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OM-2098C / Operation and Maintenance Manual 
60CU24 / Series 500060C / 400 Hz. Generator Set 

 

 

July 3, 2008 
Revision 9 

Chapter 4-3 

Page 7 

 

FIGURE 

ITEM NO. 

FACTORYP
ART NO. 

NOMENCLATURE 

EFF 

UNIT PER 

ASSY. 

2 - 

 

 

 

 

 

 

1 

289080 

Control Panel Support, Left 

 

1 

 

2 

288082 

Fuel Tank Support 

 

1 

 

3 

287972 

Door Support Panel 

 

2 

* 

 

288064-004 

Door Support Panel Insulation 

 

2 

 4 

288373  Engine 

Support 

 

1 

 5 

287984  Battery 

Tray 

 

1 

 

6 

287998 

Front Panel Bracket 

 

2 

 

7 

287950 

Stationary Mounting Frame 

C,D,F,G,J,L,O,P,R,S,U,W 

1 

* 

 

288340 

Trailer / Frame Assembly 

A,B,E,H,K,M,N,Q,T,V 

1 

 

8 

289081 

Control Panel Support, Right 

 

1 

 9 

287957  Generator 

Support 

 

1 

 

10 

287986 

Control Panel Support 

 

1 

 

11 

286862 

Fuel Tank, Assembly 

 

1 

 

12 

486719-013 

Fuel Tank, Sending Unit 

 

1 

 

13 

282562 

Fuel Cap, Green 

 

1 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for 60CU24

Page 1: ...riginal 070308 Revision 9 Operation and Maintenance Manual with Illustrated Parts List for 60CU24 60 kVA 3 Phase 115 200 Volt 400 Hz Generator Set Series 500060C ITW GSE Group Hobart Ground Power Troy...

Page 2: ......

Page 3: ...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...

Page 4: ......

Page 5: ...ically 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...

Page 6: ...nnecting 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 ser...

Page 7: ...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 immediat...

Page 8: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set April 01 2005 Safety Warnings Page 4 This page intentionally left blank...

Page 9: ...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 secti...

Page 10: ...ur Service Department by mail telephone FAX or E Mail Write ITW GSE Group Hobart Ground Power Service Department 1177 Trade Road East Troy Ohio 45373 U S A Call Inside U S A 800 422 4166 Parts 800 422...

Page 11: ...her Starting System 1 1 22 Section 1 Preparation for Use Storage or Shipping 1 2 1 Preparation For Use 1 2 1 Tips on Cold Weather Starting 1 2 3 Preparation For Storage 1 2 3 Preparation For Shipment...

Page 12: ...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...

Page 13: ...oduction 4 1 1 General 4 1 1 Purpose 4 1 1 Arrangement 4 1 1 Explanation of Parts List 4 1 1 Section 1 Manufacture s Codes 4 2 1 Explanation of Manufacture s Vendor Code List 4 2 1 Section 2 Illustrat...

Page 14: ...ttery System 4 3 26 Figure 13 Air Cleaner Components 4 3 28 Figure 14 Engine Components 4 3 30 Figure 15 Engine Exhaust Components 4 3 32 Figure 16 Generator Assembly 4 3 34 Figure 17 Trailer Componen...

Page 15: ...less Steel Fuel Tank 500060C 008 Single Output Trailer Mounted Digital AC Meters Stainless Steel Fuel Tank 500060C 009 Single Output Fixed Truck Mounted Digital AC Meters SS Fuel Tank 500060C 010 Sing...

Page 16: ...and electric governor are mentioned here and described briefly Protective Monitoring The protective monitoring system receives signals from the fault sensing units in the generator output circuit and...

Page 17: ...mm Weight Single AC output only 2595 lb 1107 kg 3070 lb 1393 kg Weight Dual AC output only 2700 lb 1225 kg 3175 lb 1440 kg Weight AC DC outputs 2875 lb 1304 kg 3350 lb 1519 5 kg AC GENERATOR Output p...

Page 18: ...ting Overload 2700 A for 2 seconds 2000 A for 10 seconds 1500 A for 30 seconds 1200 A 90 seconds 750 A 600 seconds ENGINE Manufacturer Cummins Engine Company Model No QSB4 5 Type In Line 4 cylinder 4...

Page 19: ...mmended by the engine manufacturer 3 Oil Filter The engine oil filter is a spin on full flow type located on the left side of the engine near the front 4 Pre programmed Electronic Control Module ECM T...

Page 20: ...circuit closes and the air cleaner indicator fault appears on the control panel fault display to warn the operator that the air cleaner must be changed The electrical indicator automatically resets w...

Page 21: ...g 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 mu...

Page 22: ...007 Revision 8 Chapter 1 1 Page 8 10 9 8 7 6 5 4 3 2 1 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 E...

Page 23: ...Manual 60CU24 Series 500060C 400 Hz Generator Set November 16 2007 Revision 8 Chapter 1 1 Page 9 5 4 3 2 1 6 1 Radiator 2 Cummins QSB Engine 3 Air Cleaner 4 Control Box 5 Fuel Tank 6 Generator Main Co...

