Hobart 60CU20 Operation And Maintenance Manual With Illustrated Parts List

OM-2226

ITW GSE Group

U.S.A.

05/02/2013 – Original

Operation and Maintenance Manual

with

Illustrated Parts List

for

60CU20

60 kVA, 3 Phase, 115/200 Volt,

400 Hz. Generator Set

Series 500062

Hobart Ground Systems
Palmetto, Florida 34221

Warranty

PALMETTO, FL 34221

Data Sheet 165

Index: 990223

WARNING: AT ALL TIMES, SAFETY MUST BE CONSIDERED AN IMPORTANT FACTOR IN THE

QUALIFIED PERSO NNEL SHOULD ALWAYS BE EMPLOYED FOR SU CH TASKS.

HOBART GROUND POWER

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 acco rdance with the printed instructions of HOBART,
(2) the PRODUCT is used under the normal operating conditions for which it is designed, (3) the PRODUCT is not
subjected to misuse, negligence or accident, and (4) the PRODUCT receives proper care, lubrication, protection,
and mainte nance under the supervision of trained perso nnel.

2. This warranty expires 15 months after ship ment by HOBA RT to the first user, o r 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 extended by HOBART only to the purchaser of new PRODUCTS from HOBART or one of its

authorized distributors. The PRODUCTS purchased under this warranty are intended for use exclusively by the
buyer and his employees and by no other persons and, therefore, there shall be no third party beneficiary to this
warranty.

6. A claim of defects in any PRODUCT covered by this warranty is subject to HOBART factory inspection and

judgment. HOBA RT’S liability is limited to rep a ir of any de fects found by HOBART to exist, or at H O BART’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 authoriz e d distributors be liable for any

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 i n writing, t his 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 MERCH ANT 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 thereunder shall be governed by the laws of the State of Ohio,
United States of America.

Replaces: 980601

INSTALLATION, SERVICING AND OPERATION OF THE PRODUCT, AND SKILLED, TECHNICALLY

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Revision Log

Page 1

Record of Change

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)

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Safety War nings

Page 1

Safety Warnings and Cautions

ELECTRIC SHOCK can KILL. Do not touch li ve electr ic al parts .

attached equipment.

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

IMPORTANT

WARNING

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 ENGI N ES . Diesel engine exhaust and
some of its constituents are known to the State of California to cause cancer, birth
defects and other reproductive harm.

1) General

Equipment that supplies electrical power can cause serious injury or death, damage to other equipment or
property. The operator must strictly observe all safety rules and take precautionary actions. Safe practices
have been developed from past experience in the use of power source equipment. While certain practices
below apply only to electrically powered equipment, other practices apply to engine-driven equipment, and
some practices to both.

2) Shock Prevention

Bare conductors, terminals in the output circuit, or ungrounded, electrically live equipment can fatally shock a
person. Have a certified electrician verify that the equipment is adequately grounded and learn what
terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing,
procedures, and test equipment.

The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow through it.
When inspecting or servicing the equipment, do not work in damp areas. Stand on a dry rubber mat or dry
wood, and use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry, and never
work alone.

a) Installation and Grounding of Electrica lly Powered Equipment

This equipment must be installed and m aintai ned in ac cor danc e with the Nat ion al 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-phase rated equipment to only two wires of the 3­phase line. DO NOT CONNECT 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.

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Safety War nings

Page 2

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 and 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) Electrical Short Circuits and Overlo ads

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
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.

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Safety War nings

Page 3

EMERGENCY

FIRST AID

5) Toxic Fume Prevention

Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust
fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air
conditioners.

6) Bodily Injury Prevention

Serious injury can result from contact with fans or hot spots inside some equipment. Shut DOWN such
equipment for inspection and routine maintenance. When equipment is in operation, use extreme care in
doing necessary troubleshooting and adjustment. Do not remove guards while equipment is operating.

