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OM-2226 / Operation and Maintenance Manual
60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Chapter 4-2

Page 1

Section 2 Manufacturer's Codes

1) Explanation of Manufacturer’s (Vendor) Code List

The following list is a compilation of vendor codes with names and addresses for suppliers of purchased
parts listed in this publication. The codes are in accordance with the Federal Supply Codes for
Manufacturer’s Cataloging Handbook H4-1, (CAGE CODES) and are arranged in numerical order.
Vendor codes are inserted in the nomenclature column of the parts list directly following the item name
and description. If a manufacturer does not have a code, the manufacturer’s full name is listed in the
nomenclature column.

Code

Vendor’s Name and Address

D0024

SEMIKRON ELEKTRONIK GMBH

Sigmundstrasse 200
P.O. Box 82 02 51
Nuernberg, Germany 90431

E0615

Kraus and Naimer
42 Miramar Avenue
P.O. Box 15-009
Wellington, New Zealand

S7023

Bossard LTD Fasteners
Steinhauserstrasse 70
Zug, Switzerland, 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)
2800 Fulling Mill Rd Bldg-38
Middletown, PA 17057 - 3142

01XD4

Contact Industries Inc
25 Lex-Industrial Dr
Mansfield OH 44903 - 8699

Code

Vendor’s Name and Address

01428

Tuthill Corporation
DBA Tuthill Controls Group
2110 Summit St.
New Haven, IN 46774-9524

02660

Amphenol Corp.
Spectra-Strip/Itd
40-60 Delaware Ave
SIDNEY, NY 13838 - 1395

02768

Illinois Tool Works Inc.
Fastex Division
195 S. Algonguin Rd.
Des Plaines, IL 60016-6197

02929

Newark Electronics Div
4801 N Ravenswood Ave
Chicago, IL 60640 - 4457

05HB5

Magnecomp Inc.
161 Eagles Nest Dr
Pickens, SC 29671-7808

05YB3

Acon Inc.
22 Bristol Dr.
South Easton, MA 02375-1108

1AA44

Collmer Semiconductor Inc.
2542 Highlander Way
Carrollton, TX 75006

1DG36

Phillips And Temro Industries Inc
E. M. Products Inc.
5380 Cottonwood Ln
Prior Lake, MN 55372

1DL99

Fleetguard Inc.
Div. of Cummins Engine Company
311 N. Park Street
Lake Mills, IA 50450 - 1299

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Summary of Contents for 500062-DLX

Page 1: ... 2013 Original Operation and Maintenance Manual with Illustrated Parts List for 60CU20 60 kVA 3 Phase 115 200 Volt 400 Hz Generator Set Series 500062 ITW GSE Group Hobart Ground Systems Palmetto Florida 34221 U S A ...

Page 2: ......

Page 3: ...ts 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 defects ...

Page 4: ......

Page 5: ... Rev No Release Date By Description 0 May 2 2013 MLJ This is a spec roll from OM 2175A 500061A for release of STD and DLX configurations Note the 60 kVA is similar to the 90 kVA with the following differences Air cleaner and related air intake components AC Ammeter different ranges ID Resistor different Power Module Panel assembly ...

Page 6: ......

Page 7: ...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 Avo...

Page 8: ...itch 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 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 combus...

Page 9: ... 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 Call physician immediately Seek additional assistance Use First Aid techniques recommended by...

Page 10: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Safety Warnings Page 4 This page intentionally left blank ...

Page 11: ...Box Assembly 1 1 11 Power Module Panel Assembly 1 1 22 Cold Weather Start System 1 1 24 Transformer Rectifier T R Assembly 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 and DC Op...

Page 12: ...Test 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 General 2 4 1 Equipment for Troubleshooting 2 4 1 Parts Replacement 2 4 1 Normal Operation 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 3 ...

Page 13: ...g Flexible Coupling General 3 2 1 Disassembly 3 2 1 Coupling Service 3 2 4 Coupling Installation 3 2 5 Reassemble Engine and Generator 3 2 6 Run in and Periodic Check 3 2 7 Section 3 Generator Assembly General 3 3 1 Generator Assembly Removal 3 3 1 Generator Assembly Installation 3 3 2 Chapter 4 Illustrated Parts List Chapter Section Page Section 1 Introduction 4 1 1 General 4 1 1 Purpose 4 1 1 Ar...

Page 14: ...3 16 Figure 9 400 Hz Power Module Assembly 4 3 18 Figure 10 Engine Cooling System Assembly 4 3 20 Figure 11 Engine Ground Plate and Battery Disconnect Switch 4 3 22 Figure 12 Engine Fuel Filter and Fuel Lines 4 3 24 Figure 13 Engine Exhaust Components 4 3 26 Figure 14 12 VDC Battery System 4 3 28 Figure 15 Engine Air Intake Assembly 4 3 30 Figure 16 Engine Components 4 3 32 Figure 17 Engine Electr...

Page 15: ... an appendix Each chapter is divided into as many sections as required Each new section starts with page 1 Each page is identified by chapter section and page number which are located in the lower outside corner When information located in another portion of the manual is referred to a chapter section and paragraph or figure number identify its location For example see Section 2 3 Paragraph 1 a re...

Page 16: ...r Service 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 800 899 1841 Parts 877 874 5322 Service Call From Foreign Countries 941 721 1025 Parts 941 721 1092 Service FAX Inside U S A 800 367 4945 FAX From Foreign Countries 937 332 5121 E Mail service hobartsystems com Web Page www hobartsy...

Page 17: ...iations covered in this manual Part Dash Number Fuel Tank Exhaust Mounting AC Outputs 28 5 DC Output 500062 STD Composite Vertical Trailer Single 500062 DLX Composite Vertical Trailer Single 500062TR STD Composite Vertical Trailer Single Yes 500062TR DLX Composite Vertical Trailer Single Yes Table 1 Series 500062 Generator Set Part Number Descriptions 2 Optional Equipment Appendix A Chapters 1 thr...

