Page 1 60-90 kVA, 3 Phase, 115 Volt, 400 Hz Generator Set Series no. 500100 Type 4400 ITW GSE HOBART 11001 Us Highway 41 North Palmetto, FL 34221 U.S.A T: (toll free in US): 800-899-1841 T (International): + 1 941-721-1000 E: sales@itwgse.us...
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OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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 thereon, is exclusive and confidential property of Hobart Ground Systems.
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OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set If you have any questions concerning your ITW GSE equipment, immediately contact our Service Department by mail, telephone, FAX, or E-Mail. Write: ITW GSE Service Department...
Page 5 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Safety Warnings and Cautions. 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.
Page 6 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
Page 7 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
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Page 9: Table Of Contents
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Table of Contents Chapter 1 Description/Operation Chapter-Section/Page# Section 1 Description 1-1/1 General 1-1/1 Optional Equipment - Appendix B 1-1/1 Component Locations 1-1/2 General Assembly 1-1/3 Main Components of Generator Set (Right Side)
Page 10 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Chapter 2 Servicing / Troubleshooting Chapter-Section/Page# Section 1 Maintenance Inspection/Check 2-1/1 General 2-1/1 Maintenance Schedule 2-1/1 Maintenance Schedule Check Sheet 2-1/2 Inspection / Checks 2-1/3 “AR” Checks and Operations (As Required) 2-1/4 “BR”...
Page 11 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Parts Replacement 2-4/1 Normal Operational Parameters 2-4/1 Check Connections and Leads 2-4/1 Engine Troubleshooting 2-4/2 GPU Control Monitoring 2-4/2 Cummins Engine Fault Codes & Troubleshooting 2-4/3...
Page 12 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Explanation of Parts List 4-1/1 Numerical Index 4-1/3 Explanation of Numerical Index 4-1/3 Section 2 Illustrated Parts List 4-2/1 Explanation of Parts List Arrangement 4-2/1 Symbols and Abbreviations...
Page 13: Description
Description 1) General The basic generator sets covered in this manual, manufactured by ITW GSE Group, are rated at 60-kVA and 90-kVA and are designed to produce and deliver 115/200-volt, 400 Hz, 3-phase AC power to a parked aircraft or other load. Some generator models with the Active Rectified Unit (ARU) also provide 28.5 volts DC for aircraft having those requirements.
Page 14: Component Locations
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
Page 15 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 1. Fuel Filler Neck / Manual Gauge 8. Clearance Lights (Option) 2. Operator Control Panel 9. Radiator End 3. Composite Output Cable Trays 10. Generator End 4.
Page 16: Main Components Of Generator Set (Right Side)
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 1. Cummins QSB4.5 Engine 6. Generator 2. Control Module Assembly 7. 28.5 VDC ARU (Option) 3. Batteries (inside tray pockets) 8. Engine Alternator 4. Battery Disconnect 9.
Page 17: Main Components Of Generator Set (Left Side)
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 1. Coolant fill access cover 6. Engine Oil Fill Tube 2. Lubricity Additive Fuel Pre-Filter 7. Charge-Air-Cooler Piping 3. Engine Oil Filter 8. Engine Air Intake Piping 4.
Page 18: Main Components Of Generator Set (Bottom)
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 1. Oil Drain Tube 2. Tie Down Rings 3. Muffler Assembly Figure 1-1-4: Main Components of Generator Set (Bottom) March 15, 2015 Chapter 1-1 Page 6...
Page 19: Specifications
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 4) Specifications a) Physical Specifications Length 103 in. (2615 mm) w/ towbar up Width 66.7 in. (1694.3 mm) Height 65.9 in. (1674 mm) Weight (dry) 4000 lb. (1814 kg.) Weight with 28.5 VDC T-R...
Page 20 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set d) DC Output Specifications (with optional TR unit) Output Power Rating 17.1 kW Output Voltage 28.5 VDC Load Capacity (Continuous) 600 A Current Limiting Capability 400 to 2000 A in 300 A steps...
Page 21: Special Features
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
Page 22 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set (1) Electrical System The 24 VDC electrical generating and starting system includes an alternator and starter with solenoid switch. (2) Lubricity Additive Fuel Filter The fuel filter is a spin-on disposable type located on the inside of the canopy, near the engine’s fuel pump.
Page 23 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set (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 the air inward as a conventional fan does.
Page 24: Operator Controls
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set e) Generator The 400 Hz generator is a brushless, dual bearing, revolving field, three-phase, alternating current type unit. The front end of the rotor shaft extends forward beyond the front bearing and is coupled to the engine flywheel by a flexible coupling assembly.
Page 25 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
Page 26 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Both default screens enable the user to quickly have access to other pertinent information by pressing to cycle through the display screens below: The 28V data page will only be displayed if that option is available.
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Page 28: Power Module Assembly
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Power Module Assembly The power module assembly, mounted to the back of the ARU bracket, is located at the rear of the machine over the generator. The panel assembly provides a means of connecting and disconnecting the generator output to and from the aircraft.
Page 29: Cold Weather Start System
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
