, stable and non-corrosive.

CAUTION

Ultra-Low Sulfur Diesel (ULSD) with a maximum content of 15 ppm or less must be used for Tier 4 Final engines. This is a regulatory requirement; failure to do so will result 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.

Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and the injection nozzles.

The use of low lubricity fuels can shorten life and/or damage the engine’s fuel pump. The engine manufacturer recommends only diesel fuel.

b) Cold Weather Operation

In cold weather, diesel fuel will form wax crystals, which can restrict flow and clog filters. Fuel oil suppliers approach this problem several ways. Some provide a specially refined product, while others may use flow-improving additives or winter blends. Winter blended fuel will likely contain kerosene or 1-D fuel, which provide good cloud point temperatures, but result in a lighter fuel with a lower heat content. These fuels may be used, but they may result in reduced engine power and/or increased fuel consumption.

In most cases, adequate resistance to cold can be obtained by adding an additive. For further assistance contact the nearest engine manufacturer’s service representative.

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5) Engine Fuel System

The fuel system consists of five primary components: fuel tank, lubricity filter, primary fuel filter, fuel lift pump, and the fuel return line. The following are maintenance procedures for each of these items.

a) Fuel Tank

Be sure that no foreign objects are permitted in the fuel tank. The fuel tank must be removed and flushed out if objects are found in the Fuel Water Separator or Lubricity Additive Filter.

b) Fuel Water Separator or Lubricity Additive Filter

A lubricity fuel filter, which is also a fuel/water separator, is mounted in the generator compartment 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:

Fleetguard: FS90168

Drain the water daily. Change the filter after every 500

hours of operation.

Water Drain

Figure 2-2-5: Lubricity Filter

1) To drain the water:

a) Open drain valve. b) Drain accumulated water and contaminants. c) Close drain valve.

The lubricity filter must be changed every 500 hours of operation for the fuel filter to continue adding the proper amounts of the lubricity additive into the fuel system.

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2) To change the lubricity filter:

CAUTION

c) Primary Fuel Filter

When installing new element, do not over tighten it; mechanical tools may distort or crack filter head.

a) Place a pan underneath the fuel filter to catch spilled fuel. b) Shut off fuel valve. c) Drain off some fuel by opening the drain valve. d) Undo fuel filter with commercial tool and spin off. e) Clean any dirt from the filter carrier rim f) Apply a light film of oil or diesel on the rubber seal on the new filter. g) Fill new filter with diesel fuel. h) Screw in the new fuel filter “snug”. i) Check that the cartridge is seated correctly against the gasket and tighten with 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.

A primary fuel filter is mounted above the engine starter in the engine compartment. The filter’s function is to remove foreign material from the fuel before it enters the fuel lift pump.

Replacement fuel filter part number:

Fleetguard: FF90567

Change the fuel filter after every 500 hours of operation.

Figure 2-2-6: Primary Fuel Filte

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1) To change the fuel filter:

a) Shut off fuel valve. b) Place a pan underneath the fuel filter to catch spilled fuel. c) Undo fuel filter with commercial tool and spin off. d) Catch any fuel. e) Clean any dirt from the filter carrier rim f) Apply a light film of oil or diesel on the rubber seal on the new filter.

CAUTION

When installing new element, do not over tighten it; mechanical tools may distort or crack filter head.

Make sure that all rags, or absorbent sheets, are clear of moving engine parts and cannot be drawn in to the radiator fan.

g) Fill new filter with diesel fuel. Screw in the new fuel filter “snug”. Check that the

cartridge is seated correctly against the gasket and tighten with a final half turn. h) 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

e) Fuel Return

The fuel return is a fuel line (tube) that takes unused fuel from the engine, and delivers it to the fuel tank. No maintenance is required.

f) Fuel Level Indicators

There are two fuel level indicators in the unit; a mechanical dial indicator on the back of the unit that is only accurate when the fuel tank is above 50% full and is for the use of the refueler, and an electronic sensor in the fuel tank that is used to display the actual fuel level on the operator’s screen.

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 guideline could result in

or death.

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g) Draining the Fuel Tank

1) The fuel tank should be drained and cleaned out annually, when the various fuel filters start to become excessively fouled and before storing the unit for long periods of time.

2) Before draining the fuel tank, we recommend pumping at least 90% of the fuel out of the tank (use the operator display to determine the amount of fuel remaining). The fuel tank has two 1/8” NPT fittings with thread sealant on them that are accessible under the trailer, once it is lifted up. (Use a 7/16” wrench or socket to remove the fitting.)