Page 24: ...lights and panel light push button switch S74 Meters are lighted from inside the control panel The LAMPS push button switch controls the lights 2 Engine hour meter M4 The hour meter is electrically dr...

Page 25: ...rature Gauge M24 4 Running Time Meter M4 5 Oil Pressure Gage M25 6 Battery Voltmeter M5 7 Frequency Meter M3 8 Control Panel Label 9 Fault Code Meter M6 10 Strip Lights DS60 DS62 3 Not Shown 11 AC Gen...

Page 26: ...eter Selector Switch S3 2 Test Reset Switch S77 3 Engine Stop Switch S76 4 DC Starting Current Switch S431 Optional with TR 5 DC Output Contactor Switch S430 Optional with TR 6 AC Output No 2 S275 if...

Page 27: ...d ESB A1 2 Engine Interface PC Board EIB A2 3 Digital Control PC Board CTL A3 4 Voltage Regulator PC Board REG A4 5 Transformer Rectifier PC Board TRB A404 Optional 6 5 12 VDC Power Supply PS1 7 Circu...

Page 28: ...gnals and the engine reverts to idle speed and a blinking green indicator light 7 ENGINE HEATER push button switch S79 The ENGINE HEATER push button switch activates the standard cold starting aid man...

Page 29: ...each of the three phases may be read on the ammeter by selecting the desired phase with METER SELECT switch The ammeter current transformers located in the output power module circuit lower the output...

Page 30: ...ondition 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 3 Circuit breakers CB1 CB4 CB7 A 10 amp...

Page 31: ...imary interface between the control system and the engine s electronic control module When the CTL senses the engine start button has been pressed it signals to the ESB which then communicates to the...

Page 32: ...ember 16 2007 Revision 8 Chapter 1 1 Page 18 J51 Connector Starter Disable Enable PC Board Software Engine Interface PC Board Figure 11 J52 Connector Engine Status Lights PC Board Software Engine Stat...

Page 33: ...e regulator PC board circuitry provides line drop compensation Any deviation of the alternator voltage from its set regulated level is sensed at the voltage regulator PC board The sensing signal is co...

Page 34: ...r 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 reg...

Page 35: ...ator output to and from the load aircraft a Load contactor s The load contactor s each contain a magnetic operating coil and four sets of contacts The three larger contacts conduct three phase AC gene...

Page 36: ...pen the contactors when the output current reaches 125 of the normal rated output current The monitoring circuit moniters each individual output as well as the overall current for a dual output machin...

Page 37: ...ance Manual 60CU24 Series 500060C 400 Hz Generator Set November 16 2007 Revision 8 Chapter 1 1 Page 23 1 3 2 1 Output 1 Contactor S75 2 Wire Harness 3 Output 2 Contactor S275 If Applicable Output Powe...

Page 38: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set November 16 2007 Revision 8 Chapter 1 1 Page 24 This page intentionally left blank...

Page 39: ...tening hose clamps tube fitting etc as required 5 Check security of generator set retaining components 6 Check the following for sufficient quantity a Fuel Press LAMPS push button button to energize f...

Page 40: ...l Check Oil Fill and Oil Level Check Locations Figure 2 d Check Batteries Inspect the batteries for proper connection of the terminals and also check the electrolyte level if possible Service or repla...

Page 41: ...Cold Weather Starting a Battery and Cables To start in cold weather a diesel engine must crank at a fairly high speed A worn out battery partially discharged battery and poor or loose cable connectio...

Page 42: ...th 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...

Page 43: ...r for instructions 4 Preparation for Shipment a Disconnect battery negative terminal before shipping b During long shipments vibration jolting etc may loosen the generator set retaining hardware CAUTI...

Page 44: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set April 01 2005 Chapter 1 2 Page 6 This page intentionally left blank...

Page 45: ...ubricating oil and coolant in the engine 5 Check that all circuit breakers are reset 6 Make certain the STARTER ENABLE DISABLE switch is enabled and the FREQUENCY ADJUST switch is disabled b Normal En...

Page 46: ...Gauge M24 4 Running Time Meter M4 5 Oil Pressure Gage M25 6 Battery Voltmeter M5 7 Frequency Meter M3 8 Control Panel Label 9 Fault Code Meter M6 10 Strip Lights DS60 DS62 Not Shown 11 AC Generator Am...

Page 47: ...lector Switch S3 2 Test Reset Switch S77 3 Engine Stop Switch S76 4 DC Starting Current Switch S431 Optional with TR 5 DC Output Contactor Switch S430 Optional with TR 6 AC Output No 2 S275 if applica...

Page 48: ...disengage the starter gear but does not start allow the starting motor to come to a complete stop before attempting to engage the starter again then press the start push button switch 4 Check oil pres...

Page 49: ...livered The contactors will open and power to the aircraft will be suddenly interrupted 5 A condition of over voltage under voltage under frequency over frequency or overload in the output circuit wil...

Page 50: ...automatic shutdown sequence to shut off the engine gauges lights etc after approximately 3 5 minutes c Disconnect output cable from aircraft after engine is at idle speed only 2 Emergency conditions...