Page 30: Active Rectifier Unit (Aru)
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 11)Active Rectifier Unit (ARU) The ARU provides a regulated output voltage of 28.5 VDC. Input power is provided to the DC components from the 115/200 volt, 400 Hz generator set, through an input contactor. The output contactor provides DC power to the load.
Page 31 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set ARU Board (A20): The ARU Board interfaces with the processor board and the rest of the 28 VDC unit. It has the following functions: Supplied from G20 (X2) Connection to ARU control input on A2 (X1) Control of thyristors.
Page 32: Preparation For Use, Storage Or Shipping
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Section 2 Preparation for Use, Storage, or Shipping 1) Preparation for use after receipt of unit a) Inspection/Check Inspect the unit thoroughly prior to operation. (1) Remove blocking, banding, ties, and other securing material.
Page 33 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set (8) Check the engine lubricating oil level. The oil gauge rod has H high mark and L low-level marks to indicate the operating lubrication oil supply. Oil level should be kept as near the high mark as possible, without going over it.
Page 34 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set b) Installing Three-Phase AC Output Cables Figure 1-2-3 Figure 1-2-4 Figure 1-2-5 The generator set may be shipped without aircraft cables. The output cables connect to the load contactors, which are located at the rear of the unit.
Page 35 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set (7) Tighten the clamp screws securely, but avoid damage to the cable insulation. (8) Replace the canopy. c) Installing the DC Output Cable (optional) (1) Remove canopy. (While this may not be necessary, it greatly simplifies the process.) (2) The DC output cable is not normally supplied unless specifically ordered.
Page 36: Preparation For Storage
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Preparation for Storage When a generator set is to be stored or removed from operation, special precautions should be taken to protect the internal and external parts from rust, corrosion, and gumming in the engine fuel system.
Page 37: Preparation For Shipment
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set c) Long-Term Storage (Over 30 Days) To protect the generator and other electrical components, the complete unit should be packaged using moisture proof packaging material and sealing material. Place containers of moisture- absorbing chemicals in the unit before packaging.
Page 38: Operation
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Section 3 Operation 1) General This section contains information and instructions for the safe and efficient operation of the equipment. Operating instructions are presented in systematic sequence of procedures to be followed in supplying 400-Hz or 28.5 VDC power.
Page 39 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 1. LED Graphical Display 5. Alert/Failure "Red" LED 6. Output ON "Green" LEDs 2. Navigation Keypad 3. Power ON "Blue" LED 7. Output ON/OFF (Reset) * 4.
Page 40 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set CAUTION To eliminate the possibility of wet stacking (See Appendix A), DO NOT allow the engine to idle for long periods. c) Failed Starting Procedure In the event that there is an error during initialization or if the engine fails to start after 3 attempts, the display will show a fault.
Page 41 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 1. Press and hold for approximately 5 seconds. 2. Use navigation keys ( ) to highlight the setup icon. Press to select. 3. Use navigation keys ( ) to highlight the EF Interlock line.
Page 42: Active Rectifier Unit (Aru) - 28.5 Vdc Power Supply
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 3) Active Rectifier Unit (ARU) – 28.5 VDC Power Supply CAUTION The ARU can deliver up to 2,000 amps of current during the starting of an aircraft engine.
Page 43 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 2) Starting the 28 VDC ARU. a) 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 not is fully inserted.
Page 44 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set After operation, the unit has to be turned off before removing the aircraft plug. Press the 28 VDC Start/stop button g) The aircraft cable can now be removed from the aircraft and placed at the cable rest position.
Page 45: Icon Menu
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Icon Menu The Icon Menu is accessed from the Default screen. Press the center navigation button while in the default menu and hold it down for approximately 5 seconds.
Page 46: View Parameters Menu
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 4.0.1 View Parameters Menu The View Parameters 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 icon.
Page 47: Setup Menu
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 4.0.2 Setup Menu The Setup 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 Setup icon.
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Page 51 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Output Voltage: This Setup submenu allows the output voltage to be adjusted between 80.0 VAC and 135 VAC using the UP and DOWN navigation buttons. (Please note that the acceptable voltage range for all commercial aircraft is 115V ±3V.
Page 52 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Some load banks do not provide this EF Interlock so the EF interlock function in the unit has to be bypassed. Do not set this value to Bypassed for normal operation with aircraft. This setting is only to be used by qualified personnel for testing the GPU unit or when the unit will be providing power to equipment outside of an aircraft.
Page 53 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Go into the Setup Menu and then scroll up or down to the EF Interlock Delay submenu. Press the center the up or down arrow buttons to change the select Press the LEFT arrow button to exit the submenu and return to the submenu list.
