6400 Tier 4

Manual
6400 Tier 4
28.5 VDC Generator Set Ground Power Unit
Specification.: DCE6400 28.5 VDC Tier 4
Type: OM2248
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
Operation Manual - ITW GSE 6400 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.

Latest diagram versions can be found at www.itwgse.com
Operation Manual – ITW GSE 6400 Tier 4
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 Options
Appendix B Operation in Unusual Service Conditions
Appendix C Software Installation Procedures
Appendix D Schematics
OM2248 Rev B Page 2 of 104

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.

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.

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.

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 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 1-1/16
6) Canopy 1-1/17
7) Engine and Generator 1-1/17
8) Operator Controls 1-1/20
9) Power Module Assembly 1-1/25
10) Cold Weather Starting System 1-1/25
Section 2 Preparation for Use/Storage/Shipment 1-2/26

1) Preparation for Use 1-2/26
2) Preparation for Storage 1-2/28
3) Preparation for Shipment 1-2/29
Section 3 Operation 1-3/30

1) General 1-3/30
2) 28 VDC Operating Procedure 1-3/30
3) Icon Menu 1-3/37
a) View Parameters Menu 1-3/38
b) Setup Menu 1-3/39
c) Black Box 1-3/48
d) Power Log 1-3/49
e) Update/Save Log Menu 1-3/50

Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#
Maintenance Inspection/Check 2-1/53

1) General 2-1/53
2) Maintenance Schedule 2-1/53
Figure 2-1-1 Maintenance Schedule Check Sheet 2-1/54
3) Inspection / Checks 2-1/55
a) General 2-1/55
b) “AR” Checks and Operations (As Required) 2-1/55
c) “BR” Checks and Operations (Break-In Period) 2-1/56
d) “A” Checks and Operations (10 Hours or Daily) 2-1/57
e) “B” Checks and Operations (250 Hour or 3 Months) 2-1/59
f) “C” Checks and Operations (500 Hour or 6 Months) 2-1/60
g) “D” Checks and Operations (1000 Hours or 1 Year) 2-1/61
h) “E” Checks and Operations (1500 Hrs or 1.5 Year) 2-1/62
i) “F” Checks and Operations (2000 Hour or 2 Years) 2-1/63
j) “G” Checks and Operations (Over 10,000 Hours) 2-1/64
k) Seasonal Maintenance Checks Spring/Fall 2-1/64
(E i and
l) Lamps ) Fuses 2-1/64
Figure 2-1-4 Fuse Identification Chart 2-1/64
Section 2 Maintenance Procedures 2-2/65

1) General 2-2/65
Figure 2-2-1 Lubrication and Maintenance Chart 2-2/65
2) Lubrication 2-2/66
a) General 2-2/66
b) Lubrication Schedule 2-2/66
c) Oil Specification 2-2/66
Figure 2-2-2 Lubrication Specifications 2-2/66
d) Changing Engine Oil 2-2/67
Figure 2-2-3 Oil Fill and Check Locations 2-2/67
e) Engine Accessories Lubrication 2-2/69
f) Trailer Lubrication 2-2/69
3) Servicing the Air Cleaner 2-2/70
a) Inspecting the Air Cleaner 2-2/70
Figure 2-2-4 Air Cleaner Assembly 2-2/70
b) Changing the Air Filter 2-2/70
c) Disposal 2-2/70
4) Engine Fuel 2-2/71
a) How to Select Fuel - Quality 2-2/71
b) Cold Weather Operation 2-2/71

Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#

5) Engine Fuel System 2-2/72
a) Fuel Tank 2-2/72
b) Fuel Water Separator or Lubricity Additive Filter 2-2/72
Figure 2-2-5 Lubricity Filter 2-2/72
c) Primary Fuel Filter 2-2/73
Figure 2-2-6 Primary Fuel Filter 2-2/73
d) Fuel Pump 2-2/74
e) Fuel Return 2-2/74
f) Fuel Level Indicators 2-2/74
g) Draining the Fuel Tank 2-2/75
6) Engine Cooling System 2-2/76
a) General 2-2/76
b) Radiator Cap 2-2/76
c) Coolant 2-2/76
d) Draining the Cooling System 2-2/77
e) Flushing the Cooling System 2-2/77
f) Cleaning the Radiator Core 2-2/78
g) Filling the Cooling System 2-2/78
h) Thermostat 2-2/78
7) Engine Drive Belt 2-2/79
8) Generator Maintenance 2-2/79
9) Replacing the Control Board Battery 2-2/80
Section 3 Troubleshooting Procedures 2-3/82

1) General 2-3/82
2) Equipment for Troubleshooting 2-3/82
3) Parts Replacement 2-3/82
4) Normal Operational Parameters 2-3/82
5) Check Connections and Leads 2-3/83
6) Engine Troubleshooting 2-3/83
7) GPU Control Monitoring 2-3/83
8) Cummins Engine Fault Codes & Troubleshooting 2-3/84
9) Troubleshooting Charts/Error Codes 2-3/85
…Engine Controls 2-3/87
…Generator 2-3/90
…Load Contactor Operating Circuits 2-3/91
…Protective Circuit 2-3/92

Chapter 3 Manufacturer’s Literature Chapter-Section/Page#
Appendix A – Options 3-A/95

Appendix B – Operating in Unusual Service Conditions 3-B/97
Appendix C – Initial Software Installation Procedure 3-C/98
Appendix D – Schematics 3-D/101

Chapter 1 Description/Operation
Section 1 Description
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.
Cable Model
Part Number Mounting Power Rating
Management Description
Unit rated
28.5 VDC,
DCE6400CUTT4
Trailer Cable Trays Standard 600 A continuous (17 kW),
2000 A peak (56 kW),
single output
Table 1: ITW GSE 6400 Series Generator Set Part Number Descriptions
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.

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.
10
6 11
4
5 7
3
8
3
12
1
9
1. Fuel Filler Neck / Manual Gauge 7. Radiator End

2. Operator Control Panel 8. Generator End
3. Composite Output Cable Trays 9. Forklift Pockets
4. Emergency Stop Switch 10. Low Fuel Beacon (Option)
5. Sliding/Removable Canopy 11. Operating Beacon (Option)
6. Clearance Lights (Option) 12. Canopy Locking Latch
Figure 1-1-1: General Assembly of Generator Set

7
2
1
8
6
5
1. Cummins QSF2.8 Engine 5. Output Connections

2. Control Module Assembly 6. Output Contactor (mounted under output
3. Battery (inside tray pocket) table)
4. Battery Disconnect 7. Coolant fill access cover
8. Engine ECM Module
Figure 1-1-2: Main Components of Generator Set (Right Side)

5
2 4 7 3 1
4. Engine Oil Fill Tube

1. Lubricity Additive Fuel Pre-Filter 5. Generator
2. Engine Oil Filter 6. Air Filter Assembly
3. Fuel Filter 7. Tie Down Rings Location (Option)
Figure 1-1-3: Main Components of Generator Set (Left Side)

1. Oil Drain Valve

2. Muffler Assembly
3. Fifth Wheel
Figure 1-1-4: Main Components of Generator Set (Bottom)

4) Specifications
a) Standards
This unit has been designed to be in compliance with the following standards:
US EPA Tier 4F/CARB Tier 4F
EU Stage IV
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) 2800 lbs. (1814 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 1600, 2000, 2400 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 –- 1600 RPM
1150A to 1400A –- 2000 RPM
1450A to 2000A –- 2400 RPM

f) Engine Specifications
Manufacturer Cummins, Inc.

Model No. QSF2.8
4 cylinder, 4 cycle diesel with turbocharger
Type
and fuel injection
Bore and Stroke 3.7 in x 3.94 in (94 mm x 100mm)
Displacement 171 in3 (2.8 L)
Horsepower 74 hp/55 kw @ 2400 RPM
Low Idle speed 1000 rpm
Electrical system 12 VDC
Ground Negative
Lubricating oil capacity (w/ filter) 8.66 Quarts (w/filter) (8.2L)
Coolant capacity system 5.3 Quarts (5 liters)
Fuel tank capacity 53 gallons (200 L)
g) Normal Operating Characteristics
Engine oil pressure (warm and at 45 - 55 PSI

rated speeds 1600 - 2400 RPM) (310 - 379 kPa)
Engine coolant temperature
180 ºF - 230º F (82ºC to 95ºC)
(normal operation)
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.

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 171
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)
The use of low lubricity fuels can shorten life and/or damage the engine’s fuel pump.
CAUTION 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.

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.

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
o Minor faults: Will disconnect power to the aircraft but not affect engine and generator
functions.
 Fault numbers between 6000 and 8000
o Mid-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
o Major 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.

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.
a) Operator Controls – Screen icon’s
The table below shows the different icons used in the display and what they mean.
ICON Description ICON Description

Fuel level is below 10%, refuel as soon as
Check Engine
possible
Fuel level is below 10% Fault, engine

Fuel level is acceptable
won’t start until more fuel is added
Exit Icon screen and return to the Default

Critical fault, the engine is stopping
screen
Access the Information screens Access the Setup screens
Access the Black Box logs Access the Power logs
Access the firmware upgrade screens and

the data save screen

1 2
3
4
5
7
6
8
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)
Figure 1-1-5 Control Panel
1: The color LED Graphical Display and easy to use menu system places all required operational
information at the fingertips of the operator/maintenance personnel. Its color presentation accents
critical data and simplifies the troubleshooting process by giving textual descriptions of any
potential issues.
2: The Navigation Keypad is used to navigate through the simple menu systems.
3: The Blue LED indicates that power is ON. (It is off in sleep mode)
4: The Amber LED indicates a warning. The details of that warning are available on the display.
Up to five warnings can be displayed at one time.
5: The Red LED indicates a fault. The details of this fault are also visible on the graphics display.
Only one fault can be displayed at one time.
6: The Green LED’s indicate that the respective output is ON.
7: The current limit buttons increase or decrease the maximum amount of current the unit will
provide to the connected aircraft. The step size is selected in the SETUP menu.

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. If the engine is already running, it will begin the manufacturer required 30
second cool down. If the unit has a fault, this button will reset the fault.
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.
Default Screen:
There are two default displays depending on whether the engine is running or not. When the unit
finishes its self-check after first being powered up, the display will show the number of hours the
engine has been operating. After a short delay, the engine hours are replaced with the current
time. This then becomes the default display when engine is off. (The engine operating hours are
always available on the “Engine” information screen.)
During the engine start process, the screen will be modified to show the current status until the
engine is running and the unit is ready to output power.
Note: If the engine is configured to go to idle until the output is activated, it will still say it is ready
for use. However, the engine will have to ramp up to its normal running speed (1600, 2000 or
2400 RPM) and the voltage stabilized before the output contactor will close. The running speed is
determined by the current limit setting which is shown in the lower right corner of the display.
Current Limit Setting RPM

300 A to 1100 A 1600
1150 A to 1400 A 2000
1450 A to 2000 A 2400

When output power is being provided, the screen will appear as follows:
29.5 V: 94% 560 A

28 VDC
Output Activated
40%
1500 A
The selected current limit is changed by using the up and down arrow keys that are located just
below the navigation buttons. The amount the current limit value changes per button push is
selected in the SETUP menu. The values are 50 A, 100 A, 200 A or 300 A.
Both default screens enable the user to quickly have access to other pertinent information by
pressing the ▼ or▲ navigation buttons to cycle through the display screens:
Pressing the ◄ navigation button will return the screen to the

default menu screen.
Unit information is displayed using the Parameter Information

icon. To access the information icon, press the ● from the
default menu and hold it down for approximately 5 seconds.
Note: Access to the ICON screen might be restricted. If this is
the case, then the message ”DISABLED” is displayed.
Paragraph 4.17 describes how to enable and disable access to
the ICON screen.
To Select a submenu, simply use the navigation keys ◄▼▲►

to highlight the icon and then press the ● to enter the sub-menu.
To leave the Icon Menu highlight the ”Home” icon and press ●

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
Display FW: 075100 F
◄▼▲► keys.
Control FW: 075100 F
Press ● to select ”View parameters” sub-menu. Unit Serial: 215PS00000
Unit Rating: 90 kVA
Use the the ▼/▲ to browse through the various MAC: C8:02:58:00:00:00
screens. ◄ Back ▼/▲ Next/Prev
Use ◄ to leave the sub-menu and return to basic Icon

Menu. SYSTEM
Battl Voltage: 28.1 V

Notice!
Parameters may vary depending on the mode of the unit Hour Meter: 14:57:07
Standby / operating / load profile etc. Consumption: 4527 kWh
PWM Duty Cycle: 0%
28 V
Voltage 28.0 V
Current 600 A
Power 16.8 kW
ENGINE
Engine Load:: 49 %
Engine Hours: 4122
FUEL: 85%
Baro. Pressure: 101 kPa

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. The rectifier converts the generator AC output to DC
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. The amount of time
the air intake heater stays on, in the preheat phase, is a function of the intake manifold temperature at
start up. (The pre-heat time increases with colder intake manifold temperatures). The maximum
duration of the pre-heat phase is around 30 seconds.
CAUTION
Never use an ether start system in conjunction with the air intake heater.
Air Intake Heater
Figure 1-1-6: Air Intake Heater

Operation Manual ITW GSE 6400 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.
2) If Tie Down Rings are present, make sure they are secured with both bolts. (Typically one bolt
is used to secure middle blocks to unit during shipping.)
3) Inspect exterior for shipping damage such as broken lights, damaged sheet metal, etc.
4) Slide the canopy open and inspect the interior for foreign material such as rags, tools,
shipping papers, etc.
5) Check fuel, coolant, oil hoses and connections for visible leaks. Visually inspect compartment
floor and ground surface under unit for signs of leakage. Correct any leaks by tightening hose
clamps, tube fitting, etc., as required.
6) Check tightness of generator set retaining components.
7) Check fuel level. (A manual quick reference fuel gauge is located at back of unit. This gauge
is accurate only when fuel level is above 50%.)
NOTE: For recommended fuel specifications, refer to Engine Manufacturers Operation and
Maintenance Manual provided with this manual.
8) Check engine coolant. Remove radiator cap (under hatch on top of operator section) to check
coolant level. Coolant level should be at bottom of filler neck.
CAUTION
Be sure cooling system antifreeze solution is adequate to protect below lowest
temperature expected.
NOTE: For antifreeze protection, use a solution of 50% permanent antifreeze (Ethylene
glycol) and 50% clean water.
Lubricating oil capacity (w/ filter) 2.9 gallons (11 liters)

Coolant capacity system 5 gallons (18.9 liters)
Figure 1-2-1: Engine Oil and Coolant Capacities

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.
CAUTION
NEVER operate engine with oil level below “L” level or above “H” level mark.
NOTE: See Engine Manufacturer’s Operation Maintenance Manual for oil recommendations.
Dipstick
Oil Fill Cap
Figure 1-2-2: Oil Fill and Oil Level Check Locations
10) Check battery located inside the right-side cable tray. Inspect battery for proper connection of
terminals. Service or replace if necessary.