Page 18: ...tput Cable Trays 4 5 th Wheel Assembly 5 Rear Drop Axle Assembly 6 Emergency Stop Switch S28 7 Exhaust Stack Outlet 8 Engine Air Intake 9 Lift Off Access Doors 10 CAC Radiator End 11 Generator End 12 Cable Rollers optional 13 Block Heater Receptacle optional 14 Forklift Pockets optional Figure 1 General Assembly of Generator Set 11 2 3 4 1 5 6 7 9 9 10 12 13 14 8 ...

Page 19: ...kW Output voltage 115 200 VAC Rated load capacity 174 Amps Frequency at not load and rated load 400 Hz 2 Hz Power factor 0 8 Duty Cycle 100 Operating speed 2000 RPM Overload capacity 125 rated load 218 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 ...

Page 20: ...ds 2000 A 10 seconds 1500 A 30 seconds 1200 A 90 seconds 750 A 600 seconds f Engine Specifications Manufacturer and Model Cummins Engine Company QSB4 5 Type 4 cylinder 4 cycle diesel electronic controlled Bore and Stroke 4 21 in x 4 88 in 107 mm x 124 mm Displacement 275 in 3 4 5 L Horsepower 109 hp 81 kW Idle speed 1000 50 rpm Normal governed speed 2000 rpm Firing Order 1 3 4 2 Electrical system ...

Page 21: ...quipped with a battery disconnect switch inside the unit on the LEFT side The disconnect switch can be placed in the off position during long periods of shutdown 6 Canopy A sheet metal enclosure identified as a canopy provides protection for the engine generator and electrical controls The canopy is designed to reduce the operational noise level in the immediate area of the machine 7 Engine and Ge...

Page 22: ...mponents and Protective Systems This generator set is assembled at with the following components and protective systems 1 Shutdown Reset Systems Emergency Shutdown Reset Switch S28 The emergency shutdown switch has two purposes One is to reset the starting circuit following a failed starting sequence The other is to provide instant manual shut off of the generator set by disconnecting power to the...

Page 23: ... Once the fuel level reach approximately 1 8 tank the engine will shutdown 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 Refer to Section 2 1 for servicing procedure 3 Engine cooling fan The engine fan is designed to blow air outward through the radiator rather than pulling the air inward as a co...

Page 24: ... 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 engine stop button Fuel must be added prior to attempting another engine start b Or use E S...

Page 25: ...ngine 3 Air Filter Assembly 4 Operator s Control Panel back side 5 Engine Fuel Filter behind support leg 6 Engine Oil Filter 7 12 VDC Batteries incase in housing 8 Generator 9 Turbo Exhaust Pipe Exhaust Outlet 10 Engine Alternator 11 Battery Disconnect Switch 12 Engine ECM Connector Figure 3 Main Components of Generator Set Right Side 1 2 3 4 5 6 8 7 9 10 11 12 ...

Page 26: ... Transformer Rectifier optional 2 Lubricity Additive Fuel Pre Filter 3 Engine Electronic Fuse and Relay Panel 4 Engine Control Module ECM 5 Engine Oil Level Check 6 Engine Air Intake Heater 7 Charge Air Cooler Piping 8 Power Module Contactor Panel back side Figure 4 Main Components of Generator Set Left Side 1 2 3 4 5 6 7 8 ...

Page 27: ...lectrically driven from the 12 VDC battery system The hour meter measures and records the engine s running time and will record up to 9999 9 hours on five revolving drums It is only functional when the engine is running Engine voltmeter M5 The voltmeter indicates the voltage across the 12 VDC batteries The meter scale is graduated 10 V to 16 V Engine fuel gage M13 An electric fuel gauge receives i...

Page 28: ...ter 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 Swit...

Page 29: ...splay indicates which voltage A N A B etc and amperage are shown on the meters and whether EF BY PASS is present or bypassed This EF BY PASS indicator serves to warn the operator that if the plug interlock system was by passed any exposed cable may be live DC Voltmeter Optional with TR The voltmeter monitors and displays the transformer rectifier s output voltage The voltmeter is an analog type an...

Page 30: ...e at the plug When the load contactor opens for any reason the light is turned OFF ENGINE STOP switch S76 When the ENGINE STOP switch is pressed the red indicator will blink Then a 3 to 5 minute delay will occur to permit the turbo and other engine components to cool evenly After the delay power is disconnected from the engine ECM causing the engine to shut down TEST RESET switch M6 S77 The functi...

Page 31: ...c PC Board ESB A1 3 Engine Interface PC Board EIB A2 4 Digital Control PC Board CTL A3 5 Voltage Regulator PC Board REG A4 6 Transformer Rectifier PC Board TRB 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 ...

Page 32: ...ter to test the over under frequency fault limits of the generator set system The ESB also controls the DATA REQUEST button and diagnostic indicator light to read the engine s ECM diagnostic error codes 3 Engine Interface PC Board EIB A2 The EIB is common between all engine models and monitors coolant temperature oil pressure battery voltage and fuel tank level monitoring The EIB is also responsib...

Page 33: ...ards in the control system The digital control PC board also controls the real time clock monitors the over under voltage and overload protection controls the push button panel indicator lights controls the generator output meters monitors the EF bypass switches and communicates with the optional service tool EF Bypass switches located on CTL The EF bypass switches EF1 BYPASS for OUTPUT 1 or EF2 B...

Page 34: ...s the field power supplied to the rotary exciter When the machine is started and the engine is at rated speed the rotary exciter is excited from alternator residual magnetism through the half wave rectifier bridge located on the voltage regulator PC board assembly As the rotary exciter voltage increases alternator excitation increases and the alternator voltage builds up The sensing circuit of the...

Page 35: ...xed resistance in parallel with each current transformer The current transformers detects the magnitude of current flowing through the power cables from the alternator to its load and feeds a signal into the voltage regulator PC board The PC board processes this signal to change the output voltage proportional to the current draw The regulator output increases slightly so that the alternator outpu...

