Hobart 120CU20 Operation And Maintenance Manual With Illustrated Parts List
OM-2228
10/15/13- Rev A
U.S.A.
05/06/13– Original
Operation and Maintenance Manual
with
Illustrated Parts List
for
120CU20
120 kVA, 3 Phase, 115/200 V ol t,
400 Hz. Generator Set
Series 500120
ITW GSE Group
Hobart Ground Systems
Palmetto, Florida 34221
.
Warranty
U.S.A.
Data Sheet 165
Index: 990223
QUALIFIED PERSO NNEL SHOULD ALWAYS BE EMPLOYED FOR SUC H T AS KS.
HOBART GROUND SYSTEMS
PALMETTO, FLORIDA 34221
1. Hobart Brothers Company (hereinafter called HOBART) warrants that each new and unused Hobart Ground Power
Equipment, (hereinafter called the PRODUCT) is of good workmanship and is free from mechanical defects,
provided that (1) the PRODUCT is installed and operated in accordance with the printed instructions of HOBART,
(2) the PRODUCT is used under the normal operating conditions for which it is designed, (3) the PRODUCT i s not
subjected to misuse, negligence or accident, and (4) the PRODUCT receives proper care, lubrication, protection,
and mainte nance under the supervis ion of trained personnel .
2. This warranty expires 15 months aft er shipment by HOBART to the first user, or 12 months after installation,
whichever first occurs.
3. This warranty does not apply to: primary and secondary switch contacts, cable connectors, carbon brushes, fuses,
bulbs, and filters unless found to be defective prior to use.
4. Hobart DOES NOT WARRANT THE FOLLOWING COMPONENTS: Engines, engine components; such as:
starters, alternators, regulators, governors, etc., and cable retrieving devices. Many of the foregoing components
are warranted directly by the manufacturer to the first user and serviced by a worldwide network of distributors and
others authorized to handle claims for component manufacturers. A first user’s claim should be presented directly
to such an authorized component service outlet. In the event any component manufacturer has warranted its
component to HOBART and will not dea l directly with a first user then HOBART will cooperate with the first user
in the presentation of a claim to such manufacturer. Under NO circumstances does HOBART assume any liability
for any warranty claim against or warranty work done by or in behalf of any manufacturer of the foregoing
components.
5. This warranty is extend ed by HOBART only to the purchaser of new PRODUCTS from HOBART o r one of its
authorized distributors. The P ROD UCTS 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 fou nd by HOBART to exist, or at HOBART’S
option the replacement of the defective product, F.O.B. factory, after the defective product has been returned by the
purchaser at its expense to HOBART’S shipping place. Replacement and exchange parts will be warranted for the
remainder of the original Warranty, or for a period of ninety (90) days, whichever is greater.
7. UNDER NO CIRCUMSTANCES whatsoever shall HOBART and its a uthorized distributors be liable for a ny
special or consequential damages, whether based on lost goodwill, lost resale profits, work stoppage impairment
of other goods or otherwise, and whether arising out of breach of any express or implied warranty, breach of
contract, negligence or otherwise, except only in the case of personal injury as may be required by applicable law.
8. Continued use of the PRODUCT(S) after discovery of a defect VOIDS ALL WARRANTIES.
9. Except as authorized in writing, this warranty does not cover any equipment that has been altered by any party
other than H OBART.
10. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HERE
OF. HOBART MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, OF MERCHANT ABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
11. HOBART neither assumes nor authorizes any person to assume for HOBART any liability in connection with the
PRODUCTS sold, and there are no oral agreements or warranties collateral to or affecting this written Warranty.
This warranty and all undertakings of HOBART there under shall be governed by the laws of the State of Florida,
United States of America.
Replaces: 980601
WARNING AT ALL TIMES, SAFETY MUST BE CONSIDERED AN IMPORTANT FACTOR IN THE
INSTALLATION, SERVICING AND OPERATION OF THE PRODUCT, AND SKILLED, TECHNICALLY
.
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Revision Log
Page 1
Record of Change.
Rev.
No.
Release Date.
By
Description.
0
May 06, 2013
HLC
1. New – spec roll for new starter, wire harness, etc. to create
Deluxe and Standard models.
A
October 15, 2013
H A
Created Revision Log. Changed Insulation to show that it is now an
reflect that the unit is now made in Florida.
option, removed composite fuel tank and updated the manual to
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Revision Log
Page 2
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.
