Hobart 120CU20 Manuals

Hobart 120CU20 Manuals

Manuals and User Guides for Hobart 120CU20. We have 1 Hobart 120CU20 manual available for free PDF download: Operation And Maintenance Manual With Illustrated Parts List

Hobart 120CU20 Operation And Maintenance Manual With Illustrated Parts List

Hobart 120CU20 Operation And Maintenance Manual With Illustrated Parts List (247 pages)

120 kVA, 3 Phase, 115/200 Volt, 400 Hz. Generator Set Series 500120

Brand: Hobart | Category: Portable Generator | Size: 9 MB

Table of Contents

Illustrated Parts List
1
General
7
Installation and Grounding of Electrically Powered Equipment
7
Safety Warnings and Cautions
7
Shock Prevention
7
Electrical Short Circuits and Overloads
8
Fire and Explosion Prevention
8
Output Cables and Terminals
8
Service and Maintenance
8
Bodily Injury Prevention
9
Equipment Precautionary Labels
9
Medical and First Aid Treatment
9
Toxic Fume Prevention
9
Introduction
11
Table of Contents
13
Wet Stacking
16
Chapter 1 Description/Operation

17
- General
  17
- Optional Equipment
  17
- Optional Equipment - Appendix A
  17
- Orientation
  17
- Section 1 Description
  17
- Canopy
  18
  - Engine Electronic Control Module
    18
  - Protective Monitoring
    18
- Special Features
  18
  - Voltage Regulator
    18
  - AC Generator Protective System Specifications
    19
  - AC Generator Specifications
    19
  - Physical Specifications
    19
  - DC Output Specifications
    20
  - DC Protective System Specifications
    20
  - Engine Specifications
    20
  - Basic Engine
    21
- Engine and Generator
  21
- Control Box Assembly
  27
  - Generator
    27
  - Operator Controls
    27
  - Engine Hour Meter (M4)
    29
  - Engine Oil Pressure Gauge (M24)
    29
  - Engine on Indicating Light (DS58)
    29
  - Panel Lights and Panel Light Push-Button Switch
    29
  - Engine Fuel Gauge
    30
  - Engine Voltmeter
    30
  - Fault Code Meter and “TEST/RESET” Push-Button Switch
    30
  - “ENGINE STOP” Push-Button Switch
    30
  - DC Generator Output Monitors (Meters)
    31
  - Front LED Display
    31
  - “DC OUTPUT” Contactor Switch
    31
  - “STARTING CURRENT” Switch
    31
  - Control Box Interior Components
    32
  - EF Bypass Switches
    32
  - Circuit Breakers (CB1, CB4, CB7)
    33
  - Digital Control PC Board
    33
  - Digital Control PC Board [CTL] (A3)
    33
  - Regulated-Diagnostic Switch
    33
  - Engine Interface PC Board
    34
  - Engine Specific PC Board
    34
  - Voltage Regulator PC Board
    35
  - +5, -12 VDC Power Source
    36
  - Transformer-Rectifier PC Board
    36
  - Control System Power Source
    37
  - Current Transformers
    38
  - Line-Drop Compensation
    38
  - Load Contactor
    38
- Power Module Panel Assembly
  38
  - Output Power Module Components
    39
  - Cold Weather Starting System (BH1)
    40
  - Intake Air Heater
    40
  - Heat Sink / Diode Assembly
    41
  - Input Contactor
    41
  - Transformer Assembly (T401)
    41
- Transformer-Rectifier Assembly Components
  41
- Preparation for Storage
  47
- Temporary Storage
  47
- Preparation for Shipment
  48
- 400 Hz. Operating Procedure
  49
- General
  49
  - Pre-Start Inspection
    49
  - Section 3 Operation
    49
  - Normal Engine Starting Procedures
    51
  - Failed Starting Procedure
    52
  - Power Delivery
    52
  - Discontinue Power Delivery with Unit Shutdown
    53
  - Emergency Conditions
    53
  - Failed Power Delivery
    53
  - Normal Conditions
    53
  - DC Operating Procedure
    54
  - Discontinue Power Delivery
    54
  - Normal Power Delivery
    54
- Simultaneous AC and DC Operation
  54
Chapter 2 Servicing / Troubleshooting

55
- General
  55
- Identification of Interval Periods
  55
Maintenance Inspection/Check

