ITW GSE 6400 JetEx Tier 3 Manual
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ITW GSE 6400 JetEx Tier 3 Manual

28.5 vdc generator set ground power unit
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28.5 VDC Generator Set Ground Power Unit
Specification.:
Type:
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
6400 Tier 3
DCE6400 28.5 VDC Tier 3
OM2254

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Summary of Contents for ITW GSE 6400 JetEx Tier 3

  • Page 1 Specification.: DCE6400 28.5 VDC Tier 3 Type: OM2254 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 6400 Tier 3 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 6400 Tier 3 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 6400 Tier 3 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 6400 Tier 3 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 6400 Tier 3 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 6400 Tier 3 Chapter 2 Servicing / Troubleshooting Chapter-Section/Page# Maintenance Inspection/Check 2-1/55 1) General 2-1/55 2) Maintenance Schedule 2-1/55 Figure 2-1-1 Maintenance Schedule Check Sheet 2-1/56 3) Inspection / Checks 2-1/58 a) General 2-1/58 b) “AR” Checks and Operations (As Required) 2-1/58 c) “BR”...
  • Page 9 Operation Manual – ITW GSE 6400 Tier 3 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 Additive Filter 2-2/74 Figure 2-2-5 Lubricity Filter 2-2/74 c) Primary Fuel Filter...
  • Page 10 Operation Manual – ITW GSE 6400 Tier 3 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

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

  • Page 12: Component Locations

    Operation Manual - ITW GSE 6400 Tier 3 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 6400 Tier 3 1. Cummins QSB4.8-5 Engine 4. Battery Disconnect 2. Control Module Assembly 5. Coolant fill access cover 3. Battery (inside tray pocket) 6. Output Cable Connection Figure 1-1-2: Main Components of Generator Set (Right Side)
  • Page 14 Operation Manual - ITW GSE 6400 Tier 3 Generator 1. Lubricity Additive Fuel Pre-Filter 6. Air Filter Assembly 2. Engine Oil Filter 7. Engine ECM Module 3. Fuel Filter 8. Tie Down Rings Location (Option) Engine Oil Fill Tube Figure 1-1-3: Main Components of Generator Set (Left Side)
  • Page 15 Operation Manual - ITW GSE 6400 Tier 3 1. Oil Drain Valve 2. Muffler Assembly 3. Fifth Wheel Figure 1-1-4: Main Components of Generator Set (Bottom) 1. Oil Drain Valve 2. Muffler Assembly 3. Fifth Wheel Figure 1-1-4: Main Components of Generator Set (Bottom)

  • Page 16: Specifications

    Operation Manual - ITW GSE 6400 Tier 3 4) Specifications a) Standards This unit has been designed to be in compliance with the following standards: US EPA Tier 3/CARB Tier 3 EU Stage IIIA US MIL-STD-704F, SAE ARP5015 b) Physical Specifications...

  • Page 17: Special Features

    Operation Manual - ITW GSE 6400 Tier 3 Engine Specifications Manufacturer Cummins, Inc. Model No. QSB4.5 4 cylinder, 4 cycle diesel with turbocharger Type and fuel injection Bore and Stroke 4.2 in x 4.88 in (107 mm x 124 mm)