Page 54 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 4.12 Ethernet Configuration This set of 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.
Page 55 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Go into the Setup Menu and then scroll up or down to the Unit of Measu Press the LEFT arrow button to exit the submenu and return to the submenu list.
Page 56 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set This setup submenu is used to assist in the troubleshooting procedure. The default setting is “Disabled”; use the “Engine Only” to verify engine performance; use the “AVR Battery Only” to verify the operation of the generator (with engine operation).
Page 57: Black Box
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 4.0.3 Black Box The Black Box 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 Setup icon.
Page 58: Power Log
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 4.0.4 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 Setup icon.
Page 59: Upload/Download Menu
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 4.0.5 Upload/Download Menu The Upload/Download 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 Setup icon.
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Page 62: Maintenance Inspection/Check
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
Page 63 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Hourly Interval 50-150 1000 1500 2000 Calendar Interval Once Daily 3 Mo. 6 Mo. 1 Yr. 1.5 Yr. 2 Yr. Symbol Engine Change Air Cleaner Cartridge...
Page 64: Inspection/Checks
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Hourly Interval 50-150 1000 1500 2000 Calendar Interval Once Daily 3 Mo. 6 Mo. 1 Yr. 1.5 Yr. 2 Yr. Symbol Engine (continued) Flush and Change Coolant Check Fan Mounting Spring &...
Page 65: Ar" Checks And Operations (As Required)
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set b) “AR” Checks and Operations (As Required) (1) Engine Change Air Cleaner Replace the air filter when the “Air Filter Clogged” warning is displayed. These filters should not be washed because washing breaks down the material inside the filters.
Page 66: A" Checks And Operations (10 Hours Or Daily)
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set d) “A” Checks and Operations (10 Hours or Daily). (1) Engine. Check Crankcase Oil Level. CAUTION DO NOT overfill. DO NOT operate the engine with oil level below the lower bar or above the upper bar on the dipstick.
Page 67 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Water Drain Figure 2-1-2 Fuel Lubricity Drain 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.
Page 68 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set (3) Electrical (400 Hz System). 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.
Page 69: C" Checks And Operations (500 Hours Or 6 Months)
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Check Radiator Core and Hoses. Inspect the radiator core for dirt and debris blocking the fins. Clean as necessary. Check for cracks, holes, or other damage.
Page 70: D" Checks And Operations (1000 Hours Or 1 Year)
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set (3) Electrical (400 Hz System). Protective Monitoring Circuits. Check operation of all protective monitoring circuits to make certain they will function if a fault should occurs in the output circuit. Procedures for testing these circuits are contained in the Adjustment/Test section of this manual.
Page 71: E" Checks And Operations (1500 Hours Or 1.5 Years)
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set h) “E” Checks and Operations (1500 Hours or 1.5 Years) (1) Engine. 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.
Page 72: F" Checks And Operations (2000 Hours Or 2 Years)
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set “F” Checks and Operations (2000 Hours or 2 Years). (1) Engine. Check Vibration Damper. 1. Fan Pulley 5. Alternator 2. Vibration Damper 6. Belt Tensioner 3. Engine Control Module (ECM) 7.
Page 73: Seasonal Maintenance Checks Spring/Fall (Engine)
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Seasonal Maintenance Checks Spring/Fall (Engine). (1) Check Fan Mounting. Check fan to be sure it is securely mounted. Check for fan wobble and/or broken/cracked blades. Check fan hub and crankshaft pulley for secure mounting.
Page 74: Lamps And Fuses
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set k) Lamps and Fuses: (1) Check all lamps daily. (2) Check fuses as required. (3) The fuse chart lists all fuses with their location, size, and type.
Page 75: Maintenance Procedures
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
Page 76: Engine Lubrication
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 2) Engine 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.
Page 77 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set c) 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 actual engine operating time.
Page 78 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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 30 quarts (28.4 liters).
Page 79 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Acceptable Lubricants 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.
Page 80: Servicing The Air Cleaner
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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 counter-clockwise about one inch and pull it off of the housing to access the air cleaner filter.
Page 81: Engine Fuel
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set c) Disposal Normal trash pick-up should be acceptable. NEVER burn the air filter for disposal. 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.
Page 82: Engine Fuel System
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
Page 83 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set To change the lubricity filter: CAUTION When installing new element, do not over tighten it; mechanical tools may distort or crack filter head. (1) Place a pan underneath the fuel filter to catch spilled fuel.
