Hobart 60CU24 Operation And Maintenance Manual With Illustrated Parts List

OM-2098C

040105 – Original
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, Ohio 45373

U.S.A.

Data Sheet 165

Warranty

HOBART GROUND POWER

TROY, OHIO 45373

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 is not
subjected to misuse, negligence or accident, and (4) the PRODUCT receives proper care, lubrication, protection,
and maintenance under the supervision of trained personnel.

2. This warranty expires 15 months after 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 deal 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. HOBART’S liability is limited to repair of any defects found 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 authorized 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 in writing, this warranty does not cover any equipment that has been altered by any party

other than HOBART.

10. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HERE

OF. HOBART MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, OF MERCHANTABILITY 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.

Index: 990223
Replaces: 980601

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

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

PERSONNEL SHOULD ALWAYS BE EMPLOYED FOR SUCH TASKS.

WARNING

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

Safety Warnings and Cautions

WARNING

IMPORTANT

WARNING

ELECTRIC SHOCK can KILL. Do not touch live electrical parts.
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
attached equipment.

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.

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 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, procedure s,
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-phase rated equipment to only two wires of the 3-phase line. DO NOT CO NNECT
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.

April 01, 2005 Safety Warnings

Page 1

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

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) Electrical 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
completely fill tank, because heat from the equipment may cause fuel expansion overflow. Remove

April 01, 2005 Safety Warnings

Page 2

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

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.

EMERGENCY

FIRST AID

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.

April 01, 2005 Safety Warnings

Page 3

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

This page intentionally left blank.

April 01, 2005 Safety Warnings

Page 4

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

Introduction

This manual contains operation and maintenance information for a 60CU24, 400 Hz Generator Set
manufactured by ITW GSE Group, Hobart Ground Power, Troy, Ohio 45373.

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.).”

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 Appendix is the last section. Its 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.

Contents of 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

April 01, 2005 Introduction

Page 1

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

If you have any questions concerning your Hobart Ground Power equipment, immediately contact our 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.: [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.itwgsegroup.com

April 01, 2005 Introduction

Page 2

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

Table of Contents

Chapter 1 Description/Operation Chapter-Section/Page#

Section 1

Section 2

Section 3

Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#

Section 1

Section 2

Description 1-1/1

General
Orientation
Optional Equipment - Appendix A
Special Features
Canopy
Engine and Generator
Control Box Assembly
Power Module Panel Assembly
Cold Weather Starting System

Preparation for Use, Storage or Shipping 1-2/1

Preparation For Use
Tips on Cold Weather Starting
Preparation For Storage
Preparation For Shipment

Operation 1-3/1

General
400 Hz. Operation Procedure
DC Operation Procedure

Maintenance Inspection/Check 2-1/1

General
Maintenance Schedule
Inspection / Check

Maintenance Procedures 2-2/1

General
Lubrication
Servicing The Air Cleaner
Engine Fuel
Engine Fuel System

1-1/1
1-1/1
1-1/2
1-1/2
1-1/2

1-1/4
1-1/10
1-1/21
1-1/22

1-2/1

1-2/3

1-2/3

1-2/5

1-3/1

1-3/1

1-3/6

2-1/1

2-1/1

2-1/3

2-2/1

2-2/1

2-2/5

2-2/6

2-2/7

November 16, 2007
Revision 8

Table of Contents

Page 1

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

Section 2
(cont.)

Section 3

Section 4

Engine Cooling System
Generator Maintenance
Drive Belt

Adjustments / Tests 2-3/1

General
Testing the 400 Hz. Generator Set
Generator Set Adjustments
Generator and Exciter Test
Diode Test
Testing the Transformer-Rectifier

Troubleshooting Procedures

General
Equipment for Troubleshooting
Parts Replacement
400 Hz. Test Values
Check Connections and Leads
Engine Troubleshooting
Illustrations
Connection and Schematic Diagrams
GPU Control Monitoring

Troubleshooting Charts

…Engine Controls
…Generator Excitation Circuits
…No. 1 Load Contactor Operating Circuit
…No. 2 Load Contactor Operating Circuit
…Protective Circuit
…Generator
Troubleshooting Tables – GPU Commands
Troubleshooting Tables – GPU Faults