7) Medical and First Aid Treatment

First aid facilities and a qualified first aid person should be available for each shift for immediate treatment
of all injury vict ims. 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-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Safety War nings

Page 4

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OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 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

Specifications

1-1/3

Special Features

1-1/5

Canopy

1-1/5

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 (T-R) Assembly

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-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 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

2-2/11

Drive Belt

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

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

Engine Lubrication

Engine Fuel System

Generator Maintenance

General

Generator and Exciter Test

Adjusting the Transformer-Rectifier

General

2-2/2

2-2/8

2-2/14

2-3/1

2-3/15

2-3/18

2-4/1

Normal Operation

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-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 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

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

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-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 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:Trailer / Frame Assembly

4-3/4

Figure 4: Canopy Assembly

4-3/8

Figure 5: Internal Components

4-3/10

Figure 7: Control Box Interior Components

4-3/14

Figure 8: Control Switch Panel Components

4-3/16

Figure 10: Engine Cooling System As s emb ly

4-3/20

Figure 11: Engine Ground Plate and Battery Disconnect Switch

4-3/22

Figure 13: Engine Exhaust Compone nts

4-3/26

Figure 14: 12 VDC Battery System

4-3/28

Figure 16: Engine Components

4-3/32

Figure 17: Engine Electrical Panel Com pon ents

4-3/34

Figure 19: Transformer-Rectifier Assembly – Part 1

4-3/38

Figure 20: Transformer-Rectifier Assembly – Part 2

4-3/40

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: Canopy Frame Assembly

Figure 6: Control Box and Door Assembly

Figure 9: 400 Hz. Power Module Assembly

Figure 12: Engine Fuel Filter and Fuel Lines

Figure 15: Engine Air Intake Assembly

Figure 18: Generator Assembly

4-3/1

4-3/6

4-3/12

4-3/18

4-3/24

4-3/30

4-3/36

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Introduction

Page 1

Introduction

This manual contains operation and maintenance information for a diesel engine-generator manufactured by
Hobart Ground Systems, Palmetto, Florida 34221.

This manual, including all informa tion contained thereon, is exclusive and confidential property of
Hobart Ground Systems. This manual is not to be copied, reproduced, or delivered or disclosed to
others, in whole or in part, except with e xpress written permission of Hobart Ground Systems.

This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide
information and instructions to experienced operators, electricians, and mechanics that have never operated
this equipment. It is the intent of this manual to guide and assist operators and maintenance personnel in the
proper use and care of the equipment.

Use of the manual should not be put off until trouble or a need for help develops. Read the instructions
before starting the unit. Learn to use the manual and to locate information contained in it. Its style and
arrangement are very similar to commercial aircraft manuals.

The manual is divided into 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, a chapter, section, and paragraph or
figure number identify its location. For example: “(see Section 2-3, Paragraph 1.a.)” refers to information
located in Chapter 2, Section 3, Paragraph 1.a. If a chapter and section are not indicated in a reference, the
referenced material is located in the same section as the reference, for example: “(see Paragraph 1.a.).”

The appendix is the last section. It contains a list of available options that may be purchased or have been
purchased with that unit. Items on the list with check marks next to them have been added to the standard
unit per the customer’s 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.

Contents of the manual are 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 Litera tu re
Appendix A Options

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Introduction

Page 2

If you have any questions concerning your Hobart Ground Power 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.: [phone] (Parts)
[phone] (Service)

Call From Foreign Countries: [phone] (Parts)
[phone] (Service)

FAX Inside U.S.A. [phone]
FAX From Foreign Countries: [phone]
E-Mail :

[e-mail]

Web Page :

www.hobartsystems.com

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Chapter 1-1

Page 1

Chapter 1

Description/Operation

Section 1

Description

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

1) General

The basic generator set covered in this manual, manufactured by ITW GSE Group, Hobart Ground
Systems is rated at 60 kVA and is designed to produce and deliver 115/200-volt, 400 Hz, 3-phase AC
power to a parked aircraft or other load. Some generator models with the TR option also provide 28.5
volts DC for aircraft having those requirements.

