Hobart Brothers 6910 Operation And Maintenance Manual With Illustrated Parts List Download Page 11 | Manualshive

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SUBJECT

CHAPTER/SECTION

PAGE

E. Exhaust System . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . .

1

3. Electrical System (12-V DC) . . . . . . . . .

2-2 . . . . . . . . . . . 3

A. Lights

. . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . .

3

B. Fuses . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . .

3

C. Wiring and Connections

. . . . . . . . . . . . . 2-2 . . . . . . . . . . . . .

3

4. Electrical System (115-V AC)

. . . . . . .

2-2 . . . . . . . . . . . 4

A. Monitoring Instruments . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . .

4

B. Indicating Lights

. . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . .

4

C. Protective Modules

. . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . .

4

D. Wiring and Connections

. . . . . . . . . . . . . 2-2 . . . . . . . . . . . . .

5

5 . Trailer and Truck

. . . . . . . . . . . . . .

2-2 . . . . . . . . . . . 5

SECTION 3. ADJUSTMENT/TEST

. . . . . . 2-3 . . . . . . . . . 1

1. General . . . . . . . . . . . . . . . . . . . .

2-3 . . . . . . . . . . . 1

2. Generator Set Test . . . . . . . . . . . . . .

2-3 . . . . . . . . . . . 1

A. Pre-operational Test Procedures . . . . . . . . . 2-3 . . . . . . . . . . . . .

1

B. Operational Test Procedures . . . . . . . . . . . 2-3 . . . . . . . . . . . . .

5

3. Generator Set Adjustment

. . . . . . . . .

2-3 . . . . . . . . . .

10

A. Generator Adjustment

. . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 10

B. Generator Control Adjustments

. . . . . . . . . 2-3 . . . . . . . . . . . . . 10

C. Basic Engine Adjustments . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 10
D. Engine Accessories Adjustment . . . . . . . . . 2-3 . . . . . . . . . . . . . 10
E. Electric Governor System Adjustment . . . . . . 2-3 . . . . . . . . . . . . . 11

(1) Actuator linkage adjustment

2-3

11

(2) Magnetic pickup adjustment

2-3

12

(3) Adjustment and Test of Controller and Actuator 2-3

14

(a) Preliminary Controller Settings

2-3

14

(b) Checking No-Load Operation of
Controller

2-3

14

(c) Checking Operation of Controller
Under Load

2-3

14

(d) Checking the Actuator

2-3

16

(4) Checking Magnetic Pick-up signal

2-3

16

5. Generator and Exciter Test . . . . . . . . .

2-3 . . . . . . . . . .

16

6. Diode Test . . . . . . . . . . . . . . . . . .

2-3 . . . . . . . . . .

17

A. Disconnect diode lead(s). . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . .

1

CHAPTER 3. TROUBLESHOOTING

SECTION 1. TROUBLE SHOOTING
PROCEDURES . . . . . . . . . . . . . . . . . 3-1 . . . . . . . . . 1

1. General . . . . . . . . . . . . . . . . . . . .

3-1 . . . . . . . . . . . 1

2. Trouble Shooting Chart (Figure 5) . . . . .

3-1 . . . . . . . . . . . 1

3. Equipment for Troubleshooting

. . . . . .

3-1 . . . . . . . . . . . 2

OM-2028

August 31/90 Revised

Table of Contents

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Summary of Contents for 6910

Page 1: ...3 PHASE Specification Number Mounting Voltage Regulator Used 6910 1 6910A 1 6910B 1 Trailer or Truck 430391C 6910C 1 6910A 2 6910B 2 6910C 2 Trailer or Truck 489812A 6910A 3 6910B 3 6910C 3 Fixed Unit W Fuel Tank Batteries 489812A 6910B 4 6910C 4 4 Wheel trailer 5th Wheel Trailer or Truck 489812A 6910B 5 6910C 5 Tractor 489812A Hobart Brothers Company Airport Systems Group Ground Power Equipment T...

Page 2: ...This page intentionally left blank ...

Page 3: ...nsulating gloves when dampness or sweat cannot be avoided Keep clothing dry and never work alone 1 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 break...

Page 4: ...e 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 D 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 int...

Page 5: ...ay 1 91 2 1 12 Aug 31 90 1 1 12 May 1 91 1 1 13 May 1 91 2 2 1 Jun 20 89 1 1 14 May 1 91 2 2 2 Jun 20 89 1 1 15 May 1 91 2 2 3 Jun 20 89 1 1 16 May 1 91 2 2 4 Jun 20 89 1 1 17 May 1 91 2 2 5 Jun 20 89 1 1 18 May 1 91 2 2 6 Jun 20 89 1 1 19 May 1 91 1 1 20 May 1 91 2 3 1 Jun 20 89 1 1 21 May 1 91 2 3 2 Jun 20 89 1 1 22 May 1 91 2 3 3 Jun 20 89 1 1 23 May 1 91 2 3 4 Jun 20 89 1 1 24 May 1 91 2 3 5 J...

Page 6: ...24 May 1 91 3 1 18 Jun 20 89 4 3 25 May 1 91 3 1 19 Jun 20 89 4 3 26 May 1 91 3 1 20 Jun 20 89 4 3 27 May 1 91 3 1 21 Jun 20 89 4 3 28 May 1 91 3 1 22 Jun 20 89 4 3 29 May 1 91 3 1 23 Jun 20 89 4 3 30 May 1 91 3 1 24 Jun 20 89 4 3 31 May 1 91 3 1 25 Jun 20 89 4 3 31A May 1 91 3 1 26 Jun 20 89 4 3 31B May 1 91 3 1 27 Jun 20 89 4 3 32 May 1 91 3 1 28 Jun 20 89 4 3 33 May 1 91 4 3 34 May 1 91 4 1 1 M...

Page 7: ...nal Equipment 1 1 6 A Trailer 1 1 6 B Transformer Rectifier 1 1 6 C Truck 1 1 6 D Second Output and Control Box 1 1 6 E Quick Start Kit 1 1 6 F Memory and Time Delay Board 1 1 6 6 Canopy 1 1 6 7 Engine Generator and Controls Assembly 1 1 7 A Basic Engine 1 1 7 B Engine Manufacturer s Equipment 1 1 7 C Hobart Engine Equipment 1 1 7 1 Electric governor system 1 1 7 a Magnetic pickup 1 1 7 b Control ...

Page 8: ...frequency relay 1 1 16 F Engine Control Panel 1 1 18 1 Engine instruments 1 1 18 2 Engine and generator controls 1 1 18 3 Air cleaner indicator 1 1 19 4 Test receptacle connector 1 1 20 G Power Module Panel Assembly 1 1 21 1 Load contactor 1 1 21 2 Current transformers 1 1 21 3 Overload module 1 1 22 4 Rectifier 1 1 22 5 Terminal boards 1 1 22 8 Test Box 1 1 24 A Description 1 1 24 B Theory of Ope...

Page 9: ...r Delivery Manual Voltage Control 1 3 7 H Discontinue Power Delivery 1 3 7 K Stopping the Engine 1 3 7 3 Test Box Operation 1 3 7 4 Transformer Rectifier Operation 1 3 9 A Direct Current Power Delivery 1 3 9 B Simultaneous 28 5 V DC and 115 V AC Power Delivery 1 3 9 5 Trailer Operation Optional 1 3 10 A Towing 1 3 10 B Parking 1 3 10 CHAPTER 2 SERVICE SECTION 1 MAINTENANCE 2 1 1 1 General 2 1 1 2 ...

Page 10: ...coolant solution 2 1 6 3 Preparing the coolant solution 2 1 7 4 Installing the antifreeze solution 2 1 7 E Draining the Cooling System 2 1 7 F Cleaning the Cooling System 2 1 8 G Cleaning the Radiator Core 2 1 8 H Filling the Cooling System 2 1 8 7 Generator Maintenance 2 1 8 A Cleaning 2 1 9 B Adjustment 2 1 9 8 Drive Belts 2 1 9 A Checking Belt Tension 2 1 9 B Belt Adjustment 2 1 9 9 Trailer Tru...

Page 11: ... 10 C Basic Engine Adjustments 2 3 10 D Engine Accessories Adjustment 2 3 10 E Electric Governor System Adjustment 2 3 11 1 Actuator linkage adjustment 2 3 11 2 Magnetic pickup adjustment 2 3 12 3 Adjustment and Test of Controller and Actuator 2 3 14 a Preliminary Controller Settings 2 3 14 b Checking No Load Operation of Controller 2 3 14 c Checking Operation of Controller Under Load 2 3 14 d Che...