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Safety War nings
Page 1
Safety Warnings and
Cautions.
ELECTRIC SHOCK
KILL
attached equipment.
WARNING
IMPORTANT
WARNING
ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and
ignite combustible material. DO NOT use power cables to break load and prevent tools
from causing short circuits.
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and
Protect all operating personnel. Read, understand, and follow all instructions in the
Operating/Instruction Manual before installing, operating, or servicing the equipment.
Keep the manual available for future use by all operators.
CALIFORNIA PROPOSITION 65 - DIESEL ENGINES. Diesel engine exhaust and
some of its constituents are known to the State of California to cause cancer, birth
defects and other reproductive harm.
can
. Do not touch live electrical parts.
1) General.
Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or
property. The operator must strictly observe all safety rules and take precautionary actions. Safe practices
have been developed from experience in the use of power source equipment. While certain practices below
apply only to electrically powered equipment, other practices apply to engine-driven equipment, and some
practices to both.
2) Shock Prevention.
Bare conductors, terminals in the output circuit, or ungrounded, electrically live equipment can fatally shock a
person. Have a certified electrician verify that the equipment is adequately grounded and learn what
terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing, procedures,
and test equipment.
The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow through it.
When inspecting or servicing equipment, do not work in damp areas. Stand on a dry rubber mat or dry wood,
and use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry, and never work
alone.
a) Installation and Grounding of Electrically Powered Equipment
Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installed and
maintained in accordance with the National Electrical Code, ANSI/NFPA 70, or other applicable
codes. A power disconnect switch or circuit breaker must be located at the equipment. Check the
nameplate for voltage, frequency, and phase requirements. If only 3-phase power is available,
connect any single-p has e rated equ ipment to only two wires of the 3-phase line. DO NOT CONNECT
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Safety War nings
Page 2
the equipment grounding conductor (lead) to the third live wire of the 3-phase line, as this makes the
equipment frame electrically HOT, which can cause a fatal shock.
Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box or
building ground. If not provided, use a separate grounding lead. Ensure that the current (amperage)
capacity of the grounding lead will be adequate for the worst fault current situation. Refer to the
National Electrical Code ANSI/NFPA 70 for details. Do not remove plug ground prongs. Use correctly
mating receptacles.
b) Output Cables and Terminals.
Inspect cables frequently for damage to the insulation and the connectors. Replace or repair cracked
or worn cables immediately. Do not overload cables. Do not touch output terminal while equipment is
energized.
3) Service and Maintenance.
This equipment must be maintained in good electrical condition to avoid hazards stemming from
disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of the
equipment until its safety has been assured. Repairs should be made by qualified personnel only. Before
inspecting or servicing this equipment, take the following precautions:
a) Shut off all power at the disconnecting switch, or line breaker, or by disconnecting battery, before
inspecting or servicing the equipment.
b) Lock switch OPEN (or remove line fuses) so that power cannot be turned on accidentally.
c) Disconnect power to equipment if it is out of service.
d) If troubleshooting must be done with the unit energized, have another person present who is trained
in turning off the equipment and providing or calling for first aid.
4) Fire And Explosion Prevention.
Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust
pipes, misuse of batteries and fuel, or unsafe operating or fueling conditions.
a) El ectrical Short Circuits and Overloads.
Overloaded or shorted equipment can become hot enough to cause fires by self-destruction or by
causing nearby combustibles to ignite. For electrically powered equipment, provide primary input
protection to remove short circuited or heavily overloaded equipment from the line.
b) Batteries.
Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured
battery can cause fires and additional failures. When servicing, do not smoke, cause sparking, or use
open flame near the battery.
c) Engine Fuel.
Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank is
not grounded prior to or during fuel transfer. Shut unit DOWN before opening fuel tank cap. DO NOT
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Safety War nings
Page 3
EMERGENCY
FIRST AID
completely fill tank, because heat from the equipment may cause fuel expansion overflow. Remove
all spilled fuel IMMEDIATELY, including any that penetrates the unit. After clean-up, open equipment
doors and blow fumes away with compressed air.
5) Toxic Fume Prevention.
Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust
fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air
conditioners.
6) Bodily Injury Prevention.
Serious injury can result from contact with fans or hot spots inside some equipment. Shut DOWN such
equipment for inspection and routine maintenance. When equipment is in operation, use extreme care in
doing necessary trouble-shooting and adjustment. Do not remove guards while equipment is operating.