2) 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.
a) General
Open battery disconnect switch and disconnect battery negative terminal at battery.
1) The unit should be prepared for storage as soon as possible after being removed from
service.
2) The unit should be stored in a building that is dry and can be heated during winter months.
3) Moisture-absorbing chemicals should be used where excessive dampness is a problem;

however, the unit must be completely packaged and sealed if moisture-absorbing chemicals
are to be effective.
b) Temporary Storage (30 days or less)

1) Lubricate unit completely in accordance with instructions in Chapter 2-2 Page 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. (Note: if unit is operated outside of diagnostic mode, it will run for 30
seconds in cool down mode after stop button is pressed.)
NOTE: Do not drain fuel system or crankcase after this run.
3) Cooling system antifreeze solution must be adequate to protect below lowest temperatures
expected during storage period. Be sure solution is thoroughly mixed.
4) Clean exterior of engine. Dry with clean rags and compressed air.
5) Seal all engine openings. Use water-proof, vapor-proof material strong enough to resist
puncture damage from air pressure changes.

c) Long-Term Storage (Over 30 Days)

To protect the generator and other electrical components, the complete unit should be packaged
using moisture proof packaging and sealing material. Place containers of moisture-absorbing
chemicals in unit before packaging.
From the Cummins 4BT shop manual: long term storage is up to 24 months. Change the oil and
fill with 30W Preservative oil. Then start the engine with clean diesel fuel (the units needs to be
filled with at least 10% or more of fuel in order to start) and then switch fuel lines to a can of
preservative oil (Cummins specifies Dauber Chemical NoxRust # 518). When the preservative oil
is running out the injector return tube turn off the motor and cap ends of fuel return and supply
tubes. Drain 30W preservative oil from crankcase. Add rust inhibitor to the coolant and make sure
that the radiator is full. Spray preservative oil into intake and exhaust ports on cylinder head and
under rocker housing covers. Cover all openings. Do not rotate crankshaft. Drain the fuel tank.
The unit can be stored for long periods without the above preparation if engine can be operated
once a week.
When operating once a week:
1) Make certain the cooling system is adequately protected.
WARNING ENSURE adequate ventilation before starting the engine.
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. If weekly operation is not possible, contact nearest engine
manufacturer distributor for instructions.
3) Preparation for Shipment
a) Disconnect battery negative terminal before shipping.
b) During long shipments, vibration, jolting, etc may loosen the generator set retaining hardware.
When shipping unit, provide sufficient retaining materials to ensure generator set
CAUTION
cannot roll out or off the vehicle in which it is being transported.
NOTE: It is suggested strong banding is used to secure generator set.

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.
NOTE: Read ALL operating instructions before attempting operation of equipment.
WARNING
Ear protection equipment may be necessary when working close to this equipment.
2) 28 VDC Operating Procedure

a) Pre-start Inspection
1) Check engine and generator compartments to make certain they are free of rags or other foreign
materials.
2) Make certain sufficient lubricating oil and coolant is in the engine.
3) Be sure that the battery isolation switch is closed, ensuring that 12 VDC power is available to the
engine starting and control systems.
4) Make certain the control panel is on. If not, press the Power ON/Engine Start-Stop button to wake
the unit.
b) Engine Starting Procedures
CAUTION
Refer to operating instructions in the engine manufacturer’s operation manual
(provided with the unit), when starting engine for the first time.
1) Press and release engine “Start” button. The remaining portion of the startup procedure is
automated. Startup status is shown on the display. The procedure will begin by providing power to
the engine and other vital components. Next it will check the engine to insure proper operation.
Once verified, the engine data begins processing and the engine will start its initialization and
warmup procedures. When finished, the starter will begin to crank.
2) If the Idle Mode is active (default), once the engine starts it will quickly ramp to idle speed of 1,000
RPM and hold until an output pushbutton is pressed or the unit runs out of fuel.
3) If the Idle Mode is inactive, the engine starts and ramps up to its idle speed of 1,000 RPM pauses
for a moment and then continues to ramp up to its running speed of 1600 to 2400 RPM (the actual
running speed is determined by the current limit setting) and stays there until an output pushbutton
is pressed or the unit runs out of fuel.
4) Once the engine is running at idle or rated speed, check the oil pressure to make certain it is
normal and observe all other engine values on the display screen for normal operation.
CAUTION
Never use an ether start system in conjunction with the air intake heater.

1
3
4 2
6
8
7
5. Alert/Failure "Red" LED

1. LED Graphical Display
6. Current Limit Adjustment Buttons
2. Navigation Keypad
7. Output ON "Green" LEDs
3. Power ON "Blue" LED
8. Output ON/OFF (Reset) *
4. Warning "Amber" LED
9. Power ON & Engine Start/Stop (Reset) *
* All output and engine buttons are multitasking buttons dependent on the status of the unit. The
displayed screen is NOT important. These buttons are always active.
CAUTION
To eliminate the possibility of wet stacking (See Appendix B), DO NOT allow the
engine to idle for long periods.
c) Failed Starting Procedure

If an error during initialization occurs the engine fails to start after 3 automatic attempts (15 seconds
crank, 15 seconds wait per attempt), the display will show a fault. Diagnose and treat the reason for the
fault, clear the fault, and press the engine start button again.

d) Power Delivery
After the engine has started and the display has changed to the output status default screen, insert the
aircraft cable into the aircraft. Make sure the cable is inserted until you feel a natural resistance. The
plug may be equipped with a 90% insertion switch (split “C” pin). In this case, the unit will not function if
the plug is not fully inserted. Press the output ON/OFF button. If the unit is already at rated speed, the
contactor will immediately close. If at idle speed the engine will ramp up to rated speed, the generator
will set output voltage and the contactor will close. The green LED will turn ON next to the active output.
In addition, current power status information will appear on the output status default screen.
WARNING
All output ON/OFF buttons are active regardless of the displayed screen.
1) Early in the power delivery run it is recommended that the operator check output voltage and
current in each of the three phases. Use ▼ ▲ pushbuttons to view voltage. If the load is changing,
observe the display until load conditions stabilize.
2) A condition of over-voltage, under-voltage or overload in the output circuit will automatically open
the load contactor and display a fault code to signal the operator which of the above faults caused
the protective monitor system to operate. After the fault has been corrected, press the output
pushbutton to reset the system. Proceed with power delivery by pressing the same switch.
WARNING
NEVER disconnect the output cable while power is being delivered. Output
contactor’s must be open prior to removal of the cable from the aircraft.
CAUTION
The generator set must be shut down so the failed power delivery problems can be
diagnosed. Only personnel who are trained or qualified on this type of equipment
should work on this GPU.
e) Failed Power Delivery

If the contactor indicator light goes out and EF fault is shown on the display, this indicates that the
aircraft plug interlock circuit is no longer receiving 28.5 VDC from the aircraft power connector. Correct
the condition and press the output pushbutton to reset the fault. Press the button again to close the
output contactor and provide 28.5 VDC to the aircraft/load bank.
1) If the aircraft cable does not have the Split-C wire, set the 28V Interlock to Bypassed through the
Setup icon menu using the following steps:
2) Press and hold ●

for approximately 5 seconds. (If the ICON screen doesn’t appear and
“DISABLED” appears in the display screen, contact the Maintenance department for access to the
SETUP menu to unlock.)
3) Use the navigation keys (◄▼▲►) to highlight the setup icon. Press ● to select.
4) Set EF interlock to bypass.
5) Press ● to accept the change.

6) Use the ◄ navigation key to go back to the Icon screen. The display will return to the default
screen after a period of inactivity.

f) 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.
Once all contactors are opened:
a) If Idle Mode option is active (default), the generator will turn off and the engine will return to
idle speed after a 5 second delay.
b) If Idle Mode is inactive, the generator will turn off and the engine will remain at rated speed.
c) Pushing the engine Start/Stop pushbutton once while the engine is running begins the
automatic shutdown sequence which will shut off the engine after 30 seconds.
d) If the Engine Shutdown option is active, ten minutes after all outputs are opened (OFF) the
engine will slow to idle speed and 30 seconds later it will shut down.
2) Emergency conditions
a) Depress the “EMERGENCY STOP BUTTON” located on front of the unit to the right of the
control panel. When pushed, this button shuts the generator set off. Pull the button back
out to reset it before restarting the generator set.
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 pushbutton for all normal engine shutdowns.
b) A condition of over-voltage, under-voltage or overload in the output circuit will automatically

open the load contactor and display a fault code to signal the operator which of the above
faults caused the protective monitor system to operate. After the fault has been corrected,
press the respective output pushbutton to reset the system. Proceed with power delivery
by pressing the same switch.
g) Low Fuel Warning and Fault
1) A Low Fuel Warning occurs when the unit is running and fuel levels drops below 10% in the fuel
tank. The unit will continue to operate until it is out of fuel or the operator shuts off the engine.
2) A Low Fuel Fault will display if the fuel level is below 10% and the engine is off. The engine can’t be
started until the fuel level is above 10%.
h) Display
1) The display will automatically turn off if the engine has been off at least 10 minutes. Pushing any
button will return the display to full brightness. However, if there is a warning or fault message on
the display, it will not turn off.
2) If the display is off, and the battery disconnect switch is closed, press the Engine pushbutton to
return the display to full brightness.
i) 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
12 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.

3) Starting the 28.5 VDC generator set
CAUTION
The unit can deliver up to 2000 amps of current during the starting of an aircraft
engine. This much current will shear the propeller shaft of some aircraft. Therefore,
make sure that the current limit is correctly set for the aircraft that is being powered.
1) Default setup values

28 V Voltage (V): 28.5 VDC
28 V Compensation (V/600A): 0.0 (Set if GPU supplied with cable)
28 V Current Limit (A): 800 A
Output Mode: Simultaneous
Fan Control: Normal
Plug Temperature: Normally Open
2) Adjusting the Current Limit
a) The unit remembers the last current limit that was selected. This value will be used whenever the
28VDC output is turned on.
b) If the current limit needs to be changed, use the following procedure:
i. With the unit’s engine running and the 28 VDC power is off, the up or down arrows in the
current limit section can be used to change the current limit value. The step size used for
changing the current limit is set in the Current Limit Step Size setup menu screen.
ii. Once the correct value is selected, use the below procedure to start the unit.

With the engine running and DC

power OFF, press the “Up arrow” With the engine running and DC
to increase the DC current limit. power OFF, press the “Down
arrow” to decrease the DC current
limit.
3) Providing 28.5 VDC power.

a) With the engine running and the output cable securely inserted into
the aircraft power receptacle, press the ON/OFF/Reset button to
start providing 28.5 VDC power to the aircraft.
b) During operation, various parameters can be viewed via the display. Use the navigation keys ▼▲
to browse through the available screens:

c) 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. Once the cool
down period is finished, the engine will turn off. Always ensure that the output is off before removing
the aircraft plug.
Note!
Please note that the 28 VDC Start/Stop button also functions as a Reset push button.
If, for some reason, the unit stops due to an error / failure, record the fault number and message and forward
this information to your maintenance personnel. If the fault is no longer active, press the Start/Stop/Reset to
reset the alarm and the unit.

3) Icon Menu
The Icon Menu can only be accessed from the Default screen. Press the center navigation button ● while in the
default menu and hold it down for approximately 5 seconds. If access to the Icon menu has been locked out,
the word DISABLED will be displayed when the center button is pressed. Enter the correct unlock pattern and
then press and hold the center button for approximately 5 seconds.
Center Navigation
Button

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.

b) 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.