Page 12: ...N 1 INTRODUCTION 4 1 1 1 General 4 1 1 2 Purpose 4 1 1 3 Arrangement 4 1 1 4 Explanation of Parts List 4 1 1 A Contents 4 1 1 B Parts List Form 4 1 1 SECTION 2 MANUFACTURER S CODES 4 2 1 1 Explanation of Manufacturer s Vendor Code List 4 2 1 SECTION 3 PARTS LIST 4 3 1 1 Explanation of Parts List Arrangement 4 3 1 2 Symbols and Abbreviations 4 3 1 CHAPTER 5 OPTIONAL EQUIPMENT CHAPTER 6 MANUFACTURER...

Page 13: ...rs 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 2 3 Para B refers to informati...

Page 14: ...This page intentionally left blank OM 2028 Introduction June 20 89 Revised Page 2 ...

Page 15: ...s number The specification number generally indicates the manner in which the particular individual unit is mounted such as trailer mounting tow tractor mounting stationary mounting truck mounting etc and it may also indicate some other special feature of the unit Identification of different specifications within each series will be explained later in the Description Information and instructions t...

Page 16: ... 2 Access vent covers 7 Mounting frame 3 Lifting eye 8 Engine fan exhaust deflectors 4 Windows 9 Engine exhaust pipe 5 Output receptacle cover 10 Radiator cap access cover Generator Set Figure 1 OM 2028 1 1 May 1 91 Revised Page 2 ...

Page 17: ... with wiring to various test points throughout the electrical circuitry is provided for the attachment of a test box manufactured by Hobart Brothers This test circuitry al lows electricians to perform as many as twenty four tests and checks from one location conveniently and easily E Electric Governor The engine is equipped with an all electric type governor kit 5 and 12 Fig 3 and other special eq...

Page 18: ...ts 72 KW Power factor 0 8 PF Duty cycle 100 Operating speed at 400 Hz 2000 RPM Overload capacity 125 of rated load capacity 325 A GENERATOR PROTECTIVE SYSTEM Overvoltage relay trips 130 V to 134 V resets 125 V Undervoltage relay trips 102 V or below resets 110 V Overfrequency relay trips 415 Hz to 425 Hz resets 410 Hz Underfrequency relay trips 375 Hz to 385 Hz resets 385 Hz Overload relay trips 1...

Page 19: ...e mounting design of the gener ator set For example Specification number 6910 1 identifies a machine designed for mounting on a trailer or truck SPECIFICATION DESCRIPTION 6910 1 6910A 1 Basic unit for trailer or truck mounting with top exhaust and equipped 6910B 1 6910C 1 with a magnetic amplifier type voltage regulator Hobart Part No 430391C 6910A 2 6910B 2 Basic unit for trailer or truck mountin...

Page 20: ... sensing module are connected to generator output leads between the generator and load contactor These solid state modules sense any abnormal condition of voltage or frequency and signal the solid state circuitry of the memory and time delay module to open the load contactor and disconnect output to the aircraft For overvoltage overfrequency and underfrequency conditions the memory and time delay ...

Page 21: ...nd is operable when provided with fuel and 12 V DC power The engine generator assembly is mounted on a welded steel frame A superstructure attached to the main frame provides mounting facilities for the canopy control box electrical equipment and con trols A Basic Engine This generator set is equipped with a 6 cylinder in line turbo charged John Deere Diesel engine See Figure 2 for general specifi...

Page 22: ... module 10 Engine 16 Radiator 4 Control box 11 Engine exhaust pipe 17 Fuel valve solenoid 5 Governor control box 12 Governor actuator 18 Oil pressure switch 6 Starting fluid container 13 Output cable terminal 19 Muffler 7 Voltage regulator board Generator Set Components Figure 3 OM 2028 1 1 May 1 91 Revised Page 8 ...

Page 23: ...the lubricating oil system It is mounted in the side of the cylinder block 18 Fig 3 If the pressure in the lube oil system falls to 10 psi 69 kPa this switch opens and actuates the fuel valve solenoid which shuts down the engine 4 Air cleaner The diesel engine air cleaner Fig 4 is a dry cartridge type It is equipped with a moisture elimi nator and a service indicator The indicator functions to sig...

Page 24: ...1 Viewing chamber 2 Indicating flag 3 Reset button Air Cleaner and Service Indicator Figure 4 OM 2028 1 1 May 1 91 Revised Page 10 ...

Page 25: ... into the exciter stator housing The exciter rotor is mounted on this shaft extension with a Woodruff key and is secured by a washer and 1 2 13 thd 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 controlle...

Page 26: ...d monitoring instruments Trays slide in and out on nylon rollers for easy access to internally mounted components Each tray is easily removable by disconnecting an Amphenol connector unlocking safety latches and sliding the complete tray as sembly out of the control box A shielded instrument panel light is mounted on the left side of the control box front panel to illumi nate controls and instrume...

Page 27: ...he ammeter movement without damage The ammeter dial scale is gradu ated and numbered so that the pointer will indicate the true load current value rather than the meter movement current c Meter and line switches These switches provide a means of selecting and determining which phase of voltage and current is indicated on the voltmeter and ammeter and whether the voltage is line to neutral or line ...

Page 28: ...y 11 Automatic manual switch 4 Instruction plate 12 Receptacle connector 5 Line selector toggle switch 13 Manual voltage control rheostat 6 Meter selector rotary switch 14 Manual control rectifier 7 AC ammeter 15 Tray 8 Tray fastener 16 Flyback diode Generator Control Tray Figure 7 OM 2028 1 1 May 1 91 Revised Page 14 ...

Page 29: ...r an underfre quency condition occurs For generator set operation wherein it is not desired that the overfrequency should trip in stantly the memory and time delay PC module described in the following paragraph can be ordered with a 5 to 6 second time delay For generator set operation wherein it is not desired that the overvoltage relay should trip in stantly the memory and time delay PC module ca...

Page 30: ...ugh terminals E and F on the output cable plug connector e Test bank switch A spst toggle switch 18 provides a means of by passing the interlock relay 1 when supply ing power to a load bank or to an aircraft not equipped with a plug interlock system f Resistor A 100 ohm 25 watt resistor 21 is connected in series with the plug interlock relay to protect the relay in the event that phase C contacts ...

Page 31: ...e delay module 16 Load contactor circuit fuse 5 Over undervoltage module 2 A 6 Over underfrequency module 17 Protective system fuse 2 A 7 Reset switch 18 Test bank switch 8 Light test switch 19 Receptacle connector 9 Hole plug 20 Terminal board 10 Overload indicating light 21 Resistor 100 ohm 25 watt 11 Underfrequency indicating 22 Tray light Protective Relay Tray Figure 8 OM 2028 May 1 91 Revised...

Page 32: ... five revolv ing drums The hourmeter operates only when the engine is running and the oil pressure switch is closed e Fuel gage and blocking diodes An electric fuel gage 2 Fig 9 accurately indicates the quantity of fuel oil in the tank pro vided for the generator set A sending unit mounted in the trailer or truck mounted unit fuel tank supplies the signal to the gage Twelve volt DC operating power...

Page 33: ...ring gear should fail to engage The permissive toggle switch 18 also stops the engine when the toggle is placed in the down STOP position e Indicating lights A green indicating light 14 glows to indicate that power is available to the engine protective system The light operates only when the engine is running and fuel pressure is sufficiently high to close a fuel pressure switch The purpose of the...

Page 34: ...ctor see Fig 12 1 Panel light 12 Air cleaner indicator 2 Fuel gage 13 Engine circuit fuse 10 A 3 Light switch 14 Engine ON indicating light 4 DC Ammeter 15 Engine starter switch 5 Engine generator control switch 16 Deleted 6 Hourmeter 17 Terminal board 7 Load contactor control switch 18 Permissive start switch 8 Coolant temperature gage 19 Test receptacle 9 Load contactor indicating light 20 Charg...

Page 35: ...ous 60 KVA machines This note is for the benefit of those users who may have old style contactors Part number 75GH 566 Hartman No A 874C in stock 2 Current transformers a Ammeter current transformers Three current transformers 4 lower the output load current to a lesser value of definite ratio 500 A to 5 A which will operate the ammeter 4 Fig 9 movement without damage The ammeter dial scale is gra...

Page 36: ...le characteristics NOTE The overload protective system will function when any phase carries 123 to 127 of rated load At 125 load the module will function in 4 minutes At 150 load the module will function in 16 seconds At 200 load the module will function in 4 seconds NOTE All times are plus or minus 25 and are nonadjustable 4 Rectifier A diode bridge rectifier 5 receives 400 Hz AC from phase C of ...

Page 37: ...inal board 7 Overload module 3 Overload current transformer 8 Line drop resistor 50 ohm 25 watt 4 Ammeter current transformer 9 Line drop current transformer 5 Rectifier 10 Blocking diode Power Module Panel Assembly Figure 10 OM 2028 May 1 91 Revised 1 1 Page 23 ...

Page 38: ...ctor switch is wired in such a manner that for any switch position two pre selected test points in the generator set circuitry are connected for testing The selector switch may be rotated to any one of 22 positions however not all positions are used in this installation An instruction plate mounted under the switch knob indicates switch positions and component tested in each position Normal voltag...