  • Page 18: Canopy

    Operation Manual - ITW GSE 6400 Tier 3 6) Canopy A composite enclosure, identified as a canopy, provides protection for the engine, generator and electrical controls. The canopy is also designed to reduce the operational noise level in the immediate area of the machine. The canopy is equipped with a bolted latch on the back left corner, which will require the use of a wrench to remove the canopy.
  • Page 19 Operation Manual - ITW GSE 6400 Tier 3 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 20 Operation Manual - ITW GSE 6400 Tier 3 d) Warnings/Faults The control system reacts appropriately to different detected issues. These types can be generalized between warnings and faults. Warnings are given when the system is able to function but requires servicing/user interaction. Faults are generated when the unit cannot or should not supply regulated power to the aircraft.
  • Page 21 Operation Manual - ITW GSE 6400 Tier 3 8) Operator Controls The control box is a protected enclosure on the right front panel of the GPU that has a modern graphical display and easy to understand controls. The display allows the user to easily have access to all critical operational information as well as providing textual descriptions of all warnings and failures.
  • Page 22 Operation Manual - ITW GSE 6400 Tier 3 1) LED Graphical Display 5) Alert/Failure "Red" LED 2) Navigation Keypad 6) Output ON "Green" LEDs 3) Power ON "Blue" LED 7) Current Limit Increase/Decrease 4) Warning "Amber" LED 8) Power ON & Engine Start/Stop (Reset)
  • Page 23 Operation Manual - ITW GSE 6400 Tier 3 8: The power ON & Engine Start/Stop button will wake the unit from low-power sleep mode. Pressing it again will begin the start-up sequence for the diesel engine. Pressing it again will shut down the engine.
  • Page 24 Operation Manual - ITW GSE 6400 Tier 3 When output power is being provided, the screen will appear as follows: 29.5 V: 560 A 28 VDC Output Activated 1500 The selected current limit is changed by using the up and down arrow keys that are located just below the navigation buttons.
  • Page 25 Operation Manual - ITW GSE 6400 Tier 3 Parameters – Menu structure ENGINE Status: Running RPM: 2000 Oil Pressure: 54 psi Temperature: 180 °F ◄ Back ▼/▲ Next/Prev UNIT INFORMATION Highlight the by using the navigation ◄▼▲► keys. Display FW:...

  • Page 26: Power Module Assembly

    Operation Manual - ITW GSE 6400 Tier 3 9) Power Module Assembly The power module assembly is mounted under the output table which is located at the rear of the machine over the generator. The assembly consists of the rectifier, a current transformer and an output contactor.
  • Page 27 Operation Manual ITW GSE 6400 Tier 3 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 28 Operation Manual ITW GSE 6400 Tier 3 9) Check engine lubricating oil level. The oil gauge rod has “H” high-level and “L” low-level marks to indicate operating lubrication oil supply. Oil level should be kept as near the high mark as possible, without going over. See Figure 1-2-1 for capacity.

  • Page 29: Preparation For Storage

    Operation Manual ITW GSE 6400 Tier 3 1) Preparation for Storage A generator set in storage or removed from operation, has special precautions that should be taken to protect internal and external parts from rust, corrosion, and gumming in the engine fuel system.

  • Page 30: Preparation For Shipment

    Operation Manual ITW GSE 6400 Tier 3 ENSURE adequate ventilation before starting the engine WARNING 2) Start engine and operate under full load (using a resistive load bank or aircraft) until coolant temperature has reached a minimum 176ºF (80ºC). 3) While engine is running, ensure normal operating controls are in good working condition before shutdown and storage.

  • Page 31: General

    Operation Manual – ITW GSE 6400 Tier 3 Section 3 Operation 1) General This section contains information and instructions for safe and efficient operation of the equipment. Operating instructions are presented in systematic sequence of procedures to be followed in supplying 28.5 VDC power.
  • Page 32 Operation Manual – ITW GSE 6400 Tier 3 1. LED Graphical Display 5. Alert/Failure "Red" LED 2. Navigation Keypad 6. Current Limit Adjustment buttons 3. Power ON "Blue" LED 7. Output ON "Green" LEDs 4. Warning "Amber" LED 8. Output ON/OFF (Reset) * 9.
  • Page 33 Operation Manual – ITW GSE 6400 Tier 3 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 34 Operation Manual – ITW GSE 6400 Tier 3 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 35 Operation Manual – ITW GSE 6400 Tier 3 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 36 Operation Manual – ITW GSE 6400 Tier 3 With the engine running and DC With the engine running and DC power OFF, press the “Up arrow” power OFF, press the “Down to increase the DC current limit. arrow” to decrease the DC current limit.
  • Page 37 Operation Manual – ITW GSE 6400 Tier 3 d) During operation, various parameters can be viewed via the display. Use the navigation keys ▼▲ to browse through the available screens: e) Turn off the unit by pressing the 28VDC Start/Stop button. The engine will slow down to 1000 rpm and the display will show the amount of time left in the engine cool down period.