3) Once the tank is fully drained, verify that there is no debris in the bottom of the tank on either side. If any dirt, material or build up exists inside the tank, flush with diesel fluid to remove the foreign material.

4) Use the following procedure to re-install the fittings: a) The proper method of assembling tapered threaded connectors is to assemble them

finger tight, then wrench tighten to the specified number of turns from finger tight. The following assembly procedure is recommended to minimize the risk of leakage and/or damage to components.

i. Inspect components to ensure that male and female port 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 two

turns of tape may cause distortion or cracking of the port.) c) Screw the connector into the port to the finger tight position. d) Wrench tighten the connector to 1.5 - 3 turns past finger tight. Never back off (loosen)

pipe threaded connectors to achieve alignment. e) If leakage persists after following the above steps, check for damaged threads and

total number of threads engaged. f) If threads on the fitting are badly nicked or galled, replace the fitting. If port threads

are damaged, re-tap, if possible, or replace the component. If the port is cracked,

replace the component. g) Normally, the total number of tapered threads engaged should be between 3-1/2 and

6. Any number outside of this range may indicate either under or over tightening of

the joint or out of tolerance threads. If the joint is under tightened, tighten it further but

no more than one full turn. If it is over tightened, check both threads, and replace the

part which has out-of-tolerance threads.

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6) Engine Cooling System

a) General

Cooling system service requires more than maintaining the proper coolant level in the radiato r and protecting the system against freezing. Water should be clean and free of any corrosive chemicals such as chloride, sulfate, and acids. It should be kept slightly alkaline with a pH value in the range of 8.0 to 9.5. Any water, which is suitable for drinking, can be used in the engine when properly treated as described in engine maker’s operation manual. The engine maker’s representative should be consulted regarding the selection of satisfactory brand, perm anent-type antifreeze for use in the cooling system.

b) Radiator Cap

1) General A pressure relief valve is built into the radiator cap. It is designed to open at a pressure of

approximately 15 psi (103.4 Kpa).

WARNING

2) Removal

When removing cap from a very hot radiator, DO NOT turn cap past safety stop until the pressure or steam has escaped.

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

3) Installation When installing the cap, be sure it is turned clockwise as far as it will go so that the pressure

retaining valve will be functional.

c) Coolant

The preparation and maintenance of the coolant solution is important to engine life and is completely covered in the engine manufacturer’s operation manual. For information reg arding coolant specifications, testing equipment, antifreeze, etc., refer to engine maker’s operation manual that accompanies the equipment’s manual or consult the local engine make r’s representative.

Allow engine to cool before adding coolant.

Do not attempt to repair the valve in a radiator cap in case of failure. Replace with a new cap.

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CAUTION

1) General. A permanent type antifreeze is recommended for use in the cooling system.

CAUTION

2) Selecting antifreeze. a) Select a permanent type antifreeze known to be satisfactory for use with chromate

b) When it is not known if the antifreeze is satisfactory for use with chromate resistor, check

(3) Checking antifreeze solution.

Check the solution with a 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:

Never use soluble oil in the cooling system.

1. DO NOT use methanol or alcohol as antifreeze.

2. DO NOT mix brands or type of antifreeze. A solution containing two or more types of antifreeze is impossible to test accurately.

corrosion resistor.

with local engine manufacturer’s representative for a list of compatible antifreezes.

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 hose into the drain pan.

4) Open the radiator drain valve.

5) Allow the system to drain completely.

NOTE: Be sure the drain valve doesn’t clog during draining.

6) When the system is completely drained, close the drain valve and coil the hose back up.

7) Replace the front canopy cover.

e) Flushing the Cooling System

Flushing the cooling system should be a yearly maintenance procedure. By flushing the system, clean water is forced through the engine block to remove expired coolant and other contaminants.

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f) Cleaning the Radiator Core

Blow out accumulated dirt from the radiator core air passages, using water. Bent or clogged radiator fins often cause engine overheating. When straightening bent fins, be careful not to damage the tubes or to break the bond between fins and tubes.

NOTE: Direct the water in a reverse direction to normal air flow. Normal flow on this installation is from the engine compartment out ward.

g) Filling the Cooling System

The preparation and monitoring of coolant in liquid-cooled engines is especially important because corrosion, cavitation, and freezing can lead to engine damage. For coolant system protection details see the engine manufacturer’s operations manual.

1) Install coolant a) Remove radiator cap. Be sure the radiator drain valve is closed (Front panel must be

removed to access this location).

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 check coolant level until all trapped air escapes. Add coolant if needed to fill

2) Inspection/Check a) Check system for evidence of leaks. b) Inspect all hoses. Install new hoses as necessary. Tighten hose clamps as required. c) Check the condition of fan and water pump belts. Replace belts if necessary.