Page 84 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set To change the fuel filter: (1) Shut off fuel valve. (2) Place a pan underneath the fuel filter to catch spilled fuel. (3) Undo fuel filter with commercial tool and spin off.
Page 85: Engine Cooling System
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 6) Engine Cooling System a) General Cooling system service requires more than maintaining the proper coolant level in the radiator and protecting the system against freezing. Water should be clean and free of any corrosive chemicals such as chloride, sulfate, and acids.
Page 86 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set CAUTION Never use soluble oil in the cooling system. (1) General. A permanent type antifreeze is recommended for use in the cooling system. CAUTION 1. DO NOT use methanol or alcohol as antifreeze.
Page 87 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
Page 88: Drive Belt
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
Page 89: Preventive Maintenance
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 8. Preventive Maintenance Here are the replacement filters for ACE4400 ground power unit (GPU). This list is provided as a quick reference chart for the maintenance technician or diesel mechanic in charge of routine preventative maintenance to the ground power unit.
Page 90 ITW GSE 4400 / 400 Hz. Generator Set Hobart Ground Systems - Supply Contact Information ITW GSE has a supply staff that is able to help with the quote and sale of parts. Our helpful parts staff is also able to provide delivery information for the customer.
Page 91: Adjustments / Tests
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Section 3 Adjustment/Test 1) General These adjustments and test procedures are applicable to testing and adjusting the generator set after major repair, major parts replacements, or overhaul.
Page 92 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set c) Generator Low Power Testing: 1) Place unit in ‘AVR Battery Only’ Diagnostic Mode. 2) Press engine button to start engine. Engine should start and run at idle speed, 1000 RPM.
Page 93 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Output 2 Verification: 1) Make sure that the EF switch is in the ON position on the load bank and turn on Output 2. Contactor must close and indicator on the display illuminate.
Page 94: Generator Set Adjustments
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 3) Generator Set Adjustment a) Generator Adjustment The 400 Hz generator is a brushless type requiring no adjustments of any kind. For the following adjustment, the generator set must be running at rated speed (2000 RPM), under no-load conditions.
Page 95: Generator And Exciter Test
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 4) Generator and Exciter Test The generator fields and exciter stator may be tested with a Kelvin bridge. This is a double-bridge type instrument required for the very low resistance’s encountered in this test. It is understood that zero (0) resistance indicates a SHORT CIRCUITED condition.
Page 96: Diode Test
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 5) Diode Test Test values for diodes are not given here because they could be misleading. Test values may vary even between diodes of the same part number, rating, and manufacturer. General instructions for testing diodes are as follows: a) Disconnect exciter windings from diode lead(s).
Page 97 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set (3) Current Limiting / Soft Start Control The Current Limit default value is set using the “28V Current Limit” screen in the Setup Menu (See Chapter 1-3 Paragraph 4.19). In order to change the value for the current aircraft (and this test), use the RIGHT and LEFT navigation buttons when the diesel is running, the 28VDC ARU is NOT on and the “default”...
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Page 99: Troubleshooting Procedures
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Section 4 Troubleshooting Procedures 1) General The Troubleshooting Chart located in this section covers the common faults and malfunctions that you may find during operation or maintenance of this equipment. The chart may not list all faults and malfunctions that may occur.
Page 100: Engine Troubleshooting
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 6) Engine Troubleshooting When troubleshooting the engine, remember that the ability of the engine to start and run properly depends upon the following: An adequate supply of 24 VDC power reaching a good starter and control board.
Page 101: Cummins Engine Fault Codes & Troubleshooting
9) Fuses The following is a list of all of the fuses in the 4400 unit. F1 to F9 are located on the interface board PC1. Fuse #...
Page 102: Troubleshooting Charts
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Troubleshooting Chart Error Code Error Text in display Description 1st Corrective Action For faults in this section: Disconnect from Aircraft (if connected). Do not stop engine (if running). Do not let engine start (if not running).
Page 103 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Error Code 2nd Corrective Action 3rd Corrective Action 4th Corrective Action For faults in this section: Diconnect from Aircraft (if connected). Do not stop engine (if running). Do not let engine start (if not running).
Page 104: Engine Controls
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Engine Controls Trouble, Symptom, Probable Cause Test, Check, and/or Remedy Condition 1. The engine will not a. Emergency Stop Make sure the Emergency Stop switch is pulled out.
Page 105 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Engine Controls (continued) Trouble, Probable Cause Test, Check, and/or Remedy Symptom, Condition 3. Engine will not a. Low battery output Check the battery and recharge or replace start.
Page 106 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Engine Controls (continued) Trouble, Symptom, Probable Cause Test, Check, and/or Remedy Condition 8. Engine either goes a. Low fuel was detected or the Add No. 2 diesel fuel.
