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Hobart 120CU20, Operation And Maintenance Manual With Illustrated Parts List

The Hobart 120CU20 is a high-quality industrial product that requires proper handling and maintenance. Ensure its longevity with our comprehensive Operation and Maintenance Manual with Illustrated Parts List. Download the manual for free from our website, manualshive.com, and discover detailed instructions to keep your Hobart 120CU20 performing at its best.

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OM-2228 / Operation and Maintenance Manual 
120CU20 / Series 500120 / 400 Hz. Generator Set 

 

 

October 15, 2013 

Chapter 4-3 

Page 35 

 

 

FIGURE 

ITEM NO. 

HOBART 
PART NO. 

NOMENCLATURE 

UNITS 

PER 

ASSY. 

17 - 

1 

291695 

Engine, Cummins, QSB6.7, 220 HP 

1 

* 

 

286897-029 

…Engine Oil Filter, Replacement 

Ref. 

* 

 

289815 

…Valve, Oil, Drain 

1 

* 

 

289843 

… Hose, 5/8”, ID 

24” 

* 

 

W10869-009 

…Clamp, Hose 

1 

 

 

 

Engine Electrical Components 

 

 

2 

286850 

Starter Solenoid 

(V13445 # 24059)

 

1 

 

 

288973-001 

…Diode Assembly, Starter Solenoid 

1 

 

3 

403809-001 

Switch, Oil Pressure 

(V75419 #1042-08210-10)

 

1 

 

4 

78B1118-002 

Sender, Oil Pressure, 0 – 125 PSI

 

(V16476 #16476)

 

1 

 

 

287419 

…Adapter, M10-1.0 x 1/8 NPTF 

1 

 

 

W10910-000 

…Fitting, Tee 

1 

 

 

W10750-001 

…Nipple, Pipe, 

1

/

8

” 

1 

 

5 

403782-002 

Switch, Shutdown, 210° F 

(V75418 #1002-04880-36)

 

1 

 

 

W7814-004 

…Adapter, 

3

/

8

” x ½” NPT 

1 

 

6 

287909 

Sender, Water Temperature 

(V16476 #02019)

 

1 

* 

7 

289261-001 

Kit, Block Heater, 120v. 

Ref. 

 

 

289249-005 

…Heater, Engine Block 

1 

 

 

289250-001 

…Cable, Engine Block Heater 

1 

 

 

 

Engine Mounting Components 

 

* 

8 

480603-001 

Mount, Shock, Engine 

1 

* 

7 

282852 

Mount, Engine, Front, Assembly 

1 

* 

10 

289816 

Mount, Engine, Front, Assembly 

1 

 

11 

289557 

Support, Engine, Front (see also Figure 17) 

1 

* 

12 

 

Drain, Blow-by 

Ref. 

* 

 

056535 

…Hose, 3/4” ID (Rear Hose) 

36 in. 

* 

 

 

…Clamp, Hose (Supplied by Cummins) 

Ref. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for 120CU20

Page 1: ...ginal 10 15 13 Rev A Operation and Maintenance Manual with Illustrated Parts List for 120CU20 120 kVA 3 Phase 115 200 Volt 400 Hz Generator Set Series 500120 ITW GSE Group Hobart Ground Systems Palmetto Florida 34221 U S A ...

Page 2: ... ...

Page 3: ... of its authorized distributors The PRODUCTS purchased under this warranty are intended for use exclusively by the buyer and his employees and by no other persons and therefore there shall be no third party beneficiary to this warranty 6 A claim of defects in any PRODUCT covered by this warranty is subject to HOBART factory inspection and judgment HOBART S liability is limited to repair of any def...

Page 4: ... ...

Page 5: ...ge Rev No Release Date By Description 0 May 06 2013 HLC 1 New spec roll for new starter wire harness etc to create Deluxe and Standard models A October 15 2013 H A Created Revision Log Changed Insulation to show that it is now an option removed composite fuel tank and updated the manual to reflect that the unit is now made in Florida ...

Page 6: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Revision Log Page 2 This page is intentionally left blank ...

Page 7: ...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 l...

Page 8: ...rvicing this equipment take the following precautions a Shut off all power at the disconnecting switch or line breaker or by disconnecting battery before inspecting or servicing the equipment b Lock switch OPEN or remove line fuses so that power cannot be turned on accidentally c Disconnect power to equipment if it is out of service d If troubleshooting must be done with the unit energized have an...

Page 9: ...extreme care in doing necessary trouble shooting 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...

Page 10: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Safety Warnings Page 4 This page is intentionally left blank ...

Page 11: ...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 its location is identified by a chapter section and paragraph or figure number 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 i...

Page 12: ... Department by mail telephone FAX or E Mail Write Hobart Ground Systems Service Department 11001 US Highway 41 North Palmetto FL 34221 U S A Call Inside U S A 800 422 4166 Parts 877 874 5322 Customer Service Call From Foreign Countries 941 721 1000 Parts 941 721 1092 Service Technical Support FAX Inside U S A 941 723 3160 FAX From Foreign Countries 941 721 1087 E mail service hobartsystems com Web...

Page 13: ...Box Assembly 1 1 11 Power Module Panel Assembly 1 1 22 Cold Weather Start System 1 1 24 Transformer Rectifier Assembly Components 1 1 25 Section 2 Preparation for Use Storage or Shipping 1 2 1 Preparation For Use 1 2 1 Preparation for Storage 1 2 5 Preparation for Shipment 1 2 6 Section 3 Operation 1 3 1 General 1 3 1 400 Hz Operation Procedure 1 3 1 DC Operation Procedure 1 3 6 Simultaneous AC an...

Page 14: ...2 3 15 Diode Test 2 3 16 Testing the Transformer Rectifier 2 3 16 Adjusting the Transformer Rectifier 2 3 18 Section 4 Troubleshooting Procedures 2 4 1 General 2 4 1 Equipment for Troubleshooting 2 4 1 Parts Replacement 2 4 1 400 Hz Test Values 2 4 2 Check Connections and Leads 2 4 2 Engine Troubleshooting 2 4 2 Illustrations 2 4 2 Connection and Schematic Diagrams 2 4 2 GPU Control Monitoring 2 4...

Page 15: ...lexible Coupling 3 2 1 General 3 2 1 Disassembly 3 2 1 Coupling Service 3 2 4 Coupling Installation 3 2 5 Reassemble Engine and Generator 3 2 6 Run in and Periodic Check 3 2 7 Section 3 Generator Assembly 3 3 1 General 3 3 1 Generator Assembly Removal 3 3 1 Generator Assembly Installation 3 3 4 Chapter 4 Illustrated Parts List Chapter Section Page Section 1 Introduction 4 1 1 General 4 1 1 Purpose...

Page 16: ... 4 3 18 Figure 10 400 Hz Power Module Assembly 4 3 20 Figure 11 Cooling System Components 4 3 22 Figure 12 Engine Ground Plate and Cables 4 3 24 Figure 13 Fuel System Components 4 3 26 Figure 14 Engine Exhaust Components 4 3 28 Figure 15 12 VDC Battery System 4 3 30 Figure 16 Air Cleaner Components 4 3 32 Figure 17 Engine Components 4 3 34 Figure 18 Engine Electrical Panel Components 4 3 36 Figure...

Page 17: ...iler 2 Stainless 500120 DLX Trailer 2 Stainless 500120TR STD Trailer 2 Yes Stainless 500120TR DLX Trailer 2 Yes Stainless Table 1 Series 500120 Generator Set Part Number Descriptions 2 Optional Equipment Appendix A Chapters 1 through 5 of this Operation and Maintenance Manual identifies only the stripped down version of the 120CU20 generator set A list of optional equipment that makes this manual ...

Page 18: ...enerator if an abnormal condition of voltage frequency or load develops b Voltage Regulator A microprocessor type adjustable voltage regulator provides automatic voltage regulation at the aircraft The regulator is also adjustable for a variety of output cable sizes and lengths c Engine Electronic Control Module The engine is equipped with an electronic control module that monitors records and cont...

Page 19: ...oltage 115 200 VAC Rated load capacity 348 Amps Frequency 400 Hz Power factor 0 8 Duty Cycle 100 Operating speed 2000 RPM Overload capacity both outputs 125 rated load 435 Amps Output cable size 2 0 c AC Generator Protective System Specifications Condition Trip Point Time Delay Over voltage 126 volts 1 second 140 volts 160 milliseconds 180 volts 50 milliseconds Under voltage any voltage below 100 ...

Page 20: ... Delay Over Voltage 32 34 VDC 2 seconds Output Overload 2700 A 2 seconds 2000 A 10 seconds 1500 A 30 seconds 1200 A 90 seconds 750 A 600 seconds f Engine Specifications Manufacturer Cummins Engine Company Model No QSB6 7 Type 6 cylinder 4 cycle diesel electronic controlled Bore and Stroke 4 21 in x 4 88 in 107 mm x 124 mm Displacement 409 in 3 6 7 L Horsepower 220 hp 164 kW Idle speed 1000 50 rpm ...