Setup (continued) – Menu structure
11:27:47 Setup Menu 28/06/2013
Settings:
Cable Temperature
Normally Open Normally Open
Normally Closed
Refer to Section 3 – 4.7

◄ Back ● Modify
11:27:47 Setup Menu 28/06/2013 11:27:47 Setup Menu 28/06/2013
Cable Temperature
Settings:
Allow Engine Idle Allow Engine Idle
Automatic Engine Shutdown Enabled Enabled
Real Time Clock Setup
Date / Time Format Disabled
Ethernet Configuration
◄ Back ● Select Parameter. ◄ Back ● Modify
11:27:47 Setup Menu 28/06/2013
Settings:
Highlight the by using the Automatic Engine Shutdown
navigation ◄▼▲► keys. Bypassed Bypassed
Active
Press ● to select ”Setup” sub-menu. Refer to Section 3 – 4.9

◄ Back ● Modify
Use the the ▼/▲ to browse through the
various set-up lines / parameters. The
selectable line will be highlighed in 11:27:47 Setup Menu 28/06/2013
green. Settings in additional sub-menu:

Real Time Clock Setup
Month , Day, Year, Hour, Minute,
Press ● to select the parameter you Second
want to change.
◄ Back ● Modify
Press ● to Modify the parameter.
Parameter will now be highlighted in
green. 11:27:47 Setup Menu 28/06/2013
Settings:
Use the the ▼/▲ to adjust parameter. Date / Time Format HH:MM:SS I DD:MM:YYYY
HH:MM:SS I DD:MM:YYYY HH:MM:SS AM I MM:DD:YYYY
Press ● to save changes. Refer to Section 3 – 4.11
Use ◄ to leave the sub-menu and ◄ Back ● Modify
return to The basic Icon Menu.

11:27:47 Setup Menu 28/06/2013
Settings in additional sub-menu:
Notice! Ethernet Mode
Availability of parameters may vary Ethernet Configuration IP Address, Subnet Mask,
depending on the mode of the unit Gateway, DNS1
Standby / Engine Running etc.
Format: 000.000.000.000
◄ Back ● Modify

11:27:47 Setup Menu 28/06/2013
Settings:
Modbus Slave Address
1 1 – 247
◄ Back ● Modify
11:27:47 Setup Menu 28/06/2013

Settings:
LED Brightness Low
Low Medium
11:27:47 Setup Menu 28/06/2013 High
Modbus Slave Address
LED Brightness
Unit of Measure ◄ Back ● Modify
Diagnostic Mode
Menu Lock Bypass
Battery Replaced
11:27:47 Setup Menu 28/06/2013
◄ Back ● Select Parameter.
Settings:
Unit of Measure
Imperial Metric
Imperial

Highlight the by using the ◄ Back ● Modify
navigation ◄▼▲► keys.
Press ● to select ”Setup” sub-menu. 11:27:47 Setup Menu 28/06/2013

Settings:
Disabled
Diagnostic Mode
Use the the ▼/▲ to browse through the Disabled
Engine Only
various set-up lines / parameters. The AVR Battery Only
Engine Interface
selectable line will be highlighed in
green. Refer to Section 3 – 4.16
◄ Back ● Modify
Press ● to select the parameter you

want to change. 11:27:47 Setup Menu 28/06/2013
Settings:
Press ● to Modify the parameter. Menu Lock Bypass Disabled

Disabled
Parameter will now be highlighted in Enabled
green.
◄ Back ● Modify
Use the the ▼/▲ to adjust parameter.
11:27:47 Setup Menu 28/06/2013
Press ● to save changes.
Warning: Do not confirm unless the Settings:
Control Board battery has been
Use ◄ to leave the sub-menu and replaced. Yes
return to The basic Icon Menu. No
Confirm Battery Replaced
Notice! No
Availability of parameters may vary ◄ Back ● Modify
depending on the mode of the unit


11:27:47 Setup Menu 28/06/2013

Settings:
Language English, French, German,
English Italian, Polish, Portuguese, etc.

◄ Back ● Modify
11:27:47 Setup Menu 28/06/2013
Language
◄ Back ● Select Parameter.
Use the the ▼/▲ to browse through the

various set-up lines / parameters. The
selectable line will be highlighed in
green.
Press ● to select the parameter you

want to change.
Press ● to Modify parameter.

Parameter will now be highlighted in
green.
Use the the ▼/▲ to adjust parameter.
Press ● to save changes.
Use ◄ to leave the sub-menu and

return to basic Icon Menu.
Notice!
Availability of parameters may vary
depending on the mode of the unit

1) 28V Voltage
This Setup submenu allows the 28 volt output to be adjusted between 19.0 VDC and 33.0 VDC using
the UP and DOWN navigation buttons. (Please note that the acceptable voltage range for all
commercial DC powered aircraft is 26V to 29V.
Enter the Setup Menu and then scroll up or down to the 28V Voltage submenu. Press the center ●
button to enter the submenu, and then press the ● button again to allow the value to be 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.
2) 28V Compensation
a) DC voltage drops quickly as the current increases over a given length of cable. This Setup
submenu allows the 28 volt output to be automatically adjusted as the load increases. The allowed
setting is between 0.0 and 3.0 VDC per 600 amps. Note that the maximum output voltage of the
unit is 33 VDC.
b) Enter the Setup Menu and then scroll up or down to the 28V Compensation submenu. Press the
center ● button to enter the submenu, and then press the ● button again to allow the value to be
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.
3) Current Limit Step Size
a) If too much current is supplied to an aircraft engine, it is possible for the engine to shear the
propeller shaft. The Current Limit should be set to the maximum current the aircraft to be powered
can take (per the aircraft manufacturers recommendations). The Current Limit is set using the UP
and Down arrows on the Operators Panel. This submenu is used to set the step size the current
limit is changed by every time the UP or Down button is pressed. The current limit settings are from
300 amps to 2000 amps in steps of 50/100/200/300 amps. This menu selects the size of the steps
that the operator uses to adjust the current limit before turning on the 28 VDC to the aircraft.
b) 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. 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.
4) 28V Interlock
a) The 28V interlock is a personnel and equipment safety feature. This 28VDC signal will not be
present until the GPU closes its output contactor and provides power to the aircraft connector. The
connector typically has a split “C” socket with +28VDC on one side and a jumper to the return wire
on the other side of the socket. The GPU will not keep the output contactor closed if this voltage is
not detected on the return wire in the cable. (This option requires a special cable such as the
JB2840-30CS, JB2840-40CS or JB2840-50CS.)
Note! The value will be automatically reset to Active if the unit detects 28 volts on the "F" pin input of
the I/O board.
b) Go into the Setup Menu and then scroll up or down to the 28V Interlock submenu. Press the center
● button to enter the submenu, and then press the ● button again to allow the value to be 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.

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 28V Interlock Delay submenu. Press the
list.
6) Aircraft Connector Insertion
a) Some aircraft power cables are equipped with a split "C" socket in the connector. This device sends
a 28 VDC signal to the unit when the connector is inserted at least 90% of the way into the aircraft
power receptacle. Set this sub-menu value to Enable when such a cable is connected to the unit.
The default value is set to Disable.
b) Go into the Setup Menu and then scroll up or down to the Aircraft Connector Insertion submenu.
Press the center ● button to enter the submenu, and then press the ● button again to allow the
value to be 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.
7) Cable Temperature
a) Some aircraft cables have temperature sensors installed in the connector body and/or replaceable
nose. This sub-menu allows the unit to accept Normally Opened or Normally Closed temperature
sensor switches to be used.
b) Go into the Setup Menu and then scroll up or down to the Plug Temperature submenu. Press the
list.
8) Allow Engine Idle
a) When this option is set to Enable, the engine will ramp up to its idle speed (1,000 RPM) and wait for
an output to be turned on. Once an output is turned on, the unit will ramp up to its running speed
(1,600, 2,000 or 2,400 RPM) and energize the generator and close the selected output contactor
when the generator is stabilised. The unit will return to idle speed five seconds after all outputs are
turned off.
b) Enter the Setup Menu and scroll up or down to the Allow Engine Idle submenu. Press the center ●
button to enter the submenu, and press the ● button again to allow the value to be changed. Press
the up or down arrow buttons to change selection. Press the center ● button to record the new
9) Automatic Engine Shutdown
a) If the engine is running at its rated speed and all outputs are off for ten (10) minutes or the total load
is less than 5 amps, the engine will automatically go into its 30 second shutdown mode when this
function is active. The Setup submenu allows this option to be activated or bypassed.
b) Enter the Setup Menu and then scroll up or down to the Automatic Engine Shutdown submenu.
Press the center ● button to enter the submenu, and then press the ● button again to allow the
value to be 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.

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
be 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.
11) Date/Time Format
a) The date and time format that is displayed on all the screens and reports can be adjusted using this
submenu. The selection is a 24 hour clock and DD:MM:YYYY date format or a 12 hour clock with
the MM:DD:YYYY date format.
b) Go into the Setup Menu and then scroll up or down to the Date/Time Format submenu. Press the
list.
12) Ethernet Configuration
a) The sub-menu s allows the user to enter the Ethernet IP address, Subnet Mask, Gateway address
and DNS1 values for TCP/IP communications with a BMS or RMS central monitoring system.
b) Go into the Setup Menu and then scroll up or down to the Ethernet Configuration submenu. Press
be changed. Press the up or down arrow buttons to change selection. Press the center ● button to
list.
13) Modbus Slave Address
a) If the unit will be part of an RS-485 Modbus RTU BMS/RMS monitoring system, it must be assigned
a Modbus Slave Address. This sub-menu allows the user to enter the slave address.
b) Go into the Setup Menu and scroll up or down to the Modbus Slave Address submenu. Press
center ● button to enter the submenu, and press the ● button again to allow the value to 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.
14) LED Brightness
a) The unit status LED’s have three brightness levels. The default is set to medium.
b) Go into the Setup Menu and then scroll up or down to the LED Brightness submenu. Press the
list.
15) Unit of Measure
a) This submenu is used to set the unit of measurements to Metric or Imperial.
b) Go into the Setup Menu and then scroll up or down to the Unit of Measure submenu. Press the
list.

16) Diagnostic Mode Disabled

a) This setup submenu is used to assist in the troubleshooting procedure. The default setting is
“Disabled”; use the “Engine Only” to verify engine performance. The “Engine Interface” allows read
only access to the engine ECM module. In the “Engine Interface” mode, the engine ECM will
perform a self-test and then enter its Run mode. (The display will indicate running in the engine
screen). In this mode the output contactor can be toggled on and off to verify that is functioning
correctly.
b) The engine must be stopped before any of these modes can be changed.
c) Enter the Setup Menu and then scroll up or down to the Diagnostic Mode submenu. Press the
list.
17) Menu Lock Bypass
a) This submenu is used to lock out the center button on the navigation keypad which will prevent
access to the ICON screen. Disabled allows access to the Icon screen when the center button is
pressed for 5 seconds. Enabled locks out the center button. When the center button is pressed the
screen will display DISABLED. Technicians can gain temporary access to the Icon menu by
performing the following sequence of button presses: Right Arrow, Up Arrow, Down Arrow, Down
Arrow. Holding the center button again (approx. 5 seconds) will take you to the main Icon menu.
The default is set to disabled.
b) Go into the Setup Menu and then scroll up or down to the Menu Lock Bypass submenu. Press the
list.
18) Confirm Battery Replaced

Situated on the back of the control board, is a coin type lithium battery which ensures that Firmware /
Set-up data etc. are not lost during utility drop-outs. The expected life of the battery is approximately 7
years. Note, a low battery voltage does not affect the internal safety system of the GPU that monitors
the output voltage, among others. Thus, aircraft connected to the GPU are not exposed to any danger.
However, to avoid loss of data and Control Board lock up *, we recommend changing the battery after 5
years of use.
Note!
A time stamp is stored in the ID chip (A6) upon production and after 5 years a warning occurs at the
display, telling the user/operator to replace the Control Board battery. It is strongly recommended to
change the battery when this message is shown:
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). If this message is
ignored for 6 months, the controls will be locked out and the below failure message will be displayed.
Fig. 8.2.2
The battery must be changed before the unit can be operated again.
To ensure high reliability of the back-up battery, the only type of battery that can be used on
the Control Board is the Panasonic BR-2032
Go into the Setup Menu and then scroll up or down to the Confirm Battery Replaced submenu. Press
the center ● button to enter the submenu, and then press the ● button again to allow the value to be
record the new value. Press the LEFT arrow button to exit the submenu and return to the submenu list.
19) Language
This submenu is used to change the language that all of the display screens, messages, alarms and
reports are displayed in. The unit comes with English, French, German, Italian, Polish, Portuguese,
Czech, Russian, Turkish and Spanish already installed. Other languages can be added as required.
The default is set to English.
Go into the Setup Menu and then scroll up or down to the Language submenu. Press the center ●
button to enter the submenu, and then press the ● button again to allow the value to be changed. Press
the up or down arrow buttons to change the selection. Press the center ● button to record the new

c) Black Box

d) 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.

e) 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.
Update/Save Log – Menu structure
10:30:00 USB MENU 28/06/2013
USB Firmware Update Detected
Do you wish to update?
Press ● to update firmware
10:30:00 USB MENU 28/06/2013

10:30:00 USB MENU 28/06/2013
Update Display Software
Update Control Card Software
Save Logs Update in Progress
Do not turn off or reset during update
18%
◄ Back ● Select
10:30:00 USB MENU 28/06/2013
Updating Display
Highlight the by using the navigation ◄▼▲► Update Succesful! Please Reboot!
keys.
Press ● to select ”Update/Save Log Menu” sub-menu.
The default function ”Update Display Software”

is green highlighted. If another function is wanted, use
the the ▼/▲ to highlight the function.
Before pressing ● to select ”Update Display Software”,

please remember to insert a USB stick into the USB port
on the Display (located on the side of the Display
enclosure inside the unit).
Press ● to select the function.
Press ● to confirm update firmware.
The firmware is now being uploaded to the display card.

Upload % is counting from 0% to 100%. The system
automatically reboots if the update is successful.
Otherwise, an Update has failed! Message is displayed.