Page 107: Generator Excitation Circuits
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Generator Excitation Circuits Trouble, Symptom, Probable Cause Test, Check, and/or Remedy Condition 1. No (or low) a. Defective generator or In the Setup Menu, go to the Diagnostic Mode generator output excitation circuit.
Page 108 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Generator Trouble, Symptom, Probable Cause Test, Check, and/or Remedy Condition 1. No (or low) voltage output a. Shorted diode in exciter Check diodes in accordance with Chapter rectifier (CR2).
Page 109: Load Contactor Operating Circuits
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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 a.
Page 110 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Load Contactor Operating Circuit (Continued) Trouble, Symptom, Condition Probable Cause Test, Check, and/or Remedy 2. Load contactor closes when a. The plug interlock EF circuit on Set 400 Hz Interlock to Bypassed.
Page 111: Protective Circuit
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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 shooting protective circuits.
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Page 113: Overhaul / Major Repair
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Chapter 3 Overhaul/Major Repair Section 1 Exciter Armature 1) General This section provides information and instructions for removal and installation of the exciter armature used on this generator set. Through design improvements, the exciter and rear main bearing can be removed without removing the generator from the generator set.
Page 114 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 1. Exciter Core Flange 3. Diode Mounting Plate 2. Exciter Core Lamination 4. Silicon Diode Figure 3-1-2 Exciter Armature The exciter armature is mounted on the rear portion of the main generator armature shaft, which extends rearward beyond the rear generator bearing into the exciter housing (See Figure 3-1-1).
Page 115: Exciter Armature Replacement
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set The exciter armature is mounted on the main generator armature shaft with a 3/8-inch square machine key that is held in place by a key retainer, and an M12-1.75 hex head cap screw in the center of the diode mounting plate.
Page 116 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set (4) Disconnect the two rectifier-to-generator field leads, which are attached to the rectifier mounting plate with ring terminals. (5) Take CARE to prevent damage to leads. Remove kinks in the two generator leads as much as possible before starting removal operation (The exciter armature will be sliding over these leads).
Page 117 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set WARNING To prevent personal injury, keep fingers and hands clear of generator assembly until the armature is block into place to prevent rotation. Attempt to loosen exciter armature on shaft by rotating it slightly back and forth. If armature cannot be loosened by hand, use two M10-1.5 hex-head bolts as shown in Figure 3-1-4 to...
Page 118: Exciter Armature Installation
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set CAUTION Pay close attention to field leads while pulling exciter armature from shaft. Make CERTAIN that the leads stay in the 1/2" keyway. One mechanic should watch them constantly while another operates the puller.
Page 119 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set b) Exciter Armature Installation (1) If the exciter armature-to-generator shaft fit is such that the exciter armature may be pushed on by hand, push it on very slowly while another mechanic carefully watches and pulls field leads through hole in the exciter armature diode mounting plate.
Page 120 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set (3) Install the Machine Key Clean the machine key thoroughly. All mounting surfaces must be free of rust, corrosion, oil, grease, etc. Apply LOCQUIC primer, No. 47-56 grade T to SIDES of machine key. Do not over prime. A thin film is best.
Page 121: Dual Bearing Flexible Coupling
This manual provides basic instructions for removal, service and installation of a flexible coupling assembly, with generator fan, manufactured by ITW GSE as Part Number 288481. This assembly is illustrated in Figure 3-2-1. The primary function of this assembly is to couple a Hobart 2000 RPM Generator to a Diesel engine.
Page 122 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Access to Coupling Bolts (for removal or installation) Figure 3-2-2 b) Remove Coupling Assembly WARNING To prevent personal injury, keep fingers and hands clear of generator assembly until the armature is block into place to prevent rotation.
Page 123 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Check the shaft for any damage or deformation where the coupling was mounted on it. Check rubber bushing alignment to make sure that the dimension illustrated in Figure 3-2-4 is maintained.
Page 124: Coupling Service
ITW GSE 4400 / 400 Hz. Generator Set 3) Coupling Service When ordering coupling kits from ITW GSE or an authorized distributor, be sure to include all pertinent information from the unit’s identification plate (i.e. Specification No., Model No., and unit rating).
Page 125: Coupling Installation
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set (3) Shake the container of lubricant (supplied with kit) vigorously and pour it into a small shallow dish. (4) Roll a bushing in the lubricant to coat it thoroughly. Press it into a socket (from the chamfered end) to the dimension shown in Figure 3-2-4.
Page 126: Reassemble Engine And Generator
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set (5) Slide the generator armature as far as it will go toward the fan housing. Block the armature to maintain this forward position throughout the installation procedure. Block the armature with a wooden block or wedge, being careful not to damage any components of the armature or exciter.