Page 51: ...ance 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 mai...

Page 52: ...X Check Exhaust System X Change Lubricity Fuel Filter Element X X Change Fuel Pre Filter Element X X Check Fuel Pump X Check Radiator Core and Hoses X Check Oil Pressure and Record X Change Crankcase...

Page 53: ...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 E...

Page 54: ...and be sure it is set for 115 VAC 1 V Adjustment can be made using the fine adjustment located on the Voltage Regulator PC Board REG c BR Checks and Operations Break In Period Once After 50 150 hrs T...

Page 55: ...e checked until 3 to 5 minutes after engine shutdown Keep oil level as near the upper bar as possible b Drain Fuel Pre Filter Element The life of the fuel pump and injectors can be extended if the ope...

Page 56: ...p observe the air cleaner indicator light If this light comes ON it indicates that the air cleaner should be changed f Check Exhaust System Visually inspect muffler and exhaust pipes for rust and sign...

Page 57: ...ngine a Charge Air Cooler and Piping Inspect the charge air cooler for dirt and debris blocking the fins Check for cracks holes or other damage Inspect the pipes and hoses for leaks holes cracks or lo...

Page 58: ...sary 3 Electrical 400 Hz System a Check the operation of the E F bypass system f C Checks and Operations 500 Hours or 6 Months 1 Engine a Check Engine and Generator Mounts CAUTION An unstable or loose...

Page 59: ...ive Pulley Inspect for loose bolts or worn features Tighten bolts and replace parts if necessary Refer to the engine manufacturer s operations and maintenance manual for assistance and the most update...

Page 60: ...oltage regulator alternator and electrical wiring 3 Seal all openings DO NOT use a flammable solvent 4 DO NOT use mineral spirits or solvents on a hot engine 5 Remove or protect bottom panel of unit b...

Page 61: ...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 mount...

Page 62: ...it breakers and Fuses 1 Check all lamps daily 2 Check circuit breakers and fuses as required 3 The lamp chart lists all lamps with their location and identifying trade number in table below 4 The circ...

Page 63: ...anel 1815 No 1 Load Contactor Indicator Switch Panel 1815 No 2 Load Contactor Indicator Switch Panel 1815 Test Reset Indicator Switch Panel 1815 Pre heater Indicator Switch Panel 1815 Clearance Lights...

Page 64: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set April 01 2005 Chapter 2 1 Page 14 This page intentionally left blank...

Page 65: ...re 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 hav...

Page 66: ...g temperature Change the oil filter element each time the oil is changed NOTE If lubricating oil is drained immediately after the unit has been run for some time most of the sediment will be in suspen...

Page 67: ...ations manual for usable synthetic oils and instructions Fuel Water Separator and Lubricity Additive Filter Drain filters daily Change filter elements every 250 hours or after 3 months of use whicheve...

Page 68: ...ral purpose grease Lubricants Chart Figure 2 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 mo...

Page 69: ...sealed bearings and require no periodic lubrication however check to make certain there are no lubrication points on your particular alternator 2 Starter Most starting motors are lubricated at assembl...

Page 70: ...fasten the three metal clamps on the end of the air cleaner housing 2 Remove end cover of housing 3 Pull out air filter element and replace 4 Replace end cover on housing making certain that the filte...

Page 71: ...estrict flow and clog filters Fuel oil suppliers approach this problem several ways Some provide a specially refined product while others may use flow improving additives or winter blends Winter blend...

Page 72: ...al Spin the bowl onto the new element and the spin them both onto the filter head snugly by hand only DO NOT USE TOOLS TO TIGHTEN e With the vent plug still loosened pump knob until fuel purges at the...

Page 73: ...er every 250 hours of operation 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 fue...

Page 74: ...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...

Page 75: ...r information regarding coolant specifications testing equipment antifreeze etc refer to engine manufacturer s operation manual that accompanies the equipment manufacturer s manual or consult the loca...

Page 76: ...he engine block to remove expired coolant and other contaminants f Cleaning the Radiator Core Blow out accumulated dirt from the radiator core air passages using water Bent or clogged radiator fins of...

Page 77: ...ntenance The 400 Hz generator requires no maintenance or service other than periodic cleaning The unit is brushless and has bearings that are permanently lubricated and sealed a Cleaning The generator...

Page 78: ...t will slip and cause inefficient operation of the part being driven as well as wear to the belt CAUTION Inspect and replace the belt if it has unacceptable cracks is frayed or has pieces of material...

Page 79: ...8 5 Inspect for oil fuel and coolant leaks 6 If the setting of the output voltage coarse adjustment potentiometer Figure 8 on the voltage regulator has been disturbed set it at center position halfwa...

Page 80: ...Gauge M24 4 Running Time Meter M4 5 Oil Pressure Gage M25 6 Battery Voltmeter M5 7 Frequency Meter M3 8 Control Panel Label 9 Fault Code Meter M6 10 Strip Lights DS60 DS62 Not Shown 11 AC Generator Am...