7) Medical and First Aid Treatment.
First aid facilities and a qualified first aid person should be available for each shift for immediate treatment
of all injury victims. Electric shock victims should be checked by a physician and taken to a hospital
immediately if any abnormal signs are observed.
Call physician immediately. Seek additional assistance. Use First Aid techniques
recommended by American Red Cross until medical help arrives.
IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down.
FOR ELECTRICAL SHOCK, turn off power. Remove victim; if not breathing, begin
artificial respiration, preferably mouth-to-mouth. If no detectable pulse, begin external
heart massage. CALL EMERGENCY RESCUE SQUAD IMMEDIATELY.
8) Equipment Precautionary Labels.
Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot be
easily read.
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Safety War nings
Page 4
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OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Introduction
Page 1
Introduction
This manual contains operation and maintenance information for a 120CU20, 400 Hz Generator Set
manufactured by ITW GSE Group, Hobart Ground Systems, Palmetto, Florida 34221.
This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide
information and instructions to experienced operators, electricians, and mechanics who have never operated
this equipment. It is the intent of this manual to guide and assist operators and maintenance people in the
proper use and care of the equipment.
Use of the manual should not be put off until a trouble or need for help develops. Read the instructions
before starting the unit. Learn to use the manual and to locate information contained in it. Its style and
arrangement are very similar to commercial aircraft manuals.
The manual is divided into five chapters plus 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, its location is identified by a chapter, section, and paragraph or figure number.
For example: “(see Section 2-3, Paragraph 1.a.)” refers to information located in Chapter 2, Section 3,
Paragraph 1.a. If a chapter and section are not indicated in a reference, the referenced material is located in
the same section as the reference, for example: “(see Paragraph 1.a.).”
The Appendix is the last section. It contains a list of available options that may be purchased with that unit.
Items on the list with check marks next to them, have been added to the standard unit per the customers
order. Literature for each option follows. The Appendix will help control the information in the manual:
making it unique to the unit purchased.
In addition to operation and maintenance instructions, the manual contains an illustrated parts list in Chapter
4, and a collection of manufacturer’s literature and supplemental information in Chapter 5.
The manual is arranged as follows:
Chapter 1: Description/Operation
Chapter 2: Servicing/Troubleshooting
Chapter 3: Overhaul/Major Repair
Chapter 4: Illustrated Parts List
Chapter 5: Manufacturer’s Literature
Appendix A: Options
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Introduction
Page 2
If you have any questions concerning your Hobart Ground Systems equipment, immediately contact our
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) 422-4166 (Parts)
(877) 874-5322 (Customer Service)
Call From Foreign Countries: (941) 721-1000 (Parts)
(941) 721-1092 (Service/ Technical Support)
FAX Inside U.S.A. (941) 723-3160
FAX From Foreign Countries: (941) 721-1087
E-mail :
service@hobartsystems.com
Web Page :
www.hobartsystems.com
OM-2228/ Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Table of Contents
Page 1
Chapter 1
Description/Operation.
Chapter-Section/Page#
Section 1
Description.
1-1/1
General
1-1/1
Optional Equipment - Appendix A
1-1/1
Orientation
1-1/1
Special Features
1-1/2
Canopy
1-1/2
Specifications
1-1/3
Engine and Generator
1-1/5
Control Box Assembly
1-1/11
Power Module Panel Assembly
1-1/22
Cold Weather Start System
1-1/24
Transformer-Rectifier Assembly Components
1-1/25
Section 2
Preparation for Use, Storage or Shi p p ing.
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 Operation
1-3/6
Chapter 2
Servicing / Troubleshooting.
Chapter-Section/Page#
Section 1
Maintenance Inspection/Check.
2-1/1
General.
2-1/1
Maintenance Schedule.
2-1/1
Inspection / Check.
2-1/3
Table of Contents.
OM-2228/ Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Table of Contents
Page 2
Section 2
Maintenance Procedures.
2-2/1
General
2-2/1
Servicing The Air Cleaner
2-2/6
Engine Fuel
2-2/7
Engine Cooling System
2-2/10
Generator Maintenance
2-2/14
Section 3
Adjustments / Tests.
2-3/1
Testing the 400 Hz. Generator Set
2-3/1
Generator Set Adjustments
2-3/12
Diode Test
2-3/16
Testing the Transformer-Rectifier
2-3/16
Section 4
Troubleshooting Procedures.