Page 21: ...urer the engine includes the following equipment which is more fully described in the engine manufacturer s operation manual 1 Electrical System The 12 VDC electrical generating and starting system includes an alternator voltage regulator and starter with solenoid switch 2 Lubricity Additive Fuel Filter The fuel filter is a spin on disposable type located on the interior bulkhead located in the mi...

Page 22: ...rocessor on the EIB Engine Interface Board PC Board which will stop the engine if the temperature reaches 230º F 110º C c Oil pressure shutdown system The oil pressure shutdown system consists of a factory supplied oil pressures switch This switch is monitored by the microprocessor on the EIB Engine Interface Board PC Board which will stop the engine if the oil pressure is under 12 PSI 82 7 kPA 2 ...

Page 23: ...l appropriate fault code a Press the engine stop button to reset the fault code and reset the protective system b Or use E STOP button for immediate reset Low fuel warning and shutdown Turns on the low fuel indication on the fault code meter The GPU is programmed at the factory to warn at 1 4 tank and to shutdown at 1 8 tank a The low fuel fault indicating function must be reset by pressing the en...

Page 24: ...Chapter 1 1 Page 8 1 Control Panel 2 Operator s Push button Panel 3 Output Cable Location 4 Front Axle Assembly 5 Rear Axle Assembly 6 Emergency Stop Switch S28 7 Exhaust Outlet Not Shown 8 Canopy 9 Radiator End Rear 10 Generator End Front Figure 1 General Assembly of Generator Set 4 2 1 3 10 9 8 6 5 ...

Page 25: ...15 2013 Chapter 1 1 Page 9 1 Radiator 2 Charge Air Cooler 3 Cummins QSB6 7 Engine 4 Air Cleaner 5 Control Box 6 Fuel Tank 7 12 VDC Batteries BT1 BT2 8 Generator 9 Pre Fuel Filter 10 Rear Axle 11 Air Intake Heater BH1 Figure 2 Main Components of Generator Set Right Side 6 5 4 3 2 1 10 11 9 8 7 ...

Page 26: ... Page 10 1 Dual Output Power Module 2 Exhaust Muffler Shield 3 Exhaust Muffler 4 Exhaust Piping 5 Lubricity Additive Fuel Filter Not Shown 6 Top and Bottom Fan Shroud 7 Alternator Fan Belt Guard 8 Engine Cooling Fan 9 Fan Guard 10 Control Box Figure 3 Main Components of Generator Set Left Side 8 9 7 6 4 3 2 1 10 ...

Page 27: ...d converts exciter AC output to DC for excitation of the generator revolving fields The exciter DC output to the generator fields and consequently the generator output is controlled voltage regulator PC board REG A centrifugal radial blade fan which is part of the flexible coupling assembly draws cooling air over all internal windings Air enters at the exciter end and is discharged at the drive en...

Page 28: ...tmeter M2 8 AC Generator Ammeter M1 9 Fault Code Meter M6 10 DC Voltmeter Optional with TR 11 DC Ammeter Optional with TR 12 Front LED Display A5 13 Panel Light Switch S74 14 Air Intake Heater Switch S79 15 Engine Start Switch S24 16 AC Output No 1 Switch S75 17 AC Output No 2 Switch S275 18 DC Output Switch S430 Optional with TR 19 DC Starting Current Switch S431 Optional with TR 20 Engine Stop S...

Page 29: ...ART push button switch S24 The ENGINE START push button switch when pressed connects 12 VDC power to the starter solenoid coil which actuates the solenoid switch to connect power to the engine starting motor The 12 VDC power is supplied directly to the engine ECM and the oil pressure shutdown switch is bypassed This bypass is necessary for engine starting because the low oil pressure switch is CLO...

Page 30: ...hould be performed only when disconnected from a load as the contactor s will open during the test cycle 12 Engine systems fault codes Fault codes will be shown to warn the operator of abnormal engine operations that must be corrected These indicators are over temperature air cleaner restriction low oil pressure and low fuel indication 13 AC Generator output monitors meters Three instruments a fre...

Page 31: ...er and ammeter meters are both analog type and indicate the output voltage from 0 to 50 VDC and the amperage from 0 to 2500 A 17 STARTING CURRENT Switch S431 with DC option Each time the STARTING CURRENT push button switch is pressed the BLUE indicator will glow The present current limiting amperage setting will be displayed on the fault code meter for a short time delay before incrementing at 100...

Page 32: ...RB A404 Optional 7 5 12 VDC Power Supply PS1 8 Circuit Breaker Support Bracket 9 Marker Lights Circuit Breaker 10 A CB1 10 Engine Circuit Breaker 10 A CB4 11 Controls Circuit Breaker 5 A CB7 Figure 6 Control Box Interior Components 1 EF Bypass switches located on CTL For each load contactor circuit a single pole single throw EF1 BYPASS for OUTPUT 1 or EF2 BYPASS for OUTPUT 2 provides a means of by...

Page 33: ...ed voltage of approximately 30 VAC will be produced at the generator output terminals due to the residual magnetism of the exciter 3 Circuit breakers CB1 CB4 CB7 A 10 ampere ENGINE circuit breaker protects the 12 VDC engine electrical and fault circuits and another 10 ampere MARKER LIGHTS circuit breaker protects the 12 VDC lighting system A 5 ampere CONTROL circuit breaker protects the 12 VDC con...

Page 34: ...controls the power distribution in the control system hour meter lights and the engine starter operation Figure 8 Engine Interface PC Board 6 Engine Specific PC Board ESB A1 The ESB is unique only to the engine model used in the GPU purchased The ESB is the primary interface between the control system and the engine s electronic control module When the CTL senses the engine start button has been p...

Page 35: ...ation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 1 1 Page 19 Figure 9 Engine Specific PC Board 7 Voltage regulator PC board REG A4 Figure 10 Voltage Regulator PC Board ...

Page 36: ...s removed from the alternator the alternator voltage rises The rectified three phase voltage sensing signal increases causing this signal to be higher than the reference signal The associated voltage regulator circuitry causes the field power of the rotary exciter to decrease lowering the alternator voltage until the voltage returns to regulated value The line drop voltage compensation circuit con...

Page 37: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 1 1 Page 21 Figure 11 Transformer Rectifier PC Board Figure 12 Control System Power Source ...

Page 38: ... exciter field current as required to maintain a constant predetermined voltage at the load 2 Ammeter The current transformers convert a current signal to a voltage signal which is sent to the Voltage Regulator PC Board REG The ammeter is really a voltmeter graduated and numbered in amperes to show current proportional to the voltage signal received When there is overload on the output for more th...

Page 39: ...eration and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 1 1 Page 23 Figure 13 Output Power Module Components Generator Output Leads Output Contactors Current Transformers ...

Page 40: ...he 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 heaters stay 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 During cranking the intake ai...

Page 41: ...the AC voltage from transformer assembly providing unfiltered 28 5V DC A DC shunt connected to the heat sink assembly measures the DC output current c Input Contactor K401 The input contactor applies the generator output power to the input of the transformer assembly d Output Contactor K402 The output contactor connects the output of the 28 5 VDC power supply to the output cables The contactor is ...

Page 42: ... October 15 2013 Chapter 1 1 Page 26 1 Transformer Assembly T401 2 Heat Sink Diode Assembly CR402 CR407 3 Input Contactor K401 4 Output Contactor K402 5 DC Inductor Filter Assembly L401 6 Pre Load Resistors R402 R404 7 Capacitor PC Board A401 Figure 15 Transformer Rectifier Components ...

Page 43: ...clamps tube fitting etc as required 5 Check security of generator set retaining components 6 Check the following for sufficient quantity a Fuel Press the LAMPS push button button to energize the fuel gauge when the engine is stopped Fuel is supplied from a customer furnished source NOTE For recommended fuel specifications refer to the Engine Manufacturers Operation and Maintenance Manual provided ...

Page 44: ... 2 Oil Fill and Oil Level Check Locations d Check Batteries Inspect the batteries for proper connection of the terminals and check the electrolyte level if possible Service or replace if necessary b Installing Three Phase AC Output Cables The generator set may be shipped without aircraft cables The output cables connect to the load contactors which are located on the power module assembly left sid...

Page 45: ...B to B and C to C 7 Connect the cable s neutral terminal lug securely to the neutral ground stud on the power module assembly 8 Connect the E and F cables to the E and F studs on the power module assembly 9 Tighten clamp screws securely but avoid damage to cable insulation 10 Replace Plexiglas cover panel lower panel and close canopy door c Installing the DC Output Cable optional 1 The T R output ...

Page 46: ...ation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 1 2 Page 4 Figure 3 Output Cable Connection Figure 4 Lower Panel Assembly Output Cables Contactor Output Cables Clamp ...

Page 47: ... will include changing engine oil and all filter elements 2 Start the engine and operate for about two minutes so that all internal engine components will be coated with new oil NOTE Do not drain the fuel system or crankcase after this run 3 Make certain the cooling system antifreeze solution is adequate to protect below the lowest temperatures expected during the storage period Be sure the soluti...