NOTE: It is good practice to attach a card, indicating the cooling system contents and date serviced, to the radiator filler neck.

h) Thermostat

The thermostat should be checked each fall, or as required. Refer to engine manufacturer’s operations manual for recommended instructions.

to the bottom of fill neck. Install radiator cap.

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7) Engine Drive Belt

a) General

The engine cooling fan, alternator, and water pumps are driven by one serpentine belt, which must be replaced if worn or damaged.

b) Preparation for Belt Check and Adjustment

All driven assemblies must be securely mounted in operating position before checking belt tension.

c) Checking Belt Tension

WARNING

Check belt tension every 1000 hours, or once year, whichever comes first. A belt that is too tight is destructive to bearings of the driven part. A loose belt will slip and cause inefficient operation of the part being driven as well as wear to the belt.

CAUTION

Belt tension may be checked by manually depressing 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.

DO NOT Check belt tension with engine running

Inspect and replace the belt if it has unacceptable cracks, is frayed, or has pieces of material missing.

8) Generator Maintenance

The 400 Hz generator requires no maintenance or service other than periodic cleaning. The unit is brushless and has bearings that are permanently lubricated and sealed.

a) Cleaning

The generator may be cleaned by careful use of compressed air and/or a good, SAFE commercial cleaner. Steam cleaning of the generator is not recommended because the use of steam and harsh chemical compounds may result in damage to insulation and other gene rator components.

WARNING

b) Adjustment

The generator itself requires no adjustment. Adjustment procedures for generator controls are covered in Section 2-3.

Never use solvents as this is a fire hazard

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9) Replacing the Control Board Battery

Before removing the Control Board and to avoid any static discharge to the Control Board during the replacement of the battery, please take ESD (Electro Static Discharge) precautions.

* Important Note!

Before you remove the battery from the holder, make 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)

Blue LED (D5)

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 the back side face up.

Fig. 8.2.4 Control Board (rearview)

Battery holder and battery

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Remove the battery from the holder using a small insulated screwdriver to push out the battery,

direction indicated by the two red arrows on Figure 8.2.4 and insert the new battery in the direction of the

singe green arrow on Figure 8.2.4.

Mount the control board on the interface board again by gently pressing the PCB to its rest on the Interface Board. Make sure that all 4 corners are fully pressed towards the Interface Board.

Switch on the 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 Error”, the firmware on the Control Board has been erased. The Control Board must be sent to ITW GSE to be reloaded.

To ensure high reliability of the back-up battery, the only type of battery that can be used on the Control Board is the Panasonic BR-2032

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Section 3 Troubleshooting Procedures

1) General

The Troubleshooting Chart located in this section covers the common faults and malfunctio ns that can be found during operation or maintenance of this equipment. The chart may not list all faults and malfunctions that can occur. If a fault or malfunction is not listed in the chart, start looking for the cause at the source of power in the affected circuit. Refer to the schematic and connection diagram. Test the circuit systematically until the source of the malfunction is i solated.

The Troubleshooting Chart is arranged by Error code, Error text, Description and then four columns of possible corrective actions. Always try the 1 corrective action.

WARNING

CAUTION

Exercise extreme care to avoid contact with high voltage leads and components.

HIGH VOLTAGE CAN KILL!

Maintenance personnel must be very careful 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 required. The engine electrical system can be used as a 12 VDC power source.

3) Parts Replacement

To lessen down time and get a faulty machine back on line as quickly as possible, the black box concept of parts replacement is reflected in the Troubleshooting Chart. For example, if a component on a control box board is defective, the quickest way to remedy the situation is to replace the complete board and send the old to stock.

4) Normal Operational Parameters

The system specifications, which are listed in Chapter 1-1, provide useful information when troubleshooting abnormal operation. The Protective System Specifications and Normal Operating Characteristics provide information about how the generator set should be operated.

corrective action before proceeding to the next

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5) Check Connections and Leads

ALWAYS check connections and leads to a component suspected of being faulty. Generally, it is

assumed that connections and wiring have been checked first and that power ha s not been lost as a result of defective wiring or connections.