Page 81: ...lector Switch S3 2 Test Reset Switch S77 3 Engine Stop Switch S76 4 DC Starting Current Switch S431 Optional with TR 5 DC Output Contactor Switch S430 Optional with TR 6 AC Output No 2 S275 if applica...

Page 82: ...1 2 Engine Interface PC Board EIB A2 3 Digital Control PC Board CTL A3 4 Voltage Regulator PC Board REG A4 5 Transformer Rectifier PC Board TRB A404 Optional 6 5 12 VDC Power Supply PS1 7 Circuit Brea...

Page 83: ...10 Check adjustable voltage range a Observe voltmeter Figure 1 and turn output voltage coarse adjustment potentiometer Figure 8 to full clockwise position Maximum voltage should be 134 volts or higher...

Page 84: ...button switch The No 1 contactor power indicating light within the push button switch should glow and remain on when the push button switch is released This indicates that EF bypass switch is functio...

Page 85: ...10 Disconnect the 24 V DC power source and the No 1 load contactor should open immediately and the indicating light within the push button switch should go OFF The fault code display should also read...

Page 86: ...o 2 output circuit e Testing and checking meters switches protective monitoring circuits and fault code display 1 Check accuracy of AC voltmeter a Open door of control box and connect a master voltmet...

Page 87: ...g at a normal load adjust the coarse adjustment potentiometer Figure 8 on the voltage regulator counterclockwise to decrease voltage until the under voltage sensing circuit actuates the protective mon...

Page 88: ...sing TEST RESET button switch Figure 2 to clear fault code Frequency Adjustment Switch Frequency Adjust Potentiometer Engine Codes Engine Stop Check Engine PC Board Software Engine Specific PC Board F...

Page 89: ...g TEST RESET button switch Figure 2 to clear fault code NOTE If the generator is operating under load at this point open the contactors There will be no further need for the load bank in the following...

Page 90: ...ne manufacture s manual for code meanings g Re checking the entire unit after testing 1 With the engine running at normal rated speed check the entire unit for vibration and for any parts that may hav...

Page 91: ...nd line drop compensation For making these adjustments the voltage regulator has three potentiometers A coarse output voltage potentiometer Figure 8 A fine output voltage potentiometer Figure 8 A line...

Page 92: ...se load of rated power factor not exceeding the maximum rating of the generator set Measure output voltage at the load end of the cables If the load voltage rises or drops more than 1 at the load end...

Page 93: ...SB4 5 Type In Line 4 cylinder 4 cycle diesel electronic controlled Horsepower 110 hp 82 kW Idle speed 1000 50 rpm High speed limiting 2750 75 rpm Normal governed speed 2400 rpm Lubricating oil capacit...

Page 94: ...a Disconnect exciter windings from diode lead s b Use a good quality ohmmeter An instrument which indicates 50 ohms at the center of the scale is preferable NOTE Make certain the battery is in good c...

Page 95: ...and is listed below each Test or Inspection procedure Tests and inspections called for in the Troubleshooting Chart are to be performed as described in Chapter 2 Section 1 3 of this manual 2 Equipment...

Page 96: ...requency at rated speed of 2400 RPM is 400 2 Hz at no load and rated load Engine oil pressure warm and at rated speed 2400 RPM 45 to 90 PSI 445 to 621 kPa Engine coolant temperature normal operation 1...

Page 97: ...ble 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 3...

Page 98: ...tton will start the 3 5 minutes delayed shutdown period The ENGINE STOP push button will flashed and the engine will return to idle speed The shutdown period is required to sufficiently cool the engin...

Page 99: ...nfiguration would be a high temperature fault The contactors will open and remove power from the aircraft the engine will drop to its idle speed and the fault will appear on the fault code display alo...

Page 100: ...ve 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 indi...

Page 101: ...See Figure 1 5 To continue scrolling backward through the previous fault codes press and release the TEST RESET push button again and the previous fault record number and fault code will be displayed...

Page 102: ...Gauge M24 4 Running Time Meter M4 5 Oil Pressure Gage M25 6 Battery Voltmeter M5 7 Frequency Meter M3 8 Control Panel Label 9 Fault Code Meter M6 10 Strip Lights DS60 DS62 Not Shown 11 AC Generator Am...

Page 103: ...lector Switch S3 2 Test Reset Switch S77 3 Engine Stop Switch S76 4 DC Starting Current Switch S431 Optional with TR 5 DC Output Contactor Switch S430 Optional with TR 6 AC Output No 2 S275 if applica...

Page 104: ...1 2 Engine Interface PC Board EIB A2 3 Digital Control PC Board CTL A3 4 Voltage Regulator PC Board REG A4 5 Transformer Rectifier PC Board TRB A404 Optional 6 5 12 VDC Power Supply PS1 7 Circuit Brea...

Page 105: ...s defective Replace it If starter motor does operate proceed to step d d Internal seizure If battery and starter are good and starter is unable to crank the engine internal seizure is indicated Attemp...

Page 106: ...h filter with fuel If engine will not start after priming filters fuel pump trouble is indicated If engine starts and stops after a short time trouble between fuel source and suction side of pump is i...