Page 36: ...generator or by a defective voltage regulator When this switch is in the MAINTENANCE position no current is supplied to the generator exciter In this condition a low level unregulated voltage of approximately 30 VAC will be produced at the generator output terminals due to the residual magnetism of the exciter Figure 11 Transformer Rectifier PC Board 6 Transformer Rectifier PC Board TRB A404 Optio...

Page 37: ...pplies the internal power distribution of 5 VDC and 12 VDC into the control system Figure 12 Control System Power Source 8 Circuit Breakers CB1 CB4 CB7 Breaker Number Breaker Name Rating Amps System Protected CB4 Engine 10 12 VDC engine electrical and fault circuits CB7 Control 5 12 VDC control system CB1 Marker Lights 10 12 VDC lighting system ...

Page 38: ...eed a signal to the voltage regulator that interprets the signal and alters the 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 ...

Page 39: ...s 500062 400 Hz Generator Set May 2 2013 Chapter 1 1 Page 23 Figure 13 Output Power Module Components Output 1 Contactor Current Transformers and Cabling Output 2 Contactor Location Generator Lead Connection Point and Neutral Hobart Generator Exciter End ...

Page 40: ...Section 3 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 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 th...

Page 41: ... 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 locate...

Page 42: ...2 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 8 Shunt R401 Transformer Rectifier Components Figure 15 ...

Page 43: ... hose clamps tube fitting etc as required 5 Check security of generator set retaining components 6 Check the fuel level Press the LAMPS pushbutton switch 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 with this manual 7 Check ...

Page 44: ...ar the high mark as possible without going over it See Figure 1 for capacity CAUTION NEVER operate the engine with oil level below the L level mark or above the H level mark NOTE See the Engine Manufacturer s Operation Maintenance Manual for oil recommendations Figure 2 Oil Fill and Oil Level Check Locations 9 Check the batteries Inspect the batteries for proper connection of the terminals and che...

Page 45: ...he cable clamps 4 Loosen the screws on the cable clamps 5 Route the cables through cable clamps and up to the load side of the load contactor s 6 Connect the phase cable terminal lugs to the appropriate terminal studs on the contactor s cable lug A to terminal stud A 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 Conn...

Page 46: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 1 2 Page 4 DC Cable and Clamp Figure 3 Output Cable Connections Figure 4 DC Output Cables ...

Page 47: ...ess is a problem however the unit must be completely packaged and sealed if moisture absorbing chemicals are to be effective b Temporary Storage When storing the unit for 30 days or less prepare as follows 1 Lubricate the unit completely in accordance with instructions in Section 2 2 This will include changing engine oil and all filter elements 2 Start the engine and operate for about two minutes ...

Page 48: ...fore starting the engine 2 Start the engine and operate under full load until coolant temperature has reached at least 176ºF 80ºC 3 While the engine is running ensure that normal operating controls are in good working condition before shutdown and storage If weekly operation is not possible contact the nearest engine manufacturer distributor for instructions 3 Preparation for Shipment a Disconnect...

Page 49: ...pting 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 materials 4...

Page 50: ...er 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 Switc...

Page 51: ... 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 sta...

Page 52: ...itch 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 or ...

Page 53: ...on 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 contac...

Page 54: ...raft 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 un...

Page 55: ...nce 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 in...

Page 56: ...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 Con...

Page 57: ...ck 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 Wiri...

Page 58: ...e 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...

Page 59: ...AUTION 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...

Page 60: ...exhaust system 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 vol...

Page 61: ...mplete 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 t...

Page 62: ... 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 122 N m 90 ft lb ii Generator mount bolts must be torqued to 122 N m 90 ft lb b Change oil and oil filters c Change all fuel filters d Check Coolant Additive Concentr...

Page 63: ...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 operat...

Page 64: ...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 miner...

Page 65: ... 3 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 rad...

Page 66: ...ck 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 to daily checks of hoses for leaks inspect hoses thoroughly each time the cooling system is cleaned and serviced Inspect for signs of deterioration and collapse Inspect for cracks and cuts Inspect for cutting and deformation caused by hose clamps Replace...

Page 67: ... with their location size and type 5 The fuse chart lists all fuses with their location size and type Item Protected Location Schematic Identifier Quantity Type Engine Air Intake Heater Engine Electrical Panel F110 1 125 A 300 VAC REG Load Contactor Circuit REG Board F2 1 MDL 1 A 250 V REG Diagnostics REG Board F3 1 MDL 1 A 250 V REG Field Voltage Circuit REG Board F1 1 MDL 5 A 250 V TRB Load Cont...

Page 68: ...tactor Indicator Switch Panel 1815 Test Reset Indicator Switch Panel 1815 Pre heater Indicator Switch Panel 1815 Clearance Lights optional Canopy Top 57 Engine Gauge Lights Inside Each Gauge Chapter 4 Section 3 Fig 6 Generator Gauge Light Strip Around Meter Chapter 4 Section 3 Fig 6 Lamp Identification Chart Figure 5 Item Protected Location Quantity Size Engine Circuit and Instrument Panel Inside ...

Page 69: ...tain coolant system according to Section 2 2 paragraph 6 Engine coolant capacity is approximately 20 quarts 18 9 liters Coolant hoses and connections Check coolant hoses and connections daily for leaks Air Cleaner Change air cleaner filter as required when the fault code display on engine control panel shows the Air code Fan Belt Check fan belt condition and tension every 1000 hours or 1 year of u...

Page 70: ...l evaluation b 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 ext...

Page 71: ...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 D...

Page 72: ...an 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 plug and install when engine oil has completely drained Torque the drain plug to 50 foot pounds 68 Nm 11 Refill the engine with new clean oil that meets engine manufacturer s recommendations CAUTION Remember to clos...

Page 73: ... 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 pum...

Page 74: ...pect regularly Replace when the fault code meter indicates an 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 Lift the latch and rotate the back cover to the unlocked position counterclockwise as vi...