2-4/1
Equipment for Troubleshooting
2-4/1
Parts Replacement
2-4/1
Check Connections and Leads
2-4/2
Engine Troubleshooting
2-4/2
Connection and Schematic Diagr ams
2-4/2
GPU Control Monitoring
2-4/3
…Engine Controls
2-4/10
…Generator Excitation Circuits
2-4/13
…Protective Circuit
2-4/16
…Generator
2-4/18
Troubleshooting Tables – GPU Commands
2-4/21
Troubleshooting Tables – GPU Faults
2-4/22
Lubrication
Engine Fuel System
Drive Belt
General
Generator and Exciter Test
Adjusting the Transformer-Rectifier
General
2-2/1
2-2/7
2-2/14
2-3/1
2-3/15
2-3/18
2-4/1
400 Hz. Test Values
Illustrations
2-4/2
2-4/2
Troubleshooting Charts. 2-4/10
…Load Contactor Operating Circuits
…T-R Controls and Components
2-4/14
2-4/19
OM-2228/ Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Table of Contents
Page 3
Chapter 3
Overhaul / Major Repair.
Chapter-Section/Page#
Section 1
Exciter Armature.
3-1/1
General
3-1/1
Exciter Armature
3-1/2
Exciter Armature Replacement
3-1/3
Exciter Armature Installation
3-1/6
Section 2
Dual Bearing Flexible Coupling.
3-2/1
General
3-2/1
Disassembly
3-2/1
Coupling Service
3-2/4
Coupling Installation
3-2/5
Reassemble Engine and Generator
3-2/6
Run-in and Periodic Check
3-2/7
Section 3
Generator Assembly.
3-3/1
General
3-3/1
Generator Assembly Removal
3-3/1
Generator Assembly Installation
3-3/4
Chapter 4
Illustrated Parts List .
Chapter-Section/Page#
Section 1
Introduction.
4-1/1
General
4-1/1
Purpose
4-1/1
Arrangement
4-1/1
Explanation of Parts List
4-1/1
Section 2
Manufacture's Codes.
4-2/1
Explanation of Manufacture's (Vendor) Code List
4-2/1
OM-2228/ Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Table of Contents
Page 4
Section 3
Illustrated Parts List.
4-3/1
Explanation of Parts List Arrangement
4-3/1
Figure 1: General Assembly
4-3/2
Figure 2: Labels and Reflectors
4-3/4
Figure 4: Canopy Assembly
4-3/7
Figure 5: Canopy Doors
4-3/10
Figure 7: Control Box Door Panel Assembly
4-3/14
Figure 8: Control Box Interior Components
4-3/16
Figure 10: 400 Hz. Power Module Assembly
4-3/20
Figure 11: Cooling System Compone nts
4-3/22
Figure 13: Fuel System Components
4-3/26
Figure 14: Engine Exhaust Compone nts
4-3/28
Figure 16: Air Cleaner Components
4-3/32
Figure 17: Engine Components
4-3/34
Figure 19: Generator Assembly
4-3/38
Figure 20: Transformer-Rectifier Assembly (DC Option)
4-3/40
Figure 22: T-R Interlock Kit (DC Option Acc es sor y )
4-3/44
Section 4
Numerical Index.
4-4/1
Explanation of Numerical Index
4-4/1
Chapter 5
Manufacture's Literature.
Appendix A Options/Features.
Wet Stacking.
Unusual Service Conditions.
Symbols and Abbreviations
Figure 3: Frame Assembly
Figure 6: Internal Components
Figure 9: Pushbutton Switches
Figure 12: Engine Ground Plate and Cables
Figure 15: 12 VDC Battery System
Figure 18: Engine Electrical Panel Com pon ents
4-3/1
4-3/6
4-3/12
4-3/18
4-3/24
4-3/30
4-3/36
Figure 21: DC Output Contactor (DC Option)
4-3/42
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 1
Chapter 1
Description/Operation.
Section 1
Description.
Part & Dash Number
AC
Outputs
28.5 VDC
Output
500120-STD
Trailer
2
--
Stainless
500120-DLX
Trailer
2
--
Stainless
500120TR-STD
Trailer
2
Yes
Stainless
500120TR-DLX
Trailer
2
Yes
Stainless
1) General.
The basic generator set covered in this manual, manufactured by ITW GSE Group, Hobart Ground
Systems is rated at 120 kVA and designed to produce and deliver 115/200-volt, 400 Hz, 3-phase AC
power to a parked aircraft or other load.