Page 48: ...ble contact the 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 CAUTION When shipping the unit provide sufficient retaining materials to ensure the generator set cannot roll out or off the vehicle in which it is bei...

Page 49: ...tempting to operate the equipment WARNING Ear protection equipment may be necessary when working close to this equipment 2 400 Hz Operating Procedure a Pre start Inspection 1 Be sure the fuel shutoff valve on the unit is open 2 Ensure 12 VDC power is available to the engine starting system 3 Check the engine and generator compartments to make certain they are free of rags or other foreign material...

Page 50: ...meter M2 8 AC Generator Ammeter M1 9 Fault Code Meter M6 10 DC Voltmeter Optional with TR 11 DC Ammeter Optional with TR 12 Front LED Display A5 13 Panel Light Switch S74 14 Air Intake Heater Switch S79 15 Engine Start Switch S24 16 AC Output No 1 Switch S75 17 AC Output No 2 Switch S275 18 DC Output Switch S430 Optional with TR 19 DC Starting Current Switch S431 Optional with TR 20 Engine Stop Sw...

Page 51: ...use an ether start system in conjunction with the air intake heater 3 Press the green ENGINE START push button switch and hold until engine starts The engine will start at idle speed and the green light in the ENGINE START push button switch will flash to indicate that power is available to the engine s ECM circuit CAUTION Do not attempt to bring to rated speed for at least 5 seconds after engine ...

Page 52: ... switch set to any line to line position A B B C or C A the voltmeter should read 200 volts 3 The final step in delivering power is closing one or both of the load contactors When the instruments indicate satisfactory frequency and voltage values close either load contactor or both load contactors by momentarily pressing the load contactor s OUTPUT NO 1 or OUTPUT NO 2 pushbutton switch The yellow ...

Page 53: ...ition See Load Contactor Operating Circuits in Section 2 4 for other for additional troubleshooting procedures f Discontinue Power Delivery with Unit Shutdown 1 Normal conditions a Push the OUTPUT No 1 or No 2 pushbutton switch to open the output load contactor The indicating light yellow or orange depending on the contactor used on that switch will go OFF immediately to indicate that the load con...

Page 54: ...ircraft b Current Limiting Power Delivery If current limiting is required for starting an aircraft set the current limit as follows 1 Press the STARTING CURRENT push button to activate and view the present current limiting value Continue to hold the button down to increase the setting 2 Each time the STARTING CURRENT push button is pressed the current limiting will be viewed and increased by 100 A...

Page 55: ...enance schedule check sheet such as the one in 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...

Page 56: ...ck Exhaust System X X Charge Air Cooler CAC and Piping X Change Lubricity Fuel Filter Element X X Check Fuel Pump 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 Belts ...

Page 57: ...Check Thermostats and Seals Fall Electrical 12 VDC System Check All Lights X Check Alternator Charging Rate X Check Battery and Fluid Level X Clean Battery Terminals X X Check Wiring and Connections X Check All Engine Meters X Electrical 400 Hz System Check E F By Pass Operation X Check Output Cable and Connectors X Check Volt Amp Frequency Meters X Check and or Adjust Output Voltage X X Inspect W...

Page 58: ... 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 ...

Page 59: ...y 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 Saf...

Page 60: ... could be a fire hazard 2 Electrical System 12 VDC a Check All Lights Check all indicating lights to be sure they will operate when they should If any light fails to operate check both the lamp and its protective circuit breaker Figure 5 lists all lamps with their location and part number Figure 6 lists all circuit breakers b Check Engine Battery Voltage Observe the 12 VDC engine voltmeter each ti...

Page 61: ...he hose clamps if necessary b Check and record oil pressure After each oil change check and record oil pressure at idle 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 ...

Page 62: ...sphate 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 a Wiring Inspect all cables and leads for worn or damaged insulation b Connections Inspect connectors for damaged or corroded condition 3 Electrical 400 Hz System a Protective Monitoring Circuits Check operation o...

Page 63: ...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 h...

Page 64: ...r 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 particular engine require no period...

Page 65: ...he fins Clean or replace as necessary c Flush cooling system and change coolant j Seasonal Maintenance Checks Spring Fall Engine 1 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 In addition t...

Page 66: ...t Voltage Regulator PCB 1 5 A Transformer Rectifier Optional Transformer Rectifier PCB 1 1 A Figure 4 Fuse Identification Chart Light Identification Location Lamp Bulb as per Lamp Industry Trade Number or Description Instrument Panel Lights Switch Panel 67 Engine Start Indicator Switch Panel 1815 Engine Stop Indicator Switch Panel 1815 No 1 Load Contactor Indicator Switch Panel 1815 No 2 Load Cont...

Page 67: ... Generator The 400 Hz generator requires NO lubrication c Generator Controls Generator controls and instruments require no periodic lubrication d Engine Although the engine and its accessories require no more attention than any other similar installation they still inherently require a major portion of the generator set lubrication and maintenance Recommendations regarding engine lubrication have ...

Page 68: ...nufacturer s operation manual 4 Changing engine oil Oil should be changed once after the first 50 150 hrs of use then every 500 hrs 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 Change the oil filter element each...

Page 69: ...F 29ºC and Below to 10ºC Synthetic Oils See the engine manufacturer s operations manual for usable synthetic oils and instructions Fuel Water Separator Lubricity Additive Filter Drain filters daily Change filter element every 500 hours or after 3 months of use whichever comes first Coolant Check coolant level daily Engine coolant capacity system 10 gallons 37 8 liters Coolant hoses and connections...

Page 70: ... oil filter by twisting counter clockwise and inspect it NOTE The gasket can stick to the filter head Make sure it is removed before installing a new filter CAUTION If bearing metal particles are found on the element or in the shell the source should be determined before a failure CAUTION Determine source of moisture internal leaks defective seals gaskets etc iii Fill the new filter with clean lub...

Page 71: ... Allow engine to idle for 5 minutes check for leaks than stop the engine h 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 e Engine Accessories Lubrication 1 Alternator Most alternators contain sealed bearings and require no periodic lubrication however check to make certain there are no lubri...

Page 72: ...n the operator panel shows the Air code Figure 3 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 Unfasten the three metal clamps on the end of the air cleaner housing 2 Remove end cover of housing 3 Pull out air filt...

Page 73: ...e selection of fuel to use refer to publication Engine Requirements Lubricating Oil Fuel and Filters available from authorized engine manufacturer 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 fl...

Page 74: ...th the engine off 3 Changing the fuel filter a The filter element replacement part numbers Hobart 286897 030 Cummins FF5421 b Apply a coating of clean fuel or motor oil to the new O ring and element seal Spin the filter onto the fuel filter element c The fuel filter must be change after every 500 hours of operation c Fuel Pump The fuel pump supplies pressure to the fuel system so the diesel fuel c...

Page 75: ...eration in order for the fuel filter to continue adding the proper amounts of the lubricity additive into the fuel system c Shut off fuel valve d Place a pan underneath the fuel filter to catch spilled fuel e Undo fuel filter with commercial tool and spin off f Catch any fuel g Clean any dirt from the filter carrier rim h Apply a light film of oil or diesel on the rubber seal on the new filter CAU...

Page 76: ...er vent plug and cranked the engine until the fuel reaches the injectors and the engine starts CAUTION Make sure that all rags or absorbent sheets are clear of moving engine parts and cannot be drawn in to the radiator fan CAUTION Do not crank the engine for more then 15 seconds continuously Allow the starter to cool for 15 seconds between attempts 6 Engine Cooling System a General Cooling system ...

Page 77: ...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 test...

Page 78: ...e radiator cap 2 Place a drain pan with at least a 40 quarts 28 4 liters capacity under radiator to catch coolant 3 Place the radiator drain hose that comes off the two radiator drain valves into the drain pans 4 Open the radiator drain valves 5 Allow the system to drain completely NOTE Be sure the drain valves do not clog during draining 6 When the system is completely drained close the drain val...

Page 79: ...he coolant level remains at the bottom of the fill neck c Start the engine bring it 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 Re Install radiator cap 2 Inspection Check a Check system for evi...

Page 80: ...n 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 CAUTION Checking the tension and changing the serpentine belt should only be performed with the engine off Check belt tension every 1000 hours or once year whichever c...

Page 81: ...vice Be sure the generator output N cable is grounded 2 Check engine oil level Oil should be at high bar on the dipstick 3 Check radiator coolant level See Section 2 2 4 Check tension of drive belt See Section 2 2 5 Inspect for oil fuel and coolant leaks 6 If the setting of the output voltage coarse adjustment potentiometer Figure 7 on the voltage regulator has been disturbed set it at center posi...

Page 82: ...meter M2 8 AC Generator Ammeter M1 9 Fault Code Meter M6 10 DC Voltmeter Optional with TR 11 DC Ammeter Optional with TR 12 Front LED Display A5 13 Panel Light Switch S74 14 Air Intake Heater Switch S79 15 Engine Start Switch S24 16 AC Output No 1 Switch S75 17 AC Output No 2 Switch S275 18 DC Output Switch S430 Optional with TR 19 DC Starting Current Switch S431 Optional with TR 20 Engine Stop Sw...

