ITW GSE 4400 Tier 4 Manual
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ITW GSE 4400 Tier 4 Manual

400 hz generator set ground power unit
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400 Hz Generator Set Ground Power Unit
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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
Manual
4400 Tier 4
ACE4400 60 – 90 kVA Tier 4
OM2247

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Summary of Contents for ITW GSE 4400 Tier 4

  • Page 1 ACE4400 60 – 90 kVA Tier 4 Type: OM2247 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...
  • Page 2 Operation Manual - ITW GSE 4400 Tier 4 IMPORTANT NOTICE We recommend that the battery that safeguards GPU settings etc. is changed after 5 years of use in order not to lose data. Diagrams and drawings are subject to change without prior notice.
  • Page 3 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.
  • Page 4 Operation Manual – ITW GSE 4400 Tier 4 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. DO NOT use power cables to break load. Prevent tools from causing short circuits.
  • Page 5 Operation Manual – ITW GSE 4400 Tier 4 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 6 Operation Manual – ITW GSE 4400 Tier 4 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.

  • Page 7: Table Of Contents

    Operation Manual – ITW GSE 4400 Tier 4 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 and B 1-1/10 3) Component Locations 1-1/11 Figure 1-1-1: General Assembly of Generator Set...
  • Page 8 Operation Manual – ITW GSE 4400 Tier 4 Chapter 2 Servicing / Troubleshooting Chapter-Section/Page# Maintenance Inspection/Check 2-1/56 1) General 2-1/56 2) Maintenance Schedule 2-1/56 Figure 2-1-1 Maintenance Schedule Check Sheet 2-1/57 3) Inspection / Checks 2-1/59 a) General 2-1/59 b) “AR” Checks and Operations (As Required) 2-1/59 c) “BR”...
  • Page 9 Operation Manual – ITW GSE 4400 Tier 4 Chapter 2 Servicing / Troubleshooting Chapter-Section/Page# 5) Engine Fuel System 2-2/74 a) Fuel Tank 2-2/74 b) Fuel Water Separator or Lubricity 2-2/74 Additi Filt Figure 2-2-5 Lubricity Filter 2-2/74 c) Primary Fuel Filter...
  • Page 10 Operation Manual – ITW GSE 4400 Tier 4 Chapter 2 Servicing / Troubleshooting Chapter-Section/Page# Section 4 Troubleshooting Procedures 2-4/90 1) General 2-4/90 2) Equipment for Troubleshooting 2-4/90 3) Parts Replacement 2-4/90 4) Normal Operational Parameters 2-4/90 5) Check Connections and Leads...

  • Page 11: Description

    Description 1) General The basic generator sets covered in this manual, manufactured by ITW GSE, are rated at 60kVA and 90kVA 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) option also provide 28.5 volts DC for aircraft having those requirements.

  • Page 12: Component Locations

    Operation Manual - ITW GSE 4400 Tier 4 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 13 Operation Manual - ITW GSE 4400 Tier 4 1. Cummins QSB4.5 T4 Engine 6. Generator 2. Control Module Assembly 7. 28.5 VDC ARU (Option) 8. Engine Alternator 3. Batteries (inside tray pockets) 4. Battery Disconnect 9. Output Contactors 5. N/A...
  • Page 14 Operation Manual - ITW GSE 4400 Tier 4 6. Engine Dip Stick 1. Coolant Fill Access Cover 7. Air Intake Tube 2. Lubricity Additive Fuel Pre-Filter 8. Engine Air Filter 3. Fuel Filter 9. Tow Bar/Brake Release Lever 4. Engine Oil Filter 10.
  • Page 15 Operation Manual - ITW GSE 4400 Tier 4 1. Oil Drain Valve 2. Tie Down Rings (Option) DOC Diesel Oxidation Catalyst 4. SRC Selective Catalytic Reduction DEF Fluid Holding Tank 6. DEF Dosing Module Figure 1-1-4: Main Components of Generator Set (Bottom)

  • Page 16: Specifications

    Operation Manual - ITW GSE 4400 Tier 4 4) Specifications a) Standards These units have been designed to be in compliance with the following standards: US EPA Tier 4/CARB Tier 4 EU Stage IV US MIL-STD-704F, SAE ARP5015 b) Physical Specifications Length 112.1 in.
  • Page 17 Operation Manual - ITW GSE 4400 Tier 4 d) AC Protective System Specifications Condition Trip Point Time Delay Over Voltage 130 volts 250 milliseconds 140 volts 15 milliseconds Under Voltage Any voltage below 104 volts 500 milliseconds Over Frequency 380 Hz to 420 Hz...

