ITW GSE 4400 User manual

OM2245 Mar 15, 2015
ITW GSE HOBART Ɣ11001 Us Highway 41 North ƔPalmetto, FL 34221 ƔU.S.A
T: (toll free in US): 800-899-1841 ƔT (International): + 1 941-721-1000 ƔE: [email protected]
Manual
ITW GSE 4400
60-90 kVA, 3 Phase, 115 Volt,
400 Hz Generator Set
Series no. 500100
Type 4400
it’s all about connections

OM
-2245 / Operation and Maintenance Manual
ITW GSE
4400 / 400 Hz. Generator Set
March 15, 2015
Introduction
Page 1
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. 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 Hobart Ground Systems.
This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide
information and instructions to experienced operators, electricians, and mechanics that have never operated
this equipment. It is the intent of this manual to guide and assist operators and maintenance personnel in the
proper use and care of the equipment.
Use of the manual should not be put off until trouble or a need for help develops. Read the instructions before
starting the unit. Learn to use the manual and to locate information contained in it. Its style and arrangement
are very similar to commercial aircraft manuals.
The manual is divided into five chapters plus an appendices. Each chapter is divided into as many sections
as required. Each new section starts with page 1. Each page is identified by chapter, section and page
number, which are located in the lower, outside corner.
When information located in another portion of the manual is referred to, a chapter, section, and paragraph or
figure number identify its location. For example: “(see Section 2-3, Paragraph 1.a.)” refers to information
located in Chapter 2, Section 3, Paragraph 1.a. If a chapter and section are not indicated in a reference, the
referenced material is located in the same section as the reference, for example: “(see Paragraph 1.a.).”
In addition to operation and maintenance instructions, the manual contains an illustrated parts list in Chapter
4 and a collection of manufacturer’s literature and supplemental information in Chapter 5.
Contents of the manual are arranged as follows:
Chapter 1 Description/Operation
Chapter 2 Servicing/Troubleshooting
Chapter 3 Overhaul/Major Repair
Chapter 4 Illustrated Parts List
Chapter 5 Manufacturer’s Literature
Appendix A ARU
Appendix B Options

OM
-2245 / Operation and Maintenance Manual
ITW GSE
4400 / 400 Hz. Generator Set
March 15, 2015
Introduction
Page 2
If you have any questions concerning your ITW GSE equipment, immediately contact our Service Department
by mail, telephone, FAX, or E-Mail.
Write: ITWGSE
Service Department
11001 US Highway 41, North
Palmetto,FL34221
U.S.A.
Call Inside U.S.A.: [phone] (Parts)
[phone] (Service)
Call From Foreign Countries: [phone] (Technical Support)
[phone] (Spare Parts)
FAX inside U.S.A. [phone]
FAX From Foreign Countries: [phone]
E-Mail: [e-mail]
[email protected]
Web Page: www.itwgse.com

OM
-2245 / Operation and Maintenance Manual
ITW GSE
4400 / 400 Hz. Generator Set
March 15, 2015
Safety Warnings
Page 1
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.
IMPROPER PHASE CONNECTION, PARALLELING, OR USE
can damage this and
attached equipment.
IMPORTANT
Protect all operating personnel. Read, understand, and follow all instructions in the
Operating/Instruction Manual before installing, operating, or servicing the equipment.
Keep the manual available for future use by all operators.
WARNING
CALIFORNIA PROPOSITION 65
- DIESEL ENGINES.
Diesel engine exhaust and
some of its constituents are known to cause c
ancer, birth defects and other
illnesses.
1) General
Equipment that supplies electrical power can cause serious injury or death, damage to other equipment or
property. The operator must strictly observe all safety rules and take precautionary actions. Safe practices
have been developed from past experience in the use of power source equipment. While certain practices
below apply only to electrically powered equipment, other practices apply to engine-driven equipment, and
some practices to both.
2) Shock Prevention
Bare conductors, terminals in the output circuit, or ungrounded, electrically live equipment can fatally shock a
person. Have a certified electrician verify that the equipment is adequately grounded and learn what
terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing,
procedures and test equipment.
The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow through it.
When inspecting or servicing the equipment, do not work in damp areas. Stand on a dry rubber mat or dry
wood, and use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry, and never
work alone.
a) Output Cables and Terminals
Inspect cables frequently for damage to the insulation and the connectors. Replace or repair cracked
or worn cables immediately. Do not overload cables. Do not touch output terminal while equipment
is energized.