Page 39: ...e engine water inlet from the radiator heater output to the engine thermostat housing The heater element is connected to 115 VAC 50 or 60 cycle line current by plugging an extension cord into the weatherproof inlet Item 13 Figure 19 that is mounted into the generator frame A thermostat turns the heater element ON at 140 deg F 60 deg C and OFF at 160 deg F 71 deg C Heated cool ant is circulated thr...

Page 40: ...This page intentionally left blank OM 2028 1 1 May 1 91 Revised Page 26 ...

Page 41: ...d correct by tight ening hose clamps tube fittings etc as required 5 Check security of tractor mounted generator set retaining components Sect 2 1 Fig 2 6 Check the following for sufficient quantity a Fuel Turn ON panel lights to energize fuel gage when engine is stopped Tractor mounted units are supplied from the tow tractor tank b Engine coolant The radiator cap is accessible by opening the hing...

Page 42: ... 1 13 Fig 3 b Route cables through cable horn and clamp and upward to terminal board NOTE Conductor size recommended for AC output is 2 0 size Use No 12 size for control E and F terminals Large cables A B C N should be equipped with terminals having at least a 3 8 inch diameter mounting hole Mounting hole in small leads E and F should be at least 1 4 inch diameter c Each terminal stud is identifie...

Page 43: ...hould be stored in a building which is dry and which may be heated during winter months 3 Moisture absorbing chemicals are available for use where excessive dampness is a problem how ever the unit must be completely packaged and sealed if moisture absorbing chemicals are to be ef fective B Temporary Storage When storing the unit for 30 days or less prepare as follows 1 Lubricate the unit completel...

Page 44: ...o operate the engine once each week a Make certain the cooling system is adequately protected WARNING MAKE CERTAIN OF ADEQUATE VENTILATION BEFORE STARTING THE ENGINE b Start the engine and operate at a fast idle 800 to 1000 RPM until coolant temperature has reached at least 140 deg F c Operate normal operating controls 2 If weekly operation is not possible prepare and protect the engine in accorda...

Page 45: ... Inspection 1 Open the fuel shut off valve 2 Provide 12 V DC power to the engine starting system 3 Check the engine and generator compartments and remove rags or other foreign materials B Normal Engine Starting Procedures Engine starting procedures are outlined below Engine operating controls and monitoring instruments are illustrated in Fig 1 1 If illumination is required place light switch 16 in...

Page 46: ...ssure gage 10 Load contactor circuit 24 Cold weather starting aid fuse 2 A control 11 Protective system fuse 25 Air cleaner indicator 2 A 26 Engine circuit fuse 10 A 12 Protective relay tray 27 Engine protective circuit 13 Instrument panel light indicating light 14 Generator control tray 28 Engine starter switch 15 Fuel gage 29 Blocking diodes 16 Light switch 30 Permissive start switch 17 DC Ammet...

Page 47: ...ltage control 38 Cable length compensation rheostat switch 39 Cable size compensation rheostat 34 Test bank switch 40 Line drop compensation on off switch 35 Light test switch 41 Fuse 5 A 36 Reset switch Operating Controls and Instruments Figure 1 Sheet 2 of 2 May 1 91 Revised 1 3 Page 3 OM 2028 ...

Page 48: ... in the same location on the generator set 1 Assembly of Manually Controlled Starting Aid a Position switches and controls as instructed in steps 1 through 4 paragraph B Normal En gine Starting Procedures preceding b Prepare starting aid for use The starting aid is shipped in a safe condition and is not operable until assembled Assemble as follows WARNING FIRES FUMES AND FLYING PARTS CAN KILL OR I...

Page 49: ...ocedures with Automatic Starting Aid On units having the automatic starting aid cold weather starting procedures are exactly the same as for normal starting As with the manually operated starting aid in extremely cold weather it may be necessary to repeat the starting procedure Observe all of the WARNINGS and CAU TIONS provided in Paragraphs 1 and 2 preceding 1 Clamp screws 2 Cylinder 3 Cylinder c...

Page 50: ... 22 should glow at once to indicate that the load contactor is closed and power is available at the aircraft As soon as the light glows release the switch It will automatically return to the center ON position NOTE If the indicating light 22 should go out as soon as the switch is released and no fault lights are ON it indicates that 28 5 V DC holding current is not being supplied from the aircraft...

Page 51: ...o stop the engine move the START RUN STOP switch 30 to the STOP down position 3 Test Box Operation The test box is useful and convenient in testing the generator set after repair or overhaul and also in trouble shooting To operate the test box proceed as follows A Open left rear canopy doors and connect the test box plug connector see 1 1 3 Fig 14 to the test receptacle connector Fig 4 B Connect t...

Page 52: ...Test Box Operating Ccntrols Figure 3 Test Receptacle Connector Figure 4 OM 2028 1 3 August 31 90 Revised Page 8 ...

Page 53: ...rned DOWN completely to prevent opening of the AC load contactor by an overvoltage condition Readjust T R line drop compensation so that AC voltage as indicated by the generator set voltmeter does not exceed 118 V AC when the DC load is 500 Amperes If higher DC voltage is needed adjust T R line drop compensation as re quired Observe AC voltage while making this adjustment to be certain that it doe...

Page 54: ... Be sure parking brake is released 3 Avoid turns which are shorter than the steering linkage will freely allow 4 Avoid dangerous speed and sudden turns B Parking Observe the following rules when parking the trailer 1 Apply parking brake before disconnecting tow vehicle 2 Always place drawbar in an upright vertical position when trailer is parked OM 2028 1 3 August 31 90 Revised Page 10 ...

Page 55: ...ca tion means the use of correct lubricants and adherence to a proper time schedule Frequency of lubri cation and recommended lubricants are indicated in Figure 1 B Generator The 400 Hz generator requires NO lubrication The rotor is supported by two ball bearing assemblies which are lubricated and sealed at the factory for lifetime maintenance free operation It is suggested that generator bearings...

Page 56: ...cept lubricants that con tain only barium detergent dispersants where 1 50 percent by weight is allowed Diesel lubricating oil specifications are discussed in the John Deere Diesel Handbook for Diesel Engines 3 Oil viscosity The use of an SAE 30 grade oil is recommended for year round service The engine is equipped with an ether starting aid to assist in engine starting during cold weather when SA...

Page 57: ... and Maintenance Chart Figure 1 4 Air Cleaner Service For units that were manufactured up to and during August 1990 the aircleaner used is a dry type with re placeable filter cartridges For units that were manufactured after August 1990 the air cleaner used is a one piece disposable type To service the particular filter your particular unit has proceed as follows A Air Cleaner with Replaceable Fil...

Page 58: ...leaner Cartridge Replacement Figure 2 B Disposable Air Cleaner Refer to Section 4 3 Fig 5A This air cleaner is a dry type which may be cleaned as many as six times before replacing it with a new air cleaner A definite time schedule for cleaning or changing the air cleaner cannot be determined because of varying operating conditions However since this air cleaner can be removed and replaced without...

Page 59: ...urn the air filter for disposal 5 Engine Fuel A Quality The quality of fuel oil used in the diesel engine is a major factor in long engine life and performance Fuel oil must be clean completely distilled stable and non corrosive Only distillate fuel No 1D or No 2D is recommended for use both summer and winter CAUTION CONSULT THE FUEL OIL SELECTING CHART IN THE ENGINE OPERATOR S MANUAL BEFORE SUBST...

Page 60: ...ooling system instead of an antifreeze solu tion keep the cooling system free of rust and sludge by adding a cooling system conditioner that is compatible with aluminum Instructions for use of the conditioner are printed on each can CAUTION USE ONLY A CORROSION INHIBITOR THAT IS COMPATIBLE WITH ALUMINUM DO NOT USE INHIBITORS LABELED AS ACID NEUTRALIZER D Cold Weather Operation 1 General A permanen...

Page 61: ... are securely tight ened f Install the required amount of antifreeze 20 quarts Fill the system with coolant as outlined un der Para 6 H For Specification 6910B 4 use a 54 solution for 40o engine protection FREEZING POINT PERCENTAGE OF ANTI FARENHEIT FREEZE IN SOLUTION 20o F 16 10o F 25 0o F 33 1 3 10o F 40 20o F 45 30o F 50 40o F 54 50o F 58 60o F 62 70o F 65 Antifreeze Solution Table Figure 3 E D...

Page 62: ... or to break the bond between the fins and tubes H Filling the Cooling System Add a cooling system corrosion inhibitor for warm weather operation or permanent antifreeze when the air temperatures expected are at freezing 32 deg F or lower Antifreeze may be premixed if de sired See Fig 1 for cooling system capacity 1 Engine must be STOPPED Close all drain valves except top water outlet valve Leave ...