Page 83: ...n switch a second time If the engine comes up to rated speed and a 115 V voltage value appears on the voltmeter the engine ECM and excitation circuits are functioning 7 After generator overhaul or repair the Regulated Diagnostic switch must be placed in the DIAGNOSTIC position for 3 to 5 seconds to re magnetize the exciter Then return the switch to the REGULATED position after voltage has built up...

Page 84: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 2 3 Page 4 Figure 2 Control Box Interior Components ...

Page 85: ...terlock circuit of the control PC board is not receiving 28 5 VDC signal from an outside source It indicates that the No 1 interlock circuit is OPEN as it should be when the interlock circuit is not receiving a 28 VDC signal Reset the fault by pressing the TEST RESET push button Figure 3 Digital Control PC Board 3 Verify that when the EF Bypass switch is in the BYPASS ON position or the BYPASS OFF...

Page 86: ...the BYPASS ON position or the BYPASS OFF position that the appropriate LED indication on the control panel display Figure 5 is correct during the following steps 9 and 10 9 Place the No 1 EF bypass switch to BYPASS OFF position Press the No 1 Output pushbutton switch The No 1 Output indicating light within the push button switch should glow and remain on when the push button switch is released Thi...

Page 87: ...erate the No 1 output circuit of the unit at 125 load 325 amperes for 5 minutes immediately following the full load run The overload device MUST trip within 5 minutes and the fault code display should read 70 18 indicating an overload condition in OUTPUT NO 1 Reference fault chart in Section 2 4 18 Reset the fault by pressing TEST RESET push button d Testing the No 2 output circuit 1 Repeat steps ...

Page 88: ...s At 180 volts the circuit will trip within 50 milliseconds b If the load contactor does not open under the conditions described in step a refer to the Troubleshooting Chart in Section 2 4 c Return unit to normal operating conditions by adjusting coarse adjustment potentiometer turning it counterclockwise and pressing TEST RESET button switch to clear the fault code 6 Check operation of under volt...

Page 89: ...heck the under frequency protective components proceed as follows a While the unit is operating normally under load set the frequency adjust switch Figure 5 to TEST Use the frequency adjust potentiometer Figure 6 to adjust frequency to 400 HZ b Reduce frequency in steps of 1 Hz with a time delay of 7 seconds between steps c If the protective circuit opens the load contactor and displays fault 70 2...

Page 90: ... 22 on the fault code after 5 seconds at 426 Hz all components of the system are functioning properly d If the load contactor is not opened at 426 Hz after 5 seconds refer to Troubleshooting Chart in Chapter 2 Section 4 e Return unit to normal operating condition by setting the frequency adjust switch to NORMAL and pressing TEST RESET button switch to clear fault code NOTE If the generator is oper...

Page 91: ...ber When the number has finished flashing in the red lamp the yellow lamp will appear again The fault code will repeat in the same sequence The lamps flash each fault code 3 times before advancing to the next code To skip to the next fault code move the Engine Codes Switch momentarily to the UP position You can go back to the previous fault code by momentarily moving the Engine Codes Switch to the...

Page 92: ...g and hold the other end near the ear Hold the rod with three fingers and use the index finger and thumb to form a sounding chamber between the rod and the ear Do NOT allow the rod to touch the ear Listen for grinding or pounding sounds which would indicate a defective bearing An engine noise may be telegraphed to the generator and misinterpreted as a generator noise Contact the equipment manufact...

Page 93: ...utput voltage at which the generator is regulated is adjustable by the fine voltage adjustment potentiometer Figure 7 Turn the potentiometer adjustment clockwise to increase generator output voltage and counterclockwise to decrease voltage Observe the output voltage as indicated by the voltmeter located on the control panel of the generator set Set output voltage at 115 V AC line to neutral 200 V ...

Page 94: ...d the no load voltage output adjust the fine output voltage control potentiometer to the desired value 2 Test the Voltage Regulator After necessary adjustments have been completed re test the voltage regulator as follows a Connect a voltmeter at the load end of the generator output cables b Operate the generator set at no load and observe voltage reading c Operate the generator set under load and ...

Page 95: ...pen circuit condition See Figure 8 for resistance values a Disconnect generator stator leads at the output module panel b Disconnect the two black exciter field leads from terminal block mounted on output module panel c Check resistance and compare to values given in the chart below Test Connection Resistance Ohms Generator Stator Phase A to N G1 0 0026 Generator Stator Phase B to N G1 0 0026 Gene...

Page 96: ...ted with the leads connected one way and a low readable resistance was indicated with the leads connected the opposite way the diode may be considered good 6 Testing the Transformer Rectifier for units with DC option The 28 5 VDC transformer rectifier is an optional add on to the GPU The following test procedures may be used for testing the T R following repair or for just checking performance a P...

Page 97: ...ection a Press DC OUTPUT push button to close the DC output contactor The blue DC OUTPUT lamp will glow indicating that DC power is being delivered to the load bank b Adjust the voltage adjustment potentiometer on the TRB PC Board to less than 20 VDC c With 7 to 9 seconds after the trip voltage is reached the contactor will open and an under voltage fault will be indicated on the fault code meter ...

Page 98: ...he other lead on the diode lead and the record value d Reverse the ohmmeter leads and record the value e The diode may generally be considered good if one reading is infinite or very high and the other reading is extremely low 9 Control Interlock Kit Optional a With the output cable sitting in the cable tray start the GPU and bring the engine to rated speed b Close the output contactor by pressing...

Page 99: ...ection procedure Tests and inspections called for in the Troubleshooting Chart are to be performed as described in Chapter 2 Sections 1 3 of this manual 2 Equipment for Troubleshooting 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 certai...

Page 100: ...on either output Frequency at rated speed of 2000 RPM is 400 2 Hz at no load and rated load Engine oil pressure warm and at rated speed 2000 RPM 50 to 65 PSI 345 to 448 kPa Engine coolant temperature normal operation 180 to 200º F 82 to 93º C 5 Check Connections and Leads ALWAYS make a check of connections and leads to a component suspected of being faulty With the exception of a few instances we ...

Page 101: ...able 1 The control PC board communicates these commands to all of the PC boards in the GPU The first half of the fault code identifies the command that was present when the fault occurred Commands 01 39 Self Test Mode 40 Engine Start Mode 50 Engine Idle Mode 70 Engine Run Mode 80 Engine Shutdown Mode 90 Engine Stop Mode 99 System Off Mode Table 1 Operating Commands 1 Self Test Mode When power is f...

Page 102: ...INE STOP push button starts the 3 5 minutes delayed shutdown period The ENGINE STOP push button flashes and the engine returns to idle speed The shutdown period is required to cool the engine s turbocharger 6 Engine Stop Mode After the 3 5 minutes delayed shutdown period the engine stops running 7 System Off Mode The power is removed from the GPU s entire control system b Faults Faults result when...

Page 103: ...epending on customer configuration is a high temperature fault The contactors open and remove power from the aircraft the engine drops to its idle speed and the fault appears on the fault code display along with the command Pressing the TEST RESET push button or shutting down the GPU resets the fault 4 Stop Mode Stop mode faults remove power form the aircraft and shut the engine down An example is...

Page 104: ...above fault code 70 67 the engine ceases operation due to high coolant temperatures in the engine The 70 represents the command the GPU was executing at the time of the fault and shutdown Command 70 indicates an Engine Run Mode command The 67 represents the fault code that indicates the action taken by the control system upon faulting Fault 67 indicates a Stop Mode fault which shuts the GPU down e...

Page 105: ...de See Figure 1 5 To continue scrolling backward through the previous fault codes press and release the TEST RESET push button again The previous fault record number and fault code are displayed as described in Step 4 6 Repeat Step 5 to continue scrolling backward Once the first fault record is reached the scrolling stops To begin again press the LAMPS push button to turn off the control box light...

Page 106: ...meter M2 8 AC Generator Ammeter M1 9 Fault Code Meter M6 10 DC Voltmeter Optional with TR 11 DC Ammeter Optional with TR 12 Front LED Display A5 13 Panel Light Switch S74 14 Air Intake Heater Switch S79 15 Engine Start Switch S24 16 AC Output No 1 Switch S75 17 AC Output No 2 Switch S275 18 DC Output Switch S430 Optional with TR 19 DC Starting Current Switch S431 Optional with TR 20 Engine Stop Sw...

Page 107: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 2 4 Page 9 Figure 4 Control Box Interior Components ...

Page 108: ...roceed to step d d Internal seizure If battery and starter are good and the starter is unable to crank the engine an internal seizure is indicated Attempt to hand crank engine with a inch square drive on a long flex handle on 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 e D...

Page 109: ...ose connections damaged hoses or fuel lines between tank and fuel pump Tighten all fittings and connections Replace any damaged hoses or fuel links d Plugged or defective filter Do not overlook the possibility of restricted flow through the fuel filters Also check the gaskets for leaking or damaged condition e Defective EIB board Replace EIB board 4 Engine cranks but will not start Over temperatur...