Page 107: ...6 Engine starts Stops after a few seconds by automatic shutdown b Defective EIB board Replace EIB board a Marker light circuit breaker CB1 won t close Replace marker lights circuit breaker CB1 if defe...

Page 108: ...ts a Defective generator or excitation circuit On REG place Regulated Diagnostic switch in Diagnostic position This applies 12 VDC from battery to exciter field which should produce an indicated outpu...

Page 109: ...an ohmmeter Replace circuit breaker if defective b In addition to defective wiring and connections in AC and DC load contactor actuating circuits load contactor may be prevented from closing for any o...

Page 110: ...r to aircraft cable connector defective or not plugged into aircraft receptacle connector Inspect cable connector plug thoroughly for damaged E and F terminals Be sure plug is fully mated with aircraf...

Page 111: ...oad contactor circuits c Defective REG board Replace REG board with a board known to be operating properly If contactor still doesn t close proceed to step d d Defective output No 1 push button switch...

Page 112: ...enerator to aircraft cable connector defective or not plugged into aircraft receptacle connector Inspect cable connector plug thoroughly for damaged E and F terminals Be sure plug is fully mated with...

Page 113: ...e CTL board Use REG potentiometer to reduce voltage to 110 V AC Observe voltmeter and gradually increase voltage with potentiometer If sensing circuit CTL board functions to open load contactor at any...

Page 114: ...al overload condition and correct If overload device functions to open load contactor when an overload does not exist proceed to step B 5 Load contactor opens during power delivery Overload fault indi...

Page 115: ...circuited Check stator windings See Section 2 3 a Loose connection in output circuit Check all output connections Discolored connectors indicate a loose connection Tighten or replace as required b Op...

Page 116: ...U Commands Cmd code Name Description 00 _ _ Invalid Command 01 _ _ ENGINE SELF TEST CMD All boards test the communication between each other 02 _ _ 03 _ _ 04 _ _ 05 _ _ 06 _ _ 07 _ _ 08 _ _ 09 _ _ 10...

Page 117: ..._ _ 33 _ _ 34 _ _ 35 _ _ 36 _ _ 37 _ _ 38 _ _ 39 _ _ 40 _ _ ENGINE START MODE Engine starter and engine s ECM is activated 41 _ _ 42 _ _ 43 _ _ 44 _ _ 45 _ _ 46 _ _ 47 _ _ 48 _ _ 49 _ _ 50 _ _ ENGINE...

Page 118: ..._ _ CTL TEST OUTPUT Checks the CTL communications 69 _ _ 70 _ _ ENGINE RUN MODE The engine is at rated speed and ready for aircraft load 71 _ _ 72 _ _ 73 _ _ 74 _ _ 75 _ _ ENGINE RAMP DOWN Period whe...

Page 119: ...U24 Series 500060C 400 Hz Generator Set April 01 2005 Chapter 2 4 Page 25 Troubleshooting Table GPU Commands Cmd code Name Description 93 _ _ 94 _ _ 95 _ _ 96 _ _ 97 _ _ 98 _ _ 99 _ _ System Off Mode...

Page 120: ...er cartridge or air restriction indicator _ _ 09 EIB LOW FUEL WARNING Fuel tank level is below tank Fill fuel tank _ _ 10 _ _ 11 _ _ 12 _ _ 13 _ _ 14 _ _ 15 _ _ 16 CTL OUTPUT OVER VOLTAGE FAULT Voltag...

Page 121: ...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 HIG...

Page 122: ..._ _ 57 _ _ 58 _ _ 59 _ _ 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 boar...

Page 123: ...4 Page 29 Troubleshooting Table Faults Fault code Name Possible Cause s Corrective Action _ _ 69 _ _ 70 _ _ 71 _ _ 72 _ _ 73 _ _ 74 _ _ 75 _ _ 76 _ _ 77 _ _ 78 _ _ 79 _ _ 80 _ _ 81 _ _ 82 _ _ 83 _ _...

Page 124: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set April 01 2005 Chapter 2 4 Page 30 This page intentionally left blank...

Page 125: ...ts 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 ex...

Page 126: ...emoved for rear main bearing replacement The exciter armature has two M10 1 5 tapped holes in it s diode mounting plate to accommodate pulling it off the shaft Since the removal and installation of ex...

Page 127: ...ool is necessary for removing the threaded machine key which keeps the exciter armature from spinning on the generator armature shaft You may have such a puller in your equipment inventory If not Figu...

Page 128: ...x Steel 3 required 4 Rod 1 2 Round CR Steel 5 Hammer 2 Round CR Steel 6 Washer Flat 1 2 Steel Sling Hammer Puller Figure 3 d Preparation for Exciter Armature Removal 1 Remove exciter cover from end ca...

Page 129: ...ler to the key in one operation is not recommended because the weight and bulk of the assembly make threading the 1 4 inch stud into the key rather clumsy This could result in cross threading and dama...

Page 130: ...required to avoid damage to insulation 4 Installation Exciter Armature a Preparation for Exciter Armature Installation 1 Clean generator shaft and exciter armature bore Remove all rust corrosion etc...