The number 500120 identifies the “model or series” of the GPU. The part number is followed by a
different dash number that separates the basic units available. Table 1 uses the part number to identify
the variations covered in this manual.
Mounting
Table 1: Series 500120 Generator Set Part Number Descriptions.
Fuel Tank
2) Optional Equipment - Appendix A.
Chapters 1 through 5 of this Operation and Maintenance Manual identifies only the “stripped down”
version of the 120CU20 generator set. A list of optional equipment that makes this manual uniqu e to the
generator set that you have purchased, appears in Appendix A.
The body of this manual includes documentation for the DC option, also known as the TransformerRectifier (T-R). Details for other options may be included in Appendix A.
3) Orientation.
For purpose of orientation, the radiator is considered to be at the REAR of the unit. The generator and
controls are at the FRONT. RIGHT and LEFT are determined by standing at the REAR end facing the
machine. Thus, the control box is mounted on the LEFT FRONT side of the unit.
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 2
4) Special Features.
The generator set has special features that are described more fully, under the assemblies in which they
appear.
a) Protective Monitoring.
The protective monitoring system receives signals from the fault sensing units in the generator output
circuit and functions to cause the load to be disconnected from the generator if an abnormal condition
of voltage, frequency, or load develops.
b) Voltage Regulator.
A microprocessor-type, adjustable voltage regulator provides automatic voltage regulation at the
aircraft. The regulator is also adjustable for a variety of output cable sizes and lengths.
c) Engine Electronic Control Module.
The engine is equipped with an electronic control module that monitors, records, and controls engine
performance.
5) 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.
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 3
Basic Unit
(Fixed Mount)
Length
116 in. (2946 mm)
160 in. (4064 mm) w/ tow bar up
Width
59 in. (1499 mm)
77 in. (1956 mm)
Height
55 in. (1397 mm)
72 in. (1828 mm)
Weight (Full of Fuel)
5900 lb. (2676 kg.)
6500 lb. (2948 kg.)
Weight with 28.5 VDC T-R
6200 lb. (2812 kg.)
6800 lb. (3084 kg.)
Output power rating
120 kVA (96 kW)
Output voltage
115 / 200 VAC
Rated load capacity
348 Amps
Frequency
400 Hz.
Power factor
0.8
Duty Cycl e
100%
Operating speed
2000 RPM
outputs 125% rated load
Output cable size
2/0
Condition
Trip Point
Time Delay
Over voltage
126 volts
1-second
140 volts
160 milliseconds
180 volts
50 milliseconds
Under voltage
any voltage below 100 volts
7 seconds
Over frequency
420 Hz to 480 Hz
5 seconds
above 480 Hz
immediate
Under frequency
380 Hz. or less
7-seconds
Output overload
125% load of 90 kVA
on either output or
approximately 5 minutes
125% load of 120 kVA
on both outputs combined
approximately 5 minutes
150% load
30 seconds
200% load
10 seconds
6) Specifications
a) Physical Specifications
Physical
b) AC Generator Specifications
Overload capacity, both
With Trailer
435 Amps
c) AC Generator Protective System Specifications
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 4
Output Power Rating
17.1 kW
Output Voltage
28.5 VDC
Load Capacity (Continuous)
600 A
Current Limiting Capability
100 to 2500 A
Condition
Trip Point
Time Delay
Over Voltage
32-34 VDC
2 seconds
2700 A
2 seconds
2000 A
10 seconds
1500 A
30 seconds
1200 A
90 seconds
750 A
600 seconds
Manufacturer
Cummins Engine Company
Model No.
QSB6.7
6 cylinder, 4 cycle diesel, electronic
controlled
Bore and Stroke
4.21 in. x 4.88 in. (107 mm x 124 mm)
Displacement
409 in3 (6.7 L)
Horsepower
220 hp (164 kW)
Idle speed
1000 ± 50 rpm
High speed limiting
2350 ± 75 rpm
Normal governed speed
2000 rpm
Firing Order
1-5-3-6-2-4
Electrical system
12 VDC
Ground
Negative
Lubricating oil capacity (w/ filter)
16 quarts (15.1 liters)
Coolant capacity system
40 quarts (37.8 liters)
d) DC Output Specifications (with optional TR unit).
Peak/Starting Load Capacity 2000 A for 10 seconds
Output cable size 4/0
e) DC Protective System Specifications.