Page 110: ...diesel fuel Replace EIB board 9 Engine has slow response time a Engine needs tune up Tune up as required Refer to engine manufacturer s operation manual 10 Engine misses or runs unevenly a Insufficient fuel Check low fuel level in accordance with engine manufacturer s operation manual Repair or replace parts as required b Faulty injector Check injectors in accordance with engine manufacturer s ope...

Page 111: ...gulator REG Connect a properly working REG board to regulator wiring assembly avoid short circuiting bottom of properly working REG board Then start generator set and perform tests and adjustments according to instructions in Section 2 3 If generator set works properly with a properly working REG board temporarily connected shut off generator set and replace defective REG board with one that is pr...

Page 112: ...closing for any one of following reasons Check all wiring and connections in load contactor circuits c Defective REG board After making certain that the output push button switch is working measure the DC output voltage at contactor coil If the voltage measured isn t approximately 90 VDC replace REG Replace REG board with a board known to be operating properly If contactor still doesn t close proc...

Page 113: ...spect cable connector plug thoroughly for damaged E and F terminals Be sure plug is fully 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 N O auxiliary push button switch mounted on right side of contactor Connect a jumper lead between terminals of N O auxiliary switch If l...

Page 114: ...115 VAC Adjust to normal if necessary If load contactor is opened again and the fault code meter indicates an over voltage condition proceed to step b b Defective CTL board Use REG potentiometer to reduce voltage to 110 VAC Observe voltmeter and gradually increase voltage with potentiometer If sensing circuit CTL board functions to open load contactor at any value less than 125 VAC it is defective...

Page 115: ...cy condition does not exist replace REG board 4 Load contactor opens during power delivery Under frequency fault indicated a Frequency adjust switch is enabled Set frequency adjust switch to DISABLE b Defective REG board If under frequency faults continue after engine s ECM is proven to be good and an under frequency condition does not exist replace REG board 5 Load contactor opens during power de...

Page 116: ...a Open or short circuited winding in generator stator G1 Check stator winding resistances See Section 2 3 for normal values 3 Generator overheats a Loose connection causing high resistance Check all output connections Look for discoloration caused by heat Tighten or replace as required b Improper or blocked ventilation Check for foreign material rags etc blocking airflow Provide adequate ventilati...

Page 117: ...ormation 2 Load contactor K402 opens during power delivery The engine is still running at rated speed or has returned to idle a Defective load contactor Fault Codes Display 70 46 for input contactor 70 31 for output contactor Check all wire connections or replace with a known good contactor If the above works correctly see Step c b Contactor opening could have been normal because of an over under ...

Page 118: ...utton sets the current limit but the system is not current limiting a Defective push button switch At rated speed measure the voltage across the switch The voltage should read approximately 5 VDC Press the switch again and the voltage should go to 0 V If voltage does not go to 0 V the switch is defective and needs to be replaced b Defective TRB PC Board Replace TRB PC board with a board known to b...

Page 119: ...ine idles at approximately 1000 RPM 55 _ _ ENGINE RAMP UP Period when engine goes from idle to rate speed 63 _ _ REG TEST OUTPUT FREQUENCY Check for 400 Hz output frequency 68 _ _ CTL TEST OUTPUT Check the CTL communications 70 _ _ ENGINE RUN MODE The engine is at rated speed and ready for aircraft load 75 _ _ ENGINE RAMP DOWN Period when engine goes from rated to idle speed 80 _ _ ENGINE DELAYED ...

Page 120: ...rd _ _ 06 TRB EF3 LOSS FAULT EF3 voltage signal not present TRB board defective K403 relay defective Defective Output Cable Check cable aircraft connection Place a 28 VDC signal of DC at output cable and at GPU Replace defective components _ _ 16 CTL OUTPUT OVER VOLTAGE FAULT Voltage set too high LDC set too high CTL board defective Adjust voltage or the LDC on the REG board Replace CTL board _ _ ...

Page 121: ...AULT DC load over rating of GPU Reset and restart GPU _ _ 31 TRB DC CONTACTOR FAULT Defective output contactor Defective TRB board Replace output contactor Replace TRB board _ _ 32 REG EF1 VOLTAGE TOO HIGH FAULT EF voltage being sent from aircraft on output 1 to the GPU is too high Output cable is defective Reset and restart GPU Check output cable _ _ 33 REG EF2 VOLTAGE TOO HIGH FAULT EF voltage b...

Page 122: ...Fill fuel tank _ _ 60 CTL COMM FAULT Defective CTL board Replace CTL board _ _ 61 EIB COMM FAULT Defective EIB board Replace EIB board _ _ 62 ESB COMM FAULT Defective ESB board Replace ESB board _ _ 63 REG COMM FAULT Defective REG board Replace REG board _ _ 64 TRB COMM FAULT Defective TRB board Replace TRB board _ _ 66 EIB LOW ENGINE COOLANT FAULT Engine coolant level is too low Engine is loosing...

Page 123: ...gn improvements the exciter and rear main bearing can be removed without removing the generator from the generator set The name exciter armature refers to the shaft mounted revolving three phase windings of the exciter 1 Coupling Key Not Shown 2 Flex Coupling Assembly 3 Generator Housing Stator Assembly 4 Armature Assembly 5 Exciter Housing Coils Assembly 6 Exciter Cover 7 Exciter Armature Assembl...

Page 124: ...ing replacement The exciter armature has two M10 1 5 tapped holes in its diode mounting plate to accommodate pulling it off the shaft Since the removal and installation of exciter armatures can be rather complicated this manual has been prepared to assist mechanics in the operation It may be necessary to remove the exciter armature several times for bearing replacement during the life of a generat...

Page 125: ...such a tool Sling hammer pullers are also commercially available Instructions for using tool are provided in this manual Once the threaded machine key is removed No other special tools are required for removing the exciter from the generator shaft This can be done using the two M10 1 5 fully threaded hex head bolts Instructions for doing this are provided in this manual see section e c Conditions ...

Page 126: ...and 2 into key until stud bottoms in key threads Tighten securely b If hammer 5 and rod 4 are not already assembled thread one nut 3 onto adapter end of rod 4 Thread rod into adapter until it bottoms then tighten nut securely against adapter Slide hammer 5 onto rod and install washer 6 and two nuts 3 Thread nuts onto rod until both nuts are full threaded and locked together WARNING Be very careful...

Page 127: ...nd use two M10 1 5 hex head bolts as shown in Figure 4 to force the exciter armature off the shaft Turn each of the two screws a few turns at a time into the threaded holes of the diode mounting plate until the exciter armature is sufficiently loosened from the shaft to be removed from it by hand Remove it slowly from the shaft and at the same time observe the following CAUTION 1 Stud 1 4 28 UNF 2...

Page 128: ...ough the hole Figure 2 Straighten leads and remove kinks as required to avoid damage to insulation 4 Exciter Armature Installation a Preparation for Exciter Armature Installation 1 Clean generator shaft and exciter armature bore Remove all rust corrosion etc 2 Make CERTAIN that the leads are tucked into the 1 2 keyway which is opposite from the 3 8 keyway in the generator armature shaft Figure 4 E...

Page 129: ...ads through the hole Figure 2 in the diode mounting plate Screw the nut onto the bolt until it is near the head of the bolt Insert the bolt through the hole in the center of the diode mounting plate as far as it will go and screw it into the end of the armature shaft Screw the nut up against the diode mounting plate Continue turning the nut until the diode mounting plate contacts the end of the ge...

Page 130: ...Z to the shaft and armature bore is NOT recommended because there is a danger that it may mix with and contaminate the LOCTITE Application of NEVER SEEZ will be at the customer s risk LOCTITE can lose its adhesive and tightening properties if contaminated by rust preventatives oil or other lubricants and antirust products Recommended Products Manufacturers LOCQUIC No 47 56 Primer Grade T LOCTITE N...

Page 131: ...r slight misalignment between the engine and the generator due to manufacturing tolerances A tapered bushing and hub secures the coupling to the generator shaft Figure 1 Coupling Assembly 2 Disassembly Removal of the flexible coupling is required for servicing the generator armature generator bearings or the coupling itself To remove the coupling for any reason it is necessary to separate the engi...

Page 132: ...3 To separate the bushing from the hub lubricate two of the 3 8 16 bolts and insert them into the two threaded holes in the bushing flange With socket wrench screw these bolts into the bushing such that the bushing pops loose from the hub alternating from bolt to bolt 4 When the bushing is loose in the hub use a mallet to GENTLY tap the bushing out of the hub 5 Slide the coupling assembly off the ...

Page 133: ... shaft for any damage or deformation where the coupling was mounted on it e Check rubber bushing alignment to make sure that the dimension illustrated in Figure 4 is maintained 1 Bolt 3 8 16 UNC 3 2 Taper Lock Bushing 3 Taper Lock Hub 4 Tapped holes 2 5 Key 6 Set Screw 7 Fan Coupling Disk 8 Armature Shaft Figure 3 Hub and Bushing ...