Page 75: ...higher than 0 5 oil change intervals should be reduced See engine manufacturer s operation manual In general fuels meeting the properties of ASTM designation D 975 grades 1 D and 2 D have provided satisfactory performance For more information regarding the selection of fuel to use refer to publication Engine Requirements Lubricating Oil Fuel and Filters available from authorized engine manufacture...

Page 76: ...unted 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 Repl...

Page 77: ... and tighten with a final half turn 10 Make sure that all rags or absorbent sheets are clear of moving engine parts and cannot be drawn in to the radiator fan 11 Open fuel valve 12 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 ...

Page 78: ...ts are clear of moving engine parts and cannot be drawn in to the radiator fan 7 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 8 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 wit...

Page 79: ...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 ad...

Page 80: ... tester when in doubt about antifreeze protection d Draining the Cooling System To completely empty the cooling system requires draining the engine block if furnished and the radiator assembly Both drain valves radiator and block drain can be opened closed at the same time but they do not need to be Follow these steps to drain the cooling system 1 Remove radiator cap 2 Place a drain pan with at le...

Page 81: ... both radiator drain valves are closed 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 co...

Page 82: ... missing Belt tension may be checked by hand To do so manually depress 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 b...

Page 83: ...ngth as those to be used in service Be sure the generator output N cable is grounded 2 Check engine oil level Oil should be at the high bar on the dipstick 3 Check radiator coolant level 4 Check tension of drive belt 5 Inspect for oil fuel and coolant leaks 6 If the setting of the output voltage coarse adjustment potentiometer on the voltage regulator has been disturbed set it at center position h...

Page 84: ...er 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 Switc...

Page 85: ...ime 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 8 Observe frequenc...

Page 86: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 2 3 Page 4 Figure 2 Control Box Interior Components ...

Page 87: ...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 88: ...N position or the BYPASS OFF position that the appropriate LED indication on the control panel display 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 contactor operating push button switch The No 1 contactor power on indicating light within the push button switch should glow and remain on when the push button switch is release...

Page 89: ... Operate 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 ste...

Page 90: ...0 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 voltage cir...

Page 91: ...To check the under frequency protective components proceed as follows a While the unit is operating normally under load set the frequency adjust switch to TEST Rotate the frequency adjust potentiometer 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 23 on the fa...

Page 92: ...lt 70 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...

Page 93: ... 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 DO...

Page 94: ... housing 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 m...

Page 95: ... output voltage at which the generator is regulated is adjustable by the fine voltage adjustment potentiometer 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 AC line...

Page 96: ...mpensation adjustments have affected 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 Operat...

Page 97: ...te resistance reading indicates an OPEN CIRCUITED condition 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 Test Connection Resistance Ohms Generator Stator Phase A to N G1 0 0026 Generator Stator Phase B to N G1 0 0026 Generator Stator Phase C t...

Page 98: ...ndicated 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 the 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 perfor...

Page 99: ...ion 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 whi...

Page 100: ...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 th...

Page 101: ...TION 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 multi scale voltmeter is the only instrument required for troubleshooting At lea...

Page 102: ...nstances we will assume that connections and wiring have always been checked first and that power has not been lost as a result of defective wiring or connections 6 Engine Troubleshooting When troubleshooting the engine 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 starter button An adequa...

Page 103: ...s in Table 1 The control board communicates these commands to all of the 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 Operating Commands Table 1 1 Self Test Mode When power is f...

Page 104: ...ENGINE 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 w...

Page 105: ...e depending 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 pushbutton 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 ...

Page 106: ...he 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 dow...

Page 107: ... code See Figure 1 5 To continue scrolling backward through the previous fault codes press and release the TEST RESET pushbutton 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 pushbutton to turn off the control box ligh...

Page 108: ...oltmeter 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...

Page 109: ...nerator Set May 2 2013 Revision 2 Chapter 2 4 Page 9 Control Box Interior Components Figure 4 Printed Circuit Board Name Abbreviation Engine Specific board ESB Engine Interface board EIB Voltage Regulator board REG Digital Control board CTL Transformer Rectifier board TRB ...

Page 110: ...nimum between the hot side of auxiliary starter solenoid and the starter input terminal If starter does not crank engine the starter may be defective e No voltage at auxiliary solenoid coil Check inline fuse F112 Check or replace the Engine Interface EIB board f Defective starter Remove the starter motor from engine and apply 12 VDC to test it Replace the starter if it doesn t operate g Internal s...

Page 111: ...ions Replace any damaged hoses or fuel links e Defective EIB board Replace the EIB board 5 Engine cranks but will not start Over temperature indication appears immediately a Defective engine temperature switch Check wiring to engine high temperature switch S49 on schematic which is located on top of the engine block If wiring is correct remove wires and check resistance between terminals C and N O...

Page 112: ...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 power a Improper engine adjustments and gear train timing Tune up engine in accordance with engine manufacturer s o...

Page 113: ...cated output voltage of 100 20 VAC line to neutral If voltage produced is within this range the generator is good and trouble may be in the voltage regulator circuit b Open fuse on Voltage Regulator REG board Check the fuses on the Voltage Regulator board c Defective Voltage Regulator REG Verify by swapping with a known good Voltage Regulator REG Board and replace if required d Defective connector...

Page 114: ...and replace if blown If it blows again check the contactor b Defective Output pushbutton switch At rated speed measure the voltage across the switch The voltage should read approximately 5 VDC when the switch is open and 0 V when the switch is closed If voltage does not go to 0 V the switch is defective and needs to be replaced c Defective Voltage Regulator REG board Measure the DC output voltage ...

Page 115: ...eceptacle connector Inspect 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 switch mounted on side of contactor Connect a jumper lead between terminals of the normally open auxiliary switch ...

Page 116: ...normal 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 opens the load contactor at any value less than 125 VAC it is defective ...

Page 117: ...and an over frequency condition does not exist replace the 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 contacto...

Page 118: ... 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 ventilatio...

Page 119: ...r information 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 u...

Page 120: ...NT push button 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 Board Replace TRB board with a board known t...

Page 121: ...ngine 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 DELAYE...