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 28/06/2013
Update Display Software

Update Control Card Software Updating Control Card
Save Logs
8%
◄ Back ● Select
10:30:00 USB MENU 28/06/2013
Updating Control Card

Highlight the by using the navigation
Update Succesful! Please Reboot!
◄▼▲► keys.
Press ● to select ”USB Menu” sub-menu.
Use the the ▼/▲ to highlight the function

”Update Control Card software”.
Before pressing ● to select ”Update control card

software”, please remember to insert an USB stick
into the USB port on the control card (located on
the interface board).
Press ● to select function.
Press ● to confirm update firmware.
The firmware is now being uploaded to the display

card. Upload % is counting from 0% to 100%. The
system automatically reboots if the update is
successful. Otherwise, an Update has failed!
Message is displayed.
USB connection
Control card


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.
Warning
STOP operations at once if a serious or possibly dangerous fault is discovered
2) Maintenance Schedule
a) General
A periodic maintenance schedule should be established and maintained. A suggested schedule
is provided in Figure 2-1-1 on the following pages. It may be modified, as required to meet
varying operating and environmental conditions. It is suggested that generator set and vehicle
inspections
be coordinated as much as possible.
b) Maintenance Schedule Check Sheet
It is strongly recommended that the customer use a maintenance schedule check sheet such
as the one in the engine manufacture’s operation manual. The check sheet will provide a record
and serve as a guide for establishment of a schedule to meet the customer’s maintenance
requirements for his specific operation.
c) Time Intervals.
The schedule is based on both hours of operation and calendar intervals. These two intervals
are not necessarily the same. For example, in normal operation the oil change period, based
on hours of operation, will be reached long before the three months calendar period. The
calendar period is included to make certain services are performed regularly when the
equipment is stored, or being operated infrequently. Lubricating oil standing in engines that are
stored, or used very little, may tend to oxidize and may require changing although it is not dirty.
Perform all services on a whichever- comes-first basis.
d) Identification of Interval Periods.
Each interval period is identified by a letter A, B, C, etc. For example, services under B
schedule should be performed at the end of each 250 hours of operation, or every three
months, BR service is performed during the BREAK IN period (first 50-150 hours) and AR
service is performed AS REQUIRED.

WARNNGHourly Interval AR 50-150 10 250 500 1000 1500 2000
Calendar Interval Once Daily 3 Mo. 6 Mo. 1 Yr. 1.5 Yr. 2 Yr.
Symbol AR BR A B C D E F
Engine
Change Air Cleaner Cartridge X
Check Coolant Hose and Clamps X
Check Crankcase Oil Level X
Drain Fuel PreFilter Elements X
Check Coolant Level X
Check for Leaks and Correct X X
Check Air Cleaner Indicator X
Check Exhaust System X X
Charge-Air-Cooler (CAC) and Piping X
Change Lubricity Fuel Filter Element X X
Check Radiator Core and Hoses X
Check Oil Pressure and Record X
Change Crankcase Oil X X
Change Oil Filter Element X X
Check Engine and Generator Mounts X X
Check Coolant, Additive-Concentration X X
Check Fan Hub and Drive Pulley X
Check Hose Clamps on Air Intake Side X X
Check Belt Conditions and Tensioner X X
Check and/or Adjust Valve Clearance X
Check Water Pump X X
Steam Clean Engine X X
Clean Fuel System X
Check Alternator X
Check Starter Motor X
Check Vibration Damper X
Check Cooling and CAC systems X
Figure 2-1-1 Maintenance Schedule

(Sheet 1 of 2)

Hourly Interval AR 50-150 10 250 500 1000 1500 2000
Calendar Interval Once Daily 3 Mo. 6 Mo. 1 Yr. 1.5 Yr. 2 Yr.
Symbol AR BR A B C D E F
Engine (continued)
Flush and Change Coolant X
Drain & Inspect Fuel Tank X X
Check Fan Mounting Spring & Fall

Clean Cooling System Spring & Fall
Check Hoses Spring & Fall
Clean Electrical Connections Spring & Fall
Check Thermostats and Seals Fall
Electrical (12 VDC System)
Check All Lights X
Check Alternator Charging Rate X
Check Battery X
Clean Battery Terminals X X
Check Wiring and Connections X
Check All Engine Meters X
Note: “G” service (10,000+ hours) items are covered in section j) below.
Figure 2-1-1 Maintenance Schedule
(Sheet 2 of 2)
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
i. Replace the air filter when the “Air Filter Clogged” warning is displayed. These filters
should not be washed because washing breaks down the material inside the filters.
ii. Check and tighten, as required, all coolant hose clamps, air intake hose clamps and
exhaust clamps. Check all coolant hoses, air intake hoses and exhaust pipes for leaks.

b) Electrical System (12 VDC) – Check Battery Terminals

i. Periodically, open the battery compartment panel in the right cable tray and visually
check the battery cable connectors and battery posts. If corrosion is observed,
disconnect the cables and clean battery posts and connectors with a wire brush or
special battery post-cleaning tool. Coat the posts and connectors with a light film of
petroleum lubricant before reconnecting the cables.
c) Electrical (28.5 VDC System) -- Check Output Voltage
i. Check the output voltage and be sure it is set for 28.5 VDC System. Adjustment can be
made using the Setup menu. (See Chapter 1-3, paragraph 3.a.)
c) “BR” Checks and Operations (Break-In Period, Once After 50-150 hrs.)
The following procedures are precautionary measures taken on most new engines. If a problem
occurs with any of the following issues, be sure to recheck it after the next 50-150 hours.
1) Engine
a) Check for leaks and correct. This involves an overall inspection of the engine and may
require some maintenance if leaks are found. Refer to the engine manufacturer’s
operations manual for assistance.
b) Change all fuel filter elements. Metal shavings from the new fuel tank can clog the filter.
c) Change crankcase oil. New engines often release metal shavings more frequently.
Therefore, the crankcase oil must be changed as a precautionary measure.
d) Change oil filter element. The oil filter should be changed with the oil.
e) Check engine and generator mounts to ensure they are properly installed and they have not
worked loose. (Torque is set at 100 N-m, 73.7 ft-lb.).
f) Check coolant additive concentration. Refer to the engine manufacturer’s operations
manual for assistance.
g) Steam clean the engine to free it of oil and dirt to prevent uneven engine cooling “hot
spots”. The oil and dirt can also fall into the engine and fuel system when covers are
removed during repair work.
h) Inspect the water pump weep hole for indication of a steady leak. If a steady flow of coolant
or oil is observed, replace the water pump with a new or rebuilt unit. Refer to the engine
manufacturer’s operations manual for assistance.

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.
i. Check oil level daily with oil gauge dipstick.

ii. Oil level should not be checked until 3 to 5 minutes after engine shutdown. Keep oil level
as near the upper bar as possible.
b) Drain Fuel Lubricity Filter/Pre-Filter Element
The life of the fuel pump and injectors can be extended if the operator drains about a cup
of fuel from the fuel pre-filter element to remove water and sediment before starting the
engine each day.
CAUTION
BE SURE to prime and bleed the fuel system after draining the filters, replacing filter
element, or if the fuel tank has run empty. Failure to do so can cause engine-starting
problems.
i. Provide a container for catching drained fuel.

ii. Open the drain valve on the fuel/water filter by turning it counterclockwise.)
iii. Drain the filter until clear fuel is visible.
iv. Tighten the drain valve.
v. Safely dispose of drained fuel.
vi. Purge air from fuel system if necessary.
c) Check Coolant Level
i. 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.
d) Check for Leaks and Correct

At each daily start-up, check for coolant, fuel, and oil leaks. Coolant leaks may be more
noticeable when components are cold. Observe pumps, hoses, fittings, gasket connections,
etc., for signs of leakage. Correct as required.

Water Drain
r 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.
f) Check Exhaust System.
Visually inspect muffler and exhaust pipes for rust and signs of approaching failure.
Listen for any gasket or joint leaks.
WARNING
A leaking and defective exhaust system could be a fire hazard.
2) Electrical System (12 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.
b) Check Engine Battery Voltage.
Observe the engine voltmeter each time the engine is started to be sure the alternator is
functioning correctly and charging the batteries. If the batteries need to be replaced, be sure
the replacements meet the specifications for Cold Cranking Amps (CCA) and Reserve
Capacity.
c) Check the operation of all the engine indicators.

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.
Verify that the voltage, amps and frequency readings are displaying correctly (use up and
down arrows) each time the unit is started.
e) “B” Check and Operations (250 Hours or 3 Months).
1) Engine.
a) Prevent Diesel Engines Wet Stacking.
All diesel engines operated for extended periods under light load may develop a condition
commonly referred to as wet-stacking. This condition results from the accumulation of
unburned fuel in the exhaust system. It is recognizable by fuel oil wetness around the
exhaust manifold, pipes, and muffler along with an excessive amount of soot.
Wet-stacking is common, and can be expected in diesel engines operated under light loads.
Light loads do not allow the engine to reach the most efficient operating temperature for
complete combustion of fuel and will also increase the fuel consumption rate. The unburned
fuel collects in the exhaust system to create the wet condition known as wet-stacking.
To alleviate wet-stacking in lightly loaded engines, it is recommended that the machine be
connected to a load bank after each 250 hours of use and operated under full rated load for
one hour. This will burn away and evaporate the accumulation of fuel and soot in the exhaust
system. This clean-out procedure should be considered as a regular maintenance operation
for machines operated under light loads.
b) Charge-Air-Cooler and Piping.
i. Inspect the charge-air-cooler for dirt and debris blocking the fins. Check for cracks,
holes, or other damage.
ii. Inspect the pipes and hoses for leaks, holes, cracks, or loose connections. Tighten
the hose clamps if necessary.
c) 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. A comparison of pressure at idle speed with previous readings will
give an indication of progressive wear of oil pump, bearings, shafts, etc. Investigate any
abnormal change in pressure readings.

d) Check Radiator Core and Hoses.

i. Inspect the radiator core for dirt and debris blocking the fins. Clean as necessary.
Check for cracks, holes, or other damage.
ii. Check Fuel Pump.
iii. Inspect the fuel injection pump mounting nuts for loose or damaged hardware.
2) Electrical (12 VDC System).
NOTE: The battery furnished with this generator set is MAINTENANCE FREE. Check battery
terminals and clean if necessary.
a) Check the battery terminals and clean if necessary.
f) “C” Checks and Operations (500 Hours or 6 Months)
1) Engine.
a) Check Engine and Generator Mounts
CAUTION
An unstable or loosely mounted engine can create hazardous environment and may
damage equipment.
i. Engine mount bolts must be torqued to 100 N-m (73.7 ft-lb.).

ii. Generator mount bolts must be torqued to 100 N-m (73.7 ft-lb.).
b) Change oil and oil filters.
c) Change all fuel filters.
d) Check Coolant Additive Concentration.
The cooling system protective liquid (nitrite-, amine- and phosphate free) provides
effective protection against corrosion, cavitation, and freezing. See engine
manufacturer’s operation manual for ordering and mixture details.
2) Electrical (12 VDC system).
3) Wiring.
a) Inspect all cables and leads for worn or damaged insulation.
b) Connections.
i. Inspect connectors for damaged or corroded condition.

1) Electrical (28.5 VDC 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.
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.
a) Check Fan Hub and Drive Pulley.
Inspect for loose bolts or worn features. Tighten bolts and replace parts if necessary. Refer
to the engine manufacturer’s operations and maintenance manual for assistance and the
most update to date information.
b) Check Hose Clamps on Air Intake Side.
Be sure that all clamps are properly secured to prevent leaks and all hose are in good
condition.
c) Check Belt Condition and Tensioner.
Refer to the engine manufacturer’s operations and maintenance manual for assistance and
the most update to date information.
d) Check and/or Adjust Valve Clearance.
Refer to the engine manufacturer’s operations and maintenance manual for assistance and
the most update to date information.
e) Check Water Pump.
Inspect the water pump weep hole for indication of a steady leak. If a steady flow of coolant
or oil is observed, replace the water pump with a new or rebuilt unit. Refer to the engine
manufacturer’s operations manual for assistance.
f) Drain and Inspect Fuel Tank
Annually drain the fuel tank and inspect it for dirt, debris or Diesel fuel “algae”. Clean the
tank if necessary. (See Chapter 2-2)

h) “E” Checks and Operations (1500 Hours or 1.5 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. A clean engine will run cooler and develop fewer hot-spots. Steam
cleaning is one of the most satisfactory methods of cleaning and engine; however, there are
some CAUTIONS to be observed.
WARNING
Exercise care to avoid injury and damage to eyes and skin
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.
3. Seal all openings. DO NOT use a flammable solvent.
4. DO NOT use mineral spirits or solvents on a hot engine.
5. Remove or protect bottom panel of unit (belly pan) to protect insulation.
b) Clean Fuel System.

See engine manufacturer’s operation manual for instructions.
c) Check Alternator and Cranking Motor.
The alternator and cranking motor on this engine require no periodic lubrication.

i) “F” Checks and Operations (2000 Hours or 2 Years).
1) Engine.
a) Check Vibration Damper.
2
3
1
4
5
6
1. Fan Pulley
4. Belt Tensioner
2. Exhaust Outlet
5. Fuel Pump
3. Alternator
6. V i b r a t i o n D a m p e r
Figure 2-1-3 Engine Accessories

Check vibration damper for looseness, wobble, chunking and streaking. Also verify the hub
bolts are tightened to the engine manufacturer’s specifications.
Refer to the engine manufacturer’s operations and maintenance manual for assistance
and the most update to date information.
b) Check Charge-Air-Cooler and Radiator Systems.
i. Check for damaged hoses and loose or damaged hose clamps.
ii. Check the radiator for leaks, damage, and build-up of dirt in the fins. Clean or
replace as necessary.
c) Flush cooling system and change coolant.

j) “G” Checks and Operations (Over 10,000 Hours).