The number 500061 identifies the model or series of the GPU. The part number is followed by a different
dash number that separates the basic units available. Figure 1 uses the part number to identify the
variations covered in this manual.

Table 1: Series 500062 Generator Set Part Number Descriptions

2) Optional Equipment - Appendix A

Chapters 1 through 5 of this Operation and Maintenance Manual identify only the stripped down vers io n
of the 60CU20 generator set. A list of optional equipment appears in Appendix A.

3) Orientation

For purpose of orientation when designating RIGHT and LEFT throughout this manual, the radiator is
considered to be at the FRONT of the unit and the generator and controls are at the REAR. RIGHT and
LEFT are determined by standing at the REAR facing the machine. As an example, the fuel filler neck is
mounted on the LEFT REAR side of the unit.

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Chapter 1-1

Page 2

11 2 3 4

1 5 6 7 9 9 10

12

13

14

8

1. Fuel Filler Neck

2. Operator’s Control Panel

3. Output Cable Trays

th

4. 5

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

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Chapter 1-1

Page 3

Basic Unit
(Fixed Mount)

Length

74 in. (1880 mm)

101 in. (2570 mm) w/ tow bar up

Width

67 in. (1702 mm)

67 in. (1702 mm)

Height

59 in. (1499 mm)

67 in. (1702 mm)

Weight

4000 lb. (1814 kg.)

4300 lb. (1950 kg.)

Weight with 28.5 VDC T-R

4300 lb. (1950 kg.)

4600 lb. (2087 kg.)

Output power rating

60 kVA (48 kW)

Output voltage

115 / 200 VAC

Rated load capacity

174 Amps

Frequency
(at not load and rated load)

Power factor

0.8

Duty Cycl e

100%

Operating speed

2000 RPM

Overload capacity 125% rated load

218 Amps

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 60 kVA
on either or both outputs

approximately 5 minutes
150% load

30 seconds

200% load

10 seconds

4) Specifications

a) Physical Specifications

Physical

b) AC Generator Specifications

With Trailer

400 Hz. ± 2 Hz.

c) AC Generator Protective System Speci fications

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 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 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 in3 (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

12 VDC

Lubricating oil capacity (w/ filter)

11.6 quarts (11 liters)

Coolant capacity system

20 quarts (18.9 liters)

Engine oil pressure (warm and at rated speed 2000 RPM)

45 to 90 PSI (445 to 621 kPa).

Engine coolant temperature (normal operation)

160 to 200º F (71 to 93º C).

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

g) Normal Operating Characteristics

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Chapter 1-1

Page 5

5) Special Features

The generator set has special features that are described more fully under the assemblies in which they
appear.

a) Protective Monitoring

The protective monitoring system receives signals from the fault sensing components in the generator
output circuit and functions to cause the load to be disconnected from the generator if an abnormal
condition of voltage, frequency, or load develops.

b) Voltage Regulator

A microprocessor-type, adjustable voltage regulator provides automatic voltage regulation at the
aircraft. The regulated out 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.

d) Battery System Disconnect Switch

The generator set is equipped 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 Generator

The engine and generator comprise the principal components of the generator set. They are mounted on
a welded steel frame chassis. Some of the following figures are showing the locations of all major
components and sub-assemblies.

a) Diesel Engine

The diesel engine is a fuel injection, 4-cylinder, electronically controlled engine rated at 155
horsepower. See Figure 3 for specifications and capabilities.

b) Engine Manufacturer’s Components

As received from the engine manufacturer, the engine includes some of the following components,
which are more fully described in the engine manufacturer’s manual.

(1) Elec trical System

The 12 VDC electrical generating and starting system includes an alternator and starter with
solenoid switch.

.

OM-2226 / Operation and Maintenance Manual

60CU20 / Series 500062 / 400 Hz. Generator Set

May 2, 2013

Chapter 1-1

Page 6

manufacturer’s manual for approved fuels.

(2) Lubricity Additive Fuel Filter

The fuel filter is a spin-on disposable type located on the inside near the eng ine’s fuel pump. The
fuel filter’s 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 extend the life of the fuel pump.