Page 122: ...RB 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 _ _ 17 CTL OUTPUT UNDER VOLTAGE FAULT Voltage set too low CTL boa...

Page 123: ...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 being sent from aircraft on output 2 to the GPU is too high Output cable is defective Reset and restart GPU Check output cable _ _ 34 TRB AC CONTAC...

Page 124: ...efective 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 coolant Refill radiator Check for leaks and replace defect components _ _ 67 EIB ENGINE OVERTEMP ...

Page 125: ...rovements 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 Assembly 8 Ex...

Page 126: ... 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 generator ...

Page 127: ... fabricating 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 c Conditions f...

Page 128: ... 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 du...

Page 129: ...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 2A G...

Page 130: ...gh 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 Exciter Arma...

Page 131: ...s 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 gene...

Page 132: ... 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 No 40...

Page 133: ...ight misalignment between the engine and the generator due to manufacturing tolerances A tapered bushing and hub secures the coupling to the generator shaft Coupling Assembly Figure 1 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 engine a...

Page 134: ...parate 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 shaft a...

Page 135: ...aft 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 Hub and Bushing Figure 3 ...

Page 136: ...Countries 937 332 5121 E Mail service hobartsystems com Web Page www hobartsystems com a Replacement Coupling Kit A replacement coupling kit is available from your Hobart Ground Systems The kit provides a replacement coupling assembly with attaching hardware and installation instructions b Bushing Kit A bushing kit is available from the Hobart Ground Systems for replacing the rubber bushing only i...

Page 137: ...inside of the hub be thoroughly 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 ...

Page 138: ...ghtened 10 Tighten the 3 8 16 bolts alternately and evenly as follows a Set a torque wrench to 30 foot pounds 41 N m and tighten all three 3 8 16 bolts to that value Block the coupling against clockwise rotation with a bar as illustrated 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 Recheck the d...

Page 139: ...area and operate it for a 2 hour run in 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 ope...

Page 140: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 3 2 Page 8 Bushing Installation Figure 4 ...

Page 141: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 3 2 Page 9 Assembly Procedure Figure 5 Measure from mounting face to adapter ring Figure 6 ...

Page 142: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 3 2 Page 10 Measuring From Mounting Face To Bushing Figure 7 ...

Page 143: ...back of the control box and remove the control box 5 Remove the air cleaner and the pipe hoses connecting it to the engine Note cover the turbo inlet while the air cleaner is removed 6 Remove the generator stator leads from the power module and remove the power module 7 Remove required support table components above the generator 8 Remove generator housing cover b Removing the generator Assembly 1...

Page 144: ...wheel housing 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 bolts removed earlier Torque bolts to 30 ft lb 41 N m 4 Attach the flywheel coupling to the engi...

Page 145: ...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 into...

Page 146: ...mbly and indented one space Vendor codes and part numbers for purchased parts are also listed in this column when applicable Hobart modification to vendor items is also noted in this column 4 EFF Effective Column This column is used to indicate the applicability of parts to different models of equipment When more than one model of equipment is covered by a parts list there are some parts that are ...

Page 147: ...hon 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 2800 Fulling Mill Rd Bldg 38 Middletown PA 17057 314...

Page 148: ...hase Electric Supply Co 1620 W Main St P O Box 149 Springfield OH 45501 0149 2N562 Power Transmission Sales Inc 531 Washington P O Box 229 Chagrin Falls OH 44022 0229 Code Vendor s Name and Address 23803 N T N Bearing Corp of America 191 Sheree Blvd Ste 101 Exton PA 19341 1265 24161 Gates Corporation 900 S Broadway Denver CO 80217 5887 24446 General Electric Co 3135 Easton Tpke Fairfield CT 06431 ...

Page 149: ...emke Industries Inc 310 Chadick Drive Wheeling IL 60090 6039 57347 Wall Industries Inc 5 Watson Brook Rd Exeter NH 03833 4589 Code Vendor s Name and Address 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 Components Group Inc 300 Enterprise Dr Westerville OH 43081 8840 6Y440 Micron ...

Page 150: ... 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 81703 Mulberry Metal Products Inc 2199 Stanley Terrace Union NJ 07083 4399 Code Vendor s Name ...

Page 151: ...ist 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 or 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 pr...

Page 152: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 2 General Assembly Figure 1 ...

Page 153: ...83714 004 Label kVA Rating 60 2 9 402987 Label Hobart 2 10 288164 001 Label TR Unit 2 11 76B1148 Label Diesel Fuel 1 12 287461 Label Fuel under Diesel Fuel label 1 13 290216 Low Emissions Label near diesel fuel label 1 14 Wheel Assembly See Figure 2 Ref 15 287571 Label Tire Pressure 4 16 Cable Tray See Figure 2 Ref 17 291253 001 Bracket Fixed Mount LH fixed mount units 2 291253 002 Bracket Fixed M...

Page 154: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 4 Trailer Frame Assembly Figure 2 1 4 5 2 3 6 6 7 8 9 9 10 11 7 6 12 13 14 7 12 13 14 8 ...

Page 155: ...enerator Support part of trailer 1 4 Battery Tray Assembly See Fig 14 Ref 5 287998 Front Panel Bracket 2 6 291088 Bracket Cable Tray Fender 3 7 291089 Bracket Cable Tray Fender 3 8 291092 Cable Tray 2 9 291093 Panel Battery Tray Cover 2 10 Fuel Tank see Figure 12 Ref 11 285418 Trailer Wheel Assembly 4 288987 006 Kit Cable Tray Rollers 1 output Ref 12 288961 002 Roller Cable Tray 2 13 288966 Suppor...

Page 156: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 6 Canopy Frame Assembly Figure 3 1 2 2 3 4 5 6 7 ...

Page 157: ...ITEM NO PART NO NOMENCLATURE UNITS PER ASSY 3 1 291069 Front Panel 1 287998 Front Panel Bracket See Figure 2 2 2 291152 TR Panel Support Leg 2 3 291066 TR Support Panel 1 4 291056 Control Panel Support 1 5 287986 Control Panel Support Bar 1 6 Trailer Frame Assembly See Figure 2 Ref 7 Fuel Tank Assembly See Figure 12 Ref ...

