ITW GSE 6400 JetEx Tier 3 User manual

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
Specification.: DCE6400 28.5 VDC Tier 3
Type: OM2254
Manual
6400 Tier 3
28.5 VDC Generator Set Ground Power Unit

Operation Manual - ITW GSE 6400 Tier 3
Diagrams and drawings are subject to change without prior notice.
Latest diagram versions can be found at www.itwgse.com
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.
OM2254 Rev A
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Operation Manual – ITW GSE 6400 Tier 3
Introduction
This manual contains operation and maintenance information for a diesel engine-generator manufactured
by ITW GSE, Palmetto, Florida 34221
This manual, including all information contained therein, is exclusive and confidential property of
ITW GSE. This manual is not to be copied, reproduced, or delivered or disclosed to others, in
whole or in part, except with express written permission of ITW GSE.
This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide
information and instructions to experienced operators, electricians, and mechanics that have never
operated this equipment. It is the intent of this manual to guide and assist operators and maintenance
personnel in the proper use and care of the equipment.
Use of the manual should not be put off until trouble or a need for help develops. Read the instructions
before starting the unit. Learn to use the manual and to locate information contained in it. Its style and
arrangement are very similar to commercial aircraft manuals.
The manual is divided into three chapters plus appendices. Each chapter is divided into as many sections
as required. Each page is identified by chapter, section and page number, which are located in the lower,
outside corner.
When information located in another portion of the manual is referred to, a chapter, section, and
paragraph or figure number identify its location. For example: “(see Section 2-3, Paragraph 1.a.)” refers
to information located in Chapter 2, Section 3, Paragraph 1.a. If a chapter and section are not indicated in
a reference, the referenced material is located in the same section as the reference, for example: “(see
Paragraph 1.a.).”
Contents of the manual are arranged as follows:
Chapter 1 Description/Operation
Chapter 2 Servicing/Troubleshooting
Chapter 3 Manufacturer’s Literature
Appendix A Active Rectifier Unit (ARU)
Appendix B Options
Appendix C Operation in Unusual Service Conditions
Appendix D Software Installation Procedures
Appendix E Schematics
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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.
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 cancer, birth defects and other illnesses.
1) General
Equipment that supplies electrical power can cause serious injury or death, damage to other equipment or
property. The operator must strictly observe all safety rules and take precautionary actions. Safe
practices have been developed from past experience in the use of power source equipment. While
certain practices below apply only to electrically powered equipment, other practices apply to 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.
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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. 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.
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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.
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 massa
g
e.
8) Equipment Precautionary Labels
Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot
be easily read.
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Operation Manual – ITW GSE 6400 Tier 3
Table of Contents
Chapter 1 Description/Operation Chapter-Section/Pa
g
e#
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 1-1/11
Figure 1-1-2: Main Components of Generator Set (Right Side) 1-1/12
Figure 1-1-3: Main Components of Generator Set (Left Side) 1-1/13
Figure 1-1-4: Main Components of Generator Set (Bottom) 1-1/14
4) Specifications 1-1/15
5) Special Features 1-1/17
6) Canopy 1-1/18
7) Engine and Generator 1-1/18
8) Power Module Assembly 1-1/20
9) Operator Controls 1-1/22
10) Cold Weather Starting System 1-1/26
Section 2 1) Preparation for Shipment 1-2/27
2) Preparation for Storage 1-2/30
3) Preparation for Shipment 1-2/31
Section 3 1) General 1-3/32
2) 400 Hz. Operating Procedure 1-3-32
3) Active Rectifier Unit (ARU) 1-3/36
4) Icon Menu 1-3/37
a) View Parameters Menu 1-3/38
b) Setup Menu 1-3/39
c) Black Box 1-3/50
d) Power Log 1-3/51
e) Update/Save Log Menu 1-3/52