Output Overload
f) Engine Specifications.
Type
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 5
Engine coolant temperature
(normal operation)
g) Normal Operating Characteristics.
Engine oil pressure (warm and at
rated speed 2000 RPM)
45 PSI (310 kPa) minimum
50 to 65 PSI (345 to 448 kPA) typical
180 to 200º F (82 to 93º C)
7) Engine and Generator.
The engine and generator comprise the principal components of the generator set. They are mounted on
the welded steel frame of the chassis. The engine coolant radiator is also mounted on the frame just
forward of the engine-generator combination. Figures 2 and 3 are illustrations showing the location of all
major components and sub-assemblies.
a) Basic Engine.
The basic diesel engine is a fuel injection, 6-cylinder, electronically controlled engine rated at 220
horsepower.
b) Engine Manufacturer’s Equipment.
As received from the engine manufacturer, the engine includes the following equipment, which is
more fully described in the engine manufacturer’s operation manual.
(1) Elec trical System.
The 12 VDC electrical generating and starting system includes an alternator, voltage regulator,
and starter with solenoid switch.
(2) Lubricity Additive Fuel Filter.
The fuel filter is a spin-on disposable type, located on the interior bulkhead located in the middle
of the unit, on the left-hand side. The fuel filter primary function, other than remove contaminants
from the fuel, is to automatically add a lubricity additive to the fuel. Although, the engine
manufacturer does not recommend low lubricity fuels, this additive can extends the life of the fuel
pump.
CAUTION
(3) Oil Filter.
The engine oil filter is a spin-on, full-flow type, located on the left side of the engine near the front.
(4) Pre-programmed Electronic Control Module (ECM)
The ECM is a pre-programmed engine control module, mounted directly to the engine block.
The use of low lubricity fuels can shorten life and/or damage the engine’s fuel pump.
Only diesel fuel is recommended by the engine manufacturer.
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120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
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c) Engine-cooling fan
The engine fan is designed to blow air outward through the radiator, rather than pulling the air inward
as a conventional fan does.
d) Factory Installed Equipment
This generator set is modified at the factory by the addition of the following equipment:
(1) Shut Down/Reset device
In addition to the other devices provided by the engine manufacturer, the factory also added an
engine shutdown/reset feature.
a 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 ECM through the control box. It is located on the
left side of the generator set near the control box (see Figure 1).
To operate the EMERGENCY SHUTDOWN/RESET SWITCH:
• Push the button in until engine stops or until button travel stops.
• Pull the button back out to reset.
b Coolant high temperature shutdown system.
The coolant temperature shutdown system consists of a factory supplied temperature switch.
This switch is monitored by the microprocessor on the EIB (“Engine Interface Board”) PC
Board, which will stop the engine if the temperature reaches 230º F (110º C).
c Oil pressure shutdown system.
The oil pressure shutdown system consists of a factory supplied oil pressures switch. This
switch is monitored by the microprocessor on the EIB (“Engine Interface Board”) PC Board,
which will stop the engine if the oil pressure is under 12 PSI (82.7 kPA).
(2) Radiator and Char g e-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) Air Cleaner.
The diesel engine air cleaner is so constructed that air enters through its cylindrical body, and
then is filtered in the process before being passed onto the engine turbo-charger assembly. An
air cleaner service indicator device is mounted on the air cleaner assembly to monitor the airflow
into the air cleaner. As the air cleaner becom es filled with dust, dirt, and car bon, t he intak e
system airflow becomes increasingly restricted. This restriction causes a diaphragm inside the
indicator to move toward an electrical contact. When the maximum allowable restriction level is
reached, the circuit closes and the air cleaner indicator fault appears on the control panel fault
display to warn the operator that the air cleaner must be changed. The electrical indicator
automatically resets when the restriction level drops sufficiently.
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 7
Over temperature or low
Shuts down the engine, and will be
a) Press the engine stop button to
immediate reset.
Low fuel warning and
Turns on the low fuel indication on
a) The low fuel fault indicating
immediate reset.
Clogged air cleaner or
Turns on the air cleaner restriction
a) Press the engine stop button.
immediate reset.
e) Engine faults.
The following is a table listing faults, which may occasionally occur. Column two of the table explains
what happens in the engine’s circuitry when the fault occurs, and column three tells how to return the
generator set to service once the problem is solved. Refer to Chapter 2 for more details on all other
faults.