2-2/10
2-2/13
2-2/13

2-3/1

2-3/1
2-3/12
2-3/15
2-3/16
2-3/16

2-4/1

2-4/1

2-4/1

2-4/2

2-4/2

2-4/2

2-4/2

2-4/2

2-4/3
2-4/11
2-4/11
2-4/14
2-4/15
2-4/17
2-4/19
2-4/20
2-4/22
2-4/26

Chapter 3 Overhaul / Major Repair Chapter-Section/Page#

Section 1

Exciter Armature 3-1/1

General
Exciter Armature
Exciter Armature Replacement
Installation Exciter Armature

3-1/1

3-1/2

3-1/3

3-1/6

November 16, 2007
Revision 8

Table of Contents

Page 2

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

Section 2

Section 3

Dual Bearing Flexible Coupling

General
Disassembly
Coupling Service
Coupling Installation
Reassemble Engine and Generator
Run-in and Periodic Check

Generator Assembly

General
Generator Assembly Removal
Generator Assembly Installation

3-2/1

3-2/1

3-2/4

3-2/5

3-2/6

3-2/7

3-3/1

3-3/1

3-3/2

Chapter 4 Illustrated Parts List Chapter-Section/Page#

Section 1

Section 2

Section 3

Introduction 4-1/1

General
Purpose
Arrangement
Explanation of Parts List

Manufacture's Codes 4-2/1

Explanation of Manufacture's (Vendor) Code List

Illustrated Parts List 4-3/1

Explanation of Parts List Arrangement
Symbols and Abbreviations
Figure 1: General Assembly
Figure 2: Frame Assembly
Figure 3: Canopy Assembly
Figure 4: Internal Components
Figure 5: Control Box Door Panel Assembly
Figure 6: Control Box Interior Components
Figure 7: Control Switch Panel Components
Figure 8: Push-Buttons Details
Figure 9: 400 Hz. Power Module Assembly
Figure 10: Cooling System Components

4-1/1

4-1/1

4-1/1

4-1/1

4-2/1

4-3/1

4-3/1

4-3/2

4-3/6

4-3/8
4-3/10
4-3/12
4-3/14
4-3/16
4-3/18
4-3/20
4-3/22

November 16, 2007
Revision 8

Table of Contents

Page 3

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

Section 3
(cont.)

Figure 11: Fuel System Components
Figure 12: 12 VDC Battery System
Figure 13: Air Cleaner Components
Figure 14: Engine Components
Figure 15: Engine Exhaust Components
Figure 16: Generator Assembly
Figure 17: Trailer Components

Numerical Index 4-4/1Section 4

Explanation of Numerical Index

Chapter 5 Manufacture's Literature
Appendix A Options/Features
Wet Stacking
Unusual Service Conditions

4-3/24
4-3/26
4-3/28
4-3/30
4-3/32
4-3/34
4-3/36

4-4/1

November 16, 2007
Revision 8

Table of Contents

Page 4

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

Chapter 1 Description/Operation

Section 1 Description

1) General

Hobart Ground Power part of the ITW GSE Group in Troy, Ohio, manufactures the basic generator set
covered in this manual. Is rated at 60 kVA and designed to produce and deliver 115/200-volt, 400 Hz, 3­phase AC, or 28.5V DC power to a parked aircraft or to Hobart approved test banks only.

The number 500060C 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.

Part & Dash Number Model Description

500060C-001 Single Output, Trailer Mounted (Stainless Steel Fuel Tank)
500060C-002 Dual Output, Trailer Mounted (Stainless Steel Fuel Tank)
500060C-003 Single Output, Fixed/Truck Mounted (Stainless Steel Fuel Tank)
500060C-004 Dual Output, Fixed/Truck Mounted (Stainless Steel Fuel Tank)
500060C-005 Single Output, Trailer Mounted, 28.5V DC TR (Stainless Steel Fuel Tank)
500060C-006 Single Output, Fixed/Truck Mounted, 28.5V DC TR (Stainless Steel Fuel Tank)
500060C-007 Single Output, Fixed Mounted, 28.5V DC TR (Special) (Stainless 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 Single Output, Trailer Mounted, 28.5V DC TR, Digital AC/DC Meters(SS Tank)
500060C-011 Single Output, Fixed/Truck Mounted, 28.5V DC TR, Digital AC/DC Meters (SS Tank)
500060C-101 Single Output, Trailer Mounted (Composite Fuel Tank)
500060C-102 Dual Output, Trailer Mounted (Composite Fuel Tank)
500060C-103 Single Output, Fixed/Truck Mounted (Composite Fuel Tank)
500060C-104 Dual Output, Fixed/Truck Mounted (Composite Fuel Tank)
500060C-105 Single Output, Trailer Mounted, 28.5V DC TR (Composite Fuel Tank)
500060C-106 Single Output, Fixed/Truck Mounted, 28.5V DC TR (Composite Fuel Tank)
500060C-107 Single Output, Fixed Mounted, 28.5V DC TR (Special) (Composite Fuel Tank)
500060C-108 Single Output, Trailer Mounted, Digital AC Meters (Composite Fuel Tank)
500060C-109 Single Output, Fixed/Truck Mounted, Digital AC Meters (Composite Fuel Tank)
500060C-110 Single Output, Trailer Mounted, 28.5V DC TR, Digital AC/DC Meters (C Tank)
500060C-111 Single Output, Fixed/Truck Mounted, 28.5V DC TR, Digital AC/DC Meters (C Tank)