Page 134: ...rom Foreign Countries 941 721 1087 E mail service hobartsystems com Web Page www hobartsystems com a Replacement Coupling Kit A replacement coupling kit is available from your ITW GSE Group Distributor This kit provides a replacement coupling assembly with attaching hardware and installation instructions b Bushing Kit A bushing kit is available from Hobart for replacing the rubber bushing only in ...

Page 135: ...ly CLEANED FREE OF DIRT AND GRIT CAUTION Do not lubricate any of the surfaces listed above Lubrication of these surfaces can cause the coupling to fail and damage the generator set Slight traces of rust are permissible on the surfaces b Assembly 1 If an adapter ring must be replaced remove the bolts that secure it to the flywheel Discard the old adapter ring and bolts Install the new adapter ring ...

Page 136: ...lustrated in Figure 2 Observe the CAUTION above when it is necessary to rotate the shaft b Repeat step a above until 3 8 16 bolts can no longer be tightened c Check the dimension in Figure 7 to be sure it is the same as the dimension in Figure 6 5 Reassemble Engine and Generator CAUTION Use of the proper coupling bolts is very important Failure to use the proper bolts as outlined below can result ...

Page 137: ...n b Shut down the engine after 2 hours and re torque all coupling bolts to 85 foot pounds 115 N m to compensate for normal torque relaxation c Return the unit to normal service d After 200 hours of operation check all coupling bolts with a torque wrench set at 85 foot pounds 115 N m e Return the unit to normal service f After each additional 2 000 hours of operation or every year recheck all coupl...

Page 138: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 3 2 Page 8 Figure 4 Bushing Installation ...

Page 139: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 3 2 Page 9 Figure 5 Assembly Procedure Figure 6 Measure from mounting face to adapter ring ...

Page 140: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 3 2 Page 10 Figure 7 Measuring from Mounting Face to Bushing ...

Page 141: ...ssembly is mounted on the generator set remove T R assembly 5 Disconnect clearance light wires from the top canopy 4 if installed 6 Remove top canopy panel 4 7 Remove the left front 5 and right front 6 doors 8 Remove the following right front lower panel 8 and left front lower panel 7 Disconnect the clear power module cover 9 from the angle bracket on the frame and loosen cable clamps to so that t...

Page 142: ...nd hoist if available 3 Using the hoist support the generator assembly For lifting convenience a M12 1 75 threaded hole is drilled in the top of the generator housing Insert a M12 1 75 eyebolt in the hole and attach the hoist chain to the eyebolt as shown in Figure 1 4 Remove the M12 1 75 bolts generator to flywheel coupling bolts 5 Detach the generator housing from the engine Do this by removing ...

Page 143: ...Charge Air Cooler Hood Gasket 4 Canopy Top Assembly 5 Right Front Door 6 Control Box Door Left Front Door 7 Left Front Lower Panel 8 Right Front Lower Panel 9 Power Module Cover 10 Power Module Assembly 11 Control Box Assembly 12 Air Filter Assembly 13 Bulkhead Panel 14 Front Canopy Panel 15 Control Box Support 16 Generator Cover Figure 2 Component Removal Required for Access to Generator ...

Page 144: ...ousing with wooden blocks or second hoist if available 2 Using the hoist support the generator assembly and lower it carefully and slowly into position for attachment to the engine 3 While still supporting the generator assembly with the hoist attach the generator housing to the engine using the six M10 1 5 x 35 metric bolts Torque bolts to 30 ft lb 41 N m 4 Attach the generator to the flywheel co...

Page 145: ...arts of the equipment are listed except Standard hardware items attaching parts such as nuts screws washers etc which are available commercially Bulk items such as wire cable sleeving tubing etc which are also commercially available Permanently attached parts which lose their identity by being welded soldered riveted etc to other parts weldments or assemblies b Parts List Form This form is divided...

Page 146: ...ect No Number and the vendor s number will be shown in the NOMENCLATURE column Parts manufactured by Hobart will reflect no vendor or part number in the NOMENCLATURE column 3 NOMENCLATURE Column The item identifying name appears in this column The indenture method is used to indicate item relationship Thus components of an assembly are listed directly below the assembly and indented one space Vend...

Page 147: ...and CH 6300 0CYC7 Western Rubber Supply 7888 Marathon Dr Ste Livermore CA 94550 9314 0E8J0 Emka Inc 1961 Fulling Mill Rd Middletown PA 17057 3125 0HZP9 Diesel Radiator Co 1985 Janice Ave Melrose Park IL 60160 1008 0MR72 Henkel Corp 26941 Cablot Rd Suite 124 Laguna Hills CA 92653 7007 0TSE6 Infineon Technologies Industrial Power Inc 1050 US HWY 22 Lebanon NJ 08833 4208 00779 Tyco Electronics Amp 28...

Page 148: ...es Inc DBA Hughes Peters 8000 Technology Blvd Huber Heights OH 45424 1573 2B664 All Phase Electric Supply Co 1620 W Main St P O Box 149 Springfield OH 45501 0149 Code Vendor s Name and Address 2N562 Power Transmission Sales Inc 531 Washington P O Box 229 Chagrin Falls OH 44022 0229 23803 N T N Bearing Corp of America 191 Sheree Blvd Ste 101 Exton PA 19341 1265 24161 Gates Corporation 900 S Broadwa...

Page 149: ... 56289 Sprague Electric Company 678 Main St Sanford MA 04073 7003 57330 Remke Industries Inc 310 Chadick Drive Wheeling IL 60090 6039 Code Vendor s Name and Address 57347 Wall Industries Inc 5 Watson Brook Rd Exeter NH 03833 4589 57733 Stewart Warner Corporation 333 Ludlow St Stamford CT 06902 6987 59656 Dean Technology Inc DBA CKE 1000 Lucerne Road Lucernemines PA 15754 0211 6S553 Wes Garde Compo...

Page 150: ...ronics Corporation 8010 Piedmont Triad Pkwy Greensboro NC 27409 78388 Woodward Controls Inc 6250 W Howard St Niles Il 60714 3433 8A334 Cummins Bridgeway LLC 2297 SW Blvd Ste K Grove City OH 43123 1822 8T246 Whitesell RO Associates Inc 7009 CORPORATE WAY Dayton OH 45459 4238 81483 International Rectifier Corp 233 Kansas St El Segundo CA 90245 Code Vendor s Name and Address 81703 Mulberry Metal Prod...

Page 151: ...s a list of symbols and abbreviations used in the parts list Item not illustrated A or AMP Ampere AC Alternating current AR As required DC Direct current Fig Figure hd Head hex Hexagon Hz Hertz cycles per second I D Inside diameter IN Inch KVA Kilovolt ampere uF Microfarad No Number NHA Next higher assembly PRV Peak reverse voltage PSI Pounds per square inch Ref Reference the item has been listed ...

Page 152: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 2 Fixed Mount Bracket Figure 1 General Assembly 18 ...

Page 153: ...re 3 Ref 8 287120 Front Axle 1 W11439 001 Fitting Grease Screw Type 1 9 285418 Tire 20 5 x 8 00 10 Ay 4 10 Frame Assembly See Figure 2 Ref 11 288696 Tray Cable Left 1 288695 Cover AC Cable 1 288695 Cover AC Cable 2 12 287376 Bumper Side 2 13 287377 Support Fender 4 14 288703 Rear Axle 1 15 288697 Tray Cable Right 1 288698 Cover DC Cable 1 288694 Panel Cable Guide 1 288694 Panel Cable Guide 2 16 7J...

Page 154: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 4 Figure 2 Labels and Reflectors ...

Page 155: ...1 10 282658 Label Warning Clearance 1 11 288862 Label Caution Engine Speed 1 12 288866 Label Support Center 1 13 287571 Label Tire Pressure 4 14 288917 002 Label I D 1 15 288918 002 Label Options Inside Control Box 1 16 76B1148 Label Diesel Fuel 1 17 287460 Label High Voltage 3 Label High Voltage 4 18 287461 Label Fuel 1 19 287462 Label Radiator 1 20 287463 Label Hot Muffler 2 21 287464 Label Movi...

Page 156: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 6 Figure 3 Frame Assembly ...

Page 157: ...khead Center 1 4 289224 Tray Battery 1 5 289223 001 Battery Tray Bracket Right Hand 1 6 289223 002 Battery Tray Bracket Left Hand 1 289239 Pad Battery Tray 1 7 282562 Cap Fuel V49234 1275 0003 1 8 Tank Fuel see Figure 13 Ref 9 289557 Support Engine Front see also Figure 17 1 10 290446 Panel Bottom Belly pan 1 287738 003 Insulation Bottom Panel Option 1 287738 015 Insulation Noise Bottom Generator ...

Page 158: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 8 Figure 4 Canopy Assembly ...

Page 159: ...Noise Plenum Right Option 1 287805 Deflector Radiator Left 1 287806 Deflector Radiator Right 1 287793 Bracket Mounting Plenum 2 287794 Door Access Fuel Cap 1 403127 Catch Magnetic 1 9 287800 Screen Plenum 1 10 287703 Panel Side RF RR LR 3 287738 004 Insulation Noise Lower Panel Option 3 287785 Fastener Panel Access 12 VA5733 7800 00 263 000006 00 0017 11 288878 Panel Side Left Front 1 287738 027 I...