Page 158: ...2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 8 Canopy Assembly Figure 4 1 2 3 4 5 5 6 7 7 6 8 8 9 11 12 14 14 15 16 17 18 19 10 Item 12 detail ...

Page 159: ...ess Door Hinge Assembly To Door PN 291084 6 10 283597 Access Door Hinge Assembly To Door PN 291297 6 11 Access Door Top Latch Assembly Ref 291335 Access Door Latch Pawl 4 287542 001 Access Door Latch Hex Recess 4 287526 002 Access Door Latch Pull Tab 4 12 Access Door Bottom Latch Assembly Ref 291386 Access Door Latch Pawl 4 287542 001 Access Door Latch Hex Recess 4 287526 002 Access Door Latch Pul...

Page 160: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 10 Right Side Left Side Internal Components Figure 5 1 2 3 4 5 6 7 8 9 10 6 5 4 12 13 11 ...

Page 161: ...n generator 1 24656 Mount Shock 1 5 Engine Cooling System Assembly See Figure 10 1 6 292051 Engine Cummins QSB4 5 109 HP 1 292011 Bracket Engine Support mounted on generator 2 24656 Mount Shock 2 290678 Wire Harness Engine 1 482496 002 Clamp Universal 2 W10869 003 Clamp Hose Stainless Steel 4 W10869 005 Clamp Hose Stainless Steel 4 W10869 014 Clamp Hose Stainless Steel 3 7 Engine Fuel System See F...

Page 162: ... Set May 2 2013 Chapter 4 3 Page 12 Control Box and Door Assembly Figure 6 9 11 10 11 8 7 11 6 11 3 3 2 2 12 18 13 14 18 16 18 15 18 17 18 19 4 5 20 21 25 26 27 22 23 34 28 29 31 30 33 32 1 Note Operator controls are shown with the analog generator meters and the DC output option ...

Page 163: ...al AC Voltmeter Ref 15 288814 003 Analog AC Ammeter 1 15 288858 001 Digital AC Ammeter Ref 16 400642 008 Analog DC Voltmeter 1 17 400641 015 Analog DC Ammeter 1 18 285172 Light Strip with analog generator meters and no DC 3 285172 Light Strip with analog generator meters and DC 5 19 288806 LED PC Board shown opposite side 1 288820 LED PC Board Gasket 1 20 288995 Control Panel Door 1 289017 Control...

Page 164: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 14 Control Box Interior Components Figure 7 16 15 14 12 5 8 4 3 2 1 17 9 7 6 9 ...

Page 165: ...Board 1 284316 004 PC Board Spacer 6 5 288914B T R PC Board 1 284316 004 PC Board Spacer 4 6 288818 001 Power Supply 1 288605 Power Supply Support 1 7 289122 Circuit Breaker Support 1 289060 Circuit Breaker Support Label 1 8 283978 001 5 A Circuit Breaker V77342 W23 X1A1G 5 1 9 283978 002 10 A Circuit Breaker V77342 W23 X1A1G 10 2 10 289073 Harness Wire Control Box Assembly 1 11 289072 DC Wire Har...

Page 166: ...0CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 16 Control Switch Panel Components Figure 8 18 24 23 21 20 15 12 17 14 11 1 Lamps and Meter Select Pushbuttons 3 12 4 5 6 7 13 16 19 22 25 All Other Pushbuttons 3 4 5 6 7 8 9 ...

Page 167: ...lange V61706 704 950 5 1 7 284475 001 N O Contact Block V61706 704 900 3 1 8 400613 004 Lamp 12 16 V 1815 V02929 1 9 285034 001 Lamp Holder V61706 704 950 0 1 10 290080 Contact Block Cover 1 11 Lamps Pushbutton 1 12 Output 1 Pushbutton 1 13 285030 002 Yellow Lens V61706 704 702 4 1 14 Pre heater Pushbutton 1 15 Output 2 Pushbutton 1 16 285030 004 Orange Lens V61706 704 702 3 1 17 Engine Start Push...

Page 168: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 18 400 Hz Power Module Assembly Figure 9 Note Shown with one AC and one DC output ...

Page 169: ...lat 3 8 8 10 8 W11254 006 Washer Lock 3 8 8 10 8 W11278 005 Nut 3 8 16 Hex 12 15 12 4 291058 Power Module Panel 1 1 1 5 7J422 000 Output Cable Clamp one AC output 2 4 3 6 402034 xxx Cable AC Output 30 ft optional 1 2 1 7 288120 Output Cable Bracket one AC or ACDC 1 2 1 8 290683 Harness Wire 1 1 1 401911 010 Block Terminal 1 1 1 9 286266 Standoff Short E F 2 4 2 402119 002 Screw 1 4 20 X 5 LG HHC S...

Page 170: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 20 Engine Cooling System Assembly Figure 10 1 2 3 4 5 6 8 10 11 12 14 13 15 16 17 ...

Page 171: ...1225 Fan Guard 1 6 291072 Top Radiator Hose pipe 1 7 289200 001 1 75 ID Hose two 3 pieces 6 8 291073 Bottom Radiator Hose pipe 1 9 289200 002 2 25 ID Hose two 3 pieces 6 10 403782 002 Water Temp Sw 210 F V75418 1002 04880 36 1 11 287909 Water Temperature Sender V16476 02019 1 W7814 004 Bushing Reducer 1 12 Deaeration Line Ref 288187 Fitting Straight 1 056535 Hose Low Pressure 3 8 ID 32 W10869 014 ...

Page 172: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 22 Engine Ground Plate and Battery Disconnect Switch Figure 11 1 3 2 4 ...