Page 63: ...r pulley and the crankshaft pulley A properly adjusted belt should deflect about 3 8 inch B Belt Adjustment To adjust belt tension loosen the alternator mounting bolts and change the position of the alternator Upon obtaining the correct tension re tighten both alternator mounting bolts When new belts are fitted it is necessary to run the engine for a short period to allow the new belts to settle i...

Page 64: ...s to support tray as in removal above b Align rails 4 with tracks 5 and slide tray into box Latches will lock automatically c Connect Amphenol connector 3 Generator Exciter Provisions have been made to allow removal of the generator exciter without disturbing or removing the complete generator 1 Preparation for exciter removal a Remove main frame rear cross member by removing four attaching cap sc...

Page 65: ...om its mounted position and tilted outward for access to components mounted on the back side see Fig 6 Do not disconnect the wires 1 Tilt out engine control panel a Remove clamp screw which supports wire conduit above output terminal panel b Remove four cap screws which attach engine control panel to frame superstructure c Maneuver panel to tilt it inward at the bottom and outward at the top 2 Rei...

Page 66: ...Engine Control Panel in Tilt out Position Figure 6 OM 2028 2 1 August 31 90 Revised Page 12 ...

Page 67: ...1 Check crankcase oil level DAILY 2 Lubricate in accordance with Lubrication Chart Ref 2 1 Fig 1 C Coolant 1 Check coolant level DAILY 2 Inspect for signs of rust and corrosion Change coolant if rust and sediment are present See 2 1 Para 6 E F and H 3 Inspect hoses for cracks and deterioration Inspect clamps for tightness D V Belts 1 Inspect V belts for proper tension and adjust if necessary after...

Page 68: ...s fittings clamps X Check V belt tension X Drain refill cooling system TWICE ANNUALLY Change fuel filter elements X Lubricate SEE LUBRICATION CHART Check exhaust system X Open fuel tank drain EVERY 500 HRS ELECTRICAL Check all lights X Clean battery terminals X Check wiring X Check connections X 400 Hz GENERATING AND CONTROL SYSTEM Check output cable connector X Check voltmeter X Check ammeter X C...

Page 69: ... fuses used in both the engine and generator electrical systems Lamp Identification Chart Figure 2 C Wiring and Connections 1 Inspect all cables and leads for broken worn and damaged insulation Light Lamp Lamp Identification Location Manufacturer Number Instrument Panel Control Box Lamp Industry 63 Lights Trade No Engine ON Indicating Engine Control Lamp Industry 1815 Light Panel Trade No Contacto...

Page 70: ...Size Type Instrument panel Engine control Sect 1 1 Fig 9 10A Type AGC lights engine panel item 13 circuit Protective relay Protective relay Sect 1 1 Fig 8 2A Type AGC system tray item 17 Voltage regulator Voltage regulator Sect 1 1 Fig 10 5A Type AGC item 12 Load contactor Protective relay Sect 1 1 Fig 8 2A Type AGC circuit tray item 16 Fuse Identification Chart Figure 3 B Indicating Lights Check ...

Page 71: ...le plug connector for damaged contactors in the end of the plug 5 Trailer and Truck If the generator set comes with either the trailer or truck option refer to Chapter 5 for the number of the Hobart manual which covers the particular option The manual referred to will provide the appropriate in spection procedure Both manuals cover batteries as when either option is used the batteries are in stall...

Page 72: ...This page intentionally left blank OM 2028 2 2 June 20 89 Revised Page 6 ...

Page 73: ...ion 8 Check engine circuit fuse 26 Fig 1 by placing panel light switch 16 in ON position If panel lights 13 operate the fuse 26 switch 16 and lamps are good 9 Check fault indicating lights 9 by pressing test switch 8 If lights glow fuse 11 and indicating lamps are good 10 Make a general inspection of all wiring and terminals Inspect the equipment to be certain no damage will result from starting t...

Page 74: ... in terminal F of the test receptacle and momentarily touch the other end alligator clip to the hot terminal on the starter solenoid to flash the field CAUTION FLASHING THE FIELD IN A REVERSE DIRECTION COULD CAUSE DAMAGE TO VOLTAGE REGULATOR DIODES NOTE If test leads with test prods are not available insert short pieces of wire in proper test terminals to make connections bb Disconnect leads and i...

Page 75: ...ather starting aid control 9 Fault indicating lights 25 Air cleaner indicator 10 Load contactor circuit fuse 2 A 26 Engine circuit fuse 10 A 11 Protective system fuse 2 A 27 Engine protective circuit 12 Protective relay tray indicating light 13 Instrument panel light 28 Engine starter switch 14 Generator control tray 29 Deleted 15 Fuel gage 30 Permissive start switch 16 Light switch 31 Test recept...

Page 76: ...age control rheostat 33 Automatic manual voltage control switch 34 Test bank switch 35 Light test switch 36 Reset switch Operating Controls and Instruments Figure 1 Sheet 2 of 2 OM 2028 2 3 June 20 89 Revised Page 4 ...

Page 77: ... position b Place test bank switch 34 in AIRCRAFT position c Meter switch 5 may be in any position except pointing straight down d If the adjustment of the voltage regulator rheostat See TM 759 OM 2020 has been dis turbed position the knob to mid range position 6 Bring the engine up to governed speed and also energize the generator by holding the engine gen erator control switch 18 in BUILD UP VOL...

Page 78: ...l switch to AUTOMATIC position 15 Position load bank switches etc to apply a light load to the generator 16 Place the load contactor on off switch 20 Fig 1 in the top spring loaded CLOSE position Hold in this position momentarily Hold in this position momentarily The indicating light 22 should glow GREEN and an amperage value should appear on the AC ammeter 4 17 Release the switch 2 and allow it t...

Page 79: ...arious loads Voltages should vary no more than plus or minus 1 from 115 V 28 Check accuracy of voltmeter a Open generator control tray 14 Fig 1 b Connect a master voltmeter of known accuracy to terminals of the voltmeter 2 c Compare unit voltmeter reading with master meter Error must not exceed 2 of full scale 29 Check accuracy of AC ammeter a Connect a master ammeter of known accuracy to the AC a...

Page 80: ...urn will open the load contactor to stop power delivery As a result of the action the undervoltage indicating light 9 should be turned ON A stopwatch or sweep second hand watch is required for this check Proceed as follows a With unit running at normal load use the voltage regulator rheostat to reduce voltage to 104V The load contactor should NOT open after a 5 second delay b Reduce voltage in ste...

Page 81: ...rn on the overfre quency light after some frequency between 415 Hz and 425 Hz is reached all components of the system are functioning properly If the load contactor is not opened within the above frequency range refer to Trouble Shooting Chart to determine which component is defective 42 If the generator is operating under load at this point place the contactor control switch 20 Fig 1 in OFF posit...

Page 82: ...ual Specific information for this particular engine is listed in Figure 6 D Engine Accessories Adjustment 1 Generator and fan belt adjustment Refer to 2 1 Para 8 for fan belt adjustment instructions NOTE Replace fan belts as a matched set Manufacturer John Deere Model 6359TL Type Turbocharged In line 6 cylinder 4 cycle Diesel Displacement 359 cu in 5 88 liters Compression ratio 16 8 1 Firing order...

Page 83: ...making the adjustments RULE 1 Adjust linkage to use FULL TRAVEL of actuator output shaft 1 RULE 2 Linkage must move speed control lever from FULL IDLE to FULL SPEED position or VERY CLOSE to FULL SPEED position in order for the generator to pull 125 load Check and adjust linkage as follows with engine stopped a Before making adjustment observe and note which hole in actuator lever 3 is used to mou...

Page 84: ... the pickup is too far from the flywheel ring gear If the pickup is to be removed for any reason or if the signal is weak less than 2 5 V AC as indicated by a voltage test at the pick up with the engine running at rated speed proceed as follows a Disconnect pull apart connector 1 Fig 5 b Loosen nut 3 and remove magnetic pickup 2 c Inspect to make certain the tip is not damaged from contact with th...

Page 85: ... ADJUSTMENT IS MADE f Back the pickup outward counterclockwise 1 2 turn Hold the pickup securely in this position and tighten nut 3 This adjustment will result in a clearance of approximately 0 028 inch between the pickup tip and the flywheel teeth and give an operating AC voltage of 4 V to 8 V at controller terminals 5 and 6 when the engine is running at no load and governed speed and approximate...

Page 86: ...control showly CLOCKWISE until the governor agains becomes unstable and the actuator lever 3 Fig 1 oscillates If the governor DOES NOT become unstable and the lever DOES NOT oscillate place the I potentiometer control setting at approximately EIGHT increment marks from zero or TWO increment marks from maximum setting If the governor DOES become unstable and the actuator lever DOES oscillate turn t...