Page 160: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 10 Figure 5 Canopy Doors ...

Page 161: ...38 028 Insulation Noise Door Option 1 3 287542 001 Latch Door Hex V94222 E3 16 15 4 287542 002 Latch Door T Handle V94222 E3 11 15 4 4 287526 002 Tab Pull Door Latch V94222 E3 27 1 4 5 283824 Hinge RH Access Door V94222 96 10 520 50 4 6 283597 Hinge LH Access Door V94222 96 10 510 50 4 7 288881 Window Control Side Door 1 8 291679 Guard Button 1 291681 Channel Bottom Button Guard 1 291682 Channel L...

Page 162: ...228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 12 Figure 6 Internal Components Right Side 7 5 3 18 14 1 Left Side 8 13 6 12 17 10 15 9 16 4 ...

Page 163: ...11 Ref 5 Engine Ground Plate and Cables See Figure 12 Ref 6 Fuel System Components See Figure 13 Ref 7 Engine Exhaust Components See Figure 14 Ref Right Side 8 12 VDC Battery Components See Figure 15 Ref 9 288460 001 Generator Assembly See Figure 19 Ref 10 Air Cleaner Components See Figure 16 Ref 11 Engine Components See Figure 17 Ref 12 291695 Engine Cummins QSB6 7 see Figure 17 1 13 Engine Elect...

Page 164: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 14 Figure 7 Door control Panel Assembly 6 8 7 12 11 14 9 16 10 17 18 13 4 3 5 2 ...

Page 165: ...1Type A 1 5 288999 001 Latch Control Box V94222 62 20 25 1 6 287908 Gauge Water Temperature V16476 06347 01 1 7 181358 Meter Running Time 6H359 85101 1 8 286699 001 Voltmeter Battery V16476 06351 01 1 9 494134 001 Gauge Fuel Level V16476 06339 01 1 10 78A1117 002 Gauge Oil Pressure V16476 06395 01 1 11 283167 Meter Frequency V74542 D 1255119311 1 12 W8105A 009 Voltmeter AC V74542 D 1497222103 1 13...

Page 166: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 16 Figure 8 Control Box Interior Components ...

Page 167: ... 1 6 288940B Board PC Regulator 1 288876 Label Regulator Generator Control 1 288896 Label Regulator LDC Voltage Control 1 W11166 009 Fuse 1 A 250 V V2B664 2 W11166 002 Fuse 5 A 250 V V2B664 1 7 289026 Board PC Digital Controls 1 288875 Label Control EF Bypass Control 1 8 286367 001 Power Supply V05YB3 M30D1205 12TS 1 288605 Support Power Supply 1 9 289059 Support Circuit Breakers 1 289060 Label Ci...

Page 168: ...ual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 18 Figure 9 Pushbutton Switches 3 4 5 6 7 Lamps and Meter Select Pushbuttons 3 4 5 6 8 9 All Other Push buttons 7 Common Parts 18 24 23 21 20 15 12 17 14 11 1 ...

Page 169: ... 004 Type 1815 Bulb V02929 1 9 285034 001 Lamp Holder V61706 704 950 0 1 10 290080 Contact Block Cover 1 11 289601 001 Lamps Pushbutton 1 12 289601 004 Output 1 Pushbutton 1 13 285030 002 Yellow Lens V61706 704 702 4 1 14 289601 005 Pre heater Pushbutton 1 15 289601 005 Output 2 Pushbutton 1 16 285030 004 Orange Lens V61706 704 702 3 1 17 289601 006 Engine Start Pushbutton 1 18 289601 006 Meter Se...

Page 170: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 20 Figure 10 400 Hz Power Module Assembly ...

Page 171: ...nt 1 8 050988 Trim 12 Black Alum Vinyl PVC 18 in 9 288829 Harness Wire Power Module 1 No 101 A Stator Terminal to K1 1 Output 1 No 102 B Stator Terminal to K1 1 Output 1 No 103 C Stator Terminal to K1 1 Output 1 No 110 N Stator Terminal to N Neutral 1 10 288832 Harness Wire 2nd Output 1 No 104 A Stator Terminal to K201 2 Output 1 No 105 B Stator Terminal to K201 2 Output 1 No 106 C Stator Terminal...

Page 172: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 22 Figure 11 Cooling System Components 13 10 9 8 7 6 5 2 1 ...

Page 173: ...9 003 Clamp Hose 1 9 16 2 2 10 288309 Hose Radiator Lower V24161 1 W10869 005 Clamp Hose 2 5 16 3 2 11 Line De Aeration Ref 288123 001 Connector Male 1 4 NPT 1 4 Tube 2 056534 Hose ID 40 W10869 014 Clamp Hose 7 32 5 8 2 12 283873 Valve Drain Radiator 2 056535 Hose 3 8 ID Low Pressure 48 W10869 014 Clamp Hose 7 32 5 8 2 13 289830 Hose Reducer 3 50 to 3 00 55º Elbow 1 290597 001 Clamp T Bolt Floatin...

Page 174: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 24 Figure 12 Engine Ground Plate and Cables 3 2 4 1 5 ...

Page 175: ...nerator Set October 15 2013 Chapter 4 3 Page 25 FIGURE ITEM NO HOBART PART NO NOMENCLATURE UNITS PER ASSY 12 1 288723 Plate Ground 1 2 W9407 446 Cable Engine to Ground 1 3 W9360 289 Cable 111 Power Mod To Ground 1 4 291686 Wire Harness Engine 1 5 405548 Label Frame Ground 1 ...

Page 176: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 26 Figure 13 Fuel System Components ...

Page 177: ... Filter 1 3 12CW2077 003 Elbow NPT ST 90 2 4 400819 003 Valve Ball NPT 1 5 W10760 003 Nipple Pipe 1 6 Line Fuel Filter to Pump Supplied by Cummins 1 7 291258 Line Fuel Return 1 8 286897 031 Filter Lubricity Fuel 1 8a 290388 Adapter 12 mm x 3 8 MJIC 1 8b 290389 Tube Reducer JIC 1 9 Lubricity Filter Fuel Lines Supplied by Cummins 1 10 282562 Cap Fuel Neck V49234 1275G 12T 1 11 287781 Tank Fuel 65 Ga...

Page 178: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 28 Figure 14 Engine Exhaust Components ...

Page 179: ...uffler Mounting Front 1 287431 Bracket Muffler Mounting Front 2 3 287432 Bracket Muffler Mounting Front 1 4 287691 Spring Muffler Mounting 8 5 288311 Pipe Turbo Assembly 1 6 404154 016 Clamp Full Circle 4 Pipe 4 7 404154 013 Clamp Full Circle 3 1 8 287406 Shield Heat Muffler 1 287644 Shield Heat Muffler 1 287647 Shield Heat Muffler End 1 9 287645 Support Exhaust Pipe 1 10 291260 Pipe Exhaust Ay Un...

Page 180: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 30 Figure 15 12 VDC Battery System ...

Page 181: ...egative V3Y208 1 3 291728 Cable Battery Positive V3Y208 1 4 289224 Tray Battery 1 5 289223 001 Bracket Battery Tray RH 1 6 289223 002 Bracket Battery Tray LH 1 7 289239 Pad Battery Tray 1 8 287796 Hold Down Battery V3Y208 2 9 494295 Bolt Hold Down Battery V3Y208 2 10 291704 Panel Support Door MD see Figure 4 1 287738 020 Insulation Noise Support Door Option 1 291611 Disconnect Switch Master Batter...

Page 182: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 32 Figure 16 Air Cleaner Components ...

Page 183: ...00 0349 2 3 282918 Indicator Restriction Electric V18265 REX77 0062 1 4 288054 003 Pipe Air Inlet Assembly 1 5 287371 Elbow Rubber 90 V55752 4014 03002 2 6 284925 Reducer Rubber 90 Elbow V18265 P12 1482 1 7 280732 006 Clamp T Bolt V18265 P148343 5 8 280732 007 Clamp T Bolt V18265 P148345 1 9 284461 Connector Pipe Short Air Inlet 1 10 289688 Intake Air Extension 1 11 289661 Adaptor Hump Hose 1 12 2...

Page 184: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 34 Figure 17 Engine Components 2 3 4 5 6 1 ...

Page 185: ...042 08210 10 1 4 78B1118 002 Sender Oil Pressure 0 125 PSI V16476 16476 1 287419 Adapter M10 1 0 x 1 8 NPTF 1 W10910 000 Fitting Tee 1 W10750 001 Nipple Pipe 1 8 1 5 403782 002 Switch Shutdown 210 F V75418 1002 04880 36 1 W7814 004 Adapter 3 8 x NPT 1 6 287909 Sender Water Temperature V16476 02019 1 7 289261 001 Kit Block Heater 120v Ref 289249 005 Heater Engine Block 1 289250 001 Cable Engine Blo...