Page 127: Run-In And Periodic Check
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set CAUTION Remove all armature blocks, otherwise, damage to the armature could result. 6) Run-in and Periodic Check a) Mount the engine-generator assembly in a suitable test area and operate it for a 2-hour run-in.
Page 128 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Figure 3-2-4 Bushing Installation March 15, 2015 Chapter 3-2 Page 8...
Page 129 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Figure 3-2-5 Assembly Procedure Figure 3-2-6 Measure from mounting face to adapter ring. March 15, 2015 Chapter 3-2 Page 9...
Page 130 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Figure 3-2-7 Measuring From Mounting Face To Bushing March 15, 2015 Chapter 3-2 Page 10...
Page 131: Generator Assembly
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Section 3 Generator Assembly 1) General This section provides information and instructions for removal and installation of the generator set. 2) Generator Assembly Removal a) Procedure for Gaining Access to the Generator...
Page 132: Generator Assembly Installation
OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Figure 3-3-1 Generator Lifting Arrangement 3) Generator Assembly Installation Installation of a generator assembly is essentially a reversal of the procedure for removal of the generator assembly: the re-mounting of the generator assembly to the frame of the generator set, and the remounting of the assemblies that were removed to gain access to the generator assembly.
Page 133: Introduction
1) General The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and detail parts of a Diesel Engine-Generator Set manufactured by ITW GSE, Palmetto, Florida. 2) Purpose The purpose of this list is to provide parts identification and descriptive information to maintenance and provisioning...
Page 134 ITWGSE 400 / Model ACE4400 / 400 Hz. Generator Set All part numbers appearing in this column are ITW GSE numbers. In all instances where the part is a purchased item, the vendor’s identifying five-digit code and his part number will appear in the NOMENCLATURE”...
Page 135 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set Section 2 Illustrated Parts List 1) Explanation of Parts List Arrangement The parts list is arranged so that the illustration will appear on a left-hand page and the applicable parts list will appear on the opposite right-hand page.
Page 136 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set ASSEMBLED UNIT LEFT SIDE RIGHT SIDE FRONT 4400_A-1 Figure 4-1. 4400, 60-90kVA, 3-Phase 115 Volt Generator Set (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 2...
Page 137 .Radiator/Exhaust Installation (See Figure 4-7 ) 4-1- 293038 .Electrical System Installation (See Figure 4-9 ) 4-1- 293073 .Cable Tray/Canopy Installation, 4400 (See Figure 4-15 ) Figure 4-1. 4400, 60-90kVA, 3-Phase 115 Volt Generator Set (Sheet 2). March 15, 2015 Chapter 4-2 Page 3...
Page 138 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set TYPICAL OPPOSITE SIDE 293001_B-1 Figure 4-2. Trailer Assembly Common Platform (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 4...
Page 139 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-2- 293001 Trailer Assembly, Common Platform 4-2- 293002 . Base Frame, Common Platform...
Page 140 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293003_-1 Figure 4-3. Running Gear Assembly, 4400 Platform. (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 6...
Page 141 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-3- 293003 Running Gear Assembly, 4400 Platform Rev-01 4-3- 293003-5 …5 Wheel Assembly...
Page 142 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293034XX_A-1 Figure 4-4. Genset/Fuel Tank Installation, 60/90 kVA (Sheet 1 of 3). March 15, 2015 Chapter 4-2 Page 8...
Page 143 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293034XX_A-2 Figure 4-4. Genset/Fuel Tank Installation, 60/90 kVA (Sheet 2). March 15, 2015 Chapter 4-2 Page 9...
Page 144 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-4- 293034-XX Genset/Fuel Tank Installation, 60/90kVA 4-4- 293001 .Trailer Assembly, Common Platform 4-4- 293027-02 .Genset Assembly, 90kVA (See Figure 4-5)
Page 145 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set LEFT SIDE 293027XX_A-2 Figure 4-5. Genset Assembly, 60/90kVA (Sheet 1 of 4). March 15, 2015 Chapter 4-2 Page 11...
Page 146 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set LEFT SIDE 293027XX_A-1 RIGHT SIDE Figure 4-5. Genset Assembly, 60/90kVA (Sheet 2). March 15, 2015 Chapter 4-2 Page 12...
Page 147 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-5- 293027-XX Genset Assembly, 60/90kVA Ref. 4-5- 293061 Engine, Cummins QSB4.5 Tier 3, 90kVA 293126 Engine, Cummins QSB4.5 Tier 3, 60kVA...
Page 148 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-5- *3863948 …Elbow, Male Adapter (Cummins P/N) 4-5- *3864036 …Hose, Flexible (Cummins P/N)
Page 149 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293091_A-1 Figure 4-6. Fuel Tank Composite Assembly, CP (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 15...
Page 150 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-6- 293091 Fuel Tank Assembly Composite, CP 4-6- 293090 .Fuel Tank, Machining, Composite, CP...
Page 151 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293036_A-1 Figure 4-7. Radiator/Exhaust Installation (Sheet 1 of 3). March 15, 2015 Chapter 4-2 Page 17...
Page 152 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293036_A-2 Figure 4-7. Radiator/Exhaust Installation, 4400 (Sheet 2). March 15, 2015 Chapter 4-2 Page 18...
Page 153 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set IGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-7- 293036 Radiator/Exhaust Installation, 4400 Rev-A 4-7- 293023 .Muffler Pipe 4-7- 404154-013 ..Guillotine Clamp, 3” Dia...
Page 154 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293069_A-1 Figure 4-8. Coolpack (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 20...