6) Engine Troubleshooting

Remember that the ability of the engine to start and run properly depends upon the following:

 An adequate supply of 12 VDC power reaching a good starter and control board  An adequate supply of air, compressed to a sufficiently high pressure  The injection of the correct amount of clean fuel at the proper time

7) GPU Control Monitoring

The GPU control system performs complete diagnostic testing and continuous monitoring of all critical circuits and operating electrical values. If the control system senses a problem with one of the circuits or if any of the electrical values exceeds its safe operating limit, the control system will shut the GPU down, or may allow the GPU to continue operation depending on the severity of the condition.

a) Operating Modes

1) Self-Test Mode When power is first applied to the control circuit, the GPU performs complete self-diagnostics

of the internal circuitry. If a fault is detected during the self-test, the Alert/Failure LED will be lit and the first (if there are more than one) failure will be displayed 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 successfully start after the third attempt, the fault LED will be lit and an Engine Start Failure message will be displayed.)

3) Engine Shutdown Mode Pressing the ENGINE pushbutton starts the 30 seconds delayed shutdown period. If any

output contactors are closed, they will open before starting countdown. The shutdown period is required to cool the engine’s turbocharger.

4) Automatic Engine Shutdown Automatic Shutdown mode will turn off the engine after 10 minutes when all contactors are

open or if they are closed and the total generator current is less than 5 amps. (This timer is internal and not visible.) After 10 minutes, it puts the engine in shutdown mode. (All contactors are opened and the generator is no longer regulating voltage.) A visible 30 second timer is displayed and the engine will turn off when the timer expires. The Automatic Engine Shutdown mode is changed in the Setup menu and the choices are enabled or disabled.

5) Engine Stop Mode After the 30 seconds delayed shutdown period, the engine stops running.

6) System Off Mode

The power is removed from the GPU’s entire control system when the battery disconnect is

opened.

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b) Faults

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Faults result when any of the fault limits are exceeded, an internal problem, or under certain conditions where an injury to personnel or damage to an aircraft or the GPU could occur. Faults are also stored in the Black Box memory as event records. The fault limits and conditions are preset at the factory.

1) Warning Warning faults have no effect on the operation of the GPU. An example is an intake air

restriction fault due to a dirty filter. Although the GPU continues to operate, the fault LED is lit and the fault text appears on the display. Pressing the Engine pushbutton or shutting down the GPU resets the fault.

2) Run Mode Run mode faults remove power form the aircraft but do not change the operating speed of the

engine. An example is an over voltage fault. Although the contactors open and remove power from the aircraft, the engine remains at rated speed, the fault LED is lit and the fault text appears on the display. Pressing the Engine pushbutton or shutting down the GPU resets the fault.

3) Stop Mode Stop mode faults remove power form the aircraft and shut the engine down. An example is a

low oil pressure fault. The contactors open and remove power from the aircraft, the engine shuts 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 numb ers fo r

free. (It is recommended that if you have more than one engine type/size, that you register one serial number per type/size.) Once you are registered, this website gives you access to engine information, troubleshooting assistance by fault code, parts information and service bulletin information for each serial number/engine type that you have registered with the site.

9) Error Codes

If the displayed text does not provide sufficient information to solve the problem, the tables on the next pages suggest corrective actions to be carried out for each error code.

Additional error information regarding the output voltage and overload, can be derived from the error code according to the following directions:

Output Voltage: 30xx / 31xx / 35xx Overload: 40xx / 41xx / 42xx / 43xx / 44xx / 45xx / 46xx / 47xx Phase code:

xx01 = Phase A xx05 = Phase A & C

xx02 = Phase B xx06 = Phase B & C xx03 = Phase A & B xx07 = Phase A, B & C xx04 = Phase C

Examples: Error Code 3501 refers to “Output Voltage Too Low” at phase A.

Error Code 4407 refers to “Overload I > 300% - 1 sec.” at all 3 output phases.

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Operation Manual – ITW GSE 6400 Tier 4

10.0 Troubleshooting Chart

Error Code

For faults in this section: Disconnect from Aircraft (if connected). Do not stop engine (if running). Do not let engine start (if not running).

100

201

202

250

300 FUEL LEVEL < 10%

500 STARTER FAILURE

Error Text in display Description

LOGGING UNSUCCESSFUL

CONTROL BOARD FAILURE

WRONG SOFTWARE VERSION

FAILED SOFTWARE UPDATE

Communication Failure

ID chip is missing or unreadable

Wrong Software Version Installed

The new software didn’t load properly

Fuel Level is too low to attempt an engine start.

Engine rotation is not detected when starter was activated.

1st Corrective Action

Press Engine button to Reset

Inspect ID chip connection. for damage.