Page 131: ...o the exciter armature as follows a Connect lead with ring type terminal to the screw provided to the mounting plate Figure 2 b Connect the other field lead to the three leads coming off of the excite...

Page 132: ...htening 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 31 Retaining Com...

Page 133: ...iter Armature Generator Armature Shaft 13 Threaded Hole In Armature Shaft Diode Mounting Plate 13 Nut 13 x 5 Inch Bolt Exciter Armature After Installation On Armature Shaft Remove the 13 x 5 inch bolt...

Page 134: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set April 01 2005 Chapter 3 1 Page 10 This page intentionally left blank...

Page 135: ...light 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 R...

Page 136: ...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 tha...

Page 137: ...r 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 6 1 2 5 8 7 4 3 1 Bolt 3 8 16 UN...

Page 138: ...32 5121 E Mail service itwgsegroup com Web Page www itwgsegroup com a Replacement Coupling Kit A replacement coupling kit is available from your ITW GSE Group Distributor This kit provides a replaceme...

Page 139: ...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 ru...

Page 140: ...llustrated 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 dimension in Figure 7 to be...

Page 141: ...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 ope...

Page 142: ...ance Manual 60CU24 Series 500060C 400 Hz Generator Set April 01 2005 Chapter 3 2 Page 8 Bushing 8 Required Fan and Coupling Assembly 1 Required Taper Bushing 1 Required Press bushing in from this side...

Page 143: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set April 01 2005 Chapter 3 2 Page 9 Assembly Procedure Figure 5 Measure from mounting face to adapter ring Figure 6...

Page 144: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set April 01 2005 Chapter 3 2 Page 10 Measuring From Mounting Face To Bushing Figure 7...

Page 145: ...T R assembly 3 Disconnect clearance light wires from the top canopy if installed 4 Remove top canopy panel 5 Remove all four doors and panels below door 6 Remove the control box 7 Remove the air clean...

Page 146: ...y Installation Installation of a generator assembly is essentially a reversal of the procedure for removal of the generator assembly the re mounting of the generator assembly to the frame of the gener...

Page 147: ...rque bolts to 25 ft lb 30 N m 4 Attach the generator to the flywheel coupling using the eight M12 1 75 bolts Torque bolts to 85 ft lb 115 N m 5 Mount the generator housing to the frame of the generato...

Page 148: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set April 01 2005 Chapter 3 3 Page 4 This page intentionally left blank...

Page 149: ...a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except 1 Standard hardware items attaching parts such as nuts screws washers etc which...

Page 150: ...quipment When more than one model of equipment is covered by a parts list there are some parts that are used on only one model This column is used for insertion of a code letter A B etc to indicate th...

Page 151: ...rator Set November 16 2007 Revision 8 Chapter 4 1 Page 3 5 UNITS PER ASSEMBLY Column This column indicates the quantity of parts required for an assembly or subassembly in which the part appears This...

Page 152: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set November 16 2007 Revision 8 Chapter 4 1 Page 4 This page intentionally left blank...

Page 153: ...8 01XD4 Contact Industries Inc 25 Lex Industrial Dr P O Box 3086 Mansfield OH 44904 3086 05YB3 Acon Inc 22 Bristol Dr South Easton MA 02375 01428 Tuthill Corp Superior Linkage Div 2110 Summit St New H...

Page 154: ...Bend IN 46634 1SPJ9 Hobart Ground Power 1177 Trade Road East Troy OH 45373 16238 Lord Mfg Co Inc Sterling Road South Lancaster Mass 01561 1W134 Eaton Corp 4201 N 27TH Ave Milwaukee WI 53216 1807 16476...

Page 155: ...Inc 914 Westfield Ave Elizabeth NJ 07208 1222 44655 Heico Ohmite LLC 3601 W Howard St Skokie IL 60076 4014 26794 Connectron Inc 12 Industrial Dr South Amboy NJ 08879 46922 Crawford Electric Co 445 E...

Page 156: ...62292 EBM Industries Inc 110 Hyde Rd P O Box 4009 Farmington CT 06034 4009 57733 Stewart Warner Corporation 1826 Diversey Parkway Chicago Illinois 60614 67529 All Phase Electric Supply Co 875 Rivervi...

Page 157: ...by Milford Rd Orange CT 06477 82866 Research Products Corp 1015 E Washington Ave Madison WI 53701 75418 Kysor Industrial Corporation 1100 W Wright Street Cadillac Michigan 49601 83330 Dialight Corp 19...

Page 158: ...ess Code Vendor s Name and Address 97520 Basler Electric Company Route 143 P O Box 269 Highland IL 62249 D0024 Semikron International Sigmundstrasse 200 P O Box 820251 Nuerengerg Germany 90253 E0615 K...

Page 159: ...is 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 cycle...

Page 160: ...M 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 2 9 8 15 16 7 4 5 23 19 2 V 46 Fixed Mount Bracket General Assembly Figure 1...

Page 161: ...able Clamp A C M O 2 7J422 0 Cable Clamp E F G H J K L Q R S T U V W 3 7J422 0 Cable Clamp B D N P 4 17 287698 001 Output Cable Covers A C H J M O T U 1 18 289127 Terminal Block Label 1 19 402987 Hoba...