CAUTION

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. Refer to engine

(3) Oil Filter

The engine oil filter is a spin-on, full-flow type, located on the right side of the engine near the
front.

(4) Pre-programmed Electronic Control Module (ECM)

The ECM is a pre-programmed engine control module, mounted directly to the engine block.

c) Factory Installed Components and Protective Systems

This generator set is assembled at with the following components and protective s ystems:
(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 ECM through the control box. It is located
on the rear of the generator set under the control box.

To operate the EMERGENCY SHUTDOWN/RESET SWITCH:

• Push button in until engine stops or until button travel stops

• Pull the button back out to reset

• 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 210º F (99º C).

• Low coolant shutdown system
The low coolant shutdown system consists of an engine manufactured supplied switch.

This switch is mounted in the radiator top tank and monitored by the engine’s ECM,
which will stop the engine when a low coolant level is reached.

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Air Restriction

• 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).

• Low fuel shutdown system

The low fuel shutdown system monitors the fuel level in the fuel tank. When the fuel tank
level reaches approximately

1

/4 tank the word fuel is displayed on the fault code gauge
signifying that it is time to put fuel in the tank. Once the fuel level reach approximately
the engine will shutdown.

(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) 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.

(4) Master [Battery] Disconnect Switch (MD1)

The master disconnect switch is designed to isolate the batteries from the entire electrical system
to eliminate the possibility of battery current draw by the engine ECM or any other components
between long periods of no operation. The switch can also be used to prevent starting of the
equipment for maintenance conditions.

(5) Air cleaner

1

/8 tank

Indicator

Figure 2: Air Cleaner

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May 2, 2013

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Engine Fault
Condition

Over temperature or

Shuts down the engine, and
appropriate fault code.

a) Press the engine stop button to reset the
b) Or use E-STOP button for immediate reset.

Low fuel warning and

Turns on the low fuel

shutdown at 1/8 tank.

a) The low fuel fault indicating

b) Or use E-STOP button for immediate reset.

Clogged air cleaner

inlet.

Turns on the air cleaner

a) Press the engine stop button. The

b)

The diesel engine air cleaner is so constructed that air enters through its cylindrical body, and
then is filtered before being passed into the engine turbo-charger assembly. An air cleaner
service indicator device is mounted on the air cleaner assembly to monitor the airflow into the air
cleaner. As the air cleaner becomes filled with dust, dirt, and carbon, the intake system airflow
becomes increasingly restricted. This restriction causes a diaphragm inside the indicator to move
toward an electrical contact. When the maximum allowable restriction level is reached, the circuit
closes and the air cleaner indicator fault appears on the control panel fault display to warn the
operator that the air cleaner must be changed. The electrical indicator automatically resets when
the restriction level drops sufficiently.

d) 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.

What Occurs How To Reset

ENGINE FAULTS

low oil pressure

shutdown

or other restriction in
the combustion air

e) Generator

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 by the voltage regulator PC
board (REG). A centrifugal, radial-blade fan 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’s flywheel and housing.

will be indicated will

indication on the fault code
meter. The GPU is
programmed at the factory
to warn at

1

/4 tank and to

restriction indicating fault
code.

fault code and reset the protective system.

function must be reset by
pressing the engine stop button
Fuel must be added prior to attempting another
engine start.

restriction must be removed prior to attempting
another engine start.

Or use E-STOP button for immediate reset.