Series 500060C Generator Set Part Number Descriptions

Figure 1

2) Orientation

For purpose of orientation, the radiator is considered to be at the FRONT of the unit. The generator and
controls are at the REAR. LEFT and RIGHT are determined by standing at the REAR end facing the
control box.

November 16, 2007
Revision 8

Chapter 1-1

Page 1

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

3) Optional Equipment - Appendix A

Chapters 1 through 5 of this Operation and Maintenance Manual identifies only the “strip down” version of
the 60CU24 generator set. A list of optional equipment which make this manual unique to the generator
set that you have purchased, appears in Appendix A. A few items included in Appendix A are cable trays,
trailers, 28-volt DC power transformer-rectifiers, etc.

4) Special Features

The generator set has special features that are described more fully under the assemblies in which they
appear. Three features: protective monitor, voltage regulator 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 functions to cause the load to be disconnected from the generator if an abnormal condition
of voltage, frequency, or load develops.

a) 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.

b) Engine Electronic Control Module

The engine is equipped with an electronic control module that monitors, records, and controls engin e
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.

November 16, 2007
Revision 8

Chapter 1-1

Page 2

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

Physical Basic Unit (Fixed Mount) Trailer Mounted Unit

Length 68 in. (172.7 mm) 94.5 in. (240 mm)
Width 37 in. (94 mm) 67 in. (170.1 mm)
Height 46 in. (116.8 mm) 62 in. (157.5 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 power rating 60 kVA 48 kW
Output voltage 115 / 200 VAC
Rated load capacity 174 Amps
Frequency 400 Hz.
Power factor 0.8
Duty Cycle 100%
Operating speed 2400 RPM
Overload capacity, both outputs

217.5 Amps
125% rated load
Output cable size 2/0

Specifications and Capabilities

Figure 2 (Sheet 1 of 2)

November 16, 2007
Revision 8

Chapter 1-1

Page 3

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

GENERATOR PROTECTIVE SYSTEM

Over voltage Trips at 126 volts after a 1 second time delay.

Trips at 140 volts in 160 milliseconds.

Trips at 180 volts in 50 milliseconds.
Under voltage Trips at any voltage below 100 volts after 7 seconds.
Over frequency Trips at any value between 420 Hz and 480 Hz after a 5 second time

delay. Trips immediately at any frequency exceeding 480 Hz.
Under frequency Trips at 380 Hz. or less after a 7 second time delay.
Overload time delay Trips in app roximately 5 minutes at 125% load of 90 kVA on either

output or 125% of 120 kVA on both outputs combined.

DC OUTPUT (OPTIONAL, SEE APPENDIX A)

Output Voltage 28.5 VDC
Amps (Continuous) 600 A
Amps (Peak/Starting/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 cycle diesel, electronic controlled
Bore and Stroke 4.02 in. x 5.42 in. (102 mm x 138 mm)
Displacement 275 in3 (4.5 L)
Horsepower 110 hp (82 kW)
Idle speed 1000 ± 50 rpm
High speed limiting 2750 ± 75 rpm
Normal governed speed 2400 rpm
Firing Order 1-3-4-2
Electrical system 12 VDC
Ground Negative
Lubricating oil capacity (w/ filter) 10 quarts (9.5 liters)
Coolant capacity system 38 quarts (36 liters)

Specifications and Capabilities

Figure 2 (Sheet 2 of 2)

6) Engine and Generator

The engine and generator comprise the principal components of the gene rator 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 4 and 5 are illustrations showing the location of all
major components and sub-assemblies.

November 16, 2007
Revision 8

Chapter 1-1

Page 4

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

a) Basic Engine

The basic diesel engine is a in-line 4-cylinder, electronically controlled engine rated at 110
horsepower. See Figure 2 for specifications and capabilities.