Page 87: ...May 1 91 Revised 2 3 Page 15 Electric Governor Controller and its Connections for Series 6910 6910A and 6910B Generator Sets Figure 6 OM 2028 ...

Page 88: ...e governor becomes un stable and the actuator lever oscillates If the actuator lever DOES NOT oscillate at this setting upset the lever manually to cause it to oscillate Next turn the same GAIN potentiometer control slowly COUNTERCLOCKWISE until the governor becomes stable and the oscillations cease Turn the I potentiometer control slowly CLOCKWISE until the governor again becomes unstable and the...

Page 89: ...er of these conditions e Checking Operation of Controller Under Load Apply a load to the generator set then remove the load and observe the length of time re quired for engine speed to again stablize Engine speed should stabilize within 3 to 5 dimin ishing oscilllations If this does not happen proceed as follows With the generator set operating at no load turn the GAIN setting slightly in the COUN...

Page 90: ...Electric Governor Controller With Speed Control PC Board And its Connections for Series 6910C Generator Sets Figure 7 OM 2028 2 3 June 20 89 Revised Page 18 ...

Page 91: ...YELLOW BLACK 7 23 Generator and Exciter Stator Test Values 70F Ambient Temperature Figure 8 6 Diode Test Test values for diodes are not given here because they could be misleading Test values may vary even between diodes of the same part number rating and manufacturer General instructions for testing di odes follows A Disconnect diode lead s B Use a good quality ohmmeter An instrument which indica...

Page 92: ... position 7 K Z Plug interlock relay Plug in aircraft 28 V DC 8 D F Exciter input Unit in GEN mode 8 12 V DC 9 V X Regulator output Unit in GEN mode 50 70V auto man sw in DC AUTO 10 K b Contactor operation Test bank sw closed 115 V AC contactor closed 11 K E Overload contacts at Test bank sw closed 0 V DC less than 125 load contactor closed 12 K R Contactor switch Test bank sw closed 115 V AC cont...

Page 93: ...der three headings as follows 1 Trouble Symptom and Condition 2 Probable Cause 3 Test Check and or Remedy B Use of the Trouble Shooting Chart 1 A troubleshooting chart is furnished to provide maintenance and repair personnel with a time sav ing guide for locating trouble To use the chart proceed as follows a Locate the symptom s of trouble in the Trouble column b Check the probable causes of troub...

Page 94: ...g 8 4 Safety WARNING EXERCISE EXTREME CARE TO AVOID CONTACT WITH HIGH VOLT AGE LEADS AND COMPONENTS WHICH COULD CAUSE SERIOUS SHOCK AND INJURY IF TOUCHED WHEN TROUBLE SHOOTING OR OPERATING THE EQUIPMENT 5 Parts Replacement To lessen end item down time and to get a faulty machine back on theline as quickly as possible the black box concept of parts replacement is reflected in the trouble shooting c...

Page 95: ...hat connections and wiring have always been checked first and that power has not been lost as a result of defective wiring or connections 8 Electric Governor Trouble Shooting The following facts concerning the operation of the electric governor may be helpful in understanding the system and in determining which unit in the system is faulty in case of troubles A The system requires two sources of p...

Page 96: ...h methods of de termining the cause of such conditions are covered in the Trouble Shooting Chart The ability of the engine to start and operate properly depends primarily on two things 1 The presence of an adequate supply of air compressed to a sufficiently high compression pres sure 2 The injection of the proper amount of fuel at the right time Lack of power uneven running excessive vibration sta...

Page 97: ...ather starting aid 9 Fault indicating lights control 10 Load contactor circuit fuse 2 A 25 Air cleaner indicator 11 Protective system fuse 2 A 26 Engine circuit fuse 10 A 12 Protective relay tray 27 Engine protective circuit 13 Instrument panel light indicating light 14 Generator control tray 28 Engine starter switch 15 Fuel gage 29 Deleted 16 Light switch 30 Permissive start switch 31 Test recept...

Page 98: ...age control rheostat 33 Automatic manual voltage control switch 34 Test bank switch 35 Light test switch 36 Reset switch Operating Controls and Instruments Figure 1 Sheet 2 of 2 OM 2028 3 1 June 20 89 Revised Page 6 ...

Page 99: ...al control voltage potential adjusting resistor 2 Exciter field ballast resistors Excitation Resistors Figure 2 End View of Voltage Regulator Amphenol Connector Figure 3 OM 2028 June 20 89 Revised 3 1 Page 7 ...

Page 100: ...Test Receptacle Connector Termi nals Identification Figure 4 OM 2028 3 1 June 20 89 Revised Page 8 ...

Page 101: ...l If the starter attempts to crank the engine it indi cates the starter solenoid is defective Replace If the starter did not operate proceed to step D C Defective starter C If starter did not operate in check C above the starter is defective Re place D Internal seizure E If all engine starting com ponents are good and the starter is unable to crank the engine internal seizure is indicated For repa...

Page 102: ...el source and the suction side of the pump is indicated Check and or remedy as follows 1 Insufficient fuel 1 Fill tank in tank 2 Fuel shut off 2 Make certain valve is valve closed OPEN 3 Loose connections 3 Tighten all fittings and damaged hoses or connections Replace any fuel lines between damaged hoses or fuel tank and links fuel pump 4 Plugged or defec 4 Do not overlook the tive fuel filter pos...

Page 103: ...ions therein 4 Engine is hard to A Low ambient temperature A Check causes and remedies start Cranking or limited fuel under ENGINE Trouble 3 speed normal above B Low compression which B Check compression in accor may be caused by any dance with Para 9 C and D one of the following 1 Sticking or 1 Cylinder head must be burned exhaust removed and overhauled valves to correct this condi tion 2 Compres...

Page 104: ...art engine If the engine continues to run when the permissive start switch is released to the RUN position the oil pressure switch is defective Replace oil pressure switch B Defective or incor B Check wiring to high temper rectly wired high ature switch One Red Yellow temperature switch wire should be connected to S 49 located on the the C terminal With wires engine block on the removed check resi...

Page 105: ...C The control unit may not be adjusted magnetic receiving a signal from the pickup 2 Fig 5 magnetic pickup and the 2 3 fail safe feature of the unit may be functioning to prevent any signal from reaching the actuator To check the magnetic pickup disconnect pickup from con trol unit and connect a high impedance AC voltmeter to the pickup output leads Crank engine but don t start Voltage reading sho...

Page 106: ...oltage remains low or at zero replace control unit Refer to Woodward Handbook for control unit bench tests and adjustments 8 Engine goes to A Governed speed con A Turn speed control adjusting overspeed when con trol adjustment set screw fully counterclock trol switch 18 too high see 2 3 wise Start engine Place Fig 2 is in GEN Fig 6 control switch 18 Fig 2 position in GEN position If engine speed i...

Page 107: ...ck linkage ball governor linkage joints and all connec tions for looseness or binding Be sure linkage will move from idle speed to full speed without lost motion or binding 2 GAIN and STABIL 2 Adjust GAIN and STABIL ITY controls im ITY controls on control properly adjusted unit in accordance with 2 3 Para 3 E 3 3 Magnetic pickup 3 Check and adjust pickup signal weak See 2 3 Para 3 E 2 10 Engine ha...

Page 108: ...ession listed under ENGINE Trouble 4 B above C Low compression C Check compression in accor pressure dance with John Deere Diesel Handbook See causes of low compression listed under ENGINE Trouble 4 B above 12 Engine lacks power A Improper engine A Tune up the engine in adjustments and gear accordance with John Deere train timing Diesel Handbook B Insufficient fuel B See ENGINE Trouble 3 C Insuffi...

Page 109: ...hing to MANUAL control did not affect generator output the trouble is like ly in the generator but to prove the generator is de fective proceed to step B B Defective generator B Use the test receptacle 31 Fig 1 to connect 12 V DC to the exciter field Using leads with alligator clips and test prods connect 12 V DC NEGATIVE lead to terminal D Terminal identifying letters are plainly visible on the f...

Page 110: ...reaching and or leaving the voltage reg ulator Replace switch if defective 2 Defective exci 2 Check EDR contacts A tation deenergi faulty EDR can prevent zation relay power from reaching the K16 1 1 3 voltage regulator Re Fig 7 place relay if defective 3 Defective ballast 3 If output voltage was resistor s See produced when the gener Fig 2 ator set was operated in MANUAL mode the resis tors are go...

Page 111: ... to C terminal see Fig 6 If the generator will NOT produce a normal voltage replace or repair Amphenol connector and wiring between voltage regulator and exciter field as re quired 5 Defective voltage 5 All components in the regulator excitation circuit except the voltage regulator have been tested in steps 1 through 4 above This leaves only the regulator as a cause of trouble Replace complete vol...