Page 162: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 4 37 46 Fixed Mount Bracket General Assembly Figure 1...

Page 163: ...T PER ASSY 1 39 407366 Caution Label 1 40 283691 001 Allen Wrench 1 41 288872 Fault and Command Label 1 42 287467 Glow Plug Label 2 43 488904 Frame Spacer Bracket Assembly G S 4 44 489690 Domestic Shi...

Page 164: ...M 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 6 11 8 3 7 6 5 4 3 2 1 12 13 9 Frame Assembly Stationary Frame Shown Figure...

Page 165: ...7972 Door Support Panel 2 288064 004 Door Support Panel Insulation 2 4 288373 Engine Support 1 5 287984 Battery Tray 1 6 287998 Front Panel Bracket 2 7 287950 Stationary Mounting Frame C D F G J L O P...

Page 166: ...2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 8 10 9 6 8 7 6 5 4 3 2 1 12 11 Canopy Assembly Stationary Frame Shown Figure...

Page 167: ...Tab 4 6 287978 Access Door 4 288064 001 Door Noise Insulation 3 288064 007 Door Noise Insulation 1 1 7 283824 Access Door Hinge Right Hand Side 4 8 283597 Access Door Hinge Left Hand Side 4 9 287977 S...

Page 168: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 10 9 4 7 1 8 17 2 3 6 5 10 11 Internal Components Figure 4...

Page 169: ...nents See Engine Manual Ref 9 287060 003 Generator Assembly See Figure 16 Ref 10 No Number Air Cleaner Components See Figure 13 Ref 11 289141 001 Control Box Assembly Single AC Output See Figures 5 6...

Page 170: ...peration and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 12 1 2 3 4 5 6 8 7 13 10 13 11 13 12 9 13 16 13 15 17 Control Box Door Panel Assembly...

Page 171: ...74542 D 1255119311 A B C D E F G M N O P Q R S 1 288858 002 Meter Frequency Digital Meter H J K L T U V W 1 8 289017 Label Control Box 1 9 288858 004 Meter Fault Digital 1 10 288814 003 Ammeter AC V74...

Page 172: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 14 7 6 2 3 4 5 1 10 8 9 Control Box Interior Components Figure 6...

Page 173: ...EIB 1 288791 Label EIB Starter Control 1 3 289026 Digital Controls PC Board 1 288875 Label Control EF Bypass Control 1 4 288940 Regulator PC Board 288876 Label Regulator Generator Control 1 288896 La...

Page 174: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 16 10 9 8 7 6 5 4 3 2 1 12 11 Control Switch Panel Components Figure 7...

Page 175: ...e Figure 8 B D N P 1 287038 001 Plug Hole when output 2 is not used A C E F G H J K L M O Q R S T U V W 1 6 285030 005 DC Output Pushbutton Blue See T R Manual E F G K L Q R S V W 1 287038 001 Plug Ho...

Page 176: ...Switch Panel Test Reset Push Button Control Panel 1 3 6 7 8 10 11 9 Engine Stop Push Button Control Panel 1 3 6 7 8 10 11 9 Output 1 Push Button Control Panel 1 2 6 7 8 10 11 9 Output 2 Pre Heater Pus...

Page 177: ...B D N P 8 285031 001 Holder Lens V61706 704 709 7 E F G K L Q R S V W 9 7 285032 001 Actuator Sleeve V61706 704 731 0 A C H J M O T U 7 285032 001 Actuator Sleeve V61706 704 731 0 B D N P 8 285032 00...

Page 178: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 20 7 9 11 6 10 5 5 4 4 3 2 1 12 13 400 Hz Power Module Assembly Figure 9...

Page 179: ...Pole B D N P 2 5 286266 Standoff Short E F 2 286266 Standoff Short E F B D N P 4 6 See Harness Block Terminal Ref 7 289319 Harness Wire A C E F G H J K L M O Q R ST U V W 1 Cable Power Ay Ref No 101...

Page 180: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 22 6 8 7 10 3 2 1 9 Cooling System Components Figure 10...

Page 181: ...10869 003 Hose Clamp 2 4 289042 Guard Alternator 1 5 288002 Wire Spiraled Fan Guard 1 6 287982 Top Fan Shroud 1 7 288000 Bottom Fan Shroud 1 8 288001 Cooling Fan 1 9 289043 Lower Radiator Hose 1 W1086...

Page 182: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 24 Fuel System Components Figure 11 14 15 10 11 12 13 1 2 6 9 8...

Page 183: ...k Support E F G K L See TR AY 5 Fuel Return Line Ref 288301 Elbow 90 Degree 1 W10869 014 Clamp Hose Drain 2 056544 Hose 5 16 I D 33 289940 Valve Check 1 6 287639 Filter Fuel Water Separator 1 7 288115...

Page 184: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 26 4 5 2 3 1 12 VDC Battery System Figure 12...