55
Engine

58
Maintenance Procedures

67
- Changing Engine Oil
  68
- Oil Specification
  68
- Oil Viscosity
  68
- Lubricants Chart
  70
- Lubrication System
  70
- Alternator
  71
- Engine Accessories Lubrication
  71
- Starter
  71
- Water Pump
  71
- Air Filter Element Replacement Part Number
  72
- Changing the Air Filter
  72
- Inspecting the Air Cleaner
  72
- Servicing the Air Cleaner
  72
- Cold Weather Operation
  73
- Engine Fuel System
  73
- Engine Cooling System
  76
  - Fuel Return
    76
  - Priming Fuel System (When Applicable)
    76
  - Coolant
    77
  - Radiator Cap
    77
  - Checking Antifreeze Solution
    78
  - Draining the Cooling System
    78
  - Flushing the Cooling System
    78
  - Selecting Antifreeze
    78
  - Filling the Cooling System
    79
  - Thermostat
    79
  - To Add Coolant
    79
  - Checking Belt Tension
    80
- Drive Belt
  80
- Generator Maintenance
  80
- Adjustment/Test
  81
- General
  81
- Pre-Operational Test Procedures
  81
- Testing the 400 Hz. Generator Set
  81
- Generator and Exciter Test
  95
  - Generator and Exciter Test Readings
    95
  - Generator Connections
    95
- Diode Test
  96
- Testing the Transformer-Rectifier
  96
- Adjusting the Transformer-Rectifier
  98
  - Control Interlock Kit
    98
  - Silicon Diodes
    98
  - Temperature Overload Protection
    98
- Equipment for Troubleshooting
  99
- General
  99
- Parts Replacement
  99
Troubleshooting Procedures

99
- 400 Hz. Test Values
  100
- Check Connections and Leads
  100
- Connection and Schematic Diagrams
  100
- Engine Troubleshooting
  100
- Illustrations
  100
  - Commands
    101
  - Engine Start Mode
    101
- GPU Control Monitoring
  101
  - Self-Test Mode
    101
  - Engine Idle Mode
    102
  - Engine Run Mode
    102
  - Engine Shutdown Mode
    102
  - Engine Stop Mode
    102
  - Fault Code Display
    103
  - Idle Mode
    103
  - Run Mode
    103
  - Stop Mode
    103
  - Extracting Fault Code Information
    104
  - Fault Meter Display
    104
  - Operation Monitoring
    104
- Engine Controls
  108
- Generator Excitation Circuits
  111
- Load Contactor Operating Circuits
  112
- Protective Circuit
  114
- Generator
  116
- T-R Controls and Components
  117
  - GPU Commands
    119
  - Troubleshooting Table
    119
  - Faults
    120
Chapter 3 Overhaul / Major Repair

123
- Conditions for Exciter Removal
  125
- Exciter Armature Replacement
  125
- Exciter Armature Installation
  128
  - Preparation for Exciter Armature Installation
    128
  - Install the Machine Key
    130
  - Recommended Products Manufacturers
    130
  - Coupling Assembly
    131
- Disassembly
  131
Exciter Armature

123
- General Assembly
  123
Dual Bearing Flexible Coupling

131
- General
  131
  - Separate Engine and Generator
    131
  - Access to Coupling Bolts
    132
  - Remove Coupling Assembly
    132
  - Hub and Bushing
    133
  - Bushing Kit
    134
  - Bushing Replacement
    134
- Coupling Service
  134
- Replacement Coupling Kit
  134
- Coupling Installation
  135
- Reassemble Engine and Generator
  136
- Run-In and Periodic Check
  137
  - Bushing Installation
    138
  - Assembly Procedure
    139
  - Measure from Mounting Face to Adapter Ring
    139
  - Measuring from Mounting Face to Bushing
    140
- Generator Assembly Removal
  141
- Generator Assembly Installation
  144
  - Remounting the Generator Assembly
    144
  - Remounting the Previously Removed Assemblies
    144
- Arrangement
  145
Chapter 4 Illustrated Parts List

145
- Explanation of Parts List
  145
- General
  145
- Illustrated Parts List
  145
Introduction

145
Manufacture's Codes

145
- Parts List Form
  145
- Purpose
  145
  - Section 1 Introduction
    145
  - FACTORY PART NUMBER Column
    146
  - NOMENCLATURE Column
    146
  - UNITS PER ASSEMBLY Column
    146
  - Explanation of Manufacturer’s (Vendor) Code List
    147
  - Explanation of Parts List Arrangement
    151
  - Symbols and Abbreviations
    151
  - Labels and Reflectors
    154
  - Frame Assembly
    156
  - Canopy Assembly
    158
  - Canopy Doors
    160
  - Internal Components
    162
  - Door Control Panel Assembly
    164
  - All Other Push-Buttons
    168
  - Lamps and Meter Select Pushbuttons
    168
  - 400 Hz. Power Module Assembly
    170
  - Cooling System Components
    172
  - Engine Ground Plate and Cables
    174
  - 120CU20 / Series 500120 / 400 Hz. Generator Set
    175
  - Fuel System Components
    176
  - Engine Exhaust Components
    178
  - VDC Battery System
    180
  - Air Cleaner Components
    182
  - Engine Components
    184
  - Engine Electrical Panel Components
    186
  - Transformer-Rectifier Assembly (DC Option)
    190
  - DC Output Contactor (DC Option)
    192
  - T-R Interlock Kit (DC Option Accessory)
    194
  - Explanation of Numerical Index
    197
  - Numerical Index
    197
  - Analog Meter Connections for TR Meters
    211
  - Digital Meter Connections for TR Meters
    211
  - Legend
    221
  - Option/Features Available
    239
  - Options / Features
    239
  - Diesel Engines
    241
  - Wet-Stacking in Generator Set
    241
  - Unusual Service Conditions
    243
  - Filter Part Numbers
    245
  - Generator Model Number
    245
  - Preventive Maintenance
    245
  - Filter Kits
    246
  - Hobart Ground Power - Supply Contact Information
    246

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