Page 112: ... Fig 2 depending on rheostat setting is produced replace resistor 4 Defective rheostat 4 Connect a jumper across R61 32 rheostat If maximum Fig 1 manual control voltage is produced replace rheostat NO 1 LOAD CONTACTOR OPERATING CIRCUIT 2 Load contactor K1 A In addition to defective A After checking fuse F1 in will not close when wiring and step 1 below check all control switch 20 connections in th...

Page 113: ...tray 12 Fig 1 Continued 3 Defective load 3 Set AUTO MANUAL switch contactor control S1 to AUTO position switch S5 20 Connect a jumper with Fig 1 test prods between terminals S and R on the test receptacle If the contactor closes re place control switch 4 Defective rectifier 4 With test receptacle CR6 1 1 terminals S and R 5 Fig 11 connected as above check voltage at load contactor coil terminal X2...

Page 114: ...tive E and F terminals or not plugged Be sure the plug is into aircraft fully mated with the receptacle connector aircraft receptacle connector and making good contact 2 Aircraft rejecting 2 Check aircraft on board power electrical equipment and controls B Blown fuse F2 B Press the lens housing of 1 1 17 Fig 8l in fault indicating lights If protective relay tray lamps do not glow replace fuse F2 C...

Page 115: ...emain closed replace fuse interlock relay K17 Sect 1 1 2 Fig 8 or replace the protective relay tray assembly 3 Load contactor A Fuse 1F or 2F blown A Remove and inspect fuses opens during power 1 1 16 and 17 Fig 8 delivery NO fault Replace as required indicating lights on B A fault has developed B If the load contactor cannot in the load be closed by operation of contactor holding the control swit...

Page 116: ...e tampering voltage is normal 115 V AC with voltage regulator Adjust to normal if necessary rheostat and If the load contactor may have been a is opened again and an over normal action voltage condition is indicated by light DS 37 proceed to step B B Defective over under B Use voltage adjusting rheostat voltage sensing module to reduce voltage K26 to 110 V AC Observe voltmeter and gradually increa...

Page 117: ...ostat to reduce voltage quickly to 90 V If the undervoltage indicating light DS38 is turned ON immediately the protective monitor circuitry is defective Replace pro tective monitor K14 or replace protective relay tray 3 Load contactor A Electric governor A Proceed as follows opens during power improperly adjusted delivery Over or malfunctioning frequency ind cating light DS40 1 Governor improperly...

Page 118: ...place over under frequency relay or complete protective relay tray 5 Load contactor A There may have been A Observe ammeter 4 Fig 1 opens during power an overload condition Check for abnormal overload delivery Overload which caused the condition and correct If indicating overload device K4 overload device functions to light ON to function normally open the load contactor when an overload does not ...

Page 119: ...rmine if open L1 or short circuited 2 Generator operates A Open or short cir A Check stator winding resis single phase cuited winding in tances See 2 3 Fig 12 generator stator G1 for normal values 3 Generator A Loose connection A Check all output connec overheats causing high resis tions Look for discoloration tance caused by heat Tighten or replace as required B Improper or blocked B Check for fo...

Page 120: ...AD 4 Unbalanced output C Defective connection A Check plug and receptacle Continued in output circuit connectors at aircraft Tighten repair or replace as required D Break or cut in out D Inspect Repair or replace put cable assembly as required E Unbalanced load E Check aircraft 400 Hz compo OM 2028 3 1 June 20 89 Revised Page 28 ...

Page 121: ...d except 1 Standard hardware items attaching parts such as nuts screws washers etc which are avail able commercially 2 Bulk items such as wire cable sleeving tubing etc which are also commercially available 3 Permanently attached parts which lose their identity by being welded soldered riveted etc to other parts weldments or assemblies B Parts List Form This form is divided into six columns Beginn...

Page 122: ...umn is used to indicate the applicability of parts to different models of equipment When more than one model of equipment is covered by a parts list there are some parts which are used on only one model This column is used for insertion of a code letter A B etc to indicate these parts and to identify the particular model they are used on Uncoded parts are usable on all models Parts coded A are usa...

Page 123: ...ing Div of Ambac Industries Inc 3664 Main Street Springfield Mass 01107 02231 Anchor Rubber Company 840 South Patterson Boulevard P O Box 832 Dayton OH 45401 02660 Amphenol Division Bunker Ramo Electra Corp 2801 S 25th Avenue Broadview IL 60153 03924 StratoFlex Inc 2nd and Piper Sts Baer Field Box 9190 Waynedale Station Ft Wayne IN 46809 04713 Motorola Inc Semiconductor Products Div Phoenix Arizon...

Page 124: ...94 East Street P O Box 1818 New Haven Connecticut 06508 31361 Woodward Governor Co 1000 E Drake Rd P O Box 1519 Ft Collins CO 80522 35708 Tridon Limited P O Box 1600 Nashville TN 37202 41197 Madine Manufacturing Company 1500 Dekoven Avenue Racine Wisconsin 53401 44655 Ohmite Manufacturing Company 3601 West Howard Street Skokie Illinois 60076 49234 Protectoseal Co 225 W Foster Ave Bensenville IL 60...

Page 125: ...e Boulevard Springfield Illinois 62705 75175 K D Lamp Company 1910 Elm St Cincinnati OH 45210 75358 Knape Vogt Manufacturing Company 2700 Oak Industrial Drive Grand Rapids Michigan 49505 77342 Potter and Brumfield Division AMF Inc 200 Richland Creek Drive Princeton Indiana 47670 78225 Stant Manufacturing Company Inc 1620 Columbia Avenue Connersville Indiana 47331 78388 Synchro Start Products Inc S...

Page 126: ... O Box 609 Columbus Nebraska 68601 91929 Micro Switch Division Honeywell Inc 11 W Spring Street Freeport Illinois 61032 92563 McGill Manufacturing Company Inc Bearing Division 909 N Lafayette Valparaiso Indiana 46383 94222 Southco Inc 210 N Brinton Lake Road Concordville PA 19331 95879 Alemite Instrument Division of Stewart Warner Corporation 1826 Diversey Parkway Chicago IL 60614 98738 Stewart Wa...

Page 127: ...A or AMP ampere AC alternating current AR as required DC direct current Fig Figure hd head hex hexagon Hz Hertz cycles per second I D inside diameter IN inch kVA kilovolt ampere F microfarad No number NHA next higher assembly OM Owners Manual PRV peak reverse voltage PSI pounds per square inch Ref reference the item has been listed previously T R transformer rectifier V volt when used as a prefix ...

Page 128: ...Generator Set Figure 1 OM 2028 4 3 May 1 91 Revised Page 2 ...

Page 129: ...OR TRUCK MOUNTING K 1 6910C 2 GENERATOR SET FOR TRAILER OR TRUCK MOUNTING L 1 6910C 3 FIXED UNIT W FUEL TANK BATTERIES M 1 6910C 4 GENERATOR SET FOR 5TH WHEEL TRAILER MOUNTING N 1 6910C 5 GENERATOR SET FOR TRACTOR MOUNTING P 1 1 DDW 155 EYE LIFTING 1 2 180416 CANOPY ASSEMBLY For Details See Fig 2 A G K M 1 282322 CANOPY ASSEMBLY For Details See Fig 2 H N 1 283013 CANOPY ASSEMBLY For Details See Fi...

Page 130: ...Canopy Assembly Figure 2 OM 2028 4 3 May 1 91 Revised Page 4 ...

Page 131: ...032 DOOR ASSY LEFT REAR CANOPY 1 14 489030 COVER PLEXIGLAS ENGINE CONTROLS 1 15 482426 PANEL ASSY SIDE LEFT REAR CANOPY 1 16 480695 DOOR ASSY ACCESS RECEPTACLE 1 17 403127 CATCH MAGNETIC V94222 No 02 10 201 10 2 18 482386 DOOR ASSY LEFT REAR CANOPY 1 19 404036 LATCH DOOR RECESSED V19220 No 3 4973SSU 2 20 482372 DOOR ASSY LEFT FRONT CANOPY 1 21 482328 PANEL ASSY SIDE RIGHT REAR CANOPY 1 22 481417 T...

Page 132: ...This page intentionally left blank OM 2028 4 3 May 1 91 Revised Page 6 ...

Page 133: ...HORN ASSY CABLE ENTRANCE 1 34 403091 8 PLUG PLASTIC 1 3 4 V28520 NO DP 1750 6 35 482482 BRACKET MTG DOOR LATCH 1 36 482507 ROD STOP DOOR 1 37 404101 LIGHT CLEARANCE V75175 NO 514 0168 4 38 400613 10 LAMP 12V V08108 4 39 84A 1047 LABEL ACCESS PANEL 1 40 181049 COVER REAR CANOPY 1 41 181232 SUPPORT MTG DOOR END 1 NOT ILLUSTRATED OM 2028 August 23 91 Revised 4 3 Page 7 ...

Page 134: ...Generator Set Without Canopy Figure 3 OM 2028 4 3 May 1 91 Revised Page 8 ...