Engine Fault Condition What Occurs How To Reset
ENGINE FAULTS
oil pressure.
shutdown.
other restriction in the
combustion air inlet.
indicated will appropriate fault
code.
the fault code meter. The GPU is
programmed at the factory to warn
1
/4 tank and to shutdown at 1/8
at
tank.
indicating fault code.
reset the fault code and reset the
protective system.
b) Or use E-STOP button for
function must be reset by
pressing the engine stop button
Fuel must be added prior to
attempting another engine s tar t.
b) Or use E-STOP button for
The restriction must be removed
prior to attempting another engine
start.
b) Or use E-STOP button for
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120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 8
4
2 1 3
10
9 8 6
5
1. Control Panel
2. Operator’s Push-button Panel
3. Output Cable Location
4. Front Axle Assembly
5. Rear Axle Assembly
6. Emergency Stop Switch (S28)
7. Exhaust Outlet (Not Shown)
8. Canopy
9. Radiator End (Rear)
10. Generator End (Front)
Figure 1: General Assembly of Generator Set.
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 9
6 5 4 3 2
1
10
11
9 8 7
1. Radiator
2. Charge-Air-Cooler
3. Cummins QSB6.7 Engine
4. Air Cleaner
5. Control Box
6. Fuel Tank
Figure 2: Main Components of Generator Set (Right Side).
7. 12 VDC Batteries (BT1, BT2)
8. Generator
9. Pre-Fuel Filter
10. Rear Axle
11. Air Intake Heater (BH1)
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120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 10
8,9
7 6 4 3 2 1 10
1. Dual Output Power Module
2. Exhaust Muffler Shield
3. Exhaust Muffler
4. Exhaust Piping
5. Lubricity Additive Fuel Filter (Not Shown)
Figure 3: Main Components of Generator Set (Left Side)
6. Top and Bottom Fan Shroud
7. Alternator Fan/Belt Guard
8. Engine Cooling Fan
9. Fan Guard
10. Control Box
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 11
Air Cleaner
Service Indicator
Figure 4: Air Cleaner and Service Indicator
f) Generator.
The 400 Hz generator is a brushless, revolving field, three-phase, alternating current type. The
generator set covered by this manual is a dual-bearing type. The front end of the rotor shaft extends
forward beyond the front bearing and is attached to the engine flywheel by a flexible coupling
assembly. The rear end of the rotor shaft extends rearward beyond the rear bearing and into the
exciter stator housing. The exciter rotor is mounted on this shaft extension with a key and is secured
by a washer and 1/2-13 thread cap screw. A rectifier with six diodes is mounted on the exciter rotor
and converts exciter AC output to DC for excitation of the generator revolving fields. The exciter DC
output to the generator fields, and consequently the generator output, is controlled voltage regulator
PC board (REG). A centrifugal, radial-blade fan, which is part of the flexible coupling assembly,
draws cooling air over all internal windings. Air enters at the exciter end and is discharged at the
drive end. The complete generator assembly is bolted to the engine flywheel housing.
8) Control Box Assembly.
The control box is a sheet metal enclosure that houses and provides mounting facilities for engine and
generator controls and monitoring equipment.
a) Operator Controls.
The control system is divided into three sections. On the left side of the control panel, as one faces it,
are engine meters. On the right side of the control panel are generator meters. Below the control
panel are push-button switches for operating the engine and generator.
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 12
1. Engine Coolant Temperature Gauge (M24)
2. Running Time Meter (M4)
3. Battery Voltmeter (M5)
4. Fuel Gauge (M13)
5. Oil Pressure Gauge (M25)
6. Frequency Meter (M3)
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)
7. AC Generator Voltmeter (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)
18. DC Output Switch (S430) [Optional with TR]
19. DC Starting Current Switch (S431) [Optional with TR]
20. Engine Stop Switch (S76)
21. Test/Reset Switch (S77)
22. Meter Selector Switch (S3)
Figure 5: Operator Controls.
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120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 13
(1) Panel lights and pan el li ght 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 driven from the 12-volt DC 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.
(3) Engine oil pressure gauge (M24)
The oil pressure gauge is an electrical type that is connected by a wire to an oil pressure sensor
installed in the engine lubricating system. The range is 0 to 125 PSI (0 to 862 kPA).