1) Engine.
a. Refer to Cummins Engine Manual for recommended maintenance and overhaul.
2) Engine/ Generator Assembly
a. Note: All Generator Overhaul items to be performed by a qualified generator/ motor
facility
b. Replace Generator Bearings
i. Contact Factory for Detailed Instructions
c. Inspect Front and Rear Bearing Housings
i. Bearing is a press fit, contact the factory for detailed instructions
d. Inspect Generator Shaft for Wear
i. Replace Rotor Assembly if required. Contact the factory for detailed
instructions.
e. Replace engine and generator shock mounts.
i. Contact factory for detailed instructions
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. Clean if necessary. (3) Check All Hoses.
4) In addition to daily checks of hoses for leaks, inspect hoses thoroughly each time the cooling
system is cleaned and serviced.
a) Inspect for signs of deterioration and collapse. Inspect for cracks and cuts. Inspect for
cutting and deformation caused by hose clamps. Replace hoses as required.
5) Check thermostat and seals each fall when cooling system is serviced.

l) Lamps and Fuses:

1) Check all lamps daily.
2) Check fuses as required.
3) The fuse chart lists all fuses with their location, size, and type.
Schematic
Item Protected Location Type ITW PART NO.
Identifier
Display Board Interface Board F1 2A AP-SI2076
Control Board Interface Board F2 5A AP-SI2075
Exciter Circuit (12V) Interface Board F3 5A AP-SI2075
Contactors Interface Board F4 5A AP-SI2075
Relays Interface Board F5 2A AP-SI2076

Key
Interface Board F6 5A AP-SI2075
Switch(Ignition)
ECM Dongle Interface Board F7 5A AP-SI2075
10A
Exciter (Out) Interface Board F8 500V Cylindrical AP-SI2085
f
ECM Interface Board F9 30A AP-SI2078
Engine Air Intake Engine Electrical FU11370

F10 ANL-150
Heater Panel
Figure 2-1-4 Fuse Identification Chart

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.
Item Maintenance Required

Check oil level daily or after every 10 hours of use. Change oil and the oil filter
Engine Oil after the first 50 to 150 hours of use, then at 500 hours or 6 month intervals
thereafter. Engine oil capacity is approximately 11.6 quarts (11 liters).
Fuel/water Pre-Filter Drain filters daily. Change the filter elements every 500 hours or after 6 months
of use, whichever comes first.
Check coolant level daily. Service and maintain coolant system according to
Coolant Section 2-2, paragraph 6. Engine coolant capacity is approximately 15.5 quarts
(14.7 liters)
Coolant hoses and
Check coolant hoses and connections daily for leaks.
connections
Change air cleaner filter as required when the fault code display on engine control
Air Cleaner
panel shows the “Air” code.
Fan Belt Check fan belt condition and tension every 1000 hours or 1 year of use.
Alternator Alternator bearings are sealed and require no periodic lubrication.
Starter Starter motor bearings are sealed and require no periodic lubrication.
Water Pump The water pump is packed at assembly and requires no periodic lubrication.
Fan Hub The fan hub is lubricated at assembly and requires no periodic lubrication.
AC Generator Periodic cleaning – no lubrication or adjustment required
Generator Controls No periodic maintenance is required. Adjustments are covered in Section 2-3.
Trailer Annually grease the wheel bearings.
Figure 2-2-1: Lubrication and Maintenance Chart
WARNING
STOP all operations at once if a serious or dangerous fault is discovered.

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.
Lubrication points, frequency of lubrication, recommended lubricants and filters are indicated in
Figures 2-2-1 and 2-2-2.
This section incorporates the engine maker’s, engine lubrication recommendations from their
Operation and Maintenance Manual.
b) Lubrication schedule
Time schedules indicated on the Maintenance Schedule, Figure 2-2-1, are approximate and
based on average operating conditions. It may be necessary to lubricate more frequently under
severe operating conditions such as: low engine temperatures, high oil temperatures, or
intermittent operation. However, time intervals should not exceed those indicated in the chart
without careful evaluation.
c) Oil specification
The engine lubricating oil that is recommended by the engine manufacturer is identified by an API
(American Petroleum Institute) classification designation. The manufacturer does not recommend
any specific brand of lubricating oil.
The use of quality lubricating oil, combined with appropriate lubricating oil drain and filter change
intervals, are important factors in extending engine life.
Use oil specification API CF-4, HT/HS Viscosity 3.7cP minimum.

Oil Type Oil recommended for the diesel engines in this application is API Class CCMC.
Refer to the manufacturer’s operation manual.
Capacity Approximately 10 quarts (9.5 liters)
Oil Filter
Replacement Cummins: LF9279
Part Number
VISCOSITY AMBIENT TEMPERATURE CONDITIONS
Lube Oil Viscosity
Required as per SAE 15W40 (Preferred) 0ºF (-18ºC) and above for most climates
Ambient SAE 10W30 -10ºF to +50ºF (-23ºC to +10ºC) Winter conditions
Temperatures SAE 5W30 -20ºF to +50ºF (-29ºC to +10ºC) Arctic Conditions
SAE 0W30 -20ºF and below to +50ºF (-29ºC and Below to +10ºC)
See the engine manufacturer’s operations manual for usable synthetic oils and
Synthetic Oils
instructions.
Figure 2-2-2: Lubrication Specifications

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.
The ideal time to change engine oil is soon after a power delivery run, when the engine is at
operating temperature. If lubricating oil is drained immediately after the unit has been run for
some time, most of the sediment will be in suspension and will drain readily.
Change the oil filter element each time the oil is changed.
CAUTION
 High ash oils may produce harmful deposits on valves that can cause valve
burning.
 Do not use solvents as flushing oils in running engines.
 Always use clean containers, funnels, etc.
Dipstick
Oil Fill
Figure 2-2-3: Oil Fill and Check Locations

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 20 quarts (18.9 liters).
2) The oil drain tube can be found by the
muffler at the front of the unit.
3) Remove the drain cap (older models or
turn the valve handle.
4) While oil is draining, change the oil
filter element. See instructions below.
5) Provide a container for catching spilled
oil from the filter.
6) Remove the oil filter by turning it counter-clockwise
and inspecting it.
7) NOTE: The gasket can stick to the filter head. Make sure it is removed before installing a
new filter.
8) Fill the new filter with clean lubricating oil before installation.
9) Apply a light coating of lubricating oil to the gasket-sealing surface and install the filter. DO
NOT over tighten the filter.
10) Clean the drain cap and install when engine oil has completely drained or close the drain
valve.
11) Refill the engine with new, clean oil that meets engine manufacturer’s recommendations. Use
the oil fill tube by the filter or the oil fill opening at the top of the engine.
CAUTION
Remember to close the drain cap and install the new oil before starting the engine.
12) Start engine and check oil pressure at once. Allow engine to run for 5 minutes, check for
leaks then stop the engine.
13) After the engine has been stopped for about 5 minutes, recheck the oil level. Add oil, if
required, to bring the level up to the high bar on the oil dipstick.
CAUTION
If bearing metal particles are found on the element or in the shell, the source should
be determined before a failure.
WARNING
STOP operations at once, if a serious or possibly dangerous fault is discovered.

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
Most starting motors are lubricated at assembly and should be re-lubricated only when
the starter is removed and disassembled, however, inspect the starter to make certain it
has no lubrication points.
3) Water Pump
The water pump is packed at assembly and requires no periodic lubrication. Replace
pump if signs of lubricant leakage are found.
4) Fan Pulley
The fan hub is also lubricated at assembly and requires no periodic lubrication. Replace
hub if lubricant is leaking.
f) Trailer Lubrication
1) Wheel bearings
Inspect each wheel bearing annually to ensure that there is sufficient grease in the
assembly.
2) Fifth Wheel Hub Bearings
Inspect the Fifth Wheel Hub bearing every three years to ensure that there is sufficient
grease in the assembly.
Paragraph Name Specification Notes
Excludes those of sodium or soda

d) Grease, General Purpose MIL-G-3545
soap thickness.
NLGI #2 Grade Lithium Complex EP
e) Grease, Wheel Bearing ASTM D-4950
Grease

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. It may be
inspected either at prescribed service intervals or at any time deemed necessary.
Replacement air filter

element ITW GSE part
numbers: EB11485
Primary – AF55020 Latches

Secondary – AF55320
Inspect regularly. Latches

Hidden
Replace when the “Air
Filter Clogged” warning
appears on the display
Restriction Sensor
Figure 2-2-4: Air Cleaner Assembly
a) Inspecting the Air Cleaner

1) Make periodic checks of air cleaner inlet screen for obstructions. If any obstructions are
present, remove them.
2) Check outlet connection for proper seal.
b) Changing the Air Filter
1) Release (4) Clips - (2) on each end of air filter housing.
2) Remove the end cover of housing.
3) Pull out air filter elements and replace.
4) Replace end cover on housing, making certain that the filter is centered in the housing.
5) Snap (4) clips back into place.
c) Disposal
Normal trash pick-up should be acceptable. NEVER burn the air filter for disposal.

4) Engine Fuel
a) How to select Fuel—Quality
The quality of fuel oil used in the diesel engine is a major factor in engine performance and life.
Fuel oil must be clean, completely distilled, stable and non-corrosive.
CAUTION
Due to the precise tolerances of diesel injection systems, it is extremely important that
the fuel be kept clean and free of dirt or water. Dirt or water in the system can cause
severe damage to both the injection pump and the injection nozzles.
CAUTION
The use of low lubricity fuels can shorten life and/or damage the engine’s fuel pump.
The engine manufacturer recommends only diesel fuel.
Ultra-Low Sulfur Diesel (ULSD) with a maximum content of 15 ppm or less must be used for Tier
4 Final engines. This is a regulatory requirement; failure to do so will result in damage to the
engine and after-treatment system within a short period of time.
For more information regarding the selection of fuel to use, refer to publication “Engine
Requirements—Lubricating Oil, Fuel, and Filters” available from authorized engine maker’s
service
outlets.
b) Cold Weather Operation
In cold weather, diesel fuel will form wax crystals, which can restrict flow and clog filters. Fuel oil
suppliers approach this problem several ways. Some provide a specially refined product, while
others may use flow-improving additives or winter blends. Winter blended fuel will likely contain
kerosene or 1-D fuel, which provide good cloud point temperatures, but result in a lighter fuel with
a lower heat content. These fuels may be used, but they may result in reduced engine power
and/or increased fuel consumption.
In most cases, adequate resistance to cold can be obtained by adding an additive. For further
assistance contact the nearest engine manufacturer’s service representative.

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.
a) Fuel Tank
Be sure that no foreign objects are permitted in the fuel tank. The fuel tank must be removed and
flushed out if objects are found in the Fuel Water Separator or Lubricity Additive Filter.
b) Fuel Water Separator or Lubricity Additive Filter
A lubricity fuel filter, which is also a fuel/water separator, is mounted in the generator
compartment above the fuel tank outlet. The filter’s function is to add a lubricant to the fuel to
help prolong the engine seals and fuel pump life when fuels other than diesel are used (i.e., jet
fuel). The filter also removes foreign material and removes both free and emulsified water from
the fuel before it enters the fuel lift pump. Daily draining of the filter is required.
Replacement Filter Element:

Fleetguard: FS90168
Drain the water daily.
Change the filter after every 500

hours of operation.
Water Drain
Figure 2-2-5: Lubricity Filter
1) To drain the water:

a) Open drain valve.
b) Drain accumulated water and contaminants.
c) Close drain valve.
The lubricity filter must be changed every 500 hours of operation for the fuel filter to continue
adding the proper amounts of the lubricity additive into the fuel system.

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.
b) Shut off fuel valve.
c) Drain off some fuel by opening the drain valve.
d) Undo fuel filter with commercial tool and spin off.
e) Clean any dirt from the filter carrier rim
f) Apply a light film of oil or diesel on the rubber seal on the new filter.
g) Fill new filter with diesel fuel.
h) Screw in the new fuel filter “snug”.
i) Check that the cartridge is seated correctly against the gasket and tighten with a final
half turn.
j) Make sure that all rags, or absorbent sheets, are clear of moving engine parts and
cannot be drawn in to the radiator fan.
k) Open fuel valve.
l) Start the engine and check for leaks. Correct as necessary with the engine off.
c) Primary Fuel Filter
A primary fuel filter is mounted above the engine starter in the engine compartment. The filter’s
function is to remove foreign material from the fuel before it enters the fuel lift pump.
Replacement fuel filter

part number:
Fleetguard: FF90567
Change the fuel filter after
every 500 hours of
operation.
Figure 2-2-6: Primary Fuel Filter

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.
d) Catch any fuel.
e) Clean any dirt from the filter carrier rim
f) Apply a light film of oil or diesel on the rubber seal on the new filter.
CAUTION
When installing new element, do not over tighten it; mechanical tools may distort or
crack filter head.
CAUTION
Make sure that all rags, or absorbent sheets, are clear of moving engine parts and
cannot be drawn in to the radiator fan.
g) Fill new filter with diesel fuel. Screw in the new fuel filter “snug”. Check that the
cartridge is seated correctly against the gasket and tighten with a final half turn.
h) Open fuel valve.
d) Fuel Pump
The fuel pump supplies high pressure to the fuel system so the diesel fuel can circulate freely.
This engine is equipped with a common rail fuel system that is under very high pressure. DO NOT
attempt to crack fuel lines.
WARNING
DO NOT attempt to crack fuel lines. This engine is equipped with a common rail fuel
system that is under very high pressure. Failure to follow this guideline could result in
injury or death.
e) Fuel Return
The fuel return is a fuel line (tube) that takes unused fuel from the engine, and delivers it to the
fuel tank. No maintenance is required.
f) Fuel Level Indicators
There are two fuel level indicators in the unit; a mechanical dial indicator on the back of the unit
that is only accurate when the fuel tank is above 50% full and is for the use of the refueler, and an
electronic sensor in the fuel tank that is used to display the actual fuel level on the operator’s
screen.