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Operation Manual – ITW GSE 6400 Tier 3
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” Checks and Operations (Break-In Period) 2-1/58
d) “A” Checks and Operations (10 Hours or Daily) 2-1/59
e) “B” Checks and Operations (250 Hours or 3
Mth)
2-1/61
f) “C” Checks and Operations (500 Hours or 6
Mth)
2-1/62
g) “D” Checks and Operations (1000 Hours or 1 Year) 2-1/63
h) “E” Checks and Operations (1500 Hours or 1.5
Y)
2-1/64
i) “F” Checks and Operations (2000 Hours or 2
Y)
2-1/65
j) Seasonal Maintenance Checks Spring/Fall
(E i )
2-1/66
k) Lamps and Fuses 2-1/66
Figure 2-1-4 Fuse Identification Chart 2-1/66
Section 2 Maintenance Procedures 2-2/67
1) General 2-2/67
Figure 2-2-1 Lubrication and Maintenance Chart 2-2/67
2) Lubrication 2-2/68
a) General 2-2/68
b) Lubrication Schedule 2-2/68
c) Oil Specification 2-2/68
Figure 2-2-2 Lubrication Specifications 2-2/68
d) Changing Engine Oil 2-2/69
Figure 2-2-3 Oil Fill and Check Locations 2-2/69
e) Engine Accessories Lubrication 2-2/71
f) Trailer Lubrication 2-2/71
3) Servicing the Air Cleaner 2-2/72
a) Inspecting the Air Cleaner 2-2/72
Figure 2-2-4 Air Cleaner Assembly 2-2/72
b) Changing the Air Filter 2-2/72
c) Disposal 2-2/72
4) Engine Fuel 2-2/73
a) How to Select Fuel - Quality 2-2/73
b) Cold Weather Operation 2-2/73
Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#
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Operation Manual – ITW GSE 6400 Tier 3
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 2-2/75
Figure 2-2-6 Primary Fuel Filter 2-2/75
d) Fuel Pump 2-2/76
e) Fuel Return 2-2/76
f) Fuel Level Indicators 2-2/76
g) Draining the Fuel Tank 2-2/77
6) Engine Cooling System 2-2/78
a) General 2-2/78
b) Radiator Cap 2-2/78
c) Coolant 2-2/78
d) Draining the Cooling System 2-2/79
e) Flushing the Cooling System 2-2/79
f) Cleaning the Radiator Core 2-2/80
g) Filling the Cooling System 2-2/80
h) Thermostat 2-2/80
7) Engine Drive Belt 2-2/81
8) Generator Maintenance 2-2/81
9) Replacing the Control Board Battery 2-2/81
Section 3 Adjustments / Tests 2-3/84
1) General 2-3/84
2) Testing the 400 Hz. Generator Set 2-3/84
a) Pre-operational Test Procedures 2-3/84
b) Engine Test Procedures 2-3/84
c) 400Hz Initial Testing and Setup 2-3/85
d) Output 1 Verification 2-3/85
e) Output 2 Verification 2-3/85
f) Sensor Testing 2-3/85
g) Re-checking the entire unit after testing 2-3/86
3) Generator Set Adjustment 2-3/86
4) Generator and Exciter Test 2-3/87
Figure 2-3-1 Generator and Exciter Test Readings 2-3/87
Figure 2-3-2 Generator Connections 2-3/88
5) Diode Test 2-3/88
6) Testing the Active Rectifier Unit (ARU) units w/DC Option 2-3/88
Chapter 2 Servicin
g
/ Troubleshootin
g
Chapter-Section/Pa
g
e#
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Operation Manual – ITW GSE 6400 Tier 3
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 2-4/91
6) Engine Troubleshooting 2-4/91
7) GPU Control Monitoring 2-4/91
8) Cummins Engine Fault Codes & Troubleshooting 2-4/92
9) Troubleshooting Charts/Error Codes 2-4/92
…Engine Controls 2-4/97
…Generator Excitation Circuits 2-4/100
…Generator 2-4/101
…Load Contactor Operating Circuits 2-4/102
…Protective Circuit 2-4/103
Chapter 3 Manufacturer’s Literature
C
hapter-Section/Page#
Vendor Literature 3-1/104
Appendix A
–
A
ctive Rectifier Unit
(
ARU 3-
A
/106
Appendix B – Options
Appendix C – Operating in Unusual Service Conditions
Appendix D – Initial Software Installation Procedure
3-B/115
3-C/117
3-D/118
Chapter 2 Servicing / Troubleshooting
C
hapter-Section/Page#
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Operation Manual - ITW GSE 6400 Tier 3
Chapter 1
Description/Operation
1) General
This manual describes a 28.5 V generator set manufactured by ITW GSE, Palmetto, FL 34221. This
generator system is designed to provide ground power for maintenance and startup of aircraft or other
loads.
2) Optional Equipment - Appendix A
Chapters 1 through 3 of this Operation and Maintenance Manual identify only the basic version of the
ITW GSE 6400 Tier 4 generator set. Appendix A contains a list of the rest of the optional equipment
that can be ordered with the unit. Each item has a brief description of the optional equipment.
Section 1
Description
Part Number Mounting
Cable
Management
Model
Description
Power Rating
DCE6400CUTT3
Trailer Cable Trays Standard
Unit rated
28.5 VDC,
600 A continuous (17 kW),
2000 A peak (56 kW),
single output
Table 1: ITW GSE 6400 Series Generator Set Part Number Descriptions
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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. As an example, the control panel is
mounted on the RIGHT FRONT side of the unit.