The 400 Hz generator is a brushless, dual bearing, revolving fiel d, three-phase,
alternating current type. The front end of the rotor shaft extends forward beyond
the front bearing and is coupled 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 has six diodes mounted on the exciter rotor and converts

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May 2, 2013

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1 2 3 4 5 6 8

7 9 10

11

12

1. 28.5 VDC Con tac tor (optio nal)

2. Cummins QSB4.5 Engine

3. Air Filter Assembly

4. Operator’s Control Panel (back side)

5. Engine Fuel Filter (behind support leg)

6. Engine Oil Filter

Figure 3: Main Components of Generato r Set (Right Side)

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

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May 2, 2013

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1 2 3 4 5 6 7

8

1. 28.5 VDC Transformer-Rectifier (optional)

2. Lubric it y Addit i ve Fuel Pre-Filter

3. Engine Electronic Fuse and Relay Panel

4. Engine Control Module (ECM)

Figure 4: Main Components of Generato r Set (Left Side)

5. Engine Oil Level Check

6. Engine Air Intake Heater

7. Charge-Air-Cooler Piping

8. Power Module / Contactor Panel (back side)

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8) Control Box Assembly

The control box is a sheet metal enclosure that houses and provides mounting facilities for engine and
generator controls, as well as, monitoring device and circuits.

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 pushbutton switches for operating the engine and generator.

(1) Engine Monitoring Section

• Engine coolant temperature gage (M24)
The temperature gage is an electrical type that is connected by a wire to a water temperature

sensor installed in the engine cooling system. The gage indicates engine coolant
temperature in the range of 100-280 º F (38-138º C).

• Engine hour meter (M4)
The hour meter is electrically 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 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 pushbutton
switch is pressed. The fuel leve l can also be checked when the unit isn’t running by pressing
the panel light LAMPS pushbutton switch.

• Engine oil pressure gage (M25)
The oil pressure gage 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).

(2) Generator Monitoring Section (shown with analog meters)

• Frequency Meter (M3)
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).

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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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• AC Voltmeter (M2)
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, B-C and C-A) as selected by the METER SELECT switch. The
voltmeter has a scale of 0 to 300 V.

• AC Ammeter (M1)
The ammeter indicates the generator output current in each phase (A, B and C) as selected

by the METER SELEC T switch. The ammeter has a scale of 0 to 520 A.

• Fault Code meter (M6)
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 switch is
pressed. Pressing the TEST/RESET 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.

• Front LED Display (A5)
The front LED display 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 and indicates the output voltage from 0 to 50 VDC.

• DC Ammeter [Optional with TR]
The ammeter monitors and displays the transformer-rectifier’s output current. The ammeter is

an analog type and indicates the output voltage from 0 to 2500 A.

(3) Operator Pushbutton Switch Section

• LAMPS switch (S74)
The LAMPS switch controls the lights. Meters are lighted from inside the control panel.

• ENGINE HEATER switch (S79)
The ENGINE HEAT ER 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.

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May 2, 2013

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• ENGINE START switch (S24)
The ENGINE START 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). When the engine is running at idle speed, a
green indicating light, within the ENGIN E START push button switch, flashes at a rate of 1
second on, 1 second off.

When pressed a second time, this switch provides a signal to the ECM to adjust the engine
speed to 2000 RPM. The green indicator light glows continuously. At the same time, a
ground signal is provided to the regulator, enabling the generator to build up voltage for 400­Hz generator output. Pressing the switch once more removes these signals and the engine
reverts to idle speed with a blinking green indicator light.

• OUTPUT switch(s) [Yellow # 1 and/or Orange # 2] (S75, S275)
The load contactor push button switch, when pressed, closes the output contactor and turns

on the respective indicating light within contactor control switches (OUTPUT NO. 1 and or
OUTPUT NO. 2), indicating that power is available 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 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 is activated, it shows the code on the fault code
meter. The fault will remain on for a short period of time or until the TEST/RESET switch is
pressed. Pressing the TEST/RESET 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.

• STARTING CURRENT Switch (S431) [Optional with TR]
Each time the STARTING CURRENT switch is pressed, the BLUE indicator will glow. The

present current limiting amperage setting will be displayed on the fault code meter for a short
time delay, before incrementing, at 100 A increments, up to 2500 A. Once 2500 A has been
reached, the incrementing will start over from the beginning.

• DC OUTPUT Switch (S430) [Optional with TR]
Each time the DC OUTPUT switch is pressed, the BLUE indicator will 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.