Page 135: ...R ASSY For Details See Fig 6 A J 1 5 282948 KIT ELECTRICAL GOVERNOR ASSY For Details See Fig 6 K P 1 6 180961 KIT QUICK START B G K M 1 282320 KIT QUICK START H J N P 1 7 DELETED 8 430391C REGULATOR ASSEMBLY VOLTAGE For Details See Technical Manual TM 759 AB E K 1 489812A REGULATOR ASSEMBLY VOLTAGE For Details See Technical Manual OM 2020 CD F J L P1 9 180417 KIT AIR CLEANER ASSY For Details See F...

Page 136: ...This page intentionally left blank OM 2028 4 3 May 1 91 Revised Page 10 ...

Page 137: ...Details See Figure 15 J P 1 21 482325 BRACKET MOUNTING PANEL CONTROL 2 22 482317 PANEL ASSEMBLY OUTPUT TERMINAL For Details See Figure 16 A 1 280515 PANEL ASSEMBLY OUTPUT TERMINAL For Details See Figure 16 B G K M 1 23 482318 COVER PANEL OUTPUT TERMINAL AND STATOR TERMINAL 2 24 HF 2752 MOUNT RUBBER For mounting electrical panels on control box support panel and muffler V16238 No 4624 105 16 25 482...

Page 138: ...Radiator and Cooling System Group Figure 4 OM 2028 4 3 May 1 91 Revised Page 12 ...

Page 139: ...FAN 1 8 405743 CAP RADIATOR V78225 NO AAX 4018 1 9 181829 PIPE HOSE COUPLING 1 10 351541 LABEL CAUTION FAN 2 11 W 10869 7 CLAMP HOSE RADIATOR V35708 NO HS 12 6 12 403782 2 SWITCH SHUTDOWN TEMP V51377 NO 1002 04880 34 1 13 W 7814 4 BUSHING PIPE STEEL 1 14 181040 HOSE ENGINE INLET 1 15 56531 HOSE RADIATOR OUTLET 11 1 2 16 280742 SUPPORT RADIATOR HOSE 1 17 DELETED 18 180981 GUARD FAN LEFT 1 19 280637...

Page 140: ...Air Cleaner Assembly For units manufactured before and during August 1990 Figure 5 OM 2028 4 3 May 1 91 Revised Page 14 ...

Page 141: ...90 6 1 6 W 10869 6 CLAMP HOSE V35708 No HS 32 3 7 400059 3 CONNECTOR FEMALE SAE 45 V79470 No 46 X 4 1 8 W 10893 2 FITTING HOSE SWIVEL FEMALE V30327 No KA04 04NS 2 9 56534 HOSE LOW PRESSURE 1 4 ID 48 10 84A 1045 REDUCER RUBBER V82372 NO 40R30SL 1 11 83A 1026 INDICATOR SERVICE FILTER AIR CLEANER V21585 No 14440 001 Mounted on Engine Control Panel See Fig 15 Item 13 1 12 W 10750 3 NIPPLE PIPE 1 8 1 1...

Page 142: ...Electric Governor Kit Figure 6 OM 2028 4 3 May 1 91 Revised Page 16 ...

Page 143: ...OR ACTUATOR ELECTRIC V03613 1 4 84A 1091 ARM THROTTLE GOVERNOR V03613 1 5 402908 JOINT BALL GOVERNOR LINKAGE V57448 No TF 4Y 2 6 W 9476 41 ROD THREADED 1 4 28 X 4 1 7 W 11280 3 NUT HEX 1 4 28 5 8 181891 BOARD P C SPEED CONTROL ASSY K P 1 9 84A 1075 MOUNT SHOCK RUBBER TECH PRODUCTS CORP NO 50 DURO 4 10 482989 STRAP WIRE GRND 2 11 280460 BRACKET GOVERNOR MTG 1 12 180889 BRACKET MTG CONTROLLER 2 13 2...

Page 144: ...Fuel Lines Assembly Figure 7 OM 2028 4 3 May 1 91 Revised Page 18 ...

Page 145: ...LE PIPE 1 2 1 8 400818 1 FITTING 1 2 X 3 8 1 9 400819 2 VALVE BALL ECON O MITE V98991 No 4211B 1 10 W 7814 2 BUSHING PIPE STEEL 1 4 X 3 8 1 11 W 10759 1 NIPPLE PIPE 1 4 1 12 403592 VALVE CHECK 1 4 X 1 4 1 13 400333 2 ELBOW MALE FEMALE 1 4 X 5 8 1 14 W 10891 6 ELBOW MALE 1 8 X 5 8 1 15 78B 1019 3 TUBE RIGID HOSE END 1 4 1 16 56534 HOSE LOW PRESSURE 1 4 60 17 W 10893 2 FITTING HOSE SWIVEL FEMALE 1 4...

Page 146: ...Oil Line Assembly Figure 8 OM 2028 4 3 May 1 91 Revised Page 20 ...

Page 147: ... REF 1 403809 1 SWITCH LOW OIL PRESSURE V51377 No C 25900 10 1 2 W 10909 1 TEE STREET BRASS V79470 No 3750 X 2 1 3 W 10886 1 CONNECTOR MALE WEATHERHEAD V79470 No 48 X 4 1 4 403590 1 SWIVEL FEMALE 7 16 20 SAE THDS V03924 No 7115 4S 2 5 56548 HOSE 4 3 16 ID 52 NOT ILLUSTRATED OM 2028 August 23 91 Revised 4 3 Page 21 ...

Page 148: ...Stator Terminal Panel Assembly Figure 9 OM 2028 4 3 May 1 91 Revised Page 22 ...

Page 149: ...IN 9 4 482446 RETAINER CABLE 6 5 482443 BAR BUS 3 6 W 10854 4 CAPACITOR 0 1 MFD 500 V V90201 No B 206143 3 7 482471 STRAP CONNECTING CAPACITORS 1 8 482449 BRACKET MOUNTING BOARD 2 9 401937 1 BLOCK TERMINAL V98410 No 35005 3526 1 10 W 11112 3 SCREW ROUND HEAD MH STEEL 10 24 X 3 4 3 11 W 11254 3 WASHER LOCK 10 STEEL 3 12 W 11245 3 WASHER FLAT BRASS 3 13 482450 PANEL TERMINAL OUTPUT 1 NOT ILLUSTRATED...

Page 150: ...Power Module Panel Assembly Figure 10 OM 2028 4 3 May 1 91 Revised Page 24 ...

Page 151: ... 01 4 13 363136 5 TRANSFORMER CURRENT AMMETER 3 14 400701 CONNECTOR RIGHT ANGLE V59730 No TA 250 8 5 15 401939 ADAPTER TERMINAL V98410 No VWA 0 1 16 400830 15 TERMINAL RING TONGUE V89110 No 31159 3 17 402197 1 TERMINAL QUICK CONNECT PIGGYBACK V89110 No 61944 2 1 18 400480 2 TERMINAL QUICK CONNECT V00779 No 41274 5 19 400480 3 TERMINAL QUICK CONNECT V00779 No 42640 2 2 20 1CZ 93B DIODE SILICON V052...

Page 152: ...Control Box Assembly Figure 11 OM 2028 4 3 May 1 91 Revised Page 26 ...

Page 153: ...etails see Fig 13 1 3 No Number CONTROL BOX AND INTERNAL COMPONENTS GROUP For Details See Fig 14 1 4 76A 1130 CLAMP TUBE V78553 No C 4362S 031 5 16DA 4029 BRACKET MOUNTING RELAY H N 1 6 16DA 4004A 10 RELAY PLUG IN V77342 No KAP 14DG H N 1 7 16DA 4052 0 SOCKET RELAY 02660 No 77 MIP 11 H N 1 8 16DA 4253 1 RETAINER SPRING RELAY V77342 No 20C206 H N 1 9 1CZ 93B DIODE FLY BACK V05277 No IN 4820 H N 1 1...

Page 154: ...Generator Controls Tray Assembly Figure 12 OM 2028 4 3 May 1 91 Revised Page 28 ...

Page 155: ...ASTIC 3 16 IN I D 2 13 16DA 4029 BRACKET MOUNTING SOCKET RELAY 1 14 16DA 2162 KNOB RHEOSTAT V44655 No 5150 1 15 10J 178 NAMEPLATE FIELD RHEOSTAT 1 16 381439 BRACKET MOUNTING RHEOSTAT 1 17 402218 RHEOSTAT MANUAL MODEL L V44655 100 Ohms 150 Watts 1 18 HF 1459 SWITCH METER SELECTOR V82121 No 101904LN 1 19 15GH 433 NAMEPLATE METER SELECTOR SWITCH 1 20 400400 SWITCH TOGGLE V73559 No 26L61TABS 1 21 W 80...