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) Electrical System

The 12 VDC electrical generating and starting system include an alternator, voltage regulator,
and starter with solenoid switch.

(2) Fuel Filter

The fuel filter is a spin-on disposable, vacuum type connected between the fuel lift pump and
injector 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.

(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.

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) Hobart Installed Equipment

This generator set is modified at Hobart Brothers 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 3)

November 16, 2007
Revision 8

Chapter 1-1

Page 5

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

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

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) Air cleaner (Figure 6)

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 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 appea rs 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.

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.

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.

November 16, 2007
Revision 8

Chapter 1-1

Page 6

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

ENGINE FAULTS

Engine Fault Condition What Occurs How To Reset

Over temperature or low oil
pressure

Shuts down the engine, and will be
indicated will appropriate fault
code.

Low fuel warning and shutdown Turns on the low fuel indication on

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

1

/4 tank and to shutdown at 1/8

at
tank.

Clogged air cleaner or other
restriction in the combustion air

Turns on the air cleaner restriction
indicating fault code.

inlet.

Engine Faults

Figure 3

a) Press the engine stop button to

reset the fault code and reset the
protective system.
b) Or use E-STOP button for
immediate reset.
a) The low fuel fault indicating
function must be reset by
pressing the engine stop button
Fuel must be added prior to
attempting another engine start.
b) Or use E-STOP button for
immediate reset.
a) Press the engine stop button.
The restriction must be removed
prior to attempting another engine
start.
b) Or use E-STOP button for
immediate reset.

November 16, 2007
Revision 8

Chapter 1-1

Page 7

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

7

8

9

1

2

6

4

3

10

1. Control Panel

2. Operator’s Push-Button Panel

3. Output Cable Location

4. Front Axle Assembly

5. Rear Axle Assembly

November 16, 2007
Revision 8

5

6. Emergency Stop Switch (S28)

7. Exhaust Outlet

8. Canopy

9. Radiator End

10. Generator End

General Assembly of Generator Set

Figure 4

Chapter 1-1

Page 8

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

4 3 2 1

1. Radiator

2. Cummins QSB Engine

3. Air Cleaner

November 16, 2007
Revision 8

5

6

4. Control Box

5. Fuel Tank

6. Generator

Main Components of Generator Set

Figure 5

Chapter 1-1

Page 9

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

Service Indicator

Air Cleaner

Air Cleaner and Service Indicator

Figure 6

7) 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) Control Panel (Figure 7 and 8)

The control system is divided into two 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.

(1) Panel 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 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 dru ms.
It is only functional when the engine is running.

(3) Engine oil pressure gage (M24)

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).

(4) Engine ON indicating light (DS58)

When the engine is running at idle speed, a green indicating light, within the “ENGINE START”
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.

November 16, 2007
Revision 8

Chapter 1-1

Page 10

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

3 4

12

6 8 7,10 10,1110,12

5

139 10,15 10,1617

1. Fuel Gage (M13)

2. Front Panel

3. Engine Coolant Temperature 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)

November 16, 2007
Revision 8

10. Strip Lights (DS60-DS62) (3) [Not Shown]

11. AC Generator Ammeter (M1)

12. AC Voltmeter (M2)

13. Adjustable Grip Latch

14. Control Panel Door Hinge [Not Shown]

15. DC Voltmeter [Optional with TR]

16. DC Ammeter [Optional with TR]

17. Front LED PC Board (A5) [Shown Opposite Side]

Control Panel Door

Figure 7

Chapter 1-1

Page 11

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

1. Meter 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]

Control Push-Button Switch Panel

Figure 8

1245678910 3

6. AC Output No. 2 (S275) [if applicable]

7. AC Output No. 1 (S75)

8. Engine Start Switch (S24)

9. Air Intake Heater Switch (S79)

10. Panel Light Switch (S74)

November 16, 2007
Revision 8

Chapter 1-1

Page 12

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

1

2

4

5

7 6

89

10

1. Engine Specific PC Board [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}

3

6. +5, -12 VDC Power Supply (PS1)

7. Circuit Breaker Support Bracket

8. Marker Lights Circuit Breaker, 10 A (CB1)

9. Engine Circuit Breaker, 10 A (CB4)

10. Controls Circuit Breaker, 5 A (CB7)

November 16, 2007
Revision 8

Control Box Interior Components

Figure 9

Chapter 1-1

Page 13

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

(5) Engine coolant temperature gage

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).