Page 155 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-8- 293069 Coolpack Rev-A 4-8- 912001205 .JW Slab Assembly 4-8- 911001072 .CA Slab Assembly...
Page 156 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293038_A-1 Figure 4-9. Electrical System Installation, 4400 (Sheet 1 of 3) March 15, 2015 Chapter 4-2 Page 22...
Page 157 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293038_A-2 Figure 4-9. Electrical System Installation, 4400 (Sheet 2) March 15, 2015 Chapter 4-2 Page 23...
Page 158 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. .ITEM NO. PART NO. 4-9- 293038 Electrical System Installation, 4400 Rev-A 4-9- 293039-XX .Output Table Assembly, 4400 (See Figure 4-10)
Page 159 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 29309XX_A-1 Figure 4-10. Output Table Assembly, 4400 (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 25...
Page 160 4-10- 293116 …Finger Guard, Busbar 4-10- *293055 ….Harness, Output Table 4-10- *293058 ….Harness, Options 4-10- *292083 Schematic, Engine Drive, 4400 *Item Not Illustrated Figure 4-10. Output Table Assembly, Single Output, 4400 (Sheet 2). March 15, 2015 Chapter 4-2 Page 26...
Page 161 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 29309XX_A-2 Figure 11. Output Table Assembly, Single Output W/28VDC ARU 4400 (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 27...
Page 162 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-11- 293039-02 Output Table Assembly, Single Output W/28VDC Rev-A ARU, 4400 4-11- 293021 .Output Stand...
Page 163 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 29309XX_A-3 Figure 12. Output Table Assembly, Dual Output, 4400 (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 29...
Page 164 293116 …Finger Guard, Busbar 4-12- *293055 ….Harness, Output Table 4-12- *293058 ….Harness, Options 4-12- *292083 Schematic, Engine Drive, 4400 * Item Not Illustrated Figure 4-12. Output Table Assembly, Dual Output, 4400 (Sheet 2). March 15, 2015 Chapter 4-2 Page 30...
Page 165 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 29309XX_A-4 Figure 4-13. Output Table Assembly, Dual Output W/28VDC ARU, 4400 (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 31...
Page 166 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-13- 293039-04 Output Table Assembly, Dual Output W/28VDC ARU, Rev-A 4400 4-13- 293021 .Output Stand...
Page 167 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293024_A-1 Figure 4-14. Control Module Box Assembly (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 33...
Page 168 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-14- 293024 Control Module Box Assembly Rev-A 4-14- 293025 .Control Box 4-14- 579534 ..Diesel Interface Board...
Page 169 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set ASSEMBLED UNIT TYPICAL OPPOSITE SIDE 293073_A-2 Figure 4-15. Cable Tray/Canopy Installation, 4400 March 15, 2015 Chapter 4-2 Page 35...
Page 170 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293073_A-4 Figure 4-15. Cable Tray/Canopy Installation, 4400 (Sheet 2). March 15, 2015 Chapter 4-2 Page 36...
Page 171 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-15- 293073 Cable Tray/Canopy Installation, 4400 4-15- 293086 ..Cable Tray Assembly, Left Side (See Figure 4-16)
Page 172 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293086_A-1 Figure 4-16. Cable Tray Assembly, Left Side (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 38...
Page 173 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-16- 293086 Cable Tray, Assembly, Left Side Rev-A 4-16- 293085-01 .Cable Tray, Machining, Left Side...
Page 174 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293087_A-1 Figure 4-17. Cable Tray Assembly, Right Side (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 40...
Page 175 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-17- 293087 Cable Tray Assembly, Right Side Rev-B 4-17- 293085-02 .Cable Tray, Machining, Left Side...
Page 176 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293017_A-1 Figure 4-18. Display Controller Assembly, 4400 (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 42...
Page 177 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-18- 293017 Display Controller Assembly, 4400 Rev-A 4-18- 293015 ..Glastic Display Panel 4-18- 579536 ..Display Board...
Page 178 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set 293084_A-1 Figure 4-19. Top Canopy, Composite, Assembly (Sheet 1 of 2). March 15, 2015 Chapter 4-2 Page 44...
Page 179 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set FIGURE - ITW GSE NOMENCLATURE EFF. QTY. ITEM NO. PART NO. 4-19- 286810-001 Top Canopy, Composite, Assembly Rev-A 4-19- 293083 .Top Canopy Composite, Machining...
Page 180 OM-2245 / Operation and Maintenance Manual ITW GSE / Model ACE4400 / 400 Hz Generator Set This page intentionally left blank March 15, 2015 Chapter 4-2 Page 46...
Page 181: Numerical Index 4
OM-2245 / Operation and Maintenance Manual ITWGSE 4400 / Model ACE4400 / 400 Hz. Generator Set Section 3 Numerical Index 1) Explanation of Numerical Index The purpose of this index is to assist the user in finding the illustration and description of a part when the part number is known.
Page 182 OM-2245 / Operation and Maintenance Manual ITWGSE 4400 / Model ACE4400 / 400 Hz. Generator Set FIGURE FIGURE ITW GSE PART NO. ITW GSE PART NO. ITEM NO. ITEM NO. 4-7-13 IN5156 4-12-3 CA11372 4-7-14 IN5156 4-12-5 CY11387 4-8-29 AA6380...
Page 183 OM-2245 / Operation and Maintenance Manual ITWGSE 4400 / Model ACE4400 / 400 Hz. Generator Set FIGURE FIGURE ITW GSE PART NO. ITW GSE PART NO. ITEM NO. ITEM NO. 4-17-3 KH11401 4-4-11 056525 4-17-4 KH11192 4-7-10 056535 4-17-5 H11191...
Page 184 OM-2245 / Operation and Maintenance Manual ITWGSE 4400 / Model ACE4400 / 400 Hz. Generator Set FIGURE FIGURE ITW GSE PART NO. ITW GSE PART NO. ITEM NO. ITEM NO. 4-14-8 288023 4-3-1 293003-5th 4-15-9 288023 4-1-1 293001 4-7-8 288052-002...
Page 185 OM-2245 / Operation and Maintenance Manual ITWGSE 4400 / Model ACE4400 / 400 Hz. Generator Set FIGURE FIGURE ITW GSE PART NO. ITW GSE PART NO. ITEM NO. ITEM NO. 4-19-4 293018 4-5-15 293028 4-19-4 293018 4-5-22 293031 4-19-5 293019...