Page 186: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 36 Figure 18 Engine Electrical Panel Components 4 6 1 5 2 3 5 7 7 ...

Page 187: ...PART NO NOMENCLATURE UNITS PER ASSY 18 1 288333 Panel E Engine Parts 1 2 287145 002 Holder Fuse V17400 T30100 1CR 1 3 287144 002 Fuse Fast Acting V17400 JJN 125 2 4 283154 001 Insulator Standoff 1 5 288331 Relay Grid Heater Power V1FQ83 50F3662 2 6 291717 Harness Wire Engine Electronic 1 7 489658 007 Diode Assembly 2 8 291686 Harness Engine 1 ...

Page 188: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 38 Figure 19 Generator Assembly ...

Page 189: ...er Key 1 4 288440 Exciter Housing and Coils Assembly 1 5 288471 Generator Housing and Coils Assembly 1 6 W10072 068 Bearing 2 7 288447 001 Generator Rotor 1 8 288461 Front Bearing Support 1 9 288481 Flexible Coupling Kit 1 480290 Coupling Bushing 8 10 85B1039 Coupling Key 1 11 85C1004 001 Split Taper Bushing 1 12 289305 Ring Spacer Flex Coupling 1 13 288458 Generator Air Deflector 6 14 288478 Gene...

Page 190: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 40 Figure 20 Transformer Rectifier Assembly DC Option ...

Page 191: ...upport Heat Sink 1 4 286603 Heat Sink Extruded 1 5 W10931 003 Diode Silicon 275 A Positive Base 1 6 404044 004 Thermostat 1 7 288147 Bracket Heat Sink 2 8 286266 Standoff Short 2 9 282130 001 Contactor Input 1 77A1107 Label A 1 77A1108 Label B 1 77A1109 Label C 1 288428 Capacitor Resistor Varistor Ay 1 10 288095 1 Resistor Preload Ay 1 11 289006 Support PC Board 1 12 286266 Standoff Short 5 13 288...

Page 192: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 42 Figure 21 DC Output Contactor DC Option ...

Page 193: ...r DC 800 A 24 VDC 1 2 289005 Bracket Mtg Contactor 1 3 286849 Insulator Contactor 1 4 A25 Washer Insulating 2 5 288099 Bushing Insulating 1 6 Output Stud Ref W11097 008 Screw 3 8 16 X 2 HHC 1 W11242 010 Washer 3 8 Flat 6 W11254 006 Washer 3 8 Lock 2 W11254 006 Nut 3 8 16 Hex 2 7 Contactor Studs Ref W11097 002 Screw 3 8 16 X 1 0 HHC ST 2 W11242 010 Washer 3 8 Flat 2 W11254 006 Washer 3 8 Lock 2 ...

Page 194: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Chapter 4 3 Page 44 Figure 22 T R Interlock Kit DC Option Accessory ...

Page 195: ...3 Chapter 4 3 Page 45 FIGURE ITEM NO PART NO NOMENCLATURE UNIT PER ASSY 22 289795 Kit T R Interlock Ref 1 289794 Bracket 28 VDC Interlock 1 2 408567 Relay 24 VDC 1 408352 Socket Relay 1 16DA4253 000 Retainer Relay 1 3 286266 Standoff Short 1 4 289798 Harness Wire 1 5 288892 009 Resistor ID 511 ohm 1 ...

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Page 197: ...1358 20 15 280022 16 7 280732 006 16 8 280732 007 1 280763 15 1 281881 001 10 11 282089 011 10 4 282130 001 20 9 282130 001 3 7 282562 13 10 282562 2 10 282658 1 2 282667 1 282727 17 7 282852 16 3 282918 10 2 283154 001 18 4 283154 001 7 11 283167 5 6 283597 4 7 283647 FIGURE ITEM NO HOBART PART NO 2 6 283714 007 5 5 283824 11 12 283873 8 11 283978 001 8 10 283978 002 16 9 284461 9 7 284475 001 16...

Page 198: ...460 2 18 287461 2 19 287462 2 20 287463 2 21 287464 2 7 287465 2 3 287466 2 25 287467 1 17 287491 3 14 287506 5 4 287526 002 5 3 287542 001 5 287542 002 16 287548 2 13 287571 FIGURE ITEM NO HOBART PART NO 13 12 287639 14 287643 14 287644 14 9 287645 1 287646 14 287647 11 9 287659 13 287684 14 4 287691 1 20 287694 2 9 287696 4 1 287701 5 1 287701 4 10 287703 5 287738 001 3 287738 003 4 287738 004 4...

Page 199: ... 288404 20 288428 19 4 288440 19 7 288447 001 19 13 288458 6 9 288460 001 19 288460 001 19 8 288461 19 5 288471 19 14 288478 19 9 288481 19 1 288486 19 15 288491 19 2 288494 FIGURE ITEM NO HOBART PART NO 4 3 288544 8 288605 3 2 288691A 6 16 288691A 3 15 288692 6 14 288692 3 16 288693 6 15 288693 1 288694 1 288695 1 11 288696 1 15 288697 1 288698 1 14 288703 3 13 288704 12 1 288723 8 4 288745 9 29 ...

Page 200: ...88999 001 9 1 289004 21 2 289005 20 11 289006 20 1 289007 20 16 289010 9 289012 002 9 289012 004 9 289014 9 2 289015 7 2 289017 7 289018 002 7 289018 004 FIGURE ITEM NO HOBART PART NO 8 289019 001 8 289019 002 8 7 289026 8 9 289059 8 289060 8 13 289072 8 12 289073 2 24 289127 2 29 289177 002 4 289197 4 17 289208 005 4 289209 3 5 289223 001 15 5 289223 001 3 6 289223 002 15 6 289223 002 3 4 289224 ...

Page 201: ... 15 289827 11 16 289828 11 13 289830 2 1 289842 001 17 289843 11 4 289844 3 12 290011 9 10 290080 11 3 290145 2 26 290216 10 14 290227 13 290267 13 8a 290388 13 8b 290389 3 10 290446 FIGURE ITEM NO HOBART PART NO 4 12 290558 4 290582 11 290597 001 11 290597 002 13 290639 13 290640 13 290642 13 290650 13 290651 13 11 290677 13 7 291258 14 10 291260 13 291486 13 291487 1 21 291565 001 2 27 291609 15...

Page 202: ...7 8 480603 001 19 480603 001 13 486719 012 4 489658 002 18 7 489658 007 7 9 494134 001 15 9 494295 10 3 76A1131 2 16 76B1148 20 77A1107 20 77A1108 20 77A1109 1 6 77A1157 7 10 78A1117 002 17 4 78B1118 002 4 79B1140 1 16 7J422 000 19 10 85B1039 FIGURE ITEM NO HOBART PART NO 19 11 85C1004 001 21 4 A25 19 6 W10072 068 17 W10750 001 13 5 W10760 003 11 W10869 003 11 W10869 005 17 W10869 009 11 W10869 01...

Page 203: ...ulletin 4056538 Diagram Number Diagram Description 289850 rev 2 Diagram Schematic Connections 289022 rev 2 Diagram Connection Control Box 289002 rev 6 Diagram Connection Power Module 289013 rev 3 Diagram Connection Switch Box 289011 rev 5 Diagram Connection Transformer Rectifier 291687 rev 0 Diagram and Schematic Connection Contact Hobart Ground Power if copies of these drawings or manuals are not...

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Page 239: ...ion part number and document number if applicable of the feature Option Features Available Description Part Number Document Number In This Section Standard Features CE Mark 287589 NA STD Kit Unit Operating Light 289210 NA STD Kit Low Fuel Beacon 289208 XXX NA STD Kit Cable Tray Rollers 288987 NA STD 30 ft DC Output Cable 402034 NA STD 30 ft AC Output Cable Deluxe Features Fork Lift Pockets 287694 ...

Page 240: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Appendix A Page 2 This page is intentionally left blank ...

Page 241: ...ed in diesel engines operated under light load Light loads do not allow the engine to reach the most efficient operating temperature for complete combustion of fuel 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 200 hours ...

Page 242: ...OM 2228 Operation and Maintenance Manual 120CU20 Series 500120 400 Hz Generator Set October 15 2013 Appendix A Page 4 This page is intentionally left blank ...

Page 243: ...ation 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 t...

Page 244: ...20 Series 500120 400 Hz Generator Set October 15 2013 Appendix A Page 6 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 ...

Page 245: ...ower unit Generator Model Number Identify your generator model number by looking on the data plate which is located on the control box door near the emergency stop Filter Part Numbers The table below lists the filter part numbers for your generator set You can also order sets of filters as kits which are listed on the next page Filter Hobart Part Number Models Where Used Air Filter 287548 All Oil ...

Page 246: ...eparator Element 286897 031 290300 006 All 500120 specifications except the 500120 special configuration Hobart Ground Power Supply Contact Information Contact the Hobart Ground Systems supply department staff for all the preventative maintenance parts Write Hobart Ground Systems Supply Department 11001 US Highway 41 North Palmetto FL 34221 U S A Call Inside U S A 800 422 4166 Parts 877 874 5322 C...

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