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.
2) Before draining the fuel tank, we recommend pumping at least 90% of the fuel out of the
tank (use the operator display to determine the amount of fuel remaining). The fuel tank
has two 1/8” NPT fittings with thread sealant on them that are accessible under the trailer,
once it is lifted up. (Use a 7/16” wrench or socket to remove the fitting.)
3) Once the tank is fully drained, verify that there is no debris in the bottom of the tank on
either side. If any dirt, material or build up exists inside the tank, flush with diesel fluid to
remove the foreign material.
4) Use the following procedure to re-install the fittings:
a) The proper method of assembling tapered threaded connectors is to assemble them
finger tight, then wrench tighten to the specified number of turns from finger tight. The
following assembly procedure is recommended to minimize the risk of leakage and/or
damage to components.
i. Inspect components to ensure that male and female port threads and sealing
surfaces are free of burrs, nicks and scratches, or any foreign material.
ii. Apply sealant/lubricant to male pipe threads if not pre-applied.
b) With any sealant, the first one to two threads should be left uncovered to avoid
system contamination. If PTFE tape is used it should be wrapped 1-1/2 to 2 turns in
clockwise direction when viewed from the pipe thread end. (Caution: More than two
turns of tape may cause distortion or cracking of the port.)
c) Screw the connector into the port to the finger tight position.
d) Wrench tighten the connector to 1.5 - 3 turns past finger tight. Never back off (loosen)
pipe threaded connectors to achieve alignment.
e) If leakage persists after following the above steps, check for damaged threads and
total number of threads engaged.
f) If threads on the fitting are badly nicked or galled, replace the fitting. If port threads
are damaged, re-tap, if possible, or replace the component. If the port is cracked,
replace the component.
g) Normally, the total number of tapered threads engaged should be between 3-1/2 and
6. Any number outside of this range may indicate either under or over tightening of
the joint or out of tolerance threads. If the joint is under tightened, tighten it further but
no more than one full turn. If it is over tightened, check both threads, and replace the
part which has out-of-tolerance threads.

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. It should be kept slightly alkaline with a pH value
in the range of 8.0 to 9.5. Any water, which is suitable for drinking, can be used in the engine
when properly treated as described in engine maker’s operation manual. The engine maker’s
representative should be consulted regarding the selection of satisfactory brand, permanent-type
antifreeze for use in the cooling system.
b) Radiator Cap
1) General
A pressure relief valve is built into the radiator cap. It is designed to open at a pressure of
approximately 15 psi (103.4 Kpa).
WARNING
When removing cap from a very hot radiator, DO NOT turn cap past safety stop until
the pressure or steam has escaped.
2) Removal
To remove, turn the cap to the left (counterclockwise) to the safety stop. When all pressure is
released, press down on the cap and continue to turn until the cap is free to be removed.
CAUTION
Allow engine to cool before adding coolant.
CAUTION
Do not attempt to repair the valve in a radiator cap in case of failure. Replace with a
new cap.
3) Installation
When installing the cap, be sure it is turned clockwise as far as it will go so that the pressure
retaining valve will be functional.
c) Coolant
The preparation and maintenance of the coolant solution is important to engine life and is
completely covered in the engine manufacturer’s operation manual. For information regarding
coolant specifications, testing equipment, antifreeze, etc., refer to engine maker’s operation
manual that accompanies the equipment’s manual or consult the local engine maker’s
representative.

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.
2. DO NOT mix brands or type of antifreeze. A solution containing two or more types
of antifreeze is impossible to test accurately.
2) Selecting antifreeze.
a) Select a permanent type antifreeze known to be satisfactory for use with chromate
corrosion resistor.
b) When it is not known if the antifreeze is satisfactory for use with chromate resistor, check
with local engine manufacturer’s representative for a list of compatible antifreezes.
(3) Checking antifreeze solution.
Check the solution with a reliable tester when in doubt about antifreeze protection.
d) Draining the Cooling System
To completely empty the cooling system requires draining the radiator assembly. Follow these
steps to drain the cooling system:
1) Remove radiator cap.
2) Place a drain pan with at least a 40 quarts (28.4 liters) capacity under radiator to catch
coolant.
3) Remove the front grill to access the hose & valve. Place the drain hose into the drain pan.
4) Open the radiator drain valve.
5) Allow the system to drain completely.
NOTE: Be sure the drain valve doesn’t clog during draining.
6) When the system is completely drained, close the drain valve and coil the
hose back up.
7) Replace the front canopy cover.
e) Flushing the Cooling System
Flushing the cooling system should be a yearly maintenance procedure. By flushing the system,
clean water is forced through the engine block to remove expired coolant and other contaminants.

f) 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.
NOTE: Direct the water in a reverse direction to normal air flow. Normal flow on this installation
is from the engine compartment out ward.
g) Filling the Cooling System
The preparation and monitoring of coolant in liquid-cooled engines is especially important
because corrosion, cavitation, and freezing can lead to engine damage. For coolant system
protection details see the engine manufacturer’s operations manual.
1) Install coolant
a) Remove radiator cap. Be sure the radiator drain valve is closed (Front panel must be
removed to access this location).
b) Pour coolant into radiator very slowly until it reaches the bottom of fill neck. Allow time for
trapped air to escape from the system then continue filling until the coolant level remains
at the bottom of the fill neck.
c) Start the engine and bring up to rated speed and allow the thermostat to open. Add
coolant as trapped air escapes from the system and the coolant level falls.
d) Continue to check coolant level until all trapped air escapes. Add coolant if needed to fill
to the bottom of fill neck. Install radiator cap.
2) Inspection/Check
a) Check system for evidence of leaks.
b) Inspect all hoses. Install new hoses as necessary. Tighten hose clamps as required.
c) Check the condition of fan and water pump belts. Replace belts if necessary.
NOTE: It is good practice to attach a card, indicating the cooling system contents and date
serviced, to the radiator filler neck.
h) Thermostat
The thermostat should be checked each fall, or as required. Refer to engine manufacturer’s
operations manual for recommended instructions.

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.
c) Checking Belt Tension
WARNING
DO NOT Check belt tension with engine running
Check belt tension every 1000 hours, or once year, whichever comes first. A belt that is too tight
is destructive to bearings of the driven part. A loose belt will slip and cause inefficient operation of
the part being driven as well as wear to the belt.
CAUTION
Inspect and replace the belt if it has unacceptable cracks, is frayed, or has pieces of
material missing.
Belt tension may be checked by manually depressing the belt with an index finger to determine
the amount of belt deflection obtained. When a force is applied at a point halfway between
pulleys on the longest span of a belt, there should be no more than 1/2 inch of deflection attained.
Refer to the engine manufacturer’s operation manual for checking belt tension and changing worn
belts.
8) Generator Maintenance
The 400 Hz generator requires no maintenance or service other than periodic cleaning. The unit
is brushless and has bearings that are permanently lubricated and sealed.
a) Cleaning
The generator may be cleaned by careful use of compressed air and/or a good, SAFE
commercial cleaner. Steam cleaning of the generator is not recommended because the use of
steam and harsh chemical compounds may result in damage to insulation and other generator
components.
WARNING
Never use solvents as this is a fire hazard
b) Adjustment
The generator itself requires no adjustment. Adjustment procedures for generator controls are
covered in Section 2-3.

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.
* Important Note!
Before you remove the battery from the holder, make sure that the replacement battery is within reach, as
the Control Board must not be without battery power for more than 30 seconds.
Otherwise, all software and the setup data will be erased. *
Blue LED (D5)
Fig. 8.2.3 Control Board (front view)
To replace the battery, Switch OFF the unit by means of Q1. Remove the Control Board from its 4 posts
marked with a in Figure 8.2.3. Place the PCB on an insulated surface, with the back side face up.
Battery holder and

battery
Fig. 8.2.4 Control Board (rearview)

Remove the battery from the holder using a small insulated screwdriver to push out the battery,
direction indicated by the two red arrows on Figure 8.2.4 and insert the new battery in the direction of the
singe green arrow on Figure 8.2.4.
Mount the control board on the interface board again by gently pressing the PCB to its rest on the
Interface Board. Make sure that all 4 corners are fully pressed towards the Interface Board.
Switch on the unit via the input switch Q1 and close the door. The unit now passes through the
initialization test and goes into standby mode.
Enter the setup menu and select menu item “Battery Replaced” to confirm new battery installation.
* Important Note!
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.
To ensure high reliability of the back-up battery, the only type of battery that can be used
on the Control Board is the Panasonic BR-2032

Section 3 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. If a fault or malfunction is not listed in the chart, start looking for the
cause at the source of power in the affected circuit. Refer to the schematic and connection diagram.
Test the circuit systematically until the source of the malfunction is isolated.
The Troubleshooting Chart is arranged by Error code, Error text, Description and then four columns of
possible corrective actions. Always try the 1st corrective action before proceeding to the next
corrective action.
WARNING
Exercise extreme care to avoid contact with high voltage leads and components.
HIGH VOLTAGE CAN KILL!
CAUTION
Maintenance personnel must be very careful when performing terminal-to-terminal
checks to be certain the proper terminals are being used, especially when using
jumper leads. Damage to electrical components may result from the application of
improper voltage and current.
2) Equipment for Troubleshooting

A good quality multimeter is the only instrument required for troubleshooting. At least two jumper
leads with alligator, or similar clips, will be required. The engine electrical system can be used as a
12 VDC power source.
3) Parts Replacement
To lessen down time and get a faulty machine back on line as quickly as possible, the black box
concept of parts replacement is reflected in the Troubleshooting Chart. For example, if a component
on a control box board is defective, the quickest way to remedy the situation is to replace the
complete board and send the old to stock.
4) Normal Operational Parameters

The system specifications, which are listed in Chapter 1-1, provide useful information when
troubleshooting abnormal operation. The Protective System Specifications and Normal Operating
Characteristics provide information about how the generator set should be operated.

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.
6) Engine Troubleshooting
Remember that the ability of the engine to start and run properly depends upon the following:
 An adequate supply of 12 VDC power reaching a good starter and control board
 An adequate supply of air, compressed to a sufficiently high pressure
 The injection of the correct amount of clean fuel at the proper time
7) GPU Control Monitoring

The GPU control system performs complete diagnostic testing and continuous monitoring of all critical
circuits and operating electrical values. If the control system senses a problem with one of the circuits
or if any of the electrical values exceeds its safe operating limit, the control system will shut the GPU
down, or may allow the GPU to continue operation depending on the severity of the condition.
a) Operating Modes
1) Self-Test Mode
When power is first applied to the control circuit, the GPU performs complete self-diagnostics
of the internal circuitry. If a fault is detected during the self-test, the Alert/Failure LED will be lit
and the first (if there are more than one) failure will be displayed on the LED display.
2) Engine Run Mode
When the ENGINE pushbutton is pressed, the blue power indicator LED and the Operating
Beacon will start flashing. The starter will engage when the engine is ready. After the engine
reaches its idle speed (1000 rpm) the GPU is ready to supply power to the aircraft. (Note that the
engine will make three 15 second attempts to start the engine. If the engine doesn’t successfully
start after the third attempt, the fault LED will be lit and an Engine Start Failure message will be
displayed.)
3) Engine Shutdown Mode
Pressing the ENGINE pushbutton starts the 30 seconds delayed shutdown period. If any
output contactors are closed, they will open before starting countdown. The shutdown period is
required to cool the engine’s turbocharger.
4) Automatic Engine Shutdown
Automatic Shutdown mode will turn off the engine after 10 minutes when all contactors are
open or if they are closed and the total generator current is less than 5 amps. (This timer is
internal and not visible.) After 10 minutes, it puts the engine in shutdown mode. (All
contactors are opened and the generator is no longer regulating voltage.) A visible 30 second
timer is displayed and the engine will turn off when the timer expires. The Automatic Engine
Shutdown mode is changed in the Setup menu and the choices are enabled or disabled.
5) Engine Stop Mode
After the 30 seconds delayed shutdown period, the engine stops running.
6) System Off Mode
The power is removed from the GPU’s entire control system when the battery disconnect is
opened.