  • Page 38: Icon Menu

    Operation Manual – ITW GSE 6400 Tier 3 3) 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 39: A) View Parameters Menu

    Operation Manual – ITW GSE 6400 Tier 3 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 40: B) Setup Menu

    Operation Manual – ITW GSE 6400 Tier 3 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 41 Operation Manual – ITW GSE 6400 Tier 3 Setup (continued) – Menu structure Setup Menu 11:27:47 28/06/2013 Settings: Cable Temperature Normally Open Normally Open Normally Closed Refer to Section 3 – 4.7 ◄ Back ● Modify Setup Menu Setup Menu...
  • Page 42 Operation Manual – ITW GSE 6400 Tier 3 Setup (continued) – Menu structure Setup Menu 11:27:47 28/06/2013 Settings: Modbus Slave Address 1 – 247 Refer to Section 3 – 4.13 ◄ Back ● Modify Setup Menu 11:27:47 28/06/2013 Settings: LED Brightness...
  • Page 43 Operation Manual – ITW GSE 6400 Tier 3 OM2254 Rev A Page 42 of 103...
  • Page 44 Operation Manual – ITW GSE 6400 Tier 3 1) 28V Voltage This Setup submenu allows the 28-volt output voltage 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 45 Operation Manual – ITW GSE 6400 Tier 3 5) 28V Interlock Delay a) The default value is 3.5 seconds. For safety, it is recommended to remain at this value or less. b) Go into the Setup Menu and then scroll up or down to the EF Interlock Delay submenu. Press the center ●...
  • Page 46 Operation Manual – ITW GSE 6400 Tier 3 10) Real Time Clock Setup a) This set of sub-menu s allows the user to adjust the internal clock to the correct local time. b) Go into the Setup Menu and then scroll up or down to the Real-Time Clock Setup submenu. Press the center ●...
  • Page 47 Operation Manual – ITW GSE 6400 Tier 3 record the new value. Press the LEFT arrow button to exit the submenu and return to the submenu list. c) Enter the Setup Menu and then scroll up or down to the 28V Compensation submenu. Press the center ●...
  • Page 48 Operation Manual – ITW GSE 6400 Tier 3 Fig. 8.2.1 To allow the user/operator to use the converter, it is possible to postpone the battery change, by pressing the ◄ (left arrow) push button. The warning message occurs 90 seconds after the unit is powered on or the output contactor(s) are opened (the unit is in Standby Mode).

  • Page 49: C) Black Box

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

  • Page 50: D) Power Log

    Operation Manual – ITW GSE 6400 Tier 3 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 51: E) Update/Save Log Menu

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

  • Page 54: Maintenance Inspection/Check

    Operation Manual – ITW GSE 6400 Tier 3 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 55 Operation Manual – ITW GSE 6400 Tier 3 WARNNGHourly 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 Check Coolant Hose and Clamps Check Crankcase Oil Level...
  • Page 56 Operation Manual – ITW GSE 6400 Tier 3 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 Drain & Inspect Fuel Tank Check Fan Mounting Spring &...

  • Page 57: Inspection/Checks

    Operation Manual – ITW GSE 6400 Tier 3 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 58: D) "A" Checks And Operations (10 Hours Or Daily)

    Operation Manual – ITW GSE 6400 Tier 3 d) “A” Checks and Operations (10 Hours or Daily). 1) Engine. a) 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 59 Operation Manual – ITW GSE 6400 Tier 3 Water Drain Figure 2-1-2 Fuel Lubricity Drain e) Check Fault Code Meter. At each daily start-up, observe the fault screen on the display of the control panel. If the display shows “AIR FILTER CLOGGED”, change the air filter. See Chapter 2-4 for other fault codes.