Install correct software version

Try to install the software again

Add Fuel

Press Engine button to Reset

2nd Corrective Action

Contact ITWGSE

Replace display or control board

Inspect fuel Sender wiring

Check starter circuit to ensure that it is properly energized. (Replace Starter Solenoid)

3rd Corrective Action

Inspect fuel Sender

Replace Starter

4th Corrective Action

600

700

2400

3200

3300

3400

3800

4000

UNABLE TO START ENGINE

BATTERY LEVEL TOO LOW

28V PLUG TEMPERATURE TOO HIGH

28V OUTPUT VOLTAGE TOO HIGH

OUTPUT VOLTAGE TOO HIGH

28V OUTPUT VOLTAGE TOO LOW

28V INTERLOCK LEVEL TOO LOW

28V OUTPUT CURRENT TOO HIGH

Engine did not start after 3 tries.

Battery voltage level is too low to attempt startup sequence.

The temperature sensor in output 2 plug has tripped.

Voltage > 32V 4s

Voltage > 40V 1s

Voltage < 20V 4s

28V F Level too low

28V Output Voltage is too high

Press Engine button to Reset

Press ARU button to reset

Check fuel valve to ensure it is open.

Check battery cables

Remove load and let plug cool down

Check output voltage setup value

Verify that output cable is correct inserted

Remove overload and re-engage output

Service Engine

Charge Battery Replace Battery

Check connector / output cabling for any malfunction

Check ARU Module and wiring

Check / correct installation

Replace Control Board A1

Replace Control Boards A1 & A2

Replace Control Board A1 Replace Interface Board A2

Replace Interface Board A2

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Operation Manual – ITW GSE 6400 Tier 4

4100

4200

4300

4700

4800

For faults in this section: Disconnect from aircraft. Shut down engine after cooldown.

6000

6100

6600

8000

8200

8400

28V OUTPUT

CURRENT TOO HIGH

28V OUTPUT

CURRENT TOO HIGH

28V OUTPUT

CURRENT TOO HIGH

BACKUP BATTERY

TIME

RTC TIME

CONTROL BOARD FAILURE

AVR SOFTSTART ERROR

ECM ERROR CODE RECEIVED

CONTROL VOLTAGE LOW

EMERGENCY STOP ACTIVATED

ECM COMMUNICATION FAILURE

Output Current is over 1200A for 60

seconds

Output Current is over 1500A for 30

seconds

Output Current is over 1500A for 30

seconds

Time to change

the control board

battery

Real Time Clock

Fault

Watchdog Timeout

AVR Soft start Error

Engine Error Code Received from ECM

Control Voltage < 20V (Running)

J1939 Communication Failure

Press ARU

button to reset

Press ARU

button to reset

Press Engine

button to reset

Correct Date in

SETUP Menu

Press Engine Button to reset

Service Engine

Press Engine button to reset

Release emergency stop and press Engine button to reset

Check ECM Power (Replace Interface Board)

Remove overload

and re-engage

output

Remove overload

and re-engage

output

Remove overload

and re-engage

output

Replace Battery &

Reset Date

Replace Control Board A1

Check Excitation Wiring/Fuse

Check Alternator Check Battery

Check emergency stop

Service Engine

Replace Control

Board A1

Replace Control

Board A1

Replace Control

Board A1

Replace Control

Board A1

Replace Control Board A1

Check user EPO (A2:X14)

Replace Interface

Board A2

Replace Interface

Board A2

Replace Interface

Board A2

Replace Interface Board A2

Replace Control Board A1

8500

ENGINE RPM OUT OF SPEC

Engine RPM out of specification or stopped

Service Engine



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Operation Manual – ITW GSE 6400 Tier 4

Engine Controls

Trouble, Symptom, Condition

1. The engine will not

start, and the starter will not crank the engine.

2. Engine will not start. Starter clicks on and off.

Probable Cause Test, Check, and/or Remedy

a. Emergency Stop

b. Battery Disconnect

switch is in the OFF position.

c. Battery discharged or

loose battery or ground connection.

d. Defective starter

solenoid (SW3).

e. No voltage at starter

solenoid coil.

f. Defective starter. Remove the starter motor from engine and apply

g. Internal seizure. If the starter is good, attempt to hand crank the engine

i. Defective Control Panel Replace the Control Panel.

a. Low batter b. Loose starting circuit

connections or faulty cables

output Check the battery and recharge or replace

 Make sure the Emergency Stop switch is pulled out

and switch has been pressed.

 Make sure the battery disconnect switch is in the ON

position.

 Make sure the voltage across the batteries is

approximately 13 VDC.

 Check battery terminals.  Make sure 13 volts DC is reaching the starter solenoid

input terminal.

 Check if you can hear the starter solenoid activate

when the start button is pressed. If not, check for voltage on the starter solenoid coil (see e. below).