Page 173: ... 2 W9407 446 Cable Engine to Ground 2 3 W9360 381 Cable 111 Power Mod To Ground 1 4 Engine Dongle and Battery Disconnect Panel Ref 291334 Panel Engine Dongle Battery Disconnect 1 290831 Switch Battery Disconnect 1 290847 Plate Disconnect Switch 1 291482 Cable Disconnect Switch to Starter 1 W9360 289 Cable Disconnect Switch to Electronics Panel 1 5 290678 Wire Harness Engine 1 HF2962 Clamp Shield I...

Page 174: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 24 Engine Fuel Filters and Fuel Lines Figure 12 1 2 3 4 7 5 8 9 10 ...

Page 175: ...8 MJIC 1 4 Call Factory Line Fuel Filter to Pump 1 5 289037 Bracket Lubricity Fuel Filter 1 6 290686 Line Fuel Return 1 7 286897 036 Filter Primary Fuel 1 8 291076 Bracket Primary Fuel Filter 1 9 291420 Fuel Tank Composite 50 Gallon 1 486719 005 Sender Gauge Fuel 12V 1 291407 Bellypan Fuel Tank 1 291408 Strap Fuel Tank 2 291409 Rubber Strap Fuel Tank 2 9 291550 Fuel Tank Stainless Steel 1 486719 0...

Page 176: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 26 Engine Exhaust Components Figure 13 1 2 8 4 6 7 5 ...

Page 177: ...lamp 3 0 1 W10869 006 Stainless Steel Hose Clamp 7 3 291394 Exhaust Hole Cover 1 291395 Vertical Exhaust Components REF 4 291379 Exhaust Outlet Elbow 1 288052 002 Accuseal Clamp 3 0 1 EB5224 Muffler Wrap Insulation 3 0 ft 2 W10869 006 Stainless Steel Hose Clamp 2 5 291380 Exhaust Outlet Pipe vertical 1 288052 002 Accuseal Clamp 3 0 1 6 291383 Stainless Steel Exhaust Clamp 2 7 291382 Guard Exhaust ...

Page 178: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 28 12 VDC Battery System Figure 14 1 4 5 6 7 8 ...

Page 179: ... ASSY 14 1 281881 001 Battery 12 V V25710 1231 PMF 2 287796 Hold Down Battery V3Y208 2 494295 Bolt Hold Down Battery V3Y208 4 2 290902 Cable Battery Negative V3Y208 1 3 291481 Cable Battery Positive V3Y208 1 4 287795 Battery Tray 1 5 291160 Battery Tray Support Bracket 1 6 291067 Battery Tray Housing 1 7 291093 Panel Battery Tray Cover 2 8 291092 Cable Tray 2 ...

Page 180: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 30 Engine Air Intake Assembly Figure 15 ...

Page 181: ...290953 Hose Hump 4 ID 1 291516 Clamp SS Gear 2 5 290938 Air Cleaner 1 290941 Replacement Air Filter Element 1 6 290940 Bracket Air Filter Mounting 1 7 282918 Air Restriction Indicator see also Figure 16 1 282919 Adapter Indicator 1 8 288197 001 Fitting Rubber Reducer Hump 4 to 3 1 290597 006 Clamp Floating Bridge 4 5 1 290597 007 Clamp Floating Bridge 3 5 1 9 291453 Tube Intake Air 1 10 290936 Hos...

Page 182: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 32 Engine Components Figure 16 1 3 4 5 6 7 8 ...

Page 183: ...ushing Pipe Steel 1 4 X 1 8 1 286903 Adapter M14 1 5 x 1 4 NPT 1 W10910 000 Fitting Tee 1 W10750 001 Nipple Pipe 1 8 1 4 403782 002 Water Temp Sw 210 F V75418 1002 04880 36 1 5 287909 Sender Water Temperature V16476 02019 1 6 290678 Wire Harness Engine 1 7 290944 Electronic Engine Wire Harness 1 8 282918 Air Restriction Indicator V18265 REX77 0062 1 282919 Adapter Indicator 1 9 289261 001 Block He...

Page 184: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 34 Engine Electronic Panel Components Figure 17 1 2 3 4 5 6 7 ...

Page 185: ...Page 35 FIGURE ITEM NO PART NO NOMENCLATURE UNITS PER ASSY 17 1 291248 Panel E Engine Parts 1 2 287145 001 Holder Fuse 1 3 287144 002 Fuse Fast Acting 1 4 283154 001 Insulator Standoff 1 5 288331 Relay Grid Heater Power V02929 50F3662 1 6 290944 Harness Wire Engine Electronic 1 7 489658 007 Diode Assembly 1 ...

Page 186: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 36 1 2 3 4 5 13 6 6 7 8 9 10 11 12 Generator Assembly Figure 18 ...

Page 187: ... 1 4 288440 Exciter Housing and Coils Assembly 1 5 291082 Generator Housing and Coils Assembly 1 6 W10072 068 Bearing 2 7 288447 003 Generator Rotor 1 8 288461 Front Bearing Support 1 9 288481 Flexible Coupling Kit 1 480290 Rubber Coupling Bushing 8 10 85B1039 Coupling Key 1 11 85C1004 001 Split Taper Bushing 1 12 290870 Flywheel Adapter Ring 1 13 288458 Generator Air Deflector 6 14 291103 Generat...

Page 188: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 38 Transformer Rectifier Assembly Part 1 Figure 19 ...

Page 189: ...404044 004 Thermostat 1 7 W10931 003 Diode Silicon 275 A Positive Base 6 8 291558 Bracket Capacitor and PC Board 1 9 289006 Support PC Board 1 10 290534 001 Kit Noise Suppression Filter 1 290533 001 Capacitor Assembly 3 290533 002 Capacitor Assembly 1 11 282130 001 Contactor Input 1 77A1107 Label A 1 77A1108 Label B 1 77A1109 Label C 1 12 286603 Heat Sink Extruded 1 13 288404 Support Heat Sink 2 1...

Page 190: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 4 3 Page 40 Transformer Rectifier Assembly Part 2 Figure 20 ...