  • Page 60: E) "B" Checks And Operations

    Operation Manual – ITW GSE 6400 Tier 3 Electrical (28.5 VDC System). a) Check Output Cables and Connector. Check the output cable and plug connection for damaged insulation and contacts each time the connector is detached from the aircraft. b) Monitoring sensors.
  • Page 61 Operation Manual – ITW GSE 6400 Tier 3 d) 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. Check Fuel Pump. iii. Inspect the fuel injection pump mounting nuts for loose or damaged hardware.

  • Page 62: H) "E" Checks And Operations

    Operation Manual – ITW GSE 6400 Tier 3 b) Inspect Wiring and Connections. Check all cables, leads, and wiring for broken, worn and damaged insulation. Check all connections for tightness. c) Clean and inspect generally. g) “D” Checks and Operations (1000 Hours or 1 Year) 1) Engine.

  • Page 63: F" Checks And Operations

    Operation Manual – ITW GSE 6400 Tier 3 CAUTION 1. If a cleaning compound is used, select one that is free from acid and will not remove paint. 2. Protect (or remove) all electrical accessories, such as voltage regulator, alternator, and electrical wiring.
  • Page 64 Operation Manual – ITW GSE 6400 Tier 3 1. Fan Pulley 5. Alternator 2. Vibration Damper 6. Belt Tensioner 3. Engine Control Module (ECM) 7. Fuel Pump 4. Exhaust Outlet Figure 2-1-3 Engine Accessories “G” Checks and Operations (Over 10,000 Hours).
  • Page 65 Operation Manual – ITW GSE 6400 Tier 3 k) Seasonal Maintenance Checks Spring/Fall (Engine). 3) Check Fan Mounting. a) Check fan to be sure it is securely mounted. b) Check for fan wobble and/or broken/cracked blades. c) Check fan hub and crankshaft pulley for secure mounting. (2) Check cooling system each spring and fall.

  • Page 66: Maintenance Procedures

    Operation Manual – ITW GSE 6400 Tier 3 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 67: Lubrication

    Operation Manual – ITW GSE 6400 Tier 3 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 68: D) Changing Engine Oil

    Operation Manual – ITW GSE 6400 Tier 3 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 69 Operation Manual – ITW GSE 6400 Tier 3 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 70: E) Engine Accessories Lubrication

    Operation Manual – ITW GSE 6400 Tier 3 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 71: Servicing The Air Cleaner

    Operation Manual – ITW GSE 6400 Tier 3 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 72: Engine Fuel

    Operation Manual – ITW GSE 6400 Tier 3 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 73: Engine Fuel System

    Operation Manual – ITW GSE 6400 Tier 3 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 74: C) Primary Fuel Filter

    Operation Manual – ITW GSE 6400 Tier 3 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 75: D) Fuel Pump

    Operation Manual – ITW GSE 6400 Tier 3 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 76: G) Draining The Fuel Tank

    Operation Manual – ITW GSE 6400 Tier 3 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 77: Engine Cooling System

    Operation Manual – ITW GSE 6400 Tier 3 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 78: D) Draining The Cooling System

    Operation Manual – ITW GSE 6400 Tier 3 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 79: F) Cleaning The Radiator Core

    Operation Manual – ITW GSE 6400 Tier 3 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 80: Engine Drive Belt

    Operation Manual – ITW GSE 6400 Tier 3 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 81: Replacing The Control Board Battery

    Operation Manual – ITW GSE 6400 Tier 3 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 82 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 83: General

    Operation Manual – ITW GSE 6400 Tier 3 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 84: Check Connections And Leads

    Operation Manual – ITW GSE 6400 Tier 3 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 85: Cummins Engine Fault Codes & Troubleshooting

    Operation Manual – ITW GSE 6400 Tier 3 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 86 Operation Manual – ITW GSE 6400 Tier 3 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 87 Operation Manual – ITW GSE 6400 Tier 3 Error 1st Corrective 2nd Corrective 3rd Corrective 4th Corrective Error Text in display Description Code Action Action Action Action Replace Control Verify that output 28V INTERLOCK 28V F Level too Press ARU...