 Temporarily connect a large-capacity jumper cable

(No. 1/0 minimum) between the hot side of the starter solenoid and the starter input terminal. If starter does not crank en

 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.

12 VDC to test it. Replace the starter if non-operable.

using a 3/4-inch square drive on the crankshaft pulley. If engine cannot be turned one complete revolution, internal seizure is indicated. Remove engine and contact the en

Check all connections and cables. Tighten or replace as required.

ine, the starter may be defective

ine manufacturer and/or nearest dealer.

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Operation Manual – ITW GSE 6400 Tier 4

Engine Controls (continued)

Trouble, Symptom, Condition

3. Engine will not

start. Cranking speed is low.

4. Engine cranks but will not start.

Caution: To prevent damage to the starting motor, do not engage the starting motor for more than 30 seconds. Wait two (2) minutes between each attempt to start.

5. Engine cranks,

but will not start. Overtemperature indication appears immediately.

6. Engine is hard to start. Cranking speed is normal and the fuel supply is adequate.

7. Engine starts but then stops after a few seconds by automatic shutdown.

Probable Cause Test, Check, and/or Remedy

a. Low batter b. Loose starting circuit

connections or fault

c. Improper lubricating oil

viscosit

a. Low fuel Make sure there is sufficient fuel in the fuel tank.

b. Fuel shutoff valve closed Open the shutoff valve on the fuel tank. c. Plugged or defective filter Replace fuel filters. Also, check the gaskets for

d. Loose connections,

damaged hoses or fuel lines between tank and fuel pump

a. Defective engine

temperature switch

b. Defective PC1 board Replace the PC1 Interface board. a. Low compression, which

may be caused by sticking or burned exhaust valves, worn or broken compression rings, leaking cylinder head gasket, or valve clearance ad

a. Low oil pressure or

defective oil pressure switch.

b. Defective PC1 board. Replace PC1 Interface board.

output Check the battery and recharge or replace

Check all connections and cables. Tighten or replace

cables

ustment.

as required. Check the oil. Refer to Section 2-2.

Remove and replace the oil as necessary.

 If engine will not start, the fuel pump may be

defective.

 If engine starts and then stops after a short time,

check fuel lines, and filters.

leakin Tighten all fittings and connections. Replace any

damaged hoses or fuel links.

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.

Check the compression in accordance with instructions in the engine manufacturer’s operation manual. Overhaul the engine to make repairs as necessary.

Restart the engine and observe oil pressure gauge. If oil pressure is 12 psi or more, disconnect wire from the normally-closed switch terminal on the oil pressure switch. Restart engine. If engine continues to run, the oil pressure switch is defective. Replace oil pressure switch. If engine stops, the PC1 Interface board mi

or damaged condition.

ht be defective.



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Operation Manual – ITW GSE 6400 Tier 4

Engine Controls (continued)

Trouble, Symptom, Condition

8. Engine either goes

from rated speed to idle speed, or shuts down.

9. Engine has slow response time when a load is applied.

10. Engine misses or

runs unevenly.

11. Engine lacks

power

12. Front clearance lights aren’t ON.

Probable Cause Test, Check, and/or Remedy

a. Low fuel was detected or the

PC1 board could be defective.

a. Engine needs tune-up. Tune-up as required. Refer to engine

a. Insufficient fuel. Check fuel system in accordance with engine

b. Faulty injector. Check injectors in accordance with engine

c. Low compression pressure. Check compression in accordance with engine

d. Air in fuel system. Check all fittings to be sure they are tight and

a. Improper engine adjustments

ear train timing.

and

b. Insufficient fuel. Check low fuel level in accordance with engine

c. Insufficient inlet air due to

dama

d. Restricted exhaust system. Check exhaust pipes for restrictions. Check

a. Loose connection

b. Defective Interface board. Replace Interface board.

ed or dirty air cleaner.

Add No. 2 diesel fuel. Replace PC1 Interface board.

manufacturer’s operation manual.

manufacturer’s operation manual. Repair or replace parts as required.

manufacturer’s operation manual.

the thread sealant is still present. Tighten the

s and add new thread sealant as required.

fittin Tune-up engine in accordance with engine

manufacturer’s operation manual.

manufacturer’s operation manual. Repair or replace parts as required.

Check air cleaner for plugging and/or damage.

muffler for clogged condition. Replace as required.

 Check Interface board connector X9

terminal 3. Check Ground plate connection of wire 79

13. Rear clearance

lights aren’t ON.

a. Loose connection

 Check Interface board connector X9  Check Interface board connector X45 wire

Check quick disconnect plug P4

terminal 4.

80.