(6) “ENGINE START” push-button switch (S24)

The “ENGINE START” push-button switch, when pressed, connects 12 VDC power to the starter
solenoid coil, which actuates the solenoid switch to connect power to the engine starting motor.
The 12 VDC power is supplied directly to the engine ECM and the oil pressure shutdown switch is
bypassed (This bypass is necessary for engine starting because the low oil pressure switch is
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 2400 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 HEATER” 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.

(8) “ENGINE STOP” push-button switch (S76)

When the “ENGINE STOP” 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 ammeter indicates the direction and value of current flow from or to the 12 VDC battery. Its
graduated 10 V to 16 V.

(10) 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” push-button switch is
pressed. The fuel level can also be checked when the unit isn’t running by pressing the panel
light “LAMPS” push-button switch.

November 16, 2007
Revision 8

Chapter 1-1

Page 14

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

(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 of time 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”, if applicable) 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.

(15) Front LED Display (A5)

The front LED display signifies to the operator which voltage (A-N, A-B, etc…) and amperage are
shown on the meters, as well as, when “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.

(16) DC Generator output monitors (meters) [Optional with TR, Reference Appendix A]

Two instruments, a voltmeter and an ammeter, monitor and display the transformer-rectifier’s
output. The voltmeter and ammeter meters are both analog type and indicate the output voltage
from 0 to 50 VDC and the amperage from 0 to 2500 A.

(17) “STARTING CURRENT” Switch (S431) [Optional with TR, Reference Appendix A]

Each time the “STARTING CURRENT” push-button switch is pressed, the BLUE indicator will
glow. The present current limiting amperage setting will be displayed on the fault code meter for
a short time delay, before incrementing, at 100 A increments, up to 2500 A. Once 2500 A has
been reached, the incrementing will start over from the beginning.

November 16, 2007
Revision 8

Chapter 1-1

Page 15

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

(18) “DC OUTPUT” Contactor Switch (S430) [Optional with TR, Reference Appendix A]

Each time the “DC OUTPUT” push-button 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.

b) Control Box Interior Components (Figure 9)

(1) EF Bypass switches (located on CTL)

For each load contactor circuit, a single-pole, single-throw “EF1 BYPASS” for “OUTPUT 1” (or
“EF2 BYPASS” for “OUTPUT 2”, if applicable) provides a means of bypassing the 28 VDC
interlock circuit for the contactor when supplying power to a load bank or to an aircraft not
equipped with a plug interlock system.

(2) Regulated-diagnostic switch (located on the REG)

When the “REGULATED/DIAGNOSTIC” switch is in the “REGULATED” (down) position, the
generator output voltage is regulated by the PC board for 115/200 VAC output to an aircraft.
When this switch is placed in the “DIAGNOSTIC” (up) position, 12 VDC is applied to the
generator exciter with the engine running at rated RPM, in order to check the operation of the
generator. This is done to determine if a particular power output malfunction is caused by a
defective generator or by a defective voltage regulator. When this switch is in the
MAINTENANCE position, no current is supplied to the generator exciter. In this condition, a low­level, 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-ampere “ENGINE” circuit breaker, protects the 12 VDC engine electrical and fault circuits,
and another 10-ampere “MARKER LIGHTS” circui t breaker p rotects the 12 VDC lighting system.
A 5-ampere “CONTROL” circuit breaker protects the 12 VDC control system.

(4) Digital Control PC Board [CTL] (A3)

The digital control PC board (see Figure 10) is the center for all communications throughout the
entire control system. All push-button panel commands run through the digital control PC board
and communicates the commands to the appropriate area (i.e. other PC boards) in the control
system. The digital control PC board also controls the real time clock, monitors the over/under
voltage and overload protection, push-button panel indicator lights, generator output meters, EF
bypass switches, and communicates with the optional service tool.

(5) Engine Interface PC Board [EIB] (A2)

The EIB (see figure 11) is common between all engine models and monitors coolant temperature,
oil pressure, battery voltage, and fuel tank level monitoring. The EIB is also responsible for the
monitoring the warning switches for high coolant temperature, low oil pressure, hi gh air
restriction, and low coolant level (optional). The warning switches signal the EIB when a fault
occurs, which then the EIB relays this information to the CTL. The CTL will issue the command
to the system that fits the fault event.

The EIB also controls the power distribution in the control system, hour meter, lights, and the
engine starter operation.

November 16, 2007
Revision 8

Chapter 1-1

Page 16