(4) Engine ON indicating light (DS58)
When the engine is running at idle speed, a green indicating light, within the “ENGINE ST ART ”
push- button switch, flashes at a rate of 1 second on, 1 second off. When the engine is running
at rated speed, the light will stay on continuously.
(5) Engine coolant temperature gauge
The temperature gauge is an electrical type that is connected by a wire to a water temperature
sensor installed in the engine cooling system. The gauge indicates engine coolant temperature in
the range of 100-280 º F (38-138º C).
(6) “ENG IN E START” push-button switch (S24)
The “ENGINE ST ART ” push-button switch, when pressed, connects 12 VDC power to the starter
solenoid coil, which actuates the solenoid switch to connect power to the engine starting motor.
The 12 VDC power is supplied directly to the engine ECM and the oil pressure shutdown switch is
bypassed (This bypass is necessary for engine starting because the low oil pressure switch is
CLOSED until the engine is running normally). The green indicator light with blink.
When pressed a second time, this push-button switch provides a signal to the ECM to adjust the
engine speed to 2000 RPM. The green indicator light will glow continuously. At the same time, a
ground signal is provided to the regulator, enabling the generator to build up voltage for 400-Hz
generator output. Pressing the push-button switch once more removes these signals and the
engine reverts to idle speed and a blinking green indicator light.
(7) “ENGINE HE ATER” push-button switch (S79)
The “ENGINE HEATER” push-button switch activates the standard cold starting aid (manifold air
intake heater), which is totally controlled by the engine’s ECM. Once the heater is activated, the
engine’s ECM will control the operation. The heater typically stays on for a period of
approximately 30 seconds, which is indicated by the light on the push-button. When the light
goes out, the engine is ready to start. Starting a cold engine without first warming the engine will
lead to excessive white smoke exhaust and the engine may be hard to start.
OM-2228 / Operation and Maintenance Manual
120CU20 / Series 500120 / 400 Hz. Generator Set
October 15, 2013
Chapter 1-1
Page 14
(8) “EN GI NE STOP” push-button switch (S76).
When the “ENGIN E ST O P” push-button switch is pressed, the red indicator will glow. Then a 3 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.
(9) Engine voltmeter (M5).
The voltmeter indicates the voltage across the 12 VDC batteries. It is graduated 10 V to 16 V.
(10) Engine fuel gauge (M13).
An electric fuel gauge receives its controlling signal from a sending unit in the fuel tank. 12 VDC
operating power is supplied to the fuel gauge when the “ENGINE START” push-button switch is
pressed. The fuel level can also be checked when the unit is not running by pressing the panel
light “LAMPS” push-button switch.
(11) Fault Code meter and “TEST/RESET” push-button switch (M6, S77)
The function of the fault code meter is to indicate to the operator, that an abnormal condition of
over voltage, under frequency, etc. occurred, which caused the protective monitoring system to
function. When one of the circuits are activated, it shows the code on the fault code meter. The
fault will remain on for a short period or until the “TEST/RESET” push-button switch is pressed.
Pressing the “TEST/RESET” push-button switch can also test the fault code meter operation. A
meter test should be performed only when disconnected from a load, as the contactor(s) will open
during the test cycle.
(12) Engine systems fault codes.
Fault codes will be shown to warn the operator of abnormal engine operations that must be
corrected. These indicators are over temperature, air cleaner restriction, low oil pressure, and
low fuel indication.
(13) AC Generator output monitors (meters).
Three instruments, a frequency meter, a voltmeter, and an ammeter monitor the generator output.
The frequency meter is an analog type and indicates the frequency of the generator output
alternating current in the range of 360 to 440 Hz (cycles per second). The voltmeter indicates the
generator output voltage in each phase-to-neutral (A-N, B-N and C-N) or phase-to-phase (A-B, BC and C-A) as selected by the “METER SELECT” switch. The voltmeter has a scale of 0 to 300
V. The ammeter has a scale of 0 to 500 A. The amperage value in 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 load
current to a lesser value, of definite ratio, which is sent to the Voltage Regulator PC Board (REG).
The ammeter dial scale is numbered so that the pointer will indicate the true load current value.
(14) Load contactor indicating lights [Yellow # 1 and Orange # 2] (S75, S275)
Indicating lights within the respective contactor control push-button switches (“OUTPUT NO. 1”
and or “OUTPUT NO. 2”) glow when the circuit is energized, indicating that power is available at
the plug. When the load contactor opens for any reason, the light is turned OFF.
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