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Generator

Operation Manual – ITW GSE 6400 Tier 4

Trouble, Symptom, Condition

1. Generator does not

build up voltage when the engine is at the rated speed.

Probable Cause Test, Check, and/or Remedy

Problem with brushes Remove, clean, and reinstall the generator brushes, replacing them

if they are shorter than 7/16 of an inch (11mm).

Exciter fuse (F3 or F8) blown

Defective wiring between interface board and generator

Defective diode on control winding.

Defective voltage regulator on interface board

Defective generator control winding

Defective generator armature G402

Problem with brushes Remove, clean, and reinstall the generator brushes, replacing them

Replace exciter fuse(s).

Check all connectors and wires between interface board and generator. Pull gently on wires to insure proper insertion in the connector.

The diode is located on the generator’s brush holder mounting bracket. Check it with an ohmmeter to see if good.

Replace interface board.

Measure resistance between two yellow wires coming from generator. It should be around 13 ohms. It is defective if shorted or open.

If no problem was found with the control winding, the generator stator is defective. Send unit to overhaul.

if they are shorter than 7/16 of an inch (11mm).

Exciter fuse (F3 or F8) blown

Defective wiring between interface board and generator

Replace exciter fuse(s).

Check all connectors and wires between the interface board and the generator. Pull gently on wires to insure proper insertion in the connector.

g g

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Operation Manual – ITW GSE 6400 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.

2. Load contactor closes when the Output pushbutton is pressed, but opens within 10 seconds.

a. Blown contactor fuse (F3) on

ulator board.

b. Defective display module Check to make sure that the other

a. The plug interlock EF circuit on

Interface board could be defective.

b. 28.5 VDC is not reaching the plug

interlock EF circuit from aircraft for followin

c. Generator-to-aircraft cable

connector defective or not plugged into aircraft receptacle connector

reasons:

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

pushbuttons on the control panel work. Replace the display board and test all buttons a

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

Proceed as follows to find the cause of this malfunction.

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

ain.

ood contact.

d. Aircraft rejecting power. Check aircraft on-board electrical

e. Defective contacts in switch

mounted on side of contactor.

equipment and controls. 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.

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Operation Manual – ITW GSE 6400 Tier 4

Protective Circuit

NOTE: Protective monitoring is not completely functional until the load contactor is CLOSED. Since it is not

advisable to vary voltages for test purposes while delivering power to an aircraft, the GPU should be connected to a load bank for trouble shootin

protective circuits.

Trouble, Symptom, Condition

1. Load contactor

opens during power delivery. Over voltage fault indicated.

2. Load contactor opens during power delivery. Under voltage fault indicated.

Probable Cause Test, Check, and/or Remedy

a. Over-voltage condition

may have been the result of a sudden drop in load and may have been a normal action.

b. Defective Interface or

control board.

a. Under-voltage condition

may have been result of a sudden shock load, or possible tampering with REG potentiometer, and may have been a normal action.

b. Defective Interface or

Control board.

Press appropriate Output pushbutton and resume power delivery. Observe voltmeter to 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.

Replace the control and/or the interface board.

Operation Manual – ITW GSE 6400 Tier 4

)

(

)

OM2248 Rev B

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Chapter 3 Manufacturer’s Literature

Vendor Literature

Type Diagram Description

ine Operation and Maintenance Manual (Cummins Bulletin # 4358560

En Service Manual

- Not Included -- purchased separately from Cummins.

Diagram Number Diagram Description

293194 Dia

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.

ram, Schematic & Connection

Cummins Bulletin # 4358561

Operation Manual – ITW GSE 6400 Tier 4

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This page is intentionally left blank.

Operation Manual – ITW GSE 6400 Tier 4

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Appendix A Options

The following is a list of options available for the ITW GSE 6400 Generator Set.

Option/Features Available

Description

DIN40 Towbar 293148 Kit, Clearance Lights 293098 Kit, Beacon, Unit Operating, Amber 293099-001 Kit, Beacon, Unit Operating, Blue 293099-002 Kit, Beacon, Unit Operating, Clear 293099-003 Kit, Beacon, Unit Operating, Red 293099-004 Kit, Beacon, Low Fuel, Amber 293100-001 Kit, Beacon, Low Fuel, Blue 293100-002 Kit, Beacon, Low Fuel, Clear 293100-003 Kit, Beacon, Low Fuel, Red 293100-004 Kit, Battery Blanket, 120V 293498-01 Kit, Battery Blanket 240 Volt 293498-03 Kit, Battery Blanket 230 Volt 293498-05 Kit, Block 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

Part

Number

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, Blue 293099-003 Kit, Beacon, Unit Operating, Clear 293099-004 Kit, Beacon, Unit Operating, Red

This option adds the selected color beacon light to the top of the front canopy. These beacons are delivered with a flashing light. If a steady light is desired, the jumper in the bottom of the light should be cut.