Page 156: ...Protective Relays Tray Assembly Figure 13 OM 2028 4 3 May 1 91 Revised Page 30 ...

Page 157: ... UNDERFREQUENCY 1 16 401563 4 HOUSING PIN CONNECTOR 1 17 76A 1118 SWITCH SNAP PUSHBUTTON 2 18 403336 RING LOCKING SWITCH 2 19 HF 2518 2 LIGHT PILOT FAULT RED 12 V 5 20 400613 4 BULB Type 1815 1 21 402658 HOLDER FUSE 2 22 W 11166 1 FUSE AGC 2 A 1 23 W 11166 1 FUSE AGC 2 A 1 24 16DA 1997 6 BUTTON PLUG HOLE 1 25 402037 9 GROMMET RUBBER 1 26 388328 52 NAMEPLATE IDENTIFICATION 1 27 401566 11 TERMINAL S...

Page 158: ...Control Box and Internal Components Group Figure 14 OM 2028 4 3 May 1 91 Revised Page 32 ...

Page 159: ...11 2 2 82B 1047 LIGHT PANEL V74400 No MI 3216 1 3 400613 4 BULB V74400 No 3271 1 4 W 10051 10 CLAMP WIRE PLASTIC V81074 No EC 10 2 5 W 10051 13 CLAMP WIRE PLASTIC V81074 No EC 14 1 6 402383 SLIDE ASSEMBLY TRAY For Details See Tray Assemblies Fig 12 or 13 REF 7 482236 BOX ASSEMBLY CONTROL A G J M P 1 489444 BOX ASSEMBLY CONTROL H N 1 NOT ILLUSTRATED OM 2028 August 23 91 Revised 4 3 Page 33 ...

Page 160: ...Engine Control Panel Assembly Figure 15 OM 2028 4 3 May 1 91 Revised Page 34 ...

Page 161: ...8 DW 4304 GAUGE TEMPERATURE WATER V57733 No 2100 1 9 HF 2518 8 LIGHT PILOT ENGINE GENERATOR GREEN 2 400613 4 BULB V74400 No 3271 1 10 DW 6080 GAUGE PRESSURE OIL V57733 No 352 AW 1 11 16DA 1997 5 BUTTON PLUG HOLE V90763 No SS 48172 1 12 No Number CONTROL COLD WEATHER STARTING AID Part of Item 7 Fig 3 1 13 83A 1026 INDICATOR SERVICE FILTER AIR CLEANER Part of Air Cleaner Kit See Fig 5 Item 11 for ve...

Page 162: ...This page intentionally left blank OM 2028 4 3 May 1 91 Revised Page 36 ...

Page 163: ...02660 No 9760 28 1 25 482304 HARNESS WIRE TEST RECEPTACLE ASSY A 1 280510 HARNESS WIRE TEST RECEPTACLE ASSY B P 1 26 W 10051 13 CLAMP WIRE PLASTIC 1 27 482298 NAMEPLATE CONTROLS A G K M 1 282311 NAMEPLATE CONTROLS H J N P 1 28 400059 3 CONNECTOR FEMALE SAE 45 V79470 No 46 X 4 1 29 12CW 2125 FITTING PIPE STREET ELL 45 V79470 No 3350 X 2 1 30 DELETED NOT ILLUSTRATED OM 2028 August 23 91 Revised 4 3 ...

Page 164: ...Output Terminal Board Assembly Figure 16 OM 2028 4 3 May 1 91 Revised Page 38 ...

Page 165: ...M OUTPUT A 2 280516 BRACKET MOUNTING BOARD TERM OUTPUT B G K M 2 5 W 11097 18 SCREW HHC STEEL 3 8 16 X 3 4 8 6 W 11254 6 WASHER LOCK STEEL 3 8 IN 8 7 W 11242 10 WASHER FLAT STEEL 3 8 IN 8 8 482446 RETAINER CABLE 4 9 482443 BAR BUS PHASE 4 10 W 11112 3 SCREW RD HD MH STEEL 10 24 X 3 4 4 11 W 11254 3 WASHER 10 LOCK STEEL 4 12 W 11245 3 WASHER 10 FLAT BRASS 4 13 482444 BOARD TERMINAL OUTPUT 1 14 W 11...

Page 166: ...Generator Assembly Figure 17 OM 2028 4 3 May 1 91 Revised Page 40 ...

Page 167: ... 386612 RING SPACER COUPLING 1 13 481379 KEY EXCITER 1 14 387624A 1 HOUSING EXCITER 1 15 100NH 2 POLEPIECE 4 16 100NH 3 INSULATION EXCITER 4 17 Data 3190 COIL FIELD EXCITER 1 SET 18 387620A 2 HOUSING FAN ASSEMBLY A 1 387620A 1 HOUSING FAN ASSEMBLY B P 1 19 480646 KEY FLEXIBLE COUPLING A 1 85B 1039 KEY FLEXIBLE COUPLING B P 1 20 W 10072 48 BEARING FRONT V21335 W314PP A 1 W 10072 68 BEARING FRONT V5...

Page 168: ...Mounting Frame Assembly and Lifting Yoke Figure 18 OM 2028 4 3 May 1 91 Revised Page 42 ...

Page 169: ... 2 4 481113 PLATE END REAR 1 5 280041 FRAME MOUNTING 1 6 402194 FITTING GREASE V95879 No 1728 J J P 10 7 401898 2 CAM FOLLOWER V92563 No CF 1 1 2 J P 10 8 387915 TRACK ROLL OUT LEFT J P 1 9 387916 TRACK ROLL OUT RIGHT J P 1 10 387947 STOP FRAME MOUNTING J P 1 11 387600 BRACKET RETAINING FRAME J P 2 12 430278 GROMMET RUBBER V89616 No TPR 1812 3 13 A 25 WASHER INSULATOR 2 14 AW 626 BUSHING 1 NOT ILL...

Page 170: ...Water Heater Figure 19 OM 2028 4 3 May 1 91 Revised Page 44 ...

Page 171: ...ITTING MALE CONNECTOR 48 X 6 X 6 H J N P 1 5 W 10890 2 FITTING ELBOW FEMALE 3 8 PIPE H J N P 1 6 404214 FITTING PIPE NIPPLE 3 8 PIPE TO 5 8 HOSE H J N P 2 7 W 10869 1 CLAMP HOSE H J N P 6 8 W 10882 2 FITTING PIPE ADAPTER 3200X6X4 4 H J N P 1 9 56537 HOSE CONNECTION HEATER INLET 5 8 I D H J N P 14 10 282334 INLET WEATHERPROOF WATER HEATER H J N P 1 11 386751 CLAMP HEATER POWER CORD H J N P 2 NOT IL...

Page 172: ...This page intentionally left blank OM 2028 4 3 May 1 91 Revised Page 46 ...

Page 173: ... 28 5 V DC OM 433 487750 1 Transformer Rectifier Mounting Kit TO 105 481387 Truck Body Package TO 109 481386 Truck Chevrolet Std TO 109 404137 Truck GMC TO 109 404238 Truck Ford TO 109 403757 Second Output TR Box Mounted for S 6810 1 2 and 3 TO 128 481428 Quick Start Assembly Operator Controlled _ OM 2028 180961 Quick Start Assembly Thermostatically Controlled OM 2028 282320 Kit Water Heater Assem...

Page 174: ...This page intentionally left blank OM 2028 5 0 May 1 91 Revised Page 2 ...

Page 175: ...al TM 360 Hobart Diagrams 482099 Connection Power Module 6910 6910A 6910B 6910C 488705 Schematic Engine 6910 180893 Schematic Engine 6910A 6910B1 thru 6910B 3 282953 Schematic Engine 6910B 4 6910B 5 6910C 4 6910C 5 482360 Schematic Generator 6910 6910A 6910B 6910C 281678 Connection Engine 6910 6910A 6910B1 thru 6910B 3 282952 Connection Engine 6910B 4 6910B 5 6910C 4 6910C 5 488747 Connection Gene...

Page 176: ...This page intentionally left blank OM 2028 6 0 June 20 89 Revised Page 2 ...

Page 177: ... I I I I I l zE I I 01 39NVN jlOVlQ t __ ...

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Page 185: ...XCITATION DE ENERGIZATION RELAY FUSE INTERLOCK I RELAY UNDERFREOUENCY AUXILIARY RELAY DVER UNDERVDLTAGE S S RELAY OVER UNDERFREOUENCY S S LOAD CONTACTOR 2 IWHEN FURN RELAY PLUG INTERLOCK 2 WHEN FURNJ RELAY FUSE INTERLOCK 2 iWHEN FURN LI L2 FIELD REVOLVING GENERATOR FIELD EXCITER GENERATOR Ml M2 MS AMMETER GENERATOR VOLTMETER FREOUENCY METER PI P2 P3 PI P6 P7 PI4 PI5 PLUG VOLTAGE REGULATOR PLUO PRO...

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