OM
-2245 / Operation and Maintenance Manual
ITW GSE
4400 / 400 Hz. Generator Set
March 15, 2015
Safety Warnings
Page 2
3) Service and Maintenance
This equipment must be maintained in good electrical condition to avoid hazards stemming from
disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of the
equipment until its safety has been assured. Repairs should be made by qualified personnel only.
Before inspecting or servicing this equipment, take the following precautions:
a) Shut off all power at the battery disconnect before inspecting or servicing the equipment.
b) Lockout the equipment at the battery disconnect switch if it is out of service.
c) If troubleshooting must be done with the unit energized, have another person present who is trained
in turning off the equipment and providing or calling for first aid.
4) Fire and Explosion Prevention.
Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust pipes,
misuse of batteries and fuel, or unsafe operating or fueling conditions.
a) Electrical Short Circuits and Overloads.
Overloaded or shorted equipment can become hot enough to cause fires by self-destruction or by
causing nearby combustibles to ignite.
b) Batteries.
Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured
battery can cause fires and additional failures. When servicing, do not smoke, cause sparking, or use
open flame near the battery.
c) Engine Fuel.
Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank is
not grounded prior to or during fuel transfer. Shut unit DOWN before opening fuel tank cap. DO NOT
completely fill tank, because heat from the equipment may cause fuel expansion overflow. Remove
all spilled fuel IMMEDIATELY, including any that penetrates the unit. After clean-up, open equipment
doors and blow fumes away with compressed air.
5) Toxic Fume Prevention.
Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust
fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air
conditioners.
6) Bodily Injury Prevention.
Serious injury can result from contact with fans or hot spots inside some equipment. Shut DOWN such
equipment for inspection and routine maintenance. When equipment is in operation, use extreme care in
doing necessary troubleshooting and adjustment. Do not remove guards while equipment is operating.

OM
-2245 / Operation and Maintenance Manual
ITW GSE
4400 / 400 Hz. Generator Set
March 15, 2015
Safety Warnings
Page 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.
EMERGENCY
FIRST AID
. SEEK ADDITIONAL ASSISTANCE. Use First Aid techniques recommended by
American Red Cross until medical help arrives.
IF BREATHING IS DIFFICULT
, give oxygen, if available, and have victim lie down.
FOR ELECTRICAL SHOCK, turn off power.
Remove victim; if not breathing, begin
artificial respiration, preferably mouth
-to-mouth.
If no detectable pulse, begin external
heart massage.
8) Equipment Precautionary Labels
Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot be
easily read.

OM
-2245 / Operation and Maintenance Manual
ITW GSE
4400 / 400 Hz. Generator Set
March 15, 2015
Safety Warnings
Page 4
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OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Table of Contents
Page 1
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) 1-1/4
Main Components of Generator Set (Left Side) 1-1/5
Main Components of Generator Set (Bottom) 1-1/6
Specifications 1-1/7
Special Features 1-1/9
Canopy 1-1/9
Engine and Generator 1-1/9
Operator Controls 1-1/12
Parameters – Menu Structure 1-1/15
Power Module Assembly 1-1/16
Cold Weather Start System 1-1/17
Active Rectifier Unit (ARU) 1-1/18
Section 2 Preparation for Use, Storage or Shipping 1-2/1
Preparation For Use 1-2/1
Preparation for Storage 1-2/5
Preparation for Shipment 1-2/6
Section 3 Operation 1-3/1
General 1-3/1
400 Hz. Operation Procedure 1-3/1
Active Rectifier Unit (ARU) – 28.5 VDC Power Supply 1-3/5
Icon Menu 1-3/8
View Parameters Menu 1-3/9
Setup Menu 1-3/10
Black Box 1-3/20
Power Log 1-3/21
Upload/Download Menu 1-3/22

OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Table of Contents
Page 2
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” Checks and Operations (Break-In Period) 2-1/4
“A” Checks and Operations (10 Hours or Daily) 2-1/5
“B” Checks and Operations (250 Hours or 3 Months) 2-1/7
“C” Checks and Operations (500 Hours or 6 Months) 2-1/8
“D” Checks and Operations (1000 Hours or 1 Year) 2-1/9
“E” Checks and Operations (1500 Hours or 1.5 Years) 2-1/10
“F” Checks and Operations (2000 Hours or 2 Years) 2-1/11
Seasonal Maintenance Checks Spring/Fall (Engine) 2-1/12
Lamps and Fuses 2-1/13
Section 2 Maintenance Procedures 2-2/1
General 2-2/1
Engine Lubrication 2-2/2
Servicing the Air Cleaner 2-2/6
Engine Fuel 2-2/7
Engine Fuel System 2-2/8
Engine Cooling System 2-2/11
Drive Belt 2-2/14
Generator Maintenance 2-2/14
Preventive Maintenance 2/2-15
Section 3 Adjustments / Tests 2-3/1
General 2-3/1
Testing the 400 Hz. Generator Set 2-3/1
Generator Set Adjustments 2-3/4
Generator and Exciter Test 2-3/5
Diode Test 2-3/6
Testing the Active Rectifier Unit 2-3/6
Adjusting the Active Rectifier Unit 2-3/7
Section 4 Troubleshooting Procedures
General 2-4/1
Equipment for Troubleshooting 2-4/1
Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#

OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Table of Contents
Page 3
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
Fuses 2-4/3
Troubleshooting Charts 2-4/4
…Engine Controls 2-4/6
…Generator Excitation Circuits 2-4/9
…Load Contactor Operating Circuits 2-4/11
…Protective Circuit 2-4/13
Chapter 3 Overhaul / Major Repair Chapter-Section/Page#
Section 1 Exciter Armature 3-1/1
General 3-1/1
Exciter Armature 3-1/2
Exciter Armature Replacement 3-1/3
Exciter Armature Installation 3-1/6
Section 2 Dual Bearing Flexible Coupling
General 3-2/1
Disassembly 3-2/1
Coupling Service 3-2/4
Coupling Installation 3-2/5
Reassemble Engine and Generator 3-2/6
Run-in and Periodic Check 3-2/7
Section 3 Generator Assembly
General 3-3/1
Generator Assembly Removal 3-3/1
Generator Assembly Installation 3-3/2
Chapter 4 Illustrated Parts List Chapter-Section/Page#
Section 1 Introduction 4-1/1
General 4-1/1
Purpose 4-1/1
Arrangement 4-1/1

OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Table of Contents
Page 4
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 4-2/1
Hierarchy 4-2/1
Figure 4-1. 4400, 60-90kVA,3-Phase 115 Volt Generator Set 4-2/2
Figure 4-2. Trailer Assembly Common Platform 4-2/4
Figure 4-3. Running Gear Assembly, 4400 Platform 4-2/6
Figure 4-4. Genset/Fuel Tank Installation, 60/90 kVA 4-2/8
Figure 4-5. Genset Assembly, 60/90kVA 4-2/11
Figure 4-6. Fuel Tank Composite Assembly, CP 4-2/16
Figure 4-7. Radiator/Exhaust Installation 4-2/18
Figure 4-8. Coolpack 4-2/21
Figure 4-9. Electrical System Installation 4-2/23
Figure 4-10. Output Table Assembly, Single Output 4-2/26
Figure 4-11. Output Table Assembly, Single Output w/28VDC ARU 4-2/28
Figure 4-12. Output Table Assembly, Dual Output 4-2/30
Figure 4-13. Output Table Assembly, Dual Output w/28VDC ARU 4-2/32
Figure 4-14. Control Module Box Assembly 4-2/34
Figure 4-15. Cable Tray/Canopy Installation 4-2/36
Figure 4-16. Cable Tray Assembly, Left Side 4-2/39
Figure 4-17. Cable Tray Assembly, Right Side 4-2/41
Figure 4-18. Display Control Assembly 4-2/43
Figure 4-19. Top Canopy, Composite, Assembly 4-2/45
Chapter 5 Manufacture's Literature
Appendix A – Active Rectifier Unit (ARU)
Appendix B – Options
Appendix C - Wet Stacking
Appendix D - Unusual Service Conditions

OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Chapter 1-1
Page 1
Chapter 1 Description/Operation
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. A comprehensive review of the 28VDC output Active
Rectifier Unit (ARU) is located in Appendix A.
Table 1-1-1 uses the model number to identify the variations covered in this manual.
Model Number kVA Mounting Engine Certification Outputs 28.5 DC Output
ACE4460STT3-US 60 Trailer Tier 3 US Labeled Single 400Hz No
ACE4460STT3-EU 60 Trailer Stage 3a EU Labeled Single 400Hz No
ACE4460S28TT3-US 60 Trailer Tier 3 US Labeled Single 400Hz Yes
ACE4460S28TT3-EU 60 Trailer Stage 3a EU Labeled Single 400Hz Yes
ACE4460DTT3-US 60 Trailer Tier 3 US Labeled Dual 400Hz No
ACE4460DTT3-EU 60 Trailer Stage 3a EU Labeled Dual 400Hz No
ACE4460D28TT3-US 60 Trailer Tier 3 US Labeled Dual 400Hz Yes
ACE4460D28TT3-EU 60 Trailer Stage 3a EU Labeled Dual 400Hz Yes
ACE4490STT3-US 90 Trailer Tier 3 US Labeled Single 400Hz No
ACE4490STT3-EU 90 Trailer Stage 3a EU Labeled Single 400Hz No
ACE4490S28TT3-US 90 Trailer Tier 3 US Labeled Single 400Hz Yes
ACE4490S28TT3-EU 90 Trailer Stage 3a EU Labeled Single 400Hz Yes
ACE4490DTT3-US 90 Trailer Tier 3 US Labeled Dual 400Hz No
ACE4490DTT3-EU 90 Trailer Stage 3a EU Labeled Dual 400Hz No
ACE4490D28TT3-US 90 Trailer Tier 3 US Labeled Dual 400Hz Yes
ACE4490D28TT3-EU 90 Trailer Stage 3a EU Labeled Dual 400Hz Yes
Table 1-1-1: ITW GSE 4400 Series Generator Set Part Number Descriptions
2) Optional Equipment - Appendix B
Chapters 1 through 5 of this Operation and Maintenance Manual identify only the basic version of the ITW
GSE 4400 generator set. A list of optional equipment appears in Appendix B.
Section 1 Description

OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Chapter 1-1
Page 2
3) Component Locations
For purpose of orientation when designating RIGHT and LEFT throughout this manual, the radiator is
considered to be at the FRONT of the unit and the generator is at the REAR. RIGHT and LEFT are
determined by standing at the REAR facing the machine. As an example, the control panel is mounted
on the RIGHT FRONT side of the unit.

OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Chapter 1-1
Page 3
1. Fuel Filler Neck / Manual Gauge
2. Operator Control Panel
3. Composite Output Cable Trays
4. Fifth Wheel Assembly
5. Rear Axle Assembly
6. Emergency Stop Switch
7. Sliding/Removable Canopy
8. Clearance Lights (Option)
9. Radiator End
10. Generator End
11. Forklift Pockets
12. Low Fuel Beacon (Option)
13. Operating Beacon (Option)
Figure 1-1-1: General Assembly of Generator Set
2
3
4
1
5
6
7
8
9
11
10
13
3
12

OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Chapter 1-1
Page 4
1. Cummins QSB4.5 Engine
2. Control Module Assembly
3. Batteries (inside tray pockets)
4. Battery Disconnect
5. Tow bar Assembly
6. Generator
7. 28.5 VDC ARU (Option)
8. Engine Alternator
9. Output Contactors
10. Air Filter Assembly
Figure 1-1-2: Main Components of Generator Set (Right Side)
1
2
3
10
6
8
7
5
9
4

OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Chapter 1-1
Page 5
1. Coolant fill access cover
2. Lubricity Additive Fuel Pre-Filter
3. Engine Oil Filter
4. Fuel Filter
5. Engine Control Module (ECM)
6. Engine Oil Fill Tube
7. Charge-Air-Cooler Piping
8. Engine Air Intake Piping
9. Tow Bar/Brake Release Lever
Figure 1-1-3: Main Components of Generator Set (Left Side)
1
2
3
4
5
7
8
96

OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Chapter 1-1
Page 6
1. Oil Drain Tube
2. Tie Down Rings
3. Muffler Assembly
Figure 1-1-4: Main Components of Generator Set (Bottom)
1
2
3

OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Chapter 1-1
Page 7
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 4300 lb. (1950 kg.)
b) AC Generator Specifications
Output power rating 90 kVA (72 kW)
Output voltage 115 / 200 VAC
Rated load capacity 260 Amps
Frequency 400 Hz.
Power factor 0.8
Duty Cycle 100%
Operating speed 2000 RPM
Overload capacity 125% rated load 325 Amps
Output cable size 2/0
c) AC Generator 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 1 second
above 480 Hz immediate
Under frequency 380 Hz. or less 5 seconds
Output overload 80% load at PF > 0.8 to 1.0 Continuous
100% load at PF > 0.7 to 0.8 Continuous
100% load at PF > 0.8 to 1.0 5 minutes
100% to 120% load (PF 0.7 to 0.8) 10 seconds
120% to 150% load (PF 0.7 to 0.8) 2 seconds

OM-2245 / Operation and Maintenance Manual
ITW GSE 4400 / 400 Hz. Generator Set
March 15, 2015 Chapter 1-1
Page 8
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
Peak/Starting Load Capacity 2000 A for 5 seconds
Output cable size 4/0 for continuous loads up to 400A
2x 4/0 for continuous loads up to 600A
e) DC Protective System Specifications
Condition Trip Point Time Delay
Over Voltage 32 - 40 VDC
Over 40 VDC 4 seconds 150 ms
Output Overload
2000 A 5 seconds
1800 A 10 seconds
1200 A 30 seconds
800 A 30 seconds
f) 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)
Displacement 275 in
3
(4.5 L)
Horsepower 171 hp (132 kW)
Idle speed (factory set option)
(Not authorized for EU units) 1000 ± 50 rpm
Normal governed speed 2000 rpm
Firing Order 1-3-4-2
Electrical system 24 VDC
Lubricating oil capacity (w/ filter) 11.6 quarts (11 liters)
Coolant capacity system 20 quarts (18.9 liters)
g) Normal Operating Characteristics
Engine oil pressure (warm and at rated speed 2000 RPM) 45 to 90 PSI (445 to 621 kPa).
Engine coolant temperature (normal operation) 160 to 200º F (71 to 93º C).