1. Fuel Filler Neck / Manual Gauge
2. Operator Control Panel
3. Composite Output Cable Trays
4. Emergency Stop Switch
5. Sliding/Removable Canopy
6. Clearance Lights (Option)
7. Radiator End
8. Generator End
9. Forklift Pockets
10. Low Fuel Beacon (Option)
11. Operating Beacon (Option)
12. Canopy Locking Latch
Figure 1-1-1: General Assembly of Generator Set
2
3
1
4
5
6
7
9
8
3
10
11
12
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Operation Manual - ITW GSE 6400 Tier 3
1. Cummins QSB4.8-5 Engine
2. Control Module Assembly
3. Battery (inside tray pocket)
4. Battery Disconnect
5. Coolant fill access cover
6. Output Cable Connection
Figure 1-1-2: Main Components of Generator Set (Right Side)
1
2
3
5
4
6
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Operation Manual - ITW GSE 6400 Tier 3
1. Lubricity Additive Fuel Pre-Filter
2. Engine Oil Filter
3. Fuel Filter
4. Engine Oil Fill Tube
5. Generator
6. Air Filter Assembly
7. Engine ECM Module
8. Tie Down Rings Location (Option)
Figure 1-1-3: Main Components of Generator Set (Left Side)
1
2
3
4
5
6
7
8
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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)
3
1
4
1
2
3
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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
Physical
(includes trailer)
Length
103 in. (2615 mm) (w/ towbar up)
Width
66.2 in. (1682 mm)
Height
63.9 in. (1622 mm)
Weight (dry fuel tank)
2929 lbs. (1329 kg.)
Ground Clearance
9 in. (22.86 cm)
c) DC Output Specifications
Output power rating
17.1 kW continuous
Output voltage
28.5 VDC
Rated load capacity
600 A continuous at 28.5 VDC
Starting current capacity
2000 A maximum
Current limiting capability
300 to 2000 A, continuously adjustable
d) DC Protective System Specifications
Condition
Trip Point
Over voltage
32 to 34 volts
High engine coolant temperature
225º F (107º C)
Low Idle oil pressure
10 PSI (69 kPa)
e) Generator Set Specifications
Output power rating
22.8 kW continuous
Rated load capacity
800 A continuous at 28.5 VDC*
Operating speed
1500, 1600, 1800 RPM**
Idle speed
1000 RPM
*The generator rating is limited to 600 A by the current carrying capacity of the output cable.
** The Operating Speed is based on the Current Limit setting:
300A to 1100A –- 1500 RPM
1150A to 1400A –- 1600 RPM
1450A to 2000A –-1800 RPM
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Operation Manual - ITW GSE 6400 Tier 3
f) Engine Specifications
Manufacturer
Cummins, Inc.
Model No.
QSB4.5
Type
4 cylinder, 4 cycle diesel with turbocharger
and fuel injection
Bore and Stroke
4.2 in x 4.88 in (107 mm x 124 mm)
Displacement
275 in3(4.5 L)
Horsepower
110 hp/82 kw @ 2500 RPM
Low Idle speed
1000 rpm
Electrical system
12 VDC
Ground
Negative
Lubricating oil capacity (w/ filter)
11.6 Quarts (w/filter) (11L)
Coolant capacity system
20 Quarts (18.9 liters)
Fuel tank capacity
53 gallons (200 L)
g) Normal Operating Characteristics
Engine oil pressure (warm and at
rated speeds 1600 - 2400 RPM)
45 - 55 PSI
(310 - 379 kPa)
Engine coolant temperature
(normal operation)
180 ºF - 230º F (82ºC to 95ºC)
5) Special Features
The generator set has special features that are described more fully under the assemblies in which
they appear.
a) Protective Monitoring
The protective monitoring system receives signals from the fault sensing components in the
generator output circuit and functions to cause the load to be disconnected from the generator if
an abnormal condition of voltage, frequency, or load develops. The nature of that abnormal
condition is then presented on the graphical display.
b) Voltage Regulator
A microprocessor-type, adjustable voltage regulator provides automatic voltage regulation at the
aircraft. The regulated output is also adjustable for a variety of output cable sizes and lengths.
c) Engine Electronic Control Module (ECM)
The engine is equipped with an electronic control module (ECM) that monitors, records, and
controls engine performance.
d) Battery System Disconnect Switch
The generator set is equipped with a battery disconnect switch outside the unit on the RIGHT
side. The disconnect switch should be placed in the OFF position for long periods of shutdown.
NOTE: DO NOT disconnect the batteries when the engine is running or within two (2)
minutes after the engine stops.
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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. Once the bolt is loosened the canopy
can be slid to the rear and removed by two people for easy access to all engine and generator
components.
We recommend using Simple Green® Industrial Cleaner & Degreaser or an equivalent to clean the
canopy and cable trays.
7) Engine and Generator
The engine and generator comprise the principal components of the generator set. They are mounted
on a galvanized, welded steel frame chassis. The following figures show the locations of all major
components and sub-assemblies.
a) Diesel Engine
The diesel engine is a fuel injection, 4-cylinder, electronically controlled engine rated at 110
horsepower.
b) Engine Manufacturer’s Components
As received from the engine manufacturer, the engine includes some of the following
components, which are more fully described in the engine manufacturer’s manual.