  • Page 88: Engine Controls

    Operation Manual – ITW GSE 6400 Tier 3 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 89 Operation Manual – ITW GSE 6400 Tier 3 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 90 Operation Manual – ITW GSE 6400 Tier 3 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 91: Generator

    Operation Manual – ITW GSE 6400 Tier 3 Generator Check Trouble, Symptom, Probable Cause Test, Check, and/or Remedy Condition 1. Generator does Problem with brushes Remove, clean, and reinstall the generator brushes, not build up replacing them if they are shorter than 7/16 of an inch voltage when the (11mm).

  • Page 92: Load Contactor Operating Circuits

    Operation Manual – ITW GSE 6400 Tier 3 Load Contactor Operating Circuits Output 1: Contactor K1 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 93: Protective Circuit

    Operation Manual – ITW GSE 6400 Tier 3 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 94: 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 95 Operation Manual – ITW GSE 6400 Tier 3 This page is intentionally left blank. OM2254 Rev A Page 94 of 103...
  • Page 96 Operation Manual – ITW GSE 6400 Tier 3 Appendix A Options The following is a list of options available for the ITW GSE 6400 Generator Set. Option/Features Available Part Description Number DIN40 Towbar 293148 Kit, Clearance Lights 293098 Kit, Beacon, Unit Operating, Amber...
  • Page 97 Operation Manual – ITW GSE 6400 Tier 3 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 98: Appendix C - Operating In Unusual Service Conditions 3

    Operation Manual – ITW GSE 6400 Tier 3 Appendix B Operating in Unusual Service Conditions This information is a general guideline and cannot cover all possible conditions of equipment use. The specific local environments may be dependent upon conditions beyond the manufacturer’s control. The manufacturer should be consulted if any unusual conditions of use exist which may affect the physical condition or operation of the equipment or safety to surrounding personnel.