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. The fault limits and conditions are
preset at the factory.
1) Warning
Warning faults have no effect on the operation of the GPU. An example is an intake air
restriction fault due to a dirty filter. Although the GPU continues to operate, the fault LED is lit
and the fault text appears on the display. Pressing the Engine pushbutton or shutting down
the GPU resets the fault.
2) Run Mode
Run mode faults remove power form the aircraft but do not change the operating speed of the
engine. An example is an over voltage fault. Although the contactors open and remove
power from the aircraft, the engine remains at rated speed, the fault LED is lit and the fault
text appears on the display. Pressing the Engine pushbutton or shutting down the GPU
resets the fault.
3) Stop Mode
Stop mode faults remove power form the aircraft and shut the engine down. An example is a
low oil pressure fault. The contactors open and remove power from the aircraft, the engine
shuts down, the Alert/Failure LED is lit and the fault text appears display. Pressing the
Engine pushbutton or shutting down the GPU resets the fault.
8) Cummins Engine Fault Codes & Trouble Shooting
The best source of information to aid in trouble shooting Cummins engine issues is at the
quickserve.cummins.com website. Go to this website and register up to five engine serial numbers for
free. (It is recommended that if you have more than one engine type/size, that you register one serial
number per type/size.) Once you are registered, this website gives you access to engine information,
troubleshooting assistance by fault code, parts information and service bulletin information for each
serial number/engine type that you have registered with the site.
9) Error Codes
If the displayed text does not provide sufficient information to solve the problem, the tables on the
next pages suggest corrective actions to be carried out for each error code.
Additional error information regarding the output voltage and overload, can be derived from the
error code according to the following directions:
Output Voltage: 30xx / 31xx / 35xx

Overload: 40xx / 41xx / 42xx / 43xx / 44xx / 45xx / 46xx / 47xx
Phase code:
xx01 = Phase A xx05 = Phase A & C
xx02 = Phase B xx06 = Phase B & C
xx03 = Phase A & B xx07 = Phase A, B & C
xx04 = Phase C
Examples: Error Code 3501 refers to “Output Voltage Too Low” at phase A.
Error Code 4407 refers to “Overload I > 300% - 1 sec.” at all 3 output phases.

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).
LOGGING Communication Press Engine

100
UNSUCCESSFUL Failure button to Reset
ID chip is Inspect ID chip
CONTROL BOARD
201 missing or connection. for Contact ITWGSE
FAILURE
unreadable damage.
WRONG SOFTWARE Wrong Software Install correct
202
VERSION Version Installed software version
The new software

FAILED SOFTWARE Try to install the Replace display
250 didn’t load
UPDATE software again or control board
properly
Fuel Level is too
Inspect fuel
300 FUEL LEVEL < 10% low to attempt an Add Fuel Inspect fuel Sender
Sender wiring
engine start.
Check starter
Engine rotation is circuit to ensure
not detected Press Engine that it is properly
500 STARTER FAILURE Replace Starter
when starter was button to Reset energized.
activated. (Replace Starter
Solenoid)
Check fuel valve

UNABLE TO START Engine did not Press Engine
600 to ensure it is Service Engine
ENGINE start after 3 tries. button to Reset
open.
Battery voltage
BATTERY LEVEL level is too low to Press Engine Check battery
700 Charge Battery Replace Battery
TOO LOW attempt startup button to Reset cables
sequence.
The temperature
28V PLUG Remove load and Check connector /
sensor in output Press ARU Replace Control
2400 TEMPERATURE TOO let plug cool output cabling for
2 plug has button to reset Boards A1 & A2
HIGH down any malfunction
tripped.
Check output
28V OUTPUT Voltage > 32V - Press ARU Check ARU Module
3200 voltage setup
VOLTAGE TOO HIGH 4s button to reset and wiring
value
Check output
OUTPUT VOLTAGE Voltage > 40V - Press ARU Check ARU Module
3300 voltage setup
TOO HIGH 1s button to reset and wiring
value
Check output
28V OUTPUT Voltage < 20V - Press ARU Check ARU Module
3400 voltage setup
VOLTAGE TOO LOW 4s button to reset and wiring
value
Replace Control
Verify that output
28V INTERLOCK 28V F Level too Press ARU Check / correct Board A1
3800 cable is correct
LEVEL TOO LOW low button to reset installation Replace Interface
inserted
Board A2
28V Output Remove overload
28V OUTPUT Press ARU Replace Control Replace Interface
4000 Voltage is too and re-engage
CURRENT TOO HIGH button to reset Board A1 Board A2
high output

Output Current is Remove overload

4100 over 1200A for 60 and re-engage
seconds output
seconds output
28V OUTPUT Press Engine Replace Control Replace Interface
seconds output
Time to change
BACKUP BATTERY
4700 the control board
TIME
battery
4800 Real Time Clock Correct Date in Replace Battery & Replace Control
RTC TIME
Fault SETUP Menu Reset Date Board A1
For faults in this section: Disconnect from aircraft. Shut down engine after cooldown.
CONTROL BOARD Watchdog Press Engine Replace Control
6000
FAILURE Timeout Button to reset Board A1
AVR SOFTSTART AVR Soft start Press Engine Check Excitation Replace Control Replace Interface
6100
ERROR Error Button to reset Wiring/Fuse Board A1 Board A2
Engine Error
ECM ERROR CODE
6600 Code Received Service Engine
RECEIVED
from ECM
CONTROL VOLTAGE Control Voltage < Press Engine

8000 Check Alternator Check Battery
LOW 20V (Running) button to reset
Release
emergency stop
EMERGENCY STOP Check emergency Check user EPO Replace Control
8200 and press
ACTIVATED stop (A2:X14) Board A1
Engine button to
reset
ECM J1939 Check ECM

8400 COMMUNICATION Communication Power (Replace Service Engine
FAILURE Failure Interface Board)
Engine RPM out

ENGINE RPM OUT OF
8500 of specification Service Engine
SPEC
or stopped

Engine Controls
Trouble, Symptom, Probable Cause Test, Check, and/or Remedy
Condition
1. The engine will not a. Emergency Stop  Make sure the Emergency Stop switch is pulled out
start, and the and switch has been pressed.
starter will not
b. Battery Disconnect  Make sure the battery disconnect switch is in the ON
crank the engine.
switch is in the OFF position.
position.
c. Battery discharged or  Make sure the voltage across the batteries is
loose battery or ground approximately 13 VDC.
connection.  Check battery terminals.
 Make sure 13 volts DC is reaching the starter solenoid
input terminal.
d. Defective starter  Check if you can hear the starter solenoid activate
solenoid (SW3). when the start button is pressed. If not, check for
voltage on the starter solenoid coil (see e. below).
 Temporarily connect a large-capacity jumper cable
(No. 1/0 minimum) between the hot side of the starter
solenoid and the starter input terminal. If starter does
not crank engine, the starter may be defective
e. No voltage at starter  Check connector X5 on the PC1 Interface board.
solenoid coil.  Verify that there is 12 VDC across the starter solenoid
+ and – terminals when the engine start pushbutton is
pressed.
 Check and replace (if necessary) the Interface board.
f. Defective starter. Remove the starter motor from engine and apply
12 VDC to test it. Replace the starter if non-operable.
g. Internal seizure. If the starter is good, attempt to hand crank the engine
using a 3/4-inch square drive on the crankshaft pulley. If
engine cannot be turned one complete revolution,
internal seizure is indicated. Remove engine and
contact the engine manufacturer and/or nearest dealer.
i. Defective Control Panel Replace the Control Panel.
2. Engine will not a. Low battery output Check the battery and recharge or replace
start. Starter clicks b. Loose starting circuit Check all connections and cables. Tighten or replace as
on and off. connections or faulty required.
cables

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. Tighten or replace
speed is low. connections or faulty cables as required.
c. Improper lubricating oil Check the oil. Refer to Section 2-2.
viscosity Remove and replace the oil as necessary.
4. Engine cranks a. Low fuel Make sure there is sufficient fuel in the fuel tank.
but will not  If engine will not start, the fuel pump may be
start. defective.
 If engine starts and then stops after a short time,
Caution: To check fuel lines, and filters.
prevent damage
b. Fuel shutoff valve closed Open the shutoff valve on the fuel tank.
to the starting
motor, do not c. Plugged or defective filter Replace fuel filters. Also, check the gaskets for
engage the leaking or damaged condition.
starting motor for d. Loose connections, Tighten all fittings and connections. Replace any
more than 30 damaged hoses or fuel damaged hoses or fuel links.
seconds. Wait lines between tank and fuel
two (2) minutes pump
between each
attempt to start.
5. Engine cranks, a. Defective engine Check wiring to engine high temperature switch (S49
but will not temperature switch on schematic), which is located on top of the engine
start. Over- block. If wiring is correct, remove wires and check
temperature resistance between terminals C and N.O. A
indication resistance of less than 10 ohms indicates a defective
appears switch. Replace switch if defective.
immediately. b. Defective PC1 board Replace the PC1 Interface board.
6. Engine is hard a. Low compression, which Check the compression in accordance with
to start. may be caused by sticking instructions in the engine manufacturer’s operation
Cranking speed or burned exhaust valves, manual. Overhaul the engine to make repairs as
is normal and worn or broken necessary.
the fuel supply compression rings, leaking
is adequate. cylinder head gasket, or
valve clearance adjustment.
7. Engine starts a. Low oil pressure or Restart the engine and observe oil pressure gauge. If
but then stops defective oil pressure oil pressure is 12 psi or more, disconnect wire from
after a few switch. the normally-closed switch terminal on the oil pressure
seconds by switch. Restart engine. If engine continues to run,
automatic the oil pressure switch is defective. Replace oil
shutdown. pressure switch. If engine stops, the PC1 Interface
board might be defective.
b. Defective PC1 board. Replace PC1 Interface board.

Engine Controls (continued)

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.
idle speed, or shuts defective.
down.
9. Engine has slow a. Engine needs tune-up. Tune-up as required. Refer to engine
response time manufacturer’s operation manual.
when a load is
applied.
10. Engine misses or a. Insufficient fuel. Check fuel system in accordance with engine
runs unevenly. manufacturer’s operation manual. Repair or
replace parts as required.
b. Faulty injector. Check injectors in accordance with engine
manufacturer’s operation manual.
c. Low compression pressure. Check compression in accordance with engine
manufacturer’s operation manual.
d. Air in fuel system. Check all fittings to be sure they are tight and
the thread sealant is still present. Tighten the
fittings and add new thread sealant as required.
11. Engine lacks a. Improper engine adjustments Tune-up engine in accordance with engine
power and gear train timing. manufacturer’s operation manual.
b. Insufficient fuel. Check low fuel level in accordance with engine
manufacturer’s operation manual. Repair or
replace parts as required.
c. Insufficient inlet air due to Check air cleaner for plugging and/or damage.
damaged or dirty air cleaner.
d. Restricted exhaust system. Check exhaust pipes for restrictions. Check
muffler for clogged condition. Replace as
required.
12. Front clearance a. Loose connection  Check Interface board connector X9
lights aren’t ON. terminal 3.
 Check Ground plate connection of wire 79
b. Defective Interface board. Replace Interface board.
13. Rear clearance a. Loose connection  Check quick disconnect plug P4
lights aren’t ON.  Check Interface board connector X9
terminal 4.
 Check Interface board connector X45 wire
80.

Generator
Condition
1. Generator does not Problem with brushes Remove, clean, and reinstall the generator brushes, replacing them
build up voltage if they are shorter than 7/16 of an inch (11mm).
when the engine is
at the rated speed. Exciter fuse (F3 or F8) Replace exciter fuse(s).
blown
Defective wiring between Check all connectors and wires between interface board and
interface board and generator. Pull gently on wires to insure proper insertion in the
generator connector.
Defective diode on control The diode is located on the generator’s brush holder mounting
winding. bracket. Check it with an ohmmeter to see if good.
Defective voltage regulator Replace interface board.
on interface board
Defective generator Measure resistance between two yellow wires coming from
control winding generator. It should be around 13 ohms. It is defective if shorted
or open.
Defective generator If no problem was found with the control winding, the generator
armature G402 stator is defective. Send unit to overhaul.
Problem with brushes Remove, clean, and reinstall the generator brushes, replacing them
if they are shorter than 7/16 of an inch (11mm).
Exciter fuse (F3 or F8) Replace exciter fuse(s).
blown
Defective wiring between Check all connectors and wires between the interface board and the
interface board and generator. Pull gently on wires to insure proper insertion in the
generator connector.

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.
when the corresponding regulator board. If it blows again, check the contactor.
Output pushbutton is pressed.
Generator is running at normal b. Defective display module Check to make sure that the other
voltage. pushbuttons on the control panel
work. Replace the display board and
test all buttons again.
2. Load contactor closes when a. The plug interlock EF circuit on Set 400 Hz Interlock to Bypassed. If
the Output pushbutton is Interface board could be load contactor remains closed,
pressed, but opens within 10 defective. proceed to step b.
seconds.
b. 28.5 VDC is not reaching the plug Proceed as follows to find the cause
interlock EF circuit from aircraft of this malfunction.
for following reasons:
c. Generator-to-aircraft cable Inspect cable connector plug
connector defective or not thoroughly for damaged E and F
plugged into aircraft receptacle terminals. Be sure plug is fully
connector mated with aircraft receptacle
connector and making good contact.
d. Aircraft rejecting power. Check aircraft on-board electrical
equipment and controls.
e. Defective contacts in switch Connect a jumper lead between
mounted on side of contactor. terminals of the normally-open
auxiliary switch. If the contactor now
remains closed, replace the auxiliary
switch or the entire contactor.

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.
Condition
1. Load contactor a. Over-voltage condition Press appropriate Output pushbutton and resume
opens during power may have been the result power delivery. Observe voltmeter to be certain
delivery. Over of a sudden drop in load voltage is normal (28.5 VDC). Adjust to normal if
voltage fault and may have been a necessary. If load contactor is opened again and
indicated. normal action. the fault message indicates an over-voltage
condition, proceed to step b.
b. Defective Interface or Replace the control and/or the interface board.
control board.
2. Load contactor a. Under-voltage condition Press appropriate Output pushbutton and resume
opens during power may have been result of power delivery. Observe voltmeter to be certain
delivery. Under a sudden shock load, or voltage is normal (28.5 VDC). Adjust to normal if
voltage fault possible tampering with necessary. If load contactor is opened again and
indicated. REG potentiometer, and the fault message indicates an under-voltage
may have been a normal condition, proceed to step b.
action.
b. Defective Interface or Replace the control and/or the interface board.
Control board.