Page 185: ...4 3 Page 27 FIGURE ITEM NO PART NO NOMENCLATURE EFF UNIT PER ASSY 12 1 281881 001 Battery 12 V V25710 1231 PMF 1 2 288047 Cable Battery Negative Ay 1 3 288046 Cable Battery Positive Ay 1 76A1132 Tubin...

Page 186: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 28 5 3 2 2 7 4 1 2 6 Air Cleaner Components Figure 13...

Page 187: ...ATURE EFF UNIT PER ASSY 13 1 288057 001 Air Cleaner Tube 1 2 280732 004 T Bolt Clamp 3 3 288056 001 Straight Rubber Fitting w Hump 1 4 282918 Electric Restriction Indicator 1 282919 Indicator Adapter...

Page 188: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 30 1 3 2 Engine Components Figure 14...

Page 189: ...476 1 287419 Adapter M10 1 0 x 1 8 NPTF 1 W10910 000 Fitting Tee 1 W10750 001 Nipple Pipe 1 8 1 4 W9407 446 Cable Ground Engine Ground Plate to Frame 2 W9360 289 Cable Ground Plate to Power Module 1 5...

Page 190: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 32 3 2 1 Muffler and Exhaust Components Figure 15...

Page 191: ...15 Kit Exhaust Ref 1 288374 Exhaust Elbow 1 042471 Insulation 3 SF 404154 013 3 Full Circle Clamp 1 W10869 006 Hose Clamp 2 2 289044 Flexible Exhaust 1 042471 Insulation 3 5 SF W10869 006 Hose Clamp 2...

Page 192: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 34 16 14 12 11 10 6 7 8 9 4 3 2 1 13 15 5 Generator Assembly Figure 16...

Page 193: ...Bearing Retainer 1 5 285121 Exciter Housing 1 6 287821 002 Housing and Stator Generator Assembly 1 7 W10072 068 Generator Bearing 1 8 287820 001 Armature Assembly 1 9 W10072 068 Generator Bearing 1 10...

Page 194: ...C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 36 31 30 29 15 27 28 38 40 37 36 37 34 33 30 32 30 32 30 33 34 36 35 18 14 18 17 16 25 24 23 22 21 20 19 8 7 26 12 11 10 9 13 3 4 1 2 6 5...

Page 195: ...V 2 285917 Lug Nut V52793 05 007805 A B E H K M N Q T V 5 19 286735 001 Grease Seal V52793 16743 CR A B E H K M N Q T V 1 20 286735 002 Inner Bearing Cone V60038 67048 A B E H K M N Q T V 1 21 286735...

Page 196: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set July 3 2008 Revision 9 Chapter 4 3 Page 38 This page intentionally left blank...

Page 197: ...12 281701 9 2 AW626 12 1 281881 001 9 3 AW626 9 9 282089 011 1 47 DWP 982 16 4 282128 10 11 W10051 007 16 11 282128 16 7 W10072 068 9 4 282130 001 16 9 W10072 068 9 4 282130 001 14 3 W10750 001 16 2 2...

Page 198: ...65 8 11 285034 001 1 42 287467 8 11 285034 001 3 5 287526 002 16 5 285121 3 4 287542 001 1 4 285125 1 35 287565 5 13 285172 17 2 287587 5 13 285172 17 7 287626 001 14 1 285200 17 8 287626 002 17 27 28...

Page 199: ...288001 17 36 288397 10 5 288002 17 33 288398 1 10 288020 6 6 288605 6 0 288020 1 45 288727 1 8 288021 4 14 288727 1 11 288022 6 1 288745 1 9 288023 6 2 288791 12 3 288046 5 17 288806 12 2 288047 5 10...

Page 200: ...1 31 408665 001 6 11 289073 4 17 482496 002 6 0 289077 16 16 483756 5 18 289078 2 12 486719 013 2 1 289080 11 8 486719 013 2 8 289081 11 13 486719 013 3 10 289086 1 15 488640 6 0 289090 9 12 488640 9...

Page 201: ...ummins Bulletin 4056478 Diagram Number Diagram Description 289154 Rev 2 Diagram Schematic Connection Analog Generator Gauges 289022 Rev 2 Diagram Connection Control Box 289102 Rev 3 Diagram Connection...

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Page 229: ...CE Certification Fixed Mount 287589 4 n a Cable Aircraft DC 4 0 30 Ft 402025 3 n a Cable Aircraft DC 4 0 40 Ft 402025 4 n a Kit Fork Lift Pockets 288405 n a Kit Water Heater 288139 3 n a Kit Cable Tra...

Page 230: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set December 28 2005 Revision 2 Appendix A Page 2 This page intentionally left blank...

Page 231: ...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...

Page 232: ...OM 2098C Operation and Maintenance Manual 60CU24 Series 500060C 400 Hz Generator Set December 28 2005 Revision 2 Appendix A Page 4 This page intentionally left blank...

Page 233: ...ccumulation 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 lo...

Page 234: ...es 500060C 400 Hz Generator Set December 28 2005 Revision 2 Appendix A Page 6 4 Operation with a Improper fuel lubricants or coolant b Parts or elements unauthorized by the manufacturer c Unauthorized...

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