Page 186 OM-2245 / Operation and Maintenance Manual ITWGSE 4400 / Model ACE4400 / 400 Hz. Generator Set FIGURE FIGURE ITW GSE PART NO. ITW GSE PART NO. ITEM NO. ITEM NO. 4-10-8 293051 4-5-1 293061 4-11-9 293051 4-3-3 293067 4-12-8 293051...
Page 187 OM-2245 / Operation and Maintenance Manual ITWGSE 4400 / Model ACE4400 / 400 Hz. Generator Set FIGURE FIGURE ITW GSE PART NO. ITW GSE PART NO. ITEM NO. ITEM NO. 4-19-1 293083 4-6-5 293108 4-19-1 293083 4-10-14 293116 4-15-12 293084...
Page 188 OM-2245 / Operation and Maintenance Manual ITWGSE 4400 / Model ACE4400 / 400 Hz. Generator Set FIGURE FIGURE ITW GSE PART NO. ITW GSE PART NO. ITEM NO. ITEM NO. 4-5-33 863948 4-5-48 5312158 4-5-39 963983 4-5-49 5318807 4-5-34 3864036...
Page 189 OM-2245 / Operation and Maintenance Manual ITWGSE 4400 / Model ACE4400 / 400 Hz. Generator Set FIGURE ITW GSE PART NO. ITEM NO. 4-8-27 890001063 4-8-28 890001064 4-8-10 896001149 4-8-7 897001225 4-8-8 897001227 4-8-9 899001279 4-8-4 900001321 4-8-5 900001452 4-8-2...
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Page 191 Diagram, Schematic & Connection Contact ITW GSE if copies of these drawings or manuals are not with this manual (unless otherwise noted above). Refer to Appendix A for specific information on the ITW GSE 4400, 400 Hz. Generator Set, optional equipment.
Page 192 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set This page is intentionally left blank. March 15, 2015 Chapter 5-1 Page 2...
Page 193 Appendix A Active Rectifier Unit (ARU) All ITW GSE 4400 units can be equipped with a 28 VDC Active Rectifier Unit (ARU) output. Both 400 Hz & 28 VDC outputs can be used simultaneously. The total continuous amount of power from the unit is calculated as the sum of 400 Hz and 28 VDC output and cannot exceed the total 400 Hz power rating of the unit.
Page 194 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set The 28 VDC part is basically an Active Rectifier Unit and supplied from the 400 Hz part, where the 28 VDC output voltage is controlled regardless of the varying 400 Hz input voltage. The DC output current is calculated very precisely on the basis of the 400 Hz parameters and via the current transformer T20, located in phase A at the main power input.
Page 195 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Connection of Cables Fig. A-2-1 Connection of Cables Recommended output cable to the aircraft is 2 x 4/0 (95 mm²) for continuous loads up to 400 amps (as shown above) and 4 x 4/0 (95 mm²) for higher continuous loads.
Page 196 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set A-3-1 Standard wiring diagram For service, maintenance and test purposes, the interlock system can be by-passed via the display setup. To ensure personnel health and safety, the converter automatically returns into normal mode once it receives a 28 VDC voltage at terminal F2.
Page 197 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Insert the aircraft cable into the aircraft. Make sure the cable is inserted till you feel a natural resistance. The plug may be equipped with a 90% Insertion switch. In this case, the unit will not function if the plug is not fully inserted.
Page 198 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Default Display Screen Standby OUTPUT Phase A: 0.0 V < 20 A 12:55.21 07-07-2014 Phase B: 0.0 V < 20 A 400 Hz I: Phase C: 0.0 V...
Page 199 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set After operation, the unit has to be turned off before removing the aircraft plug. Press the 28 VDC Start/Stop button The aircraft cable can now be removed from the aircraft and placed at the cable rest position.
Page 200 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Setup – ARU additional parameters 11:27:47 Setup Menu 28/06/2013 28 V Voltage Settings: 28.0 V 19.0 – 33.0 V ◄ Back ● Modify 11:27:47 Setup Menu...
Page 201 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
Page 202 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set A.11 Specifications Output: Voltage : 28 VDC Current : 400 A / 600 A continuously Voltage regulation : < 0.5% Voltage ripple : < 2% Voltage transient recovery...
Page 203 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set A20: ARU Board PM20: Rectifier Output terminals (- Figure A13-1 Front View (ARU) 6 x ARU Transformer Figure A13-2 Rear View (ARU) March 15, 2015 Appendix A...
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Page 205 Appendix B Options The following is a list of options available for the ITW GSE 4400, 400 Hz. Generator Set. This chart contains the description and part number of the option. The description of each option follows on the pages below.
Page 206 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 293143 DIN40 Tow bar This option replaces the standard towbar with a 40mm diameter eye version. 293098 Kit, Clearance Lights This option adds a blue clearance light to the four top corners of the canopy.
Page 207 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Appendix C Wet Stacking in Generator Set Diesel Engines 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.
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Page 209 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set Appendix D 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.
Page 210 OM-2245 / Operation and Maintenance Manual ITW GSE 4400 / 400 Hz. Generator Set 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.
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ITW GSE 4400 Manual

Chapter 1 Description/Operation

Description

Preparation for Use, Storage or Shipping

Operation

Chapter 2 Servicing / Troubleshooting

Maintenance Inspection/Check

Maintenance Procedures

Adjustments / Tests

Troubleshooting Procedures

Troubleshooting Charts

Chapter 3 Overhaul / Major Repair

Dual Bearing Flexible Coupling

Generator Assembly

Chapter 4 Illustrated Parts List

Introduction

Quick Links

Troubleshooting

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Summary of Contents for ITW GSE 4400

Table of Contents