Chapter 3 Manufacturer’s Literature
Vendor Literature
Type Diagram Description
Engine Operation and Maintenance Manual (Cummins Bulletin # 4358560)
Service Manual (Cummins Bulletin # 4358561)

- Not Included -- purchased separately from Cummins.
Diagram Number Diagram Description
293194 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 A for specific information on the ITW GSE 6400, 28.5 VDC. Generator
Set, optional equipment.

This page is intentionally left blank.

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 293099-001
Kit, Beacon, Unit Operating, Blue 293099-002
Kit, Beacon, Unit Operating, Clear 293099-003
Kit, Beacon, Unit Operating, Red 293099-004
Kit, Beacon, Low Fuel, Amber 293100-001
Kit, Beacon, Low Fuel, Blue 293100-002
Kit, Beacon, Low Fuel, Clear 293100-003
Kit, Beacon, Low Fuel, Red 293100-004
Kit, Battery Blanket, 120V 293498-01
Kit, Battery Blanket 240 Volt 293498-03
Kit, Battery Blanket 230 Volt 293498-05
Kit, Block Heater 120 V 293503-XX
Kit, Block Heater 240V 293503-XX
Tie-Down Ring Option 293192
Kit, 28VDC Only Towbar Interlock 293337-02
293148 DIN40 Tow bar

This option replaces the standard Towbar with a 40mm diameter eye version.
293098 Kit, Clearance Lights
This option adds clearance lights to the four top corners of the canopy.
293099-001 Kit, Beacon, Unit Operating, Amber
293099-002 Kit, Beacon, Unit Operating, Blue
293099-003 Kit, Beacon, Unit Operating, Clear
293099-004 Kit, Beacon, Unit Operating, Red
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.
293100-001 Kit, Beacon, Low Fuel, Amber

293100-002 Kit, Beacon, Low Fuel, Blue
293100-003 Kit, Beacon, Low Fuel, Clear
293100-004 Kit, Beacon, Low Fuel, Red

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.
293498-01 Kit, Battery Blanket, 120V
This option adds an independently powered 120 VAC powered battery blanket on top of the batteries in
the right cable tray.
293498-03 Kit, Battery Blanket, 240V
This option adds an independently powered 240 VAC powered battery blanket on top of the batteries in
the right cable tray.
293503-XX Kit, Block Heater, 120V
This option adds an independently powered 120 VAC powered block heater to the engine.
293503-XX Kit, Block Heater, 240V
This option adds an independently powered 240 VAC powered block heater to the engine.
293337-02 Kit, 28VDC Only Tow Hitch Interlock
This option adds a lock to the tow bar assembly to prevent it from being lowered if the 28VDC cable isn’t
properly inserted into the receptacle at the front of the cable tray. NOTE: When this option is installed, the
unit will not supply 28VDC power if the tow bar hitch is not up and locked in place.

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.
Among such conditions are:
1) Exposure to:
a) Combustible, explosive, abrasive or conducting dusts.

b) Environments where the accumulation of lint or excessive dirt will interfere with normal ventilation.
c) Chemical fumes, flammable, or explosive gases.
d) Nuclear radiation.
e) Steam, salt-laden air, or oil vapor.
f) Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to fungus growth.
g) Abnormal shock, vibration or mechanical loading from external sources during equipment operation.
h) Abnormal axial or side thrust imposed on rotating equipment shafts.
i) Low and/or high ambient temperatures.
j) High electromagnetic fields
2) Operation at:
a) Voltages above or below rated voltage.

b) Speeds other than rated speed.
c) Frequency other than rated frequency.
d) Standstill with rotating equipment windings energized.
e) Unbalanced voltages.
f) Operation at loads greater than rated.
3) Operation where low acoustical noise levels are required.
4) Operation with:
a) Improper fuel, lubricants or coolant.

b) Parts or elements unauthorized by the manufacturer.
c) Unauthorized modifications.
5) Operation in poorly ventilated areas.

Appendix C Initial Software Installation Procedure

RR
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. Install the Control Board software first, then the Display Board software.
First time programming of the Control Board (P/N AP-579526):

1) Make sure the Control Board is installed onto the Interface Board (P/N AP-279534), and the GPU
is powered.
2) Copy the correct Control Board software onto a USB stick. The file must be located in the root
folder of the USB stick, and the filename must be XXXXX.itw. Other files, e.g. the Display Board
software, may also be on the USB stick.
3) Inspect the blue LED next to the USB socket on the Control Board. The blue LED must be
flashing in a sequence of two rapid flashes, then a pause, then two rapid flashes, and so on.
4) Insert the USB stick into the USB socket on the Control Board. Check that the blue LED turns off.
Wait until the blue LED turns on (this may take some time).
5) When the blue LED turns constantly on, the software has been programmed into the Control
Board. Remove the USB stick from the Control Board.
If the blue LED is constantly on, the Control Board has already been programmed. Use the update
function on the Display Board to program the Control Board. (The Display Board must be programmed
first)
If the blue LED is flashing slowly in a sequence of one flash, a pause, one flash and so on, the
microcontroller on the Control Board has lost its internal programming, most likely due to a faulty or
missing battery. Contact ITW GSE technical support and request a replacement control board.
First time programming of the Display Board (P/N AP-579536):
1) Make sure that switch 1 on DIP-switch SW2 is in the ON position. This allows access to the
Display Board menu.
2) Copy the correct Display Board software onto a USB stick. The Display Board software consists
of two files: a XXXXX.itw file, and a file like AAxxxxxx.pbe, where xxxxxx is a number.
3) Do not change the filenames. The two files will only work together.
4) The files are located in the root folder of the USB stick. Other files, e.g. the Control Board
software, may also be on the USB stick.
5) Insert the USB stick into the USB socket on the Display Board.
6) Press and hold the center navigation key on the GPU to access the update function.
7) Press the center navigation key again to confirm the software update.
8) Wait for the software update to complete. Press the center navigation key when instructed to
reset the Display Board.
9) If the software update does not complete, start over from step 4.
Verify the software is installed correctly.
1) Hold the center navigation key to access the menu on the Display Board.
2) Access the Parameter Info, and navigate up/down to the Unit Information page.
3) Verify that the display reports the expected software number and revision for both Display Board
(Display FW) and Control Board (Control FW).

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). The error should disappear after the configuration step. If the error persists
even after configuring the GPU (remember to save), the EEprom Board may be defective.
 Error 250 ”Update Failed”. This is caused by an issue that may happen during the Display Board
software update. Perform the software update again.
 The Setup Tool is unable to connect to the GPU. Using the Display Board menu, make sure the
GPU Ethernet settings are set correctly. The correct settings are:
o Ethernet mode: Manual

o IP Address: 192.168.1.100
o Subnet Mask: 255.255.255.0
o Gateway: No significance
o DNS 1: No significance
 The displays shows a ”COMMUNICATION ERROR” screen.

This is caused by a failure in CAN-bus communication between the Control Board and the Display
Board, usually because the Control Board is not programmed or has halted its execution. Check
for faulty/un-programmed Control Board (flashing blue LED), and replace or program if necessary.
Check that the cable from the Display Board to the Interface Board is fully seated at both ends,
and try restarting the GPU. If the issue persists, try replacing the Control Board even if the blue
LED is not flashing.
 The unit can’t detect the USB stick or read any files on it. Reformat the USB stick using the below
procedure and then copy the needed files back into the root folder.
1. Insert the USB stick into a computers USB port.
2. Open the File Explorer window and right click on the drive for the USB stick.
3. select, ‘Format…’.

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. )
5. Copy the files into the root drive and it is ready.

Interface Board
Connector Pin Description Connector Pin Description Connector Pin Description Connector Pin Description
1 ECM (+) 1 Output Voltage (+) 1 EPO 1 Open
X9
2 ECM (+) 2 Output Voltage (‐) 2 EPO 2 CAN L
3 ECM (+) 3 NOT USED 1 NOT USED 3 GND
X1 X2 X10
4 ECM (‐) 4 Fuel Level (GND) 2 Towbar Status 4 Open
5 ECM (‐) 5 Output Contactor (+) 5 Open
X40
6 ECM (‐) 6 Output Contactor (‐) 6 Open
1 24VDC 1 NOT USED X11 1 90% SWITCH + 7 CAN H
X6
2 GND 2 Fuel Level 2 INTERLOCK 8 Open
X3
3 J1939‐L 1 NOT USED 3 PLUG TEMP + 9 Open
4 J1939‐H 2 Current Sense (‐) 4 90% SWITCH ‐ 10 GND (shell/shield)
7 NOT USED X7 3 NOT USED 5 NOT USED 1 pin 5
6 Air Filter (‐) 4 NOT USED 6 PLUG TEMP ‐ 2 pin 4
3 KeySwitch (Ignition) 5 Current Sense (+) X14 1 Stator A 3 pin3
1 Alternator (S+) 6 NOT USED 2 Stator B 4 pin 2
5 Engine Crank (+) 1 Run Beacon 3 Stator C 5 pin 1
X4 X41
4 Engine Crank (‐) 2 Low Fuel Beacon 4 Not Used 6 pin 9
2 NOT USED 3 Running Lights, Front X15 1 Exciter + 7 pin 8
8 Air Filter (+) 4 Running Lights, Rear 2 Exciter ‐ 8 pin 7
X8
9 ISC1 Control (‐) 5 Run Beacon Gnd 9 pin 6
X12, X13, X42, X43, X44 OPEN
10 ISC1 Control (+) 6 Low Fuel Gnd 10 GND (shell/shield)
1 Alternator L 7 Front Run Lights Gnd X45 Positive
X5
2 Not Used 8 Rear Run Lights Gnd X46 Negative

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
 support@itwgse.us Fax: Serial No.:
International: Phone: Error Code:

ITW GSE ApS
Contact: Date:
 + 45 63 18 60 00
 support@itwgse.com E-mail: Time:
How to retrieve parameters from the Black Box :
1. Press centre button hold it down for approximately 10 seconds to enter the Icon Menu.
2. To select Black Box, simply use the navigation keys ◄▼▲► to highlight the icon
Then press the ● to enter the menu
3. Use the ▼/▲ to highlight the failure you want to view
4. Press ● to select View information on the error. The error is then explained in clear text
5. Press ● to view detailed Alarm Data
6. Use the ▼/▲ to browse through the recorded data
7. Use ◄ to leave the submenu
8. Use ◄ to leave the submenu and return to basic Icon Menu
28VDC Output: Voltage: V Current: A

Battery Voltage: V Hour Meter: PWM DUTY CYCLE:
ENGINE Status RPM: OIL Pressure: Engine Temp:
Engine Load: Hours: FUEL:
WARNINGS (Other indication (lamps, LED’s, damages of enclosure etc.):
293521OM2248 Rev B Page 104 of 104

6400 Tier 4

Uploaded by

Copyright:

Available Formats

6400 Tier 4

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

6400 Tier 4

Uploaded by

Copyright:

Available Formats

Manual

Specification.: DCE6400 28.5 VDC Tier 4

We recommend that the battery that

Diagrams and drawings are subject to change without prior notice.

Contents of the manual are arranged as follows:

Chapter 3 Manufacturer’s Literature

Appendix B Operation in Unusual Service Conditions

Appendix C Software Installation Procedures

OM2248 Rev B Page 2 of 104

Safety Warnings and Cautions.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and

a) Output Cables and Terminals

OM2248 Rev B Page 3 of 104

3) Service and Maintenance

b) Lockout the equipment at the battery disconnect switch if it is out of service.

4) Fire and Explosion Prevention.

a) Electrical Short Circuits and Overloads.

5) Toxic Fume Prevention.

6) Bodily Injury Prevention.

OM2248 Rev B Page 4 of 104

7) Medical and First Aid Treatment.

8) Equipment Precautionary Labels

OM2248 Rev B Page 5 of 104

Section 1 Description 1-1/10

Section 2 Preparation for Use/Storage/Shipment 1-2/26

Section 3 Operation 1-3/30

OM2248 Rev B Page 6 of 104

Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#

Maintenance Inspection/Check 2-1/53

Section 2 Maintenance Procedures 2-2/65

OM2248 Rev B Page 7 of 104

Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#

Section 3 Troubleshooting Procedures 2-3/82

OM2248 Rev B Page 8 of 104

Chapter 3 Manufacturer’s Literature Chapter-Section/Page#

Appendix A – Options 3-A/95

OM2248 Rev B Page 9 of 104

2) Optional Equipment - Appendix A

OM2248 Rev B Page 10 of 104

1. Fuel Filler Neck / Manual Gauge 7. Radiator End

Figure 1-1-1: General Assembly of Generator Set

OM2248 Rev B Page 11 of 104

1. Cummins QSF2.8 Engine 5. Output Connections

Figure 1-1-2: Main Components of Generator Set (Right Side)

OM2248 Rev B Page 12 of 104

4. Engine Oil Fill Tube

Figure 1-1-3: Main Components of Generator Set (Left Side)

OM2248 Rev B Page 13 of 104

1. Oil Drain Valve

Figure 1-1-4: Main Components of Generator Set (Bottom)

OM2248 Rev B Page 14 of 104

d) DC Protective System Specifications

e) Generator Set Specifications

OM2248 Rev B Page 15 of 104

Manufacturer Cummins, Inc.

g) Normal Operating Characteristics

Engine oil pressure (warm and at 45 - 55 PSI

OM2248 Rev B Page 16 of 104

OM2248 Rev B Page 17 of 104