1) Electrical System
The 12 VDC electrical generating and starting system includes an alternator and starter with
solenoid switch.
2) Fuel/Water Filter
The fuel/Water filter is a spin-on disposable type located on the inside of the canopy, near the
engine’s fuel pump. Water that has been removed from the fuel should be removed daily.
(See Chapter 2-1)
CAUTION The use of low lubricity fuels can shorten life and/or damage the engine’s fuel pump.
Only diesel fuel is recommended by the engine manufacturer. Refer to engine
manufacturer’s manual for approved fuels.
3) Oil Filter
The engine oil filter is a spin-on, full-flow type, located on the left side of the engine near the
front.
4) Pre-programmed Electronic Control Module (ECM)
The ECM is a pre-programmed engine control module, mounted directly to the engine block.
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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. It is located on the
FRONT RIGHT of the generator set next to the control box.
To operate the EMERGENCY SHUTDOWN
•Push button in until engine stops or until button travel stops
•Pull the button back out to reset
CAUTION
Do not use the “EMERGENCY STOP BUTTON” as a normal shutdown device.
Damage to the engine turbo charger may result without proper cooling time. Use the
Engine ON/OFF push-button for all normal engine shutdowns.
•Low Fuel Warning System
The low fuel warning system monitors the fuel level in the fuel tank. When the fuel
tank level reaches approximately 10%, a warning is generated signifying it is time to
put fuel in the tank. Once the engine is not running, a low fuel fault is generated and
the engine is not allowed to start.
2) Radiator and Charge-Air-Cooler (CAC)
The radiator and charge-air-cooler is a two-piece type designed for long periods of operation
without servicing.
3) Engine-Cooling Fan
The engine fan is designed to blow air outward through the radiator, rather than pulling air
inward like a conventional fan.
4) Master [Battery] Disconnect Switch
The master disconnect switch is designed to isolate the batteries from the entire electrical
system to eliminate the possibility of battery current draw by the engine ECM or any other
components during long periods of no operation. The switch can also be used to lock-out the
starting circuit of the equipment for maintenance safety purposes.
5) Air Cleaner
The diesel engine air cleaner is constructed so that air enters through its cylindrical body, and
then is filtered before being passed into the engine turbo-charger assembly. An air cleaner
service indicator device is mounted on the air cleaner assembly to monitor the airflow into the
air cleaner. As the air cleaner becomes filled with dust, dirt, and carbon, the intake system
airflow becomes increasingly restricted. This restriction causes a diaphragm inside the
indicator to move toward an electrical contact. When the maximum allowable restriction level
is reached, the circuit closes and the air cleaner indicator fault appears on the control panel
fault display to warn the operator that the air cleaner must be changed. The electrical
indicator automatically resets when the restriction level drops sufficiently. Note: This function
should not be used as a replacement indicator. Follow recommended replacement schedule
as specified in this manual.
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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.
All faults prevent the engine from starting. However, they react differently to an operating unit.
Faults can be categorized into three subcategories as defined by the fault number.
•Fault numbers less than 6000
oMinor faults: Will disconnect power to the aircraft but not affect engine and generator
functions.
•Fault numbers between 6000 and 8000
oMid-level faults: Will disconnect power to the aircraft, turn off the generator and shut
down the engine after the required 30 second cool down.
•Fault numbers greater than 8000
oMajor faults: Result in immediate shutdown of all system components including the
engine. Service is required on the unit before it is returned to operation.
Engine generated warnings and faults are also monitored and their respective Cummins fault
numbers are shown on the display.
e) Generator
The generator is a 3-phase AC generator whose output is rectified. The generator consists of the
generator housing assembly, which holds the stator windings, and a rotor, which holds the control
winding. The generator housing assembly bolts to the engine flywheel housing. A flexible coupling
assembly connects the front end of the rotor to the engine flywheel. At the rear of the generator, a
bearing supports the rotor and brushes and slip rings provide the electrical connection to the exciter
winding.
The generator consists of six windings, which result in 12 numbered output leads. When
connected at the rectifier assembly, these windings form two three-phase delta connections. The
rectifier assembly, described later in this section, converts the three-phase AC to the DC for the
generator set output.
The generator is self-excited. Part of the generator’s output powers the rotating control winding.
One positive and one negative brush in contact with slip rings supply controlled excitation current.
The voltage regulator controls the excitation current and maintains a constant output voltage.
Access to the brushes is through holes in the rear end bracket.
A radial-blade fan behind the coupling hub draws cooling air over the generator windings. Air
flows over the rectifier assembly and then enters through the rear end of the generator and is
discharged through openings in the flywheel housing at the drive end.
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