  • Page 99: Appendix D - Initial Software Installation Procedure 3

    Appendix C Initial Software Installation Procedure Introduction: The ITW GSE 6400 GPU contains two circuit boards that may need to be programmed if they are replaced. (The Control Board (P/N AP-579526) and the Display Board (P/N AP-579536). This document instructs you how to perform this task. Make sure to program the boards with the correct software number and revision.
  • Page 100 Operation Manual – ITW GSE 6400 Tier 3     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 101 Operation Manual – ITW GSE 6400 Tier 3     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 102 This formula can be downloaded from www.itwgse.com Forward to Sender: ITW GSE 6400 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:    ...
  • Page 103 ITW GSE , DIV. GSE HOLDINGS INC. CAGE: 12867 11001 US HIGHWAY 41 NORTH, PALMETTO, FL 34221 OM2254 Rev A Page 102 of 103...
  • Page 104 ITW GSE , DIV. GSE HOLDINGS INC. CAGE: 12867 11001 US HIGHWAY 41 NORTH, PALMETTO, FL 34221 OM2254 Rev A Page 103 of 103...
  • Page 105 Illustrated Parts Breakdown 6400 Tier 3 28.5V DC Generator Set Ground Power Unit Specification.: ACE6400 28.5 V DC Type: OM2254...
  • Page 106 Operation Manual - ITW GSE 6400 Tier 3 Clearance Light Option Fire Extinguisher Option Figure 3-1. Generator Set 6400 JetEx® 8 T3 (Sheet 1 of 3). Page 1 of 26...
  • Page 107 Operation Manual - ITW GSE 6400 Tier 3 Display Controller Assembly Block Heater Option Battery Blanket Option Figure 3-1. Generator Set 6400 JetEx® 8 T3 (Sheet 2 of 3). Page 2 of 26...
  • Page 108 Operation Manual - ITW GSE 6400 Tier 3 FIGURE - ITW GSE QTY. NOMENCLATURE ITEM NO. PART NO. 3-1- 6400-T3 JetEx® 28.5V DC Tier 3 293098 Clearance Light Option 293171 Fire Extinguisher Option 293503-XX Block Heater Option 293498-XX Battery Heater Blanket Option 293454-05 .Display Controller, Output Assembly...
  • Page 109 Operation Manual - ITW GSE 6400 Tier 3 Spindles should be packed and filled with wheel bearing grease. Figure 3-2. Assy, Chassis/Running Gear JetEx® 8 T3 (Sheet 1 of 2). Page 4 of 26...
  • Page 110 Operation Manual - ITW GSE 6400 Tier 3 FIGURE - ITW GSE QTY. NOMENCLATURE ITEM NO. PART NO. 3-2- Base Frame, 4400-T3 & JetEx8 293382 TA11449 ..Heavy-Duty Rubber Wall Guard 293401 Wheel Axle Assy 293402 ..Parking Brake Assy 84655UC1-EZ ..EZ Hub Hit, Pivot Hub “5 Wheel”...
  • Page 111 Operation Manual - ITW GSE 6400 Tier 3 Figure 3-3. Genset/Fuel Tank Installation, JetEx® 8 T3 (Sheet 1 of 2). Page 6 of 26...
  • Page 112 Operation Manual - ITW GSE 6400 Tier 3 FIGURE - ITW GSE QTY. NOMENCLATURE ITEM NO. PART NO. 3-3- 293439 Genset/Fuel Tank Installation 293437 .Genset Assembly P781039 ..Air Cleaner 293395 ..Fuel Tank Composite Assembly, (See Figure 3-4) 293081 ...Panel, Fuel Filler Cover EB11439 ...Protectoseal Fuel Cap Green...
  • Page 113 Operation Manual - ITW GSE 6400 Tier 3 Figure 3-4. Genset Assembly, JetEx® 8 T3 (Sheet 1 of 2). Page 8 of 26...
  • Page 114 Operation Manual - ITW GSE 6400 Tier 3 FIGURE - ITW GSE QTY. NOMENCLATURE ITEM NO. PART NO. 3-4- 293437 Genset Assembly, 6400-T3 293438 Engine, Cummins 28.5V DC QSB4.5 282918 ..Indicator, Electrical, Restriction 288985 ..Generator Assembly FB11360 ..Fan, Radiator 288003 ..Cover, Fan Housing...
  • Page 115 Operation Manual - ITW GSE 6400 Tier 3 CUMMINS SPARE ENGINE PARTS Visit http://www.quickserve.cummins.com Setup Cummins Online Account Page 10 of 26...
  • Page 116 Operation Manual - ITW GSE 6400 Tier 3 Apply thread sealant before installing Apply thread sealant before installing Figure 3-5. Fuel Tank Composite Assembly, JetEx® 8 T3 (Sheet 1 of 2). Page 11 of 26...