  • Page 18: Special Features

    Operation Manual - ITW GSE 4400 Tier 4 g) Engine Specifications Manufacturer and Model Cummins Engine Company / QSB4.5 Type 4 cylinder, 4 cycle diesel, electronic controlled Bore and Stroke 4.21 in. x 4.88 in. (107 mm x 124 mm)

  • Page 19: Canopy

    Operation Manual - ITW GSE 4400 Tier 4 e) Exhaust System The generator set is equipped with an Airless Selective Catalytic Reduction (SCR) system. The SCR system is used to decrease the mono-nitrogen oxides (NOx) emissions from the engines exhaust pipe. The system is composed of several main components: 1.

  • Page 20: Engine And Generator

    Operation Manual - ITW GSE 4400 Tier 4 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.
  • Page 21 Operation Manual - ITW GSE 4400 Tier 4 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.
  • Page 22 Operation Manual - ITW GSE 4400 Tier 4 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.

  • Page 23: Power Module Assembly

    Operation Manual - ITW GSE 4400 Tier 4 8) Power Module Assembly The Power Module Assembly is mounted on the ARU table located to 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 24: Operator Controls

    Operation Manual - ITW GSE 4400 Tier 4 9) Operator Controls The control box is a protected enclosure on the right front panel of the GPU with 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.
  • Page 25 Operation Manual - ITW GSE 4400 Tier 4 b) Operator Controls – Operator Panel 1. LED Graphical Display 5. Alert/Failure "Red" LED 2. Navigation Keypad 6. Output ON "Green" LEDs 3. Power ON "Blue" LED 7. Output ON/OFF (Reset) 4. Warning "Amber" LED 8.
  • Page 26 Operation Manual - ITW GSE 4400 Tier 4 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.
  • Page 27 Operation Manual - ITW GSE 4400 Tier 4 OM2247 Rev B Page 26 of 125...

  • Page 28: Cold Weather Starting System

    Operation Manual - ITW GSE 4400 Tier 4 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 29 Operation Manual ITW GSE 4400 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.
  • Page 30 Operation Manual ITW GSE 4400 Tier 4 10) 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.
  • Page 31 Operation Manual ITW GSE 4400 Tier 4 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. Output cables connect to the load contactors, which are located at rear of unit. (See Figure 1-2-3) The conductor size recommended for AC output cables is 2/0 AWG.
  • Page 32 Operation Manual ITW GSE 4400 Tier 4 c) Installing DC Output Cable (optional) 1) Remove canopy. (While not necessary, it greatly simplifies the process.) 2) For normal aircraft service, use cable assembly JB2840-30 (which meets Mil-C-7974D Assembly Specification) with 30 feet of AWG 4/0 cables having a positive and negative connection.
  • Page 33 Operation Manual ITW GSE 4400 Tier 4 b) Temporary Storage (30 days or less) 1) Lubricate unit completely in accordance with instructions in Chapter 2-2. 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.

  • Page 34: General

    Operation Manual – ITW GSE 4400 Tier 4 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 400-Hz or 28.5 VDC power.
  • Page 35 Operation Manual – ITW GSE 4400 Tier 4 1. LED Graphical Display 5. Alert/Failure "Red" LED 2. Navigation Keypad 6. Output ON "Green" LEDs 3. Power ON "Blue" LED 7. Output ON/OFF (Reset) * 4. Warning "Amber" LED 8. Power ON & Engine Start/Stop (Reset) * * All output and engine buttons are multitasking buttons dependent on the status of the unit.
  • Page 36 Operation Manual – ITW GSE 4400 Tier 4 d) Power Delivery After the engine has started and the display has changed to the output status default screen, any output ON/OFF buttons can be pressed. If the unit is already at rated speed, the contactor will immediately close.
  • Page 37 Operation Manual – ITW GSE 4400 Tier 4 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.
  • Page 38 Operation Manual – ITW GSE 4400 Tier 4 Battery Disconnect Switch If the unit is not going to be used for a long period of time, open the battery disconnect switch to remove 24 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.