Page 191: ...SSY 20 1 286810 001 Contactor DC 800 A 24 VDC 1 2 286849 Insulator Contactor 1 3 A25 Washer Insulating 2 4 288099 Bushing Insulating 1 5 Output Stud Ref Screw 3 8 16 X 2 HHC 1 Washer 3 8 Flat 6 Washer 3 8 Lock 2 Nut 3 8 16 Hex 2 6 Contactor Studs Ref Screw 3 8 16 X 1 0 HHC ST 2 Washer 3 8 Flat 2 Washer 3 8 Lock 2 7 400435 Label 28 Volts 1 Standard SAE hardware ...

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Page 193: ...19 281971 002 9 12 282089 011 9 1 282130 001 19 11 282130 001 12 10 282562 6 25 282658 15 7 282918 16 8 282918 15 282919 16 282919 17 4 283154 001 6 12 283167 4 10 283597 1 8 283714 004 4 9 283824 10 283873 7 8 283978 001 7 9 283978 002 7 284316 004 5 24656 FIGURE ITEM NO HOBART PART NO 8 7 284475 001 6 11 284486 001 8 3 285029 001 8 25 285030 001 8 13 285030 002 8 19 285030 003 8 16 285030 004 8 ...

Page 194: ...8 10 11 287909 16 5 287909 2 3 292016 3 5 287986 2 5 287998 3 287998 6 2 288020 6 24 288023 13 288052 002 19 15 288085 19 3 288092 19 5 288095 001 FIGURE ITEM NO HOBART PART NO 20 4 288099 5 24656 19 2 288117 9 7 288120 19 17 288147 1 10 288164 001 10 288187 15 8 288197 001 6 32 288300 17 5 288331 19 288380 001 19 13 288404 18 4 288440 18 7 288447 003 18 13 288458 5 4 288460 003 18 8 288461 18 9 2...

Page 195: ... 4 289026 12 5 289037 7 289060 7 11 289072 7 10 289073 6 289078 19 21 289096 7 16 289104 001 7 7 289122 5 289127 19 20 289156 10 7 289200 001 10 9 289200 002 FIGURE ITEM NO HOBART PART NO 6 34 289208 16 289249 005 16 289250 001 16 9 289261 001 9 11 289318 10 14 289827 10 13 289828 1 24 289842 001 8 10 290080 10 290145 1 13 290216 12 3 290388 19 290533 001 19 290533 002 19 10 290534 001 10 18 29059...

Page 196: ...0 8 291073 10 17 291074 10 16 291075 12 8 291076 13 2 291077 15 11 291078 11 1 291079 4 1 291080 4 3 291081 18 5 291082 4 5 291084 4 17 291085 FIGURE ITEM NO HOBART PART NO 4 16 291087 2 6 291088 2 7 291089 2 8 291092 14 8 291092 2 9 291093 14 7 291093 10 291097 18 14 291103 12 2 291114 9 291115 003 9 291115 004 3 2 291152 5 12 291152 14 5 291160 13 1 291168 13 8 291169 9 18 291180 10 1 291223 10 ...

Page 197: ...1481 11 291482 15 291516 12 9 291550 19 8 291558 1 25 400435 20 7 400435 8 8 400613 004 6 17 400641 015 6 16 400642 008 9 401911 010 FIGURE ITEM NO HOBART PART NO 9 10 402025 xxx 9 6 402034 xxx 9 402119 002 1 9 402987 10 10 403782 002 16 4 403782 002 16 2 403809 002 19 6 404044 004 13 404154 013 11 405548 1 21 407366 1 408665 001 1 4 408665 001 1 408665 002 18 480290 5 482496 002 12 486719 005 9 1...

Page 198: ...M NO HOBART PART NO 12 4 Call Factory 11 HF2962 18 6 W10072 068 16 W10750 001 5 W10869 003 5 W10869 005 13 W10869 006 5 W10869 014 10 W10869 014 16 W10910 000 19 7 W10931 003 9 W11097 028 9 W11242 010 9 W11242 018 9 W11254 006 9 W11278 005 16 W7814 000 10 W7814 004 6 14 W8105A 009 11 W9360 289 11 3 W9360 381 11 2 W9407 446 ...

Page 199: ...ed separately from Cummins Diagram Number Diagram Description 291331 Rev 1 Diagram Schematic Connection 289022 Rev 2 Diagram Connection Control Box 289102 Rev 3 Diagram Connection Power Module 289013 Rev 3 Diagram Connection Switch Box 289155 Rev 3 Diagram Schematic Connection Transformer Rectifier Contact Hobart Ground Systems if copies of these drawings or manuals are not with this manual unless...

Page 200: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Chapter 5 1 Page 2 This page intentionally left blank ...

Page 201: ...n 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 003 NA Kit Unit Operating Light 289210 004 NA Kit Low Fuel Beacon 291365 005 NA Kit Cable Tray Rollers 288987 002 NA 30 ft DC Output Cable 402025 003 NA 30 ft AC Output Cable 402034 002 NA Deluxe Features Fork Lift Pockets...

Page 202: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Appendix A Page 2 This page intentionally left blank ...

Page 203: ... is common and may be expected 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 loa...

Page 204: ...OM 2226 Operation and Maintenance Manual 60CU20 Series 500062 400 Hz Generator Set May 2 2013 Appendix A Page 4 This page intentionally left blank ...

Page 205: ...ere 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 ...

Page 206: ...CU20 Series 500062 400 Hz Generator Set May 2 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 207: ...ound power unit Generator Set Model Number Make sure your generator set is the model listed above Identify the model number by looking on the data plate which is located next to the gauges on the back of the unit Filter Part Numbers The table below lists the filter part numbers for your generator set You can also order sets of filters as kits Filter Number Hobart Part Number Filter Kit 290300 13 F...

Page 208: ...l filter elements Hobart Ground Systems Supply Contact Information Hobart Ground Systems has a supply staff that is able to help with the quote and sale of parts Our helpful supply staff is also able to provide delivery information for the customer Contact the Hobart Ground Systems supply department staff for all the preventative maintenance parts e mail service hobartsystems com call inside USA 8...

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