  • Page 117 Operation Manual - ITW GSE 6400 Tier 3 IGURE - ITW GSE QTY. NOMENCLATURE ITEM NO. PART NO. 3-5- 293395 Fuel Tank Assembly Composite 293090 ..Plate, Fuel Neck, Internal 293093 ..Gasket, Fuel Neck 293094 .. Fuel Filler Neck, 2-1/2, NPT Weldment 293366 ..Fuel Sender Nipple...
  • Page 118 Operation Manual - ITW GSE 6400 Tier 3 4 5 6 Figure 3-6. Radiator/After-Treatment Installation, JetEx® 8 T3 (Sheet 1 of 2). Page 13 of 26...
  • Page 119 Operation Manual - ITW GSE 6400 Tier 3 FIGURE - ITW GSE QTY. NOMENCLATURE ITEM NO. PART NO. 3-6- 293440 Radiator /Exhaust Installation 293069 .Radiator (Coolpack) AA6380 ...Sensor, Coolant Level, 3 Pin 293175 .Muffler Assembly 293349 ..Assy, Muffler Pipe w/Thermo Jacket 293023 ...Muffler Pipe...
  • Page 120 Operation Manual - ITW GSE 6400 Tier 3 Figure 3-7. Coolpack, Radiator Assy JetEx® 8 T3 (Sheet 1 of 2). Page 15 of 26...
  • Page 121 Operation Manual - ITW GSE 6400 Tier 3 FIGURE - ITW GSE QTY. NOMENCLATURE ITEM NO. PART NO. 3-7- 293069 Coolpack, Radiator Assy 892001025 Top Radiator Hose 892001126 Bottom Radiator Hose Figure 3-7. 6400-T3 Coolpack, Radiator Assy JetEx® 8 (Sheet 2 of 2).
  • Page 122 Operation Manual - ITW GSE 6400 Tier 3 Figure 3-8. 6400-T3, Electrical System Installation, JetEx® 8 (Sheet 1 of 2). Page 17 of 26...
  • Page 123 Operation Manual - ITW GSE 6400 Tier 3 FIGURE - ITW GSE QTY. NOMENCLATURE ITEM NO. PART NO. 293441 Electrical System Installation, 6400-T3 293268-XX .Output Table Assembly, 4400 FH11369 ..Fuse Holder FU11370 ..Fuse, Fast Acting RE11371 ..Relay, Grid Power Heater *293054 ...Harness, Exciter/Display...
  • Page 124 Operation Manual - ITW GSE 6400 Tier 3 Figure 3-9. 6400-T3, Output Table Assembly, JetEx® 8 (Sheet 1 of 2). Page 19 of 26...
  • Page 125 Operation Manual - ITW GSE 6400 Tier 3 FIGURE - ITW GSE QTY. NOMENCLATURE ITEM NO. PART NO. 293268-XX Output Table Assy – 6400-T3 / T4 293132 .Output Stand *293208 ..Harness, Output Table 293273 .Rectifier TRU Assembly *293203 ..Harness Kit, Rectifier Assembly 286810-002 .Contactor, DC, 800 AMP, 12VDC...
  • Page 126 Operation Manual - ITW GSE 6400 Tier 3 Enclosure is equipped with Snap-On standoffs (6 PL) to attach PCB Figure 3-10. 6400-T3, Control Module Box Assembly JetEx® 8 (Sheet 1 of 2). Page 21 of 26...
  • Page 127 Operation Manual - ITW GSE 6400 Tier 3 FIGURE ITW GSE QTY. NOMENCLATURE ITEM NO. PART NO. 3-10- 293303 Control Module Box Assembly 293249 .Control Box 579542 ..Diesel Interface Board, 12V System *AP-SI2076 ...Fuse, F1, 2 amp Protects Display *AP-SI2075 ...Fuse, F2, 5 amp Protects Control Board...
  • Page 128 Operation Manual - ITW GSE 6400 Tier 3 Figure 3-11. Cable Tray Assembly, Right Side JetEx® 8 T3 (Sheet 1 of 2). Page 23 of 26...
  • Page 129 Operation Manual - ITW GSE 6400 Tier 3 FIGURE ITW GSE QTY. NOMENCLATURE ITEM NO. PART NO. 3-11- *293086 Cable Tray Assembly,Left Side *293087 Cable Tray Assembly, Right Side 293085 Cable Tray, Symmetrical 293193 .Compression Latch, Modified 293013 ..Battery Cover * Item Not Illustrated Figure 3-11.
  • Page 130 Operation Manual - ITW GSE 6400 Tier 3 FASTEN WITH M6-1 SCREWS, GR8 OR HIGHER FASTEN WITH 4.55 SELF CUTTING SCREWS, GR8 OR HIGHER FASTEN WITH M6-1 SCREWS, GR8 OR HIGHER Figure 3-12. Top Canopy, Composite, Assembly JetEx® 8 T3 (Sheet 1 of 2).
  • Page 131 Operation Manual - ITW GSE 6400 Tier 3 FIGURE ITW GSE NOMENCLATURE QTY. ITEM NO. PART NO. 3-12- 293517 Top Canopy, Composite, Assembly 293020 ..Panel, Top Grid 293078 …Latch Assembly, Top Canopy 293018 …Hook Slide, Main Canopy 293019 ..Heat Shield, Side, Top Canopy Figure 3-12.

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