Hobart 60CU24 Setup guide

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.

Warranty
HOBART GROUND POWER
TROY, OHIO 45373
Data Sheet 165
Index: 990223
Replaces: 980601
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, workstoppage 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.
WARNING
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.

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
April 01, 2005 Safety Warnings
Page 1
Safety Warnings and Cautions
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.
IMPORTANT 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.
WARNING 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, 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-phase rated equipment to only two wires of the 3-phase 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-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
April 01, 2005 Safety Warnings
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. 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

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
April 01, 2005 Safety Warnings
Page 3
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.

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
April 01, 2005 Safety Warnings
Page 4
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OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
April 01, 2005 Introduction
Page 1
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

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
April 01, 2005 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: 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 : [email protected]
Web Page : www.itwgsegroup.com

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
November 16, 2007
Revision 8 Table of Contents Page 1
Table of Contents
Chapter 1 Description/Operation Chapter-Section/Page#
Description 1-1/1
General 1-1/1
Orientation 1-1/1
Optional Equipment - Appendix A 1-1/2
Special Features 1-1/2
Canopy 1-1/2
Engine and Generator 1-1/4
Control Box Assembly 1-1/10
Power Module Panel Assembly 1-1/21
Cold Weather Starting System 1-1/22
Section 1
Preparation for Use, Storage or Shipping 1-2/1
Preparation For Use 1-2/1
Tips on Cold Weather Starting 1-2/3
Preparation For Storage 1-2/3
Preparation For Shipment 1-2/5
Section 2
Operation 1-3/1
General 1-3/1
400 Hz. Operation Procedure 1-3/1
Section 3
DC Operation Procedure 1-3/6
Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#
Maintenance Inspection/Check 2-1/1
General 2-1/1
Maintenance Schedule 2-1/1
Inspection / Check 2-1/3
Section 1
Maintenance Procedures 2-2/1
General 2-2/1
Lubrication 2-2/1
Servicing The Air Cleaner 2-2/5
Engine Fuel 2-2/6
Section 2
Engine Fuel System 2-2/7

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
November 16, 2007
Revision 8 Table of Contents Page 2
Engine Cooling System 2-2/10
Generator Maintenance 2-2/13
Drive Belt 2-2/13
Section 2
(cont.)
Adjustments / Tests 2-3/1
General 2-3/1
Testing the 400 Hz. Generator Set 2-3/1
Generator Set Adjustments 2-3/12
Generator and Exciter Test 2-3/15
Diode Test 2-3/16
Testing the Transformer-Rectifier 2-3/16
Section 3
Troubleshooting Procedures
General 2-4/1
Equipment for Troubleshooting 2-4/1
Parts Replacement 2-4/1
400 Hz. Test Values 2-4/2
Check Connections and Leads 2-4/2
Engine Troubleshooting 2-4/2
Illustrations 2-4/2
Connection and Schematic Diagrams 2-4/2
GPU Control Monitoring 2-4/3
Troubleshooting Charts 2-4/11
…Engine Controls 2-4/11
…Generator Excitation Circuits 2-4/14
…No. 1 Load Contactor Operating Circuit 2-4/15
…No. 2 Load Contactor Operating Circuit 2-4/17
…Protective Circuit 2-4/19
…Generator 2-4/20
Troubleshooting Tables – GPU Commands 2-4/22
Section 4
Troubleshooting Tables – GPU Faults 2-4/26
Chapter 3 Overhaul / Major Repair Chapter-Section/Page#
Exciter Armature 3-1/1
General 3-1/1
Exciter Armature 3-1/2
Exciter Armature Replacement 3-1/3
Installation Exciter Armature 3-1/6
Section 1

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
November 16, 2007
Revision 8 Table of Contents Page 3
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 2
Generator Assembly
General 3-3/1
Generator Assembly Removal 3-3/1
Generator Assembly Installation 3-3/2
Section 3
Chapter 4 Illustrated Parts List Chapter-Section/Page#
Introduction 4-1/1
General 4-1/1
Purpose 4-1/1
Arrangement 4-1/1
Explanation of Parts List 4-1/1
Section 1
Manufacture's Codes 4-2/1
Explanation of Manufacture's (Vendor) Code List 4-2/1
Section 2
Illustrated Parts List 4-3/1
Explanation of Parts List Arrangement 4-3/1
Symbols and Abbreviations 4-3/1
Figure 1: General Assembly 4-3/2
Figure 2: Frame Assembly 4-3/6
Figure 3: Canopy Assembly 4-3/8
Figure 4: Internal Components 4-3/10
Figure 5: Control Box Door Panel Assembly 4-3/12
Figure 6: Control Box Interior Components 4-3/14
Figure 7: Control Switch Panel Components 4-3/16
Figure 8: Push-Buttons Details 4-3/18
Figure 9: 400 Hz. Power Module Assembly 4-3/20
Section 3
Figure 10: Cooling System Components 4-3/22

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
November 16, 2007
Revision 8 Table of Contents Page 4
Figure 11: Fuel System Components 4-3/24
Figure 12: 12 VDC Battery System 4-3/26
Figure 13: Air Cleaner Components 4-3/28
Figure 14: Engine Components 4-3/30
Figure 15: Engine Exhaust Components 4-3/32
Figure 16: Generator Assembly 4-3/34
Figure 17: Trailer Components 4-3/36
Section 3
(cont.)
Numerical Index 4-4/1Section 4 Explanation of Numerical Index 4-4/1
Chapter 5 Manufacture's Literature
Appendix A Options/Features
Wet Stacking
Unusual Service Conditions

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
November 16, 2007
Revision 8 Chapter 1-1 Page 1
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, 3-
phase 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.

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
November 16, 2007
Revision 8 Chapter 1-1 Page 2
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 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-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
November 16, 2007
Revision 8 Chapter 1-1 Page 3
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
125% rated load 217.5 Amps
Output cable size 2/0
Specifications and Capabilities
Figure 2 (Sheet 1 of 2)

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
November 16, 2007
Revision 8 Chapter 1-1 Page 4
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 approximately 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 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 4 and 5 are illustrations showing the location of all
major components and sub-assemblies.

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
November 16, 2007
Revision 8 Chapter 1-1 Page 5
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)

OM-2098C / Operation and Maintenance Manual
60CU24 / Series 500060C / 400 Hz. Generator Set
November 16, 2007
Revision 8 Chapter 1-1 Page 6
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 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.
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.