  • Page 39: Icon Menu

    Operation Manual – ITW GSE 4400 Tier 4 4) 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. (If the Icon menu doesn’t appear after 5 seconds, see paragraph 4.23 below to unlock access to the Icon menu.)

  • Page 40: A) View Parameters Menu

    Operation Manual – ITW GSE 4400 Tier 4 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.

  • Page 41: B) Setup Menu

    Operation Manual – ITW GSE 4400 Tier 4 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.
  • Page 42 Operation Manual – ITW GSE 4400 Tier 4 OM2247 Rev B Page 41 of 125...
  • Page 43 Operation Manual – ITW GSE 4400 Tier 4 11:27:47 Setup Menu 28/06/2013 Settings in additional sub-menu: Real Time Clock Setup Month , Day, Year, Hour, Minute, Second Refer to Section 3 – 4.13 ◄ Back ● Modify 11:27:47 Setup Menu...
  • Page 44 Operation Manual – ITW GSE 4400 Tier 4 OM2247 Rev B Page 43 of 125...
  • Page 45 Operation Manual – ITW GSE 4400 Tier 4 11:27:47 Setup Menu 28/06/2013 Settings: Tier IV Regeneration Enabled Enabled Disabled Do it now Refer to Section 3 – 4.25 ◄ Back ● Modify 11:27:47 Setup Menu 28/06/2013 Settings: Language English, French, German, English Italian, Polish, Portuguese, etc.
  • Page 46 Operation Manual – ITW GSE 4400 Tier 4 1) 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 47 Operation Manual – ITW GSE 4400 Tier 4 c) Go into the Setup Menu and then scroll up or down to the EF Interlock submenu. Press the center ● button to enter the submenu, and then press the ● button again to allow the value to be changed.
  • Page 48 Operation Manual – ITW GSE 4400 Tier 4 ● button to record the new value. Press the LEFT arrow button to exit the submenu and return to the submenu list. 10) Cable Temperature a) Some aircraft cables have temperature sensors installed in the connector body and/or replaceable nose.
  • Page 49 Operation Manual – ITW GSE 4400 Tier 4 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.
  • Page 50 Operation Manual – ITW GSE 4400 Tier 4 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.
  • Page 51 Operation Manual – ITW GSE 4400 Tier 4 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.

  • Page 52: C) Black Box

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

  • Page 53: D) Power Log

    Operation Manual – ITW GSE 4400 Tier 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 Power Log icon.

  • Page 54: E) Update/Save Log Menu

    Operation Manual – ITW GSE 4400 Tier 4 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.
  • Page 55 Operation Manual – ITW GSE 4400 Tier 4 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 10:30:00 USB MENU...
  • Page 56 Operation Manual – ITW GSE 4400 Tier 4 OM2247 Rev B Page 55 of 125...

  • Page 57: Maintenance Inspection/Check

    Operation Manual – ITW GSE 4400 Tier 4 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 58 Operation Manual – ITW GSE 4400 Tier 4 Hourly Interval 50-150 1000 2000 4500 5000 Calendar Interval Once Daily 3 Mo. 6 Mo. 1 Yr. 2 Yr. 3 Yr. 4 Yr. Symbol Engine Change Air Cleaner Cartridge Check Coolant Hose and Clamps...
  • Page 59 Operation Manual – ITW GSE 4400 Tier 4 Hourly Interval 50-150 1000 2000 4500 5000 Calendar Interval Once Daily 3 Mo. 6 Mo. 1 Yr. 2 Yr. 3 Yr. 4 Yr. Symbol Engine (continued) Steam Clean Engine Check Crankcase Breather (External)

  • Page 60: Inspection/Checks

    Operation Manual – ITW GSE 4400 Tier 4 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 Replace the air filter when the “Air Filter Clogged”...

  • Page 61: D) "A" Checks And Operations (10 Hours Or Daily)

    Operation Manual – ITW GSE 4400 Tier 4 d) “A” Checks and Operations (10 Hours or Daily). 1) Engine. a) Check DEF tank level Check DEF tank level gauge and add enough DEF to bring the tank back to full.
  • Page 62 Operation Manual – ITW GSE 4400 Tier 4 Water Drain Valve Figure 2-1-2 Fuel Lubricity Drain e) Check Coolant Level Check coolant level daily or at each fuel fill interval. Investigate for cause of any coolant loss. WARNING Cooling system is pressurized. To avoid personal injury, DO NOT remove radiator cap when engine is hot.
  • Page 63 Operation Manual – ITW GSE 4400 Tier 4 Electrical System (24 VDC) a) Check All Lights. Check all indicating lights to be sure they operate when they should. If any light fails to operate, check the indicator and insure proper power is being given. If power is present and the light does not activate, replace the light fixture.

  • Page 64: F) "C" Checks And Operations (500 Hours Or 6 Month)

    Operation Manual – ITW GSE 4400 Tier 4 d) 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.

  • Page 65: G) "D" Checks And Operations (1000 Hours Or 1 Year)

    Operation Manual – ITW GSE 4400 Tier 4 3) Electrical (400 Hz 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.

  • Page 66: H) "E" Checks And Operations (2000 Hours Or 2 Year)

    Operation Manual – ITW GSE 4400 Tier 4 h) “E” Checks and Operations (2000 Hours or 2 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.

  • Page 67: I) "F" Checks And Operations (4500 Hours Or 3 Year)

    Operation Manual – ITW GSE 4400 Tier 4 “F” Checks and Operations (4500 Hours or 3 Years). 1) Engine After treatment Change the DEF Dosing Unit filter using Cummins procedure 102-002. “G” Checks and Operations (Over 5000 Hours or 4 Years).

  • Page 68: Maintenance Procedures

    Operation Manual – ITW GSE 4400 Tier 4 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 69: Lubrication

    Operation Manual – ITW GSE 4400 Tier 4 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.

  • Page 70: D) Changing Engine Oil

    Operation Manual – ITW GSE 4400 Tier 4 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 actual engine operating time.
  • Page 71 Operation Manual – ITW GSE 4400 Tier 4 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). 2) The oil drain tube can be found by the muffler at the front of the unit.

  • Page 72: E) Engine Accessories Lubrication

    Operation Manual – ITW GSE 4400 Tier 4 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...

  • Page 73: Servicing The Air Cleaner

    Operation Manual – ITW GSE 4400 Tier 4 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 74: C) Disposal

    Operation Manual – ITW GSE 4400 Tier 4 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.

  • Page 75: Engine Fuel System

    Operation Manual – ITW GSE 4400 Tier 4 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 76: C) Primary Fuel Filter

    Operation Manual – ITW GSE 4400 Tier 4 2) To change the lubricity filter: CAUTION 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.

  • Page 77: D) Fuel Pump

    Operation Manual – ITW GSE 4400 Tier 4 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.

  • Page 78: G) Draining The Fuel Tank

    Operation Manual – ITW GSE 4400 Tier 4 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.

  • Page 79: Engine Cooling System

    Operation Manual – ITW GSE 4400 Tier 4 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 80: D) Draining The Cooling System

    Operation Manual – ITW GSE 4400 Tier 4 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 81: F) Cleaning The Radiator Core

    Operation Manual – ITW GSE 4400 Tier 4 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 82: Engine Drive Belt

    Operation Manual – ITW GSE 4400 Tier 4 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.

  • Page 83: Replacing The Control Board Battery

    Operation Manual – ITW GSE 4400 Tier 4 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.
  • Page 84 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.

  • Page 85: Adjustments / Tests

    Operation Manual – ITW GSE 4400 Tier 4 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. IMPORTANT To perform most of the following tests, a load bank with an EF interlock circuit is required.

  • Page 86: C) 400Hz Initial Testing And Setup

    Operation Manual – ITW GSE 4400 Tier 4 400Hz Initial Testing and Setup: 1) Connect Output cable(s) to the appropriate load bank(s) with interlock enabled (as required) 2) Press engine button to start engine. Engine should go straight to rated speed.

  • Page 87: G) Re-Checking The Entire Unit After Testing

    Operation Manual – ITW GSE 4400 Tier 4 g) Re-checking the entire unit after testing: 1) Start the engine. With the engine running at normal rated speed, check the entire unit for vibration and for any parts that may have become loosened during the above checks.

  • Page 88: Generator And Exciter Test

    Operation Manual – ITW GSE 4400 Tier 4 b) Basic Engine Adjustments Adjustment procedures applicable to the diesel engine are included in the engine manufacturer’s operation manual, which is referenced in Chapter 5. Refer to the engine operation manual for detailed information on the following engine adjustments.

  • Page 89: Diode Test

    Operation Manual – ITW GSE 4400 Tier 4 Interface Board Figure 2-3-2: Generator Connections 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 90 Operation Manual – ITW GSE 4400 Tier 4 b) Operational Test Procedure 1) Power Delivery a) Press “28 VDC” pushbutton to close the DC output contactor. The green “DC OUTPUT” LED will glow indicating that DC power is being delivered to the load bank.

  • Page 91: Troubleshooting Procedures

    Operation Manual – ITW GSE 4400 Tier 4 Section 4 Troubleshooting Procedures 1) General The Troubleshooting Chart located in this section covers the common faults and malfunctions that can be found during operation or maintenance of this equipment. The chart may not list all faults and malfunctions that can occur.

  • Page 92: Check Connections And Leads

    Operation Manual – ITW GSE 4400 Tier 4 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 has not been lost as a result of defective wiring or connections.

  • Page 93: Cummins Engine Fault Codes

    Operation Manual – ITW GSE 4400 Tier 4 b) Faults 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.
  • Page 94 Operation Manual – ITW GSE 4400 Tier 4 10.0 Troubleshooting Chart Error 1st Corrective 2nd Corrective 3rd Corrective 4th Corrective Error Text in display Description Code Action Action Action 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 95 Operation Manual – ITW GSE 4400 Tier 4 Error 1st Corrective 2nd Corrective 3rd Corrective 4th Corrective Error Text in display Description Code Action Action Action Action Current was Remove overload OVERLOAD: 125% < between 125% Press Output Replace Control...
  • Page 96 Operation Manual – ITW GSE 4400 Tier 4 Error 1st Corrective 2nd Corrective 3rd Corrective 4th Corrective Error Text in display Description Code Action Action Action Action 90% Signal Is output cable 90% SIGNAL DROP Press ARU Check / correct...
  • Page 97 Operation Manual – ITW GSE 4400 Tier 4 Error 1st Corrective 2nd Corrective 3rd Corrective 4th Corrective Error Text in display Description Code Action Action Action Action For faults in this section: Disconnect from aircraft. Shut down engine after cooldown.

  • Page 98: Engine Controls

    Operation Manual – ITW GSE 4400 Tier 4 Engine Controls Trouble, Symptom, Probable Cause Test, Check, and/or Remedy Condition  Make sure the Emergency Stop switch is pulled out 1. The engine will not a. Emergency Stop start, and the and switch has been pressed.
  • Page 99 Operation Manual – ITW GSE 4400 Tier 4 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. Cranking b. Loose starting circuit Check all connections and cables.
  • Page 100 Operation Manual – ITW GSE 4400 Tier 4 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. from rated speed to PC1 board could be Replace PC1 Interface board.

  • Page 101: Generator Excitation Circuits

    Operation Manual – ITW GSE 4400 Tier 4 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 102: Generator

    Operation Manual – ITW GSE 4400 Tier 4 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). 2-3 Section 4 and 5. If diodes are good, proceed to step b.

  • Page 103: Load Contactor Operating Circuits

    Operation Manual – ITW GSE 4400 Tier 4 Load Contactor Operating Circuits Output 1: Contactor K1 Output 2: Contactor K2 Trouble, Symptom, Condition Probable Cause Test, Check, and/or Remedy 1. Load contactor will not close a. Blown contactor fuse (F3) on Check the fuse and replace if blown.

  • Page 104: Protective Circuit

    Operation Manual – ITW GSE 4400 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 shooting protective circuits.

  • Page 105: Vendor Literature

    Diagram, Schematic & Connection Contact ITW GSE if copies of these drawings or manuals are not delivered with the unit (unless otherwise noted above). Refer to Appendix B for specific information on the ITW GSE 4400, 400 Hz. Generator Set, optional equipment.
  • Page 106 Operation Manual – ITW GSE 4400 Tier 4 This page is intentionally left blank. OM2247 Rev B Page 105 of 125...

  • Page 107: Appendix A - Active Rectifier Unit

    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 108 Operation Manual – ITW GSE 4400 Tier 4 ARU Transformers (T20): The ARU transformers steps down the 3 phased 400 Hz voltage (3 x 200 Vac) to an appropriate level for obtaining 28 VDC at the output. ARU Rectifier (PM20): The output voltage is kept at 28 VDC by using thyristors, regardless of the input voltage level and the load.
  • Page 109 Operation Manual – ITW GSE 4400 Tier 4 Safety Interlock To ensure personnel health and safety, the converter is equipped with an interlock system. * The system ensures that the output only stays engaged while the plug is inserted into the aircraft receptacle. (28 VDC must be present at terminal strip TB3 lug 5.)
  • Page 110 Operation Manual – ITW GSE 4400 Tier 4 Press “Left arrow” to decrease current Press “Right arrow” to increase limit. current limit.  Insert the aircraft cable into the aircraft. Make sure the cable is inserted till you feel a natural resistance.
  • Page 111 Operation Manual – ITW GSE 4400 Tier 4 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 < 20 A Ready For Use Average: 0.0 V...
  • Page 112 Operation Manual – ITW GSE 4400 Tier 4 Additional menu items for ARU OM2247 Rev B Page 111 of 125...
  • Page 113 Operation Manual – ITW GSE 4400 Tier 4 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 28/06/2013 11:27:47 Setup Menu 28/06/2013 28 V Voltage...
  • Page 114 Operation Manual – ITW GSE 4400 Tier 4 0.0 and 3.0 VDC at the rated continuous load of the unit. Note that the maximum output voltage of the unit is 33 VDC. Enter the Setup Menu and then scroll up or down to the 28V Compensation submenu. Press the center ●...
  • Page 115 Operation Manual – ITW GSE 4400 Tier 4 A20: ARU Board PM20: Rectifier Output terminals (- & +) Figure A13-1 Front View (ARU) 6 x ARU Transformer Figure A13-2 Rear View (ARU) OM2247 Rev B Page 114 of 125...

  • Page 116: Appendix B - Options 3

    Operation Manual – ITW GSE 4400 Tier 4 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 117 Operation Manual – ITW GSE 4400 Tier 4 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.

  • Page 118: Appendix C - Operating In Unusual Service Conditions 3

    Operation Manual – ITW GSE 4400 Tier 4 Appendix C 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 119: Appendix D - Initial Software Installation Procedure 3

    Appendix D Initial Software Installation Procedure Introduction: The ITW GSE 4400 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.
  • Page 120 Operation Manual – ITW GSE 4400 Tier 4     RRRPossible issues that may be encountered during this procedure:  Error 201 ”CRITICAL”: Memory Error. Call Technician”. This is caused by the Control Board being unable to read the GPU configuration from the EEprom Board (P/N 579.533).
  • Page 121 Operation Manual – ITW GSE 4400 Tier 4     4. Set File system to FAT32 and make sure that Quick Format is NOT clicked. Press start. (The USB should function without issue after the format is complete. This may take several minutes to complete on larger drives.
  • Page 122 This formula can be downloaded from www.itwgse.com Forward to Sender: ITW GSE 4400 Information Americas: ITW GSE Americas Company: Model:  + 1 941 721 1092  Fax: Serial No.: support@itwgse.us Phone: Error Code: International: ITW GSE ApS Date:    ...
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