293100-001 Kit, Beacon, Low Fuel, Amber 293100-002 Kit, Beacon, Low Fuel, Blue 293100-003 Kit, Beacon, Low Fuel, Clear 293100-004 Kit, Beacon, Low Fuel, Red

Operation Manual – ITW GSE 6400 Tier 4

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293498-01 Kit, Battery Blanket, 120V This option adds an independently powered 120 VAC powered battery blanket on top of the batteries in

the right cable tray. 293498-03 Kit, Battery Blanket, 240V This option adds an independently powered 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 assembly to prevent it from being lowered if the 28VDC cable isn’t

properly inserted into the receptacle at the front of the cable tray. NOTE: When this option is installed, the unit will not supply 28VDC power if the tow bar hitch is not up and locked in place.

Operation Manual – ITW GSE 6400 Tier 4

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Appendix B Operating in Unusual Service Conditions

This information is a general guideline and cannot cover all possible conditions of equipment use. The specific local environments may be dependent upon conditions beyond the manufacturer’s control. The manufacturer should be consulted if any unusual conditions of use exist which may affect the physical condition or operation of the equipment or safety to surrounding personnel.

Among such conditions are:

1) Exposure to:

a) Combustible, explosive, abrasive or conducting dusts. b) Environments where the accumulation of lint or excessive dirt will interfere with normal ventilation. c) Chemical fumes, flammable, or explosive gases. 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) Operation at:

a) Voltages above or below rated voltage. b) Speeds other than rated speed. c) Frequency other than rated frequency. d) Standstill with rotating equipment windings energized. e) Unbalanced voltages.

f) Operation at loads greater than rated.

3) Operation where low acoustical noise levels are required.

4) Operation with:

a) Improper fuel, lubricants or coolant. b) Parts or elements unauthorized by the manufacturer.

c) Unauthorized modifications.

5) Operation in poorly ventilated areas.

Operation Manual – ITW GSE 6400 Tier 4

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 

Appendix C Initial Software Installation Procedure

Introduction:

The ITW GSE 6400 GPU contains two circuit boards that may need to be programmed if they are replaced. (The Control Board (P/N AP-579526) and the Display Board (P/N AP-579536).

This document instructs you how to perform this task. Make sure to program the boards with the correct software number and revision. Install the Control Board software first, then the Display Board software.

First time programming of the Control Board (P/N AP-579526):

1) Make sure the Control Board is installed onto the Interface Board (P/N AP-279534), and the GPU is powered.

2) Copy the correct Control Board software onto a USB stick. The file must be located in the root folder of the USB stick, and the filename must be XXXXX.itw. Other files, e.g. the Display Board software, may also be on the USB stick.

3) Inspect the blue LED next to the USB socket on the Control Board. The blue LED must be flashing in a sequence of two rapid flashes, then a pause, then two rapid flashes, and so on.

4) Insert the USB stick into the USB socket on the Control Board. Check that the blue LED turns off. Wait until the blue LED turns on (this may take some time).

5) When the blue LED turns constantly on, the software has been programmed into the Control Board. Remove the USB stick from the Control Board.

If the blue LED is constantly on, the Control Board has already been programmed. Use the update function on the Display Board to 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 (P/N AP-579536):

1) Make sure that switch 1 on DIP-switch SW2 is in the ON position. This allows access to the Display Board menu.

2) Copy the correct Display Board software onto a USB stick. The Display Board software consists of two files: a XXXXX.itw file, and a file like AAxxxxxx.pbe, where xxxxxx is a number.

3) Do not change the filenames. The two files will only work together.

4) The files are located in the root folder of the USB stick. Other files, e.g. the Control Board software, may also be on the USB stick.

5) Insert the USB stick into the USB socket on the Display Board.

6) Press and hold the center navigation key on the GPU to access the update function.

7) Press the center navigation key again to confirm the software update.

8) Wait for the software update to complete. Press the center navigation key when instructed to reset the Display Board.

9) If the software update does not complete, start over from step 4.

Verify the software is installed correctly.

1) Hold the center navigation key to access the menu on the Display Board.

2) Access the Parameter Info, and navigate up/down to the Unit Information page.

3) Verify that the display reports the expected software number and revision for both Display Board (Display FW) and Control Board (Control FW).



ITW GSE 6400 Tier 4, 6400 JetEx Tier 3 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual