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3. Equipment for Troubleshooting

A good quality multi-scale voltohmmeter is the only instrument required for trouble shooting. At least

two “jumper” leads with “alligator” clips and test prods will be required. The 12-V, engine electrical system may
be used as a 12-V DC power source. If a test box, part number 388318-2, is available, tests may be made
more quickly and accurately, however, the test receptacle connector

(31, Fig. 1)

may be used by inserting the

test points of a voltohmmeter into proper terminals of the connector. Refer to Fig. 8.

4. Safety

WARNING: EXERCISE EXTREME CARE TO AVOID CONTACT WITH HIGH
VOLTAGE LEADS AND COMPONENTS WHICH COULD CAUSE SERIOUS
SHOCK AND INJURY IF TOUCHED WHEN TROUBLE SHOOTING OR OPER-
ATING 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 chart. For example, if a com-
ponent in the protective relay tray is defective, the quickest way to remedy the situation is to replace the
complete tray assembly and send the old tray to stock.

Assemblies which lend themselves to this concept are:
Generator control tray
Over-undervoltage module
Protective relay tray
Over-underfrequency module
Voltage regulator
Overload module
Protective monitor module
Electric governor control “box”
Governor actuator

The above items are in addition to normally replaced items such as fuel pump, injectors, relays,
etc.

6. Test Values

Although test values are provided throughout the trouble shooting chart, where applicable, additional infor-
mation and values are given here.

Generator output at maximum
voltage regulator rheostat setting 134 V or higher
7Generator output at minimum
voltage regulator rheostat setting 108 V or lower
Overload relay trips at any value above 112 KVA in 5 minutes.
Overvoltage relay trips at 130 to 134 V AC, resets at 125 V AC.
Undervoltage relay trips at 93 to 102 V AC, resets at 110 V AC.
Undervoltage time delay circuit functions in 4 to 12 seconds.
Overfrequency relay trips at 415 to 425 Hz, resets at 410 Hz.
Underfrequency relay trips at 375 to 380 Hz, resets at 385 Hz.
Overload relay trips at 125% rated load in 5 minutes.
See 2-3, Fig. 8 for typical test values at test receptacle and test box.

OM-2029

3-1

September 30/89 Revised

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Summary of Contents for 140GT17K

Page 1: ... mounted 6906 3 Basic Series 6906 generator set mounted on 5th wheel trailer with T R provisions fuel tank battery and trays for battery and cables 6906 4 Basic Series 6906 generator set truck mounted and equipped with magnetic amplifier type voltage regulator Part No 281407 6906 5 Basic Series 6906 generator set mounted on 5th wheel trailer 6906 6 Basic Series 6906 generator set mounted on 5th wh...

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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: ... 2 Sept 30 89 2 1 12 Sept 30 89 1 1 3 Mar 16 90 2 1 13 Sept 30 89 1 1 4 Mar 16 90 2 1 14 Sept 30 89 1 1 5 July 27 90 1 1 6 July 27 90 2 2 1 Sept 30 89 1 1 7 Sept 30 89 2 2 2 Sept 30 89 1 1 8 Sept 30 89 2 2 3 Sept 30 89 1 1 9 Sept 30 89 2 2 4 Sept 30 89 1 1 10 Sept 30 89 2 2 5 Sept 30 89 1 1 11 Sept 30 89 2 2 6 Sept 30 89 1 1 12 Sept 30 89 1 1 13 Sept 30 89 2 3 1 July 27 90 1 1 14 July 27 90 2 3 2 ...

Page 6: ...1 20 July 27 90 4 3 27 Sept 30 89 3 1 21 Sept 30 89 4 3 28 Sept 30 89 3 1 22 Sept 30 89 4 3 29 July 27 90 3 1 23 Sept 30 89 4 3 30 July 27 90 3 1 24 Sept 30 89 4 3 31 July 27 90 3 1 25 Sept 30 89 4 3 32 Sept 30 89 3 1 26 Sept 30 89 4 3 33 July 27 90 3 1 27 Sept 30 89 4 3 34 Sept 30 89 3 1 28 Sept 30 89 4 3 35 July 27 90 4 3 36 Mar 16 90 4 1 1 July 27 90 4 3 37 July 27 90 4 1 2 Mar 16 90 4 3 38 Mar...

Page 7: ...tifier 6906 3 and 6906 4 ONLY 1 1 6 C Truck 1 1 6 D Quick Start Kit 1 1 6 6 Canopy 1 1 6 7 Engine Generator and Controls Assembly 1 1 6 A Basic Engine 1 1 6 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 unit 1 1 7 c Actuator 1 1 7 2 Engine electrical system 1 1 7 3 Engine protective devices 1 1 9 4 Air cle...

Page 8: ...h 1 1 15 j Excitation deenergization relay 1 1 15 k Voltage Regulator 1 1 17 F Engine Control Panel See Fig 9 1 1 18 1 Engine instruments 1 1 18 2 Engine and generator controls 1 1 18 H Power Module Panel Assembly 1 1 20 1 Load contactor 1 1 21 2 Current transformers 1 1 21 3 Rectifiers 1 1 21 4 Overload module 1 1 22 5 Terminal boards 1 1 22 SECTION 2 PREPARATION FOR USE STORAGE OR SHIPPING 1 2 1...

Page 9: ...neous 28 5 V DC and 115 V AC Power Delivery 1 3 7 4 Trailer Operation Optional 1 3 8 A Towing 1 3 8 B Parking 1 3 8 CHAPTER 2 SERVICE SECTION 1 MAINTENANCE 2 1 1 1 General 2 1 1 2 Inspection 2 1 1 3 Lubrication 2 1 1 A General 2 1 1 B Generator 2 1 1 C Generator Controls 2 1 1 D Engine 2 1 1 1 Lubrication schedule 2 1 2 2 Oil specification 2 1 2 3 Oil viscosity 2 1 2 4 Changing engine oil 2 1 2 5 ...

Page 10: ...ension 2 1 8 B Belt Adjustment 2 1 8 9 Trailer and Truck Maintenance 2 1 9 A General 2 1 9 B Cleaniness 2 1 9 C Grease application 2 1 9 D Lubrication chart 2 1 9 2 1 10 E Checking Wheel Bearings 2 1 12 F Adjusting Wheel Bearings 2 1 12 10 Battery Service 2 1 12 A General 2 1 12 B Battery Location and Accessibility 2 1 12 C Battery Care 2 1 12 D Liquid Level 2 1 12 E Cleaning the Battery 2 1 13 F ...

Page 11: ... 3 8 C Basic Engine Adjustments 2 3 9 D Engine Accessories Adjustment 2 3 9 E Electric Governor System Adjustment 2 3 9 1 Actuator linkage adjustment 2 3 9 2 Magnetic pickup adjustment 2 3 11 3 Governor Control Unit Adjustment 2 3 12 5 Generator and Exciter Test 2 3 14 6 Diode Test 2 3 14 CHAPTER 3 TROUBLESHOOTING SECTION 1 TROUBLESHOOTING PROCEDURES 3 1 1 1 General 3 1 1 2 Troubleshooting Chart 3...

Page 12: ...2 5 EFF Effectivity Column 4 1 2 6 UNITS PER ASSEMBLY Column 4 1 2 SECTION 2 MANUFACTURERS CODES 4 2 1 1 Explanation of Manufacturers Vendors 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 SECTION 4 NUMERICAL INDEX 1 Explanation of Numerical Index 4 3 1 CHAPTER 5 OPTIONAL EQUIPMENT CHAPTER 6 MANUFACTURERS LITERATURE UNUSUA...

Page 13: ...an in a compartment on the truck See Figure 1 2 Description In regard to physical appearance electrical output ratings and operation the Specification 6906 2 or 6906 4 generator set with the aforementioned modification as covered by this addendum is identical to all other Specification 6906 2 or 6906 4 generator sets Figure 2 is an illustration that shows the various components of the inboard batt...

Page 14: ...1234567 EFF ASSY 2 281926 BATTERY INSTALLATION For units having ONE battery REF 1 281871 1 BATTERY 12 VOLTS 1 2 281927 SUPPORT BATTERY 1 3 181831 FRAME HOLD DOWN BATTERY 1 4 481209 4 CABLE POSITIVE 1 5 383067 5 CABLE NEGATIVE 1 6 5CW 2048 ROD BATTERY SUPPORT ASSY 2 OM 2029 Addendum June 6 90 Page 2 ...

Page 15: ...ipment you are in vited to contact our service department by mail telephone or FAX Write Hobart Brothers Company Airport Systems Group 1177 Trade Road East Troy Ohio 45373 U S A Telephone 513 332 5060 Service Assistance 513 332 5050 Parts Replacement FAX 513 332 5121 OM 2029 June 6 90 Addendum Page 3 ...

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Page 19: ...bilities 2 Orientation For purpose of orientation and to familiarize operators and maintenance personnel with the location of components the radiator is considered to be at the FRONT of the unit The generator and controls are at the REAR RIGHT and LEFT are determined by standing at the rear end facing the machine Thus the generator controls are mounted on the REAR of the unit 3 Special Features Th...

Page 20: ...1 Canopy 5 Engine fan exhaust vent 2 Lifting eye 6 Engine exhaust pipe 3 Windows 7 Radiator cap 4 Mounting frame Generator Set without trailer Figure 1 OM 2029 1 1 September 30 89 Revised Page 2 ...

Page 21: ...c type governor kit 9and 15 Fig 3 and other special equip ment more fully described under the engine description E Hinged Front Panel on Generator Control Box The control box is equipped with a hinged front panel Located conveniently on this panel are switches meters indicator lights and circuit breakers for controlling and monitoring the generator This panel swings out to provide easy access to t...

Page 22: ...of fuel and no cables 7160 pounds 3247 kg GENERATOR Output power rating 140 KVA Output voltage 115 200 V Rated load capacity 404 Amp Frequency cycles per second 400 Hz Output kilowatts 112 KW Power factor 0 8 PF Duty cycle 100 Operating speed at 400 Hz 1714 RPM Overload capacity 505 Amp 125 of rated load capacity GENERATOR PROTECTIVE SYSTEM Overvoltage relay trips 130 V to 134 V resets 125 V Under...

Page 23: ...fix The suffix number indicates either the mounting design and or some other major feature s of the generator set SPECIFICATION MOUNTING DESCRIPTION 6906 1 Trailer Basic generator set in Series 6906 having a fuel tank battery plus a tray for battery and cables 6906 2 Truck Basic generator set in Series 6906 similar to Spec 6906 1 except for mounting 6906 3 5th Wheel Trailer Has provisions for tran...

Page 24: ...1 3 Para 2C 6 Canopy A sheet metal enclosure identified as a canopy 1 Fig 1 provides protection for the engine generator and electrical controls The canopy is designed to reduce operational noise in the immediate area of the machine Four hinged doors on the left side provide easy access for service and maintenance Two hinged doors near the front on the right side provide access to the engine compa...

Page 25: ...gnetic pickup The magnetic pickup is a device for detecting the speed of the engine It is mounted in the fly wheel housing directly over the ring gear It produces an AC signal to the control unit when the ferrous flywheel teeth pass through the magnetic field at the end of the pickup b Control unit The control unit 9 Fig 3 is a box containing a compact assembly of solid state components It receive...

Page 26: ...se Pipe 10 Power Module Panel 17 Lube Oil Pressure Sensor 4 Diesel Engine 11 Generator Assembly 18 High Engine Temperature 5 Lifting Eye 12 Frame Switch 6 Lifting Yoke 13 Engine Control Panel 19 Water Temperature Sensor 7 Air Cleaner 14 Output Terminal Panel Generator Set Components Figure 3 OM 2029 1 1 September 30 89 Revised Page 8 ...

Page 27: ...r The indicator functions to signal the operator when the cartridge needs changing A red cylindrical flag 2 is forced upward in a glass enclosed viewing chamber 1 when air pressure within the air cleaner housing drops below the outside air pressure As the car tridge becomes loaded with dirt and air pressure within the cleaner lessens the flag gradually rises higher in the glass viewing chamber Whe...

Page 28: ... puressure gage 4 Fig 9 on the engine control panel 7 Exhaust system The exhaust system consists of a special noise reducing muffler 2 Fig 5 which is connected by a pipe 1 to a conventional exhaust manifold The tail pipe 3 directs exhaust and noise down ward 8 Radiator The radiator 1 Fig 3 is a one piece item designed for long periods of operation without servic ing Refer to Section 2 1 Para 6 G f...

Page 29: ...ntrolled by the amount of DC voltage supplied to exciter fields by the static voltage regulator A centrifugal radial blade fan which is part of the hub and coupling assembly draws cool ing air over all internal windings Air enters at the exciter end and is discharged at the drive end The complete generator is bolted to the engine flywheel housing E Control Box Assembly The control box Fig 6 is a s...

Page 30: ...eans 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 to line The meter switch 7 is a four position rotary type Around the switch knob the panel is marked and lettered to indicate the three functional positions of the meter switch When the knob is pointing straight down the switch is OFF The...

Page 31: ...mp 13 Generator ammeter 5 Test reset switch 14 Overload indicating light 6 Protective system circuit breaker 15 Undervoltage indicating light 7 Meter selector switch 16 Overvoltage indicating light 8 Line switch 17 Panel latch 9 Overfrequency indicating light Generator Control Box Front Panel Components Figure 7 OM 2029 September 30 89 Revised 1 1 Page 13 ...

Page 32: ... circuit trips at any value over 125 rated load capacity b Memory and time delay module The memory and time delay module 19 is sometimes called the protective monitor module It is a solid state device with a hermetically sealed reed type relay The printed circuit board or card includes five memory circuits and a time delay circuit Each circuit is connected to a corresponding sensing circuit in the...

Page 33: ...use interlock relay The function of the fuse interlock relay 6 is to interrupt the load contactor holding coil circuit and remove the load in case of a tripped circuit breaker in the protective relay coil circuit g Auxiliary underfrequency relay The function of the auxiliary underfrequency relay 7 is to automatically open the excitation deenergization relay and disconnect the voltage regulator any...

Page 34: ...6 Protective system interlock relay 16 Control box left side panel No 1 output 17 Over undervoltage relay 7 Auxiliary underfrequency relay 18 Over underfrequency relay 8 Plug interlock relay No 1 output 19 Memory time delay relay 9 Voltage regulator Magnetic 20 No 2 contactor hold circuit resistor Amplifier type shown 21 Ballast resistor 20 ohm 100 watt 10 Line drop compensator assembly 22 No 1 co...

Page 35: ...pter 6 of this generator set manual OM 2029 Generator set Specifications 6906 3 4 5 and 6 are equipped with a magnetic amplifier type voltage regulator Hobart Part No 281407 Information and instructions for this regulator are contained in Hobart regulator manual TM 759 found in Chapter 6 of this generator set manual OM 2029 23 Switch bracket behind generator control panel 24 Test bank aircraft swi...

Page 36: ... the generator 12 V DC control system when the engine is running d Hourmeter The hourmeter 6 is electrically driven from the 12 V DC battery system The hourmeter measures and records engine running time and will record up to 9999 9 hours on five re volving drums The hourmeter operates only when the engine is running and the oil pres sure switch is closed 2 Engine and generator controls a Engine ge...

Page 37: ...ter gear with the flywheel ring gear and apply power to the starter motor to crank the engine The auxiliary solenoid switch is neces sary because the start pushbutton switch is not capable of carrying the high amperage flow to the starter solenoid which would result if the starter gear and ring gear should fail to en gage The permissive rocker switch 14 also stops the engine when the toggle is pla...

Page 38: ...e panel lights 9 Indicator No 1 load contactor 18 Air filter service indicator Engine Control Panel Figure 9 H Power Module Panel Assembly The power module panel assembly Fig 10 sometimes referred to as the contactor panel is lo cated at the right rear of the machine behind the control box The power module panel is accessi ble by opening the left rear door on the canopy The panel assembly provides...

Page 39: ...ormers The three line drop current transformers 18 in conjunction with burden resistors 17 de tect the magnitude and power factor of current flowing from generator to load They feed a signal to the voltage regulator which interprets the signal and alters the exciter field current as required to maintain a constant predetermined voltage at the load see Voltage Regula tor Manuals No TM 759 for a Mag...

Page 40: ...lid state circuitry is designed to close relay contacts when output current in ANY phase reaches 125 of normal rated output capacity The closed relay sends a signal to the protec tive monitor This signal gates the overload SCR silicone controlled rectifier in the protec tive monitor and interrupts the load contactor holding circuit allowing the load contactor to open The following is a list of ove...

Page 41: ...esistors 25 watt No 2 output 13 No 1 overload PC module 5 Overload transformers No 1 output 14 No 2 overload PC module 6 Blocking diodes 15 Connector socket housings 7 Terminal strips 16 Ammeter current transformers 8 No 1 load contactor 17 Resistors 50 ohm 25 watt 9 No 2 load contactor 18 Line drop transformers Power Module Panel Assembly Figure 10 OM 2029 September 30 89 Revised 1 1 Page 23 ...

Page 42: ...Output Terminal Panel Figure 11 OM 2029 1 1 September 30 89 Revised Page 24 ...

Page 43: ...d inspect interior for foreign material such as rags tools shipping pa pers etc 4 Check fuel coolant and oil hoses and connections for visible leaks Visually inspect the compart ment floor and ground surface under the unit for signs of leakage If leaks are found correct by tight ening hose clamps tube fittings etc as required 5 Check the following for sufficient quantity a Fuel Turn ON panel light...

Page 44: ...terminal panel 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 identified by an identification plate Each cable should be identified by a band...

Page 45: ...g system antifreeze solution is adequate to protect below the lowest tem peratures expected during the storage period See 2 1 Para 6 D Be sure the solution is thoroughly mixed 4 Clean the exterior of the engine with fuel oil Dry with clean rags and compressed air 5 Seal all engine openings Use a waterproof vaporproof material which is strong enough to resist puncture damage from air pressures C Lo...

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Page 47: ...tem 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 25 in ON position NOTE This switch must be ON to check fuel when engine is stopped 2 Hold engine s...

Page 48: ...gine ON indicator light 8 Generator voltmeter 22 Engine START RUN STOP switch 9 Frequency meter 23 Build up voltage generate idle switch 10 Overvoltage indicating light 24 Engine start switch 11 Undervoltage indicating light 25 Switch clearance panel lights 12 Overload indicating light 26 Air filter service indicator 13 Underfrequency indicating light 27 Oil pressure gage 14 Overfrequency indicati...

Page 49: ...t switch No 1 output 32 Line drop compensation ON OFF switch 37 Test bank aircraft switch No 2 output 33 Cable size potentiometer 38 Regulated diagnostic switch 34 Damping circuit RATE potentiometer 39 Idle speed adjustment potentiometer Operating Controls and Instruments Figure 1 Sheet 2 of 2 July 27 90 Revised 1 3 Page 3 OM 2029 ...

Page 50: ...not operable until assembled Assemble as follows WARNING FIRES FUMES AND FLYING PARTS CAN KILL OR INJURE STARTING FLUID IS EXTREMELY FLAMMABLE IT IS UNDER PRESSURE USE CAUTION WHEN HANDLING AVOID CONTACT WITH SKIN AND AVOID BREATHING VAPOR a Loosen clamp screws 1 Fig 2 and slide the cylinder 2 upward sufficiently to remove protec tive cap 3 and plug 4 b Use bottle opener to remove cylinder cap 3 U...

Page 51: ...RAFT position if the aircraft being serviced is equipped with 28 5VDC interlock relay system If not place in TEST BANK position Close and fasten front door of generator control box c Meter selector switch 5 may be in any position except pointing straight DOWN 2 Connect output cable plug connector to aircraft receptacle Be sure connectors are mated fully and securely E Power Delivery No 1 Output Ci...

Page 52: ...controls and procedures that were used for No 1 output are used for the No 2 output F Discontinue Power Delivery 1 Place load contactor switches in OFF position Green light s should go OFF immediately to indi cate that the load contactor has opened and power is no longer being delivered to the aircraft 2 Place engine generator control switch 23 in IDLE position 3 Disconnect output cable from aircr...

Page 53: ...revent 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 does not go TOO HIGH with DC...

Page 54: ... 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 2029 1 3 September 30 89 Revised Page 8 ...

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: ...ts 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 To assist in engine starting during cold weather when SAE 30 oil is used an optional ether start ing aid is available f...

Page 57: ...l panel AC Generator AC generator bearings are sealed and require no periodic lubrication Lubrication and Maintenance Chart Figure 1 4 Air Cleaner Service The air cleaner is a dry type with replaceable filter cartridges A definite time schedule for changing the fil ter cartridge cannot be determined because of varying operating conditions Change the filter cartridge when the red indicator flag rea...

Page 58: ... tightening the four retaining clamps in place 3 Close the right rear doors of the generator set 1 Body Assembly 2 Cartridge 3 Cover Air Cleaner Cartridge Replacement Figure 2 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 ...

Page 59: ...down on the cap and continue to turn until the cap is free to be removed WARNING HOT STEAM AND FLUIDS WILL SEVERELY BURN WHEN RE MOVING CAP FROM A VERY HOT RADIATOR DO NOT TURN CAP PAST SAFETY STOP UNTIL ALL PRESSURE OR STEAM HAS ESCAPED USE PRO TECTIVE CLOTHING ALLOW ENGINE TO COOL BEFORE ADDING COOL ANT 3 Installation When installing the cap be sure it is turned clockwise as far as it will go so...

Page 60: ...s b Inspect all hoses and tighten all hose clamps Install new hoses if necessary c Drain and clean the system Ref Paras 6 E and 6 F d Check the condition and tension of the fan and water pump belts and alternator belts Replace the belts if necessary e Be sure radiator and engine drain valves are closed and all connections are securely tight ened f Install the required amount of coolant 12 44 gallo...

Page 61: ...directed by the instructions furnished with the compound 5 After the system has been flushed and thoroughly cleaned of the compound refill the clean cool ant Ref Para 6 H G Cleaning the Radiator Core Blow out insects and dirt from the radiator core air passages using air or water under pressure En gine overheating is often caused by bent or clogged radiator fins When straightening bent fins be car...

Page 62: ... SOLVENT B Adjustment The generator itself requires no adjustment Adjustment procedures for generator controls will be cov ered in Section 2 3 8 Drive Belts Twin belts from the crankshaft pulley are used to drive the alternator and water pump For proper engine operation these belts should be in good condition and at proper tension at all times A Checking Belt Tension Check belt tension every 200 h...

Page 63: ...tion period Most lubrication points are equipped with high pressure lubrication fittings Lubricate the trailer each 400 hours Use a good quality chassis lubricant See Figure 5 Clean lube fittings before applying grease Lubricate and check wheel bearing adjustment each 800 hours or semiannually Use a good quality bearing lubricant See Figure 5 NOTE The chart in Figure 4 shows the trailer assembly i...

Page 64: ...Trailer Lubrication Chart Trailer No 408595 illustrated Figure 4 2 1 March 16 90 Revised Page 10 OM 2029 ...

Page 65: ... Oil Engine Heavy Military MIL L 2104B SAE 30 Summer Duty or equivalent SAE 10 Winter 3 Grease Automotive Military MIL G 10924B Wheel bearings or equivalent Lubricants Figure 5 SYMBOL TIME INTERVAL D 10 hours or Daily BW 100 hours or Biweekly M 200 hours or Monthly BM 400 hours or Bimonthly SA 800 hours or Semiannually Symbols and Time Intervals Figure 6 March 16 90 Revised 2 1 Page 11 OM 2029 ...

Page 66: ...y Care 1 Never allow a battery which has been removed from the unit to sit on concrete ground or metal unless proper insulation is provided A wooden platform or board will provide sufficient insulation 2 Maintain stored batteries in a charged condition 3 Be sure batteries are fastened securely in their compartment to avoid damage from vibration 4 Maintain battery fluid at proper level 5 Keep batte...

Page 67: ...may be used to determine the battery s ability to deliver current A battery hydrometer test determines the charge condition of the battery 1 Test with Battery Starter Tester Connect battery to tester according to instructions furnished with the instrument Test battery ac cording to tester instructions If the test determines that battery has acceptable voltage this indi cates that battery has outpu...

Page 68: ...allow removal of the generator exciter without disturbing or removing the complete generator 1 Preparation for exciter removal a Remove the rear sheet metal panel of the canopy b Remove the circular sheet metal panel at the rear of the generator assembly by removing the eight hex head attaching bolts This permits access to the exciter 2 Exciter removal Refer to TM 360 in Chapter 6 for exciter inst...

Page 69: ...ubrication 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 each 200 hours of operation See 2 1 Para 8 A E Exhaust System WAR...

Page 70: ...ittings 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 Chec...

Page 71: ...f one or more circuit breaker s is stuck open or will not open for an overload condition C Wiring and Connections 1 Inspect all cables and leads for broken worn and damaged insulation 2 Check electrical connections for looseness NOTE A darkened terminal generally indicates a loose connection Light Lamp Lamp Identification Location Manufacturer Number Instrument Panel Generator Eng Lamp Industry 67...

Page 72: ... protective modules to make certain they will function if a fault should occur in the output circuit See 2 3 Para 2 B D Wiring and Connections 1 Check all cables leads and wiring for broken worn and damaged insulation 2 Check all connections for tightness WARNING STOP OPERATIONS AND STOP ENGINE BEFORE TOUCHING EX POSED CONDUCTORS OR TERMINALS 3 Check the output cable plug connector for damaged con...

Page 73: ...ounted generator set should be done at the same time that routine maintenance as required in Section 2 1 is done In addition A Check pressure in all four tires Add more air if as necessary according to each tire s require ments B For trailers having batteries check these for proper fluid level and service battery if as necessary Refer to Section 2 1 Paragraph 10 C Check operation of parking brake ...

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Page 75: ...erate the circuit breaker 16 switch 25 and lamps are good 9 Check fault indicating lights 10 11 12 13 and 14 by pressing test switch 3 If lights glow cir cuit breaker 4 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 the engine 11 At initial start up after generator overhaul or repair fla...

Page 76: ...gine ON indicator light 8 Generator voltmeter 22 Engine START RUN STOP switch 9 Frequency meter 23 Build up voltage generate idle switch 10 Overvoltage indicating light 24 Engine start switch 11 Undervoltage indicating light 25 Switch clearance panel lights 12 Overload indicating light 26 Air filter service indicator 13 Underfrequency indicating light 27 Oil pressure gage 14 Overfrequency indicati...

Page 77: ...t switch No 1 output 32 Line drop compensation ON OFF switch 37 Test bank aircraft switch No 2 output 33 Cable size potentiometer 38 Regulated diagnostic switch 34 Damping circuit RATE potentiometer 39 Idle speed adjustment potentiometer Operating Controls and Instruments Figure 1 Sheet 2 of 2 July 27 90 Revised 2 3 Page 3 OM 2029 ...

Page 78: ...lockwise position Maximum volt age should be at least 134 V AC or higher NOTE If voltage should decrease when the knob is turned clockwise it indicates that internal wiring of the voltage regulator is incorrect Replace the complete regulator tray assembly b Observe voltmeter and turn rheostat knob to full COUNTERCLOCKWISE position Minimum voltage should be 108 V AC or lower 12 Observe voltmeter an...

Page 79: ... TM 759 or OM 2020 to set voltage regulator line drop compensation potentiometers Set knob pointer on cable size potentiometer 33 to size 2 0 4 0 etc of cable being used Set knob pointer on cable length potentiometer 31 to length 20 feet 40 feet etc of cable being used See instruction plate mounted below knobs 26 Check voltage regulator at intervals from no load to full load and on up to 125 load ...

Page 80: ...tive monitor to open the load contactor and turn on the overvoltage indicating light The overvoltage sensing relay should trip when voltage reaches 130V to 134V b Return unit to normal operating conditions by adjusting voltage regulator rheostat and press ing reset switch 3 38 Check operation of undervoltage sensing relay indicating light and time delay Before starting this check let us understand...

Page 81: ...om 415 Hz to 425 Hz Its purpose also is to open the load contactor and turn on an indicating light a Check procedures are the same for overfrequency as for underfrequency above except that engine speed is INCREASED to create a condition of overfrequency b If the overfrequency system functions to open the load contactor and turn on the overfre quency light 14 after some frequency between 415 Hz and...

Page 82: ...r determines the trip point of the overload relay which is identified as K3 on sheet 1 of Diagram 280170 Both of these items are shown in Figure 8 Sheet 1 of Section 1 1 the generator overload resistor as item 24 and the overload relay as item 19 As Figure 2A shows the resistor has a slider band which fastens on the body of the resistor with a clamping screw To adjust the overload ballast resistor...

Page 83: ... 3 E Electric Governor System Adjustment Two electric governor system main components namely the magnetic pickup and controller have critical adjustments which can affect engine performance and therefore generator output The adjust ment of the actuator linkage can also affect engine performance When the complete system is to be checked and or adjusted a definite sequence of procedures should be fo...

Page 84: ... slipped on shafts If a lever has slipped position it correctly and tighten securely c Place both levers 3 and 7 in FULL IDLE position an attempt to connect ball joint 4 at the hole in actuator lever 3 from which it was removed in step a If connection cannot be made loosen nuts 5 and adjust effective length of rod assembly 6 Fig 4 so that connec tion can be made d Manually operate actuator lever b...

Page 85: ...g hole the center of a flywheel tooth and the center of the flywheel e Install the magnetic pickup into the tapped mounting hole and thread it in until the tip touches the in line flywheel gear tooth CAUTION THE PICKUP TIP MUST BE DIRECTLY OVER A TOOTH AND NOT BETWEEN TEETH WHEN ADJUSTMENT IS MADE f Back the pickup outward counterclockwise 1 2 turn Hold the pickup securely in this position and tig...

Page 86: ... for these adjustments b Start engine and allow it to warm up c Place engine generator control switch 23 Fig 1 in GEN position to make electric governor functional d Turn RATED SPEED adjusting screw clockwise to increase engine speed to 1714 RPM At 1714 RPM the frequency meter 9 Fig 1 will indicate 400 Hz e Adjust GAIN control screw to the stable region between low frequency and high frequency os ...

Page 87: ...Electric Governor Controller Illustration and Connection Diagram Figure 6 March 16 90 2 3 Page 13 OM 2029 ...

Page 88: ...D to YELLOW BLACK 7 23 Generator and Exciter Stator Test Values 70F Ambient Temperature Figure 7 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 i...

Page 89: ...hooting 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 trouble in the Probable Cause column c Test check repair or correct the trouble as indicated in the Remedy column 2 If the cause of a...

Page 90: ... the complete tray assembly and send the old tray to stock Assemblies which lend themselves to this concept are Generator control tray Over undervoltage module Protective relay tray Over underfrequency module Voltage regulator Overload module Protective monitor module Electric governor control box Governor actuator The above items are in addition to normally replaced items such as fuel pump inject...

Page 91: ...ll surge under the following conditions 1 Stability or gain adjustment set too high 2 Throttle linkage binding 9 Engine Trouble Shooting Procedures A General The following engine trouble shooting procedures were taken from John Deere Diesel Handbook Certain abnormal conditions which may interfere with satisfactory engine operation together with methods of de termining the cause of such conditions ...

Page 92: ...gine ON indicator light 8 Generator voltmeter 22 Engine START RUN STOP switch 9 Frequency meter 23 Build up voltage generate idle switch 10 Overvoltage indicating light 24 Engine start switch 11 Undervoltage indicating light 25 Switch clearance panel lights 12 Overload indicating light 26 Air filter service indicator 13 Underfrequency indicating light 27 Oil pressure gage 14 Overfrequency indicati...

Page 93: ... 33 Cable size potentiometer 34 Generator main overload relay 35 Test bank aircraft switch No 1 output 36 Test bank aircraft switch No 2 output 37 Regulated diagnostic switch 38 Idle speed adjustment potentiometer Operating Controls and Instruments Figure 1 Sheet 2 of 2 OM 2029 September 30 89 Revised 3 1 Page 5 ...

Page 94: ...End View of Voltage Regulator Amphenol Connector Figure 2 OM 2029 3 1 September 30 89 Revised Page 6 ...

Page 95: ...e of the starter solenoid and the starter input terminal 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 ...

Page 96: ...ps after a short time trouble between the fuel 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 defe...

Page 97: ...ns 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 Compressi...

Page 98: ...t 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 resist...

Page 99: ...he 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 should...

Page 100: ...age 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 is n...

Page 101: ... 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 has ...

Page 102: ...ion 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 Insufficie...

Page 103: ...ng 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 fac...

Page 104: ...ching 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 good ...

Page 105: ...o 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 volta...

Page 106: ...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 the AC wiring and c...

Page 107: ...y 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 If...

Page 108: ...ve 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 D...

Page 109: ...in 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 switch ...

Page 110: ...ampering 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 increase ...

Page 111: ...at 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 1 ...

Page 112: ...roven to be good and an underfre quency condition does not exist replace 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 indi cating overload device K4 overload device functions to light ON to ...

Page 113: ...or windings meter to determine 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 ...

Page 114: ...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 2029 3 1 September 30 89 Revised Page 26 ...

Page 115: ...ioning requisitioning purchasing storing and issuing of spare parts 3 Arrangement Chapter 4 is arranged as follows Section 1 Introduction Section 2 Manufacturer s Codes Section 3 Parts List Section 4 Numerical Index 4 Explanation of Parts List A Contents The parts list contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except ...

Page 116: ...Parts manufactured by Hobart reflect no vendor code or part number in the NOMENCLATURE column 3 NOMENCLATURE Column The item identifying name appears in this column The indenture method is used to indicate item rela tionship Thus components of an assembly are listed directly below the assembly and indented one space Vendor codes and part numbers for purchased parts are shown in this column 4 REC S...

Page 117: ...n 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 Arizona 85008 05277 Westinghouse Electric Corp...

Page 118: ...265 N 30th St Milwaukee WI 53216 28520 Heyman Mfg Co 147 Michigan Ave P O Box 160 Kenilworth NJ 07033 30327 Imperial Clevite Inc Fluid Components Division 6300 W Howard Street Chicago IL 60648 31211 Motorola Automotive 1303 E Algonquin Road Schaumburg IL 60196 31356 J B T Instruments Incorporated 394 East Street P O Box 1818 New Haven Connecticut 06508 31361 Woodward Governor Co 1000 E Drake Rd P ...

Page 119: ...c India Rubber Works Inc 571 W Polk Street Chicago IL 60607 71400 Bussman Mfg Division of McGraw Edison Company 114 Old State Rd P O Box 14460 St Louis Missouri 63178 71744 General Instrument Corp Miniature Lamp Div Worldwide 443 N Ravenswood Ave Chicago IL 60640 72582 General Motors Corp Detroit Diesel Allison Div 13400 W Outer Dr Detroit MI 48228 73559 Carlingswitch Inc 505 New Park Ave West Har...

Page 120: ...12 N Hill St Mishawaka Indiana 46544 90201 Emhart Ind Inc Mallory Capacitor Co 4760 Kentucky Ave P O Box 372 Indianapolis Indiana 46206 90763 TRW Inc United Carr Div 10544 West Lunt Ave Rosemont Illinois 60018 91637 Dale Electronics Incorporated P O Box 609 Columbus Nebraska 68601 91929 Micro Switch Division Honeywell Inc 11 W Spring Street Freeport Illinois 61032 92563 McGill Manufacturing Compan...

Page 121: ...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 to...

Page 122: ...Generator Set Figure 1 OM 2029 4 3 September 30 89 Revised Page 2 ...

Page 123: ...UEL A 1 6 180467 SUPPORT FUEL TANK A 1 7 402987 NAMEPLATE HOBART 3 8 404101 1 LIGHT CLEARANCE V75175 NO 514 0168 4 9 400613 10 LAMP 12V 4 10 408670 1 BATTERY 12V A 1 11 280038 CLAMP BATTERY HOLDDOWN A 1 12 5CW 2048 ROD BATTERY CLAMP A 2 13 481209 2 CABLE BATTERY POSITIVE A 1 14 383067 2 CABLE BATTERY NEGATIVE A 1 15 181029 KIT BRAKE RIGGING A 1 16 181030 PLATE MTG BRAKE RIGGING A 1 17 180903 PLATE...

Page 124: ...Generator Set on Fifth Wheel Trailer Specification 6906 6 Illustrated Figure 1A 4 3 July 27 90 Page 3A OM 2029 ...

Page 125: ...R RECTIFIER 28 5 V OPTIONAL C F 1 or 2 11 281799 SUPPORT MOUNTING LOWER TRANSFORMER RECTIFIER OPTIONAL C F 1 12 430278 GROMMET OPTIONAL WITH T R F 1 13 W 9407 201 CABLES TRANSFORMER RECTIFIER OPTIONAL F 3 or 6 14 No Number GENERATOR SET WITHOUT CANOPY For Details See Fig 3 1 15 180467 SUPPORT FUEL TANK C 1 16 281834 SUPPORT FUEL TANK F 1 17 281870 INSULATOR SUPPORT FUEL TANK F 1 18 180447 COMPARTM...

Page 126: ...This page intentionally left blank 4 3 July 27 90 Page 3C OM 2029 ...

Page 127: ... 26 180477 SUPPORT MTG BATTERY BOX C 1 27 281842 BUMPER ASSEMBLY F 1 28 282103 BUMPER ASSEMBLY F 1 29 282117 FENDER RIGHT REAR ASSEMBLY F 1 30 281744 SUPPORT MOUNTING UPPER TRANSFORMER RECTIFIER OPTIONAL MOUNTS ON TOP OF ITEM 11 TO SUPPORT SECOND T R F 1 31 389824 HARNESS WIRE TRANSFORMER RECTIFIER OPTIONAL F 1 32 489190 WIRE NEUTRAL TRANSFORMER RECTIFIER OPTIONAL F 1 July 27 90 4 3 Page 3D OM 202...

Page 128: ...Canopy Assembly Figure 2 OM 2029 4 3 September 30 89 Revised Page 4 ...

Page 129: ...OOR LT REAR RT FRT SM ASSY 2 8 280466 PANEL END REAR ASSEMBLY 1 9 386751 CLAMP RETAINER DOOR ASSY 8 10 387445 ROD DOOR STOP 8 11 HJ 129A JOINT BALL V01428 NO SPS1002CP 8 12 180491 PANEL SIDE LEFT 1 13 180487 COVER PANEL END REAR 1 14 81B 1019 LATCH T HANDLE NO 68 8 15 100GH 117 HORN CABLE ENTRANCE 2 16 180492 PANEL RIGHT SIDE 1 17 280145 DOOR RT REAR SM ASSEMBLY 1 18 280589 COVER DOOR PLEXIGLASS 1...

Page 130: ...Generator Set Without Canopy Figure 3 OM 2029 4 3 September 30 89 Revised Page 6 ...

Page 131: ...NERATOR GROUP For Details See Fig 11 REF 14 280172 CONTROL PANEL ENGINE For Details See Fig 7 1 15 180508 1 BOX ASSY CONTROL GENERATOR For Details See Fig 8 A B 1 180508 2 BOX ASSY CONTROL GENERATOR For Details See Fig 8 C F 1 16 280103 KIT AIR CLEANER For Details See Fig 5 1 17 280110 FRAME MOUNTING 1 18 DDW 155 EYE BOLT LIFTING 1 19 280105 YOKE LIFTING ASSEMBLY 1 20 385449 PANEL ASSY TERMINAL ST...

Page 132: ...This page intentionally left blank OM 2029 4 3 September 30 89 Revised Page 8 ...

Page 133: ...FT 1 32 280512 GUARD FAN RIGHT 1 33 78B 1119 1 SWITCH TEMERATURE SENDER 1 34 281271 CLAMP CABLE STORAGE A C 2 35 281272 PLATE MTG CABLE HANGER A C 2 36 280183 SUPPORT CONTROL BOX 1 37 281392 SUPPORT MTG T R LEFT ASSEMBLY C 1 38 281391 SUPPORT MTG T R RIGHT ASSEMBLY C 1 39 180474 SUPPORT MTG ASSEMBLY A C 2 40 408664 ELBOW EXHAUST C EF 1 41 W 9407 201 CABLES T R C 3 NOT ILLUSTRATED March 16 90 4 3 P...

Page 134: ...Radiator and Cooling System Group Figure 4 OM 2029 4 3 September 30 89 Revised Page 10 ...

Page 135: ...403782 0 SWITCH TEMPERATURE SHUTDOWN REF 14 78B 1119 1 SWITCH TEMPERATURE SENDER REF 15 56564 HOSE RADIATOR LOWER 18 1 16 56564 HOSE RADIATOR UPPER 24 1 2 1 17 W 10869 2 CLAMP HOSE RADIATOR V62295 NO G20 2 18 W 10869 7 CLAMP HOSE RADIATOR 2 19 35141 LABEL CAUTION FAN 2 20 56553 HOSE RADIATOR 35 1 21 181066 FAN COOLING 26 1 22 181397 BRACKET RADIATOR 1 23 W 799J 211 PLUG PIPE 1 4 NPT 1 24 W 7814 4 ...

Page 136: ...Air Cleaner Assembly Figure 5 OM 2029 4 3 September 30 89 Revised Page 12 ...

Page 137: ...DUCER 4 5 1 2 1 5 408591 REDUCER ELBOW 5 1 2 4 1 6 387789 PIPE AIR CLEANER 1 7 486789 PIPE AIR INTAKE ENGINE 1 8 W 10869 17 CLAMP AIR CLEANER 3 9 W 10869 6 CLAMP HOSE STAINLESS STEEL 1 10 403064 CLAMP HOSE STAINLESS STEEL 2 11 56534 HOSE LOW PRESSURE 1 4 ID 60 12 W 10893 2 FITTING HOSE SWIVEL FEMALE V30327 NO KA04 04NS 2 13 400059 3 CONNECTOR FEMALE SAE 45 DEG FLARED 1 14 400333 1 ELBOW FEMALE 90 ...

Page 138: ...Electric Governor Kit Figure 6 OM 2029 4 3 September 30 89 Revised Page 14 ...

Page 139: ...ECTRIC V03613 NO 8256 017 1 4 84A 1091 ARM THROTTLE GOVERNOR V03613 NO 396C 059 1 5 402908 JOINT BALL GOVERNOR LINKAGE V57448 No TF 4Y 2 6 280241 ROD THREADED 1 4 28 1 7 W 11280 3 NUT HEX 1 4 28 5 8 280239 BRACKET MOUNTING ACTUATOR 1 9 84A 1075 MOUNT SHOCK RUBBER TECH PRODUCTS CORP NO 50 DURO 4 10 482989 STRAP WIRE GROUND 2 11 280243 ARM THROTTLE REWORK 1 12 W 799J 211 SPRING 1 13 400829 5 TERMINA...

Page 140: ...Panel Engine Control Assembly Figure 7 OM 2029 4 3 September 30 89 Revised Page 16 ...

Page 141: ...S6288 1 7 401937 2 BLOCK TERMINAL 20A V98410 NO 35008 3526 1 8 408544 2 CIRCUIT BREAKER FUSEHOLDER TYPE 1 9 180189 2 INDICATOR ASSEMBLY 3 9A 408552 1 LAMP 12 V DC 1 10 403704 6 SWITCH DPDT 4 11 403091 4 PLUG HOLE PLASTIC 1 12 404100 SWITCH PUSHBUTTON STARTER V70040 NO 1996027 1 13 403704 7 SWITCH DPDT 1 14 406768 3 INDICATOR SERVICE AIR FILTER 1 15 84A 1008 1 ADAPTER BULKHEAD FILTER 1 16 W 10886 1...

Page 142: ...Generator Control Box Assembly Figure 8 4 3 July 27 90 Page 18 OM 2029 ...

Page 143: ...6 10 METER FREQUENCY V31356 NO 36 FX 1 13 W 8105A 4 VOLTMETER V60741 NO 331LH 1 14 W 8095A 9 AMMETER V60741 NO 331LH 1 15 180189 1 INDICATOR ASSEMBLY 5 15A 408552 1 LAMP 12 V DC 1 16 76A 1115 LATCH ADJUSTABLE GRIP V94222 NO 48 99 126 11 1 17 180507 BOX CONTROL GENERATOR 1 18 16DA 4004A 10 RELAY ENCLOSED PLUG IN 12V V77342 NO KAP 14D 12 5 19 16DA 4004A 3 RELAY ENCLOSED PLUG IN 24V V77342 NO K10 14D...

Page 144: ...This page intentionally left blank OM 2029 4 3 September 30 89 Revised Page 20 ...

Page 145: ... 1 32 W 9746 3 RESISTOR 100 OHM 25W V44655 NO 0200F 2 33 W 2974E RESISTOR VARIABLE 1 34 400078 BRACKET MOUNTING RESISTOR 2 35 180509 TOP CONTROL BOX 1 36 400701 CONNECTOR RIGHT ANGLE V59730 NO TA 250 8 2 37 406006 CLAMP WIRE 2 38 280372 BRACE 1 39 401564 4 HOUSING SOCKET 3 40 401564 3 HOUSING SOCKET A B 1 41 401564 5 HOUSING SOCKET A B 1 42 402377 PLUG VOLTAGE REGULATOR C F 1 43 16DA 5082 CLAMP CA...

Page 146: ...Stator Terminal Panel Assembly Figure 9 OM 2029 4 3 September 30 89 Revised Page 22 ...

Page 147: ... V89873 NO E6147D1 8 5 DW 1704 BUSHING INSULATING V28987 NO 300A 4 6 W 9549 19 STUD 1 4 20 4 7 W 11278 5 NUT PLAIN HEX 3 8 16 8 8 100GH 112 BAR BUS TERMINAL 8 9 5CW 975 BUSHING INSULATOR 8 10 5CW 2127 BUSHING INSULATOR SLEEVE 8 11 W 11097 8 SCREW STEEL 3 8 16 X 2 8 12 W 11254 6 WASHER LOCK STEEL 3 8 8 13 W 11242 10 WASHER FLAT 3 8 8 14 5CW 976A WASHER INSULATING 16 15 385450 PANEL TERMINAL OUTPUT ...

Page 148: ...Power Module Panel Assembly Figure 10 OM 2029 4 3 September 30 89 Revised Page 24 ...

Page 149: ... CONTACTOR LOAD V50603 NO HB200BB 2 6 W 10854 4 CAPACITOR 0 1 MFD 500V 3 7 363136 5 TRANSFORMER CURRENT AMMETER 3 8 W 9746 1 RESISTOR LINEDROP BURDEN 50 OHM 25 WATT V44655 NO 0200D 3 9 387738A BOARD P C OVERLOAD ASSEMBLY 2 10 401564 4 HOUSING SOCKET CONNECTOR V89110 NO 1 480287 0 2 11 386921 BRACKET MTG OVERLOAD BOARD 2 12 401556 MOUNT SHOCK RUBBER V81860 NO SS 01 8 13 401937 1 BLOCK TERMINAL 20 A...

Page 150: ...Generator Group Figure 11 OM 2029 4 3 September 30 89 Revised Page 26 ...

Page 151: ...No Number HOUSING EXCITER ASSEMBLY 1 12 100NH 2 POLE PIECE EXCITER 4 13 100NH 3 INSULATION EXCITER 4 14 DATA 3169 WINDINGS EXCITER SET 15 384183A 1 HOUSING EXCITER 1 16 480126A 1 HOUSING FAN 1 17 16DA 4249 11 RING RETAINER EXCITER LOCATING V79136 NO 5100 175 1 18 W 10072 48 BEARING BALL FRONT V76062 NO 314 SFFC 1 19 W 10072 1 BEARING BALL REAR V76062 NO 310 SFFC 1 20 384176 1 ARMATURE ASSEMBLY 1 2...

Page 152: ...Fuel Line Assembly Figure 12 OM 2029 4 3 September 30 89 Revised Page 28 ...

Page 153: ...BRS 1 5 356250 LINE FUEL 2 6 W 10900 3 NUT INVERTED FLARE STD 1 7 W 10869 14 CLAMP HOSE 2 8 56544 HOSE LP LUBE OIL 5 16 ID 66 9 280446 NUT FLARE 1 10 W 10905 6 SLEEVE COMPRESSION BRASS 1 11 W 10901 3 NUT COMPRESSION BRASS 1 12 78B 1019 2 TUBE RIGID HOSE END 1 13 56534 HOSE LOW PRESSURE LUBE OIL 1 4 ID 57 14 W 10893 2 FITTING HOSE SWIVEL FEMALE 1 15 W 10886 2 CONNECTOR MALE 1 16 W 7814 3 BUSHING PI...

Page 154: ...Trailer Assembly with Fifth Wheel Front Running Gear For Specifications 6906 3 6906 5 and 6906 6 Figure 13 OM 2029 4 3 September 30 89 Revised Page 30 ...

Page 155: ...80A 1056 CONE BEARING INNER V22938 No 6057 C EF 1 9 80A 1055 CONE BEARING OUTER V22938 No 6058 C EF 1 10 80A 1057 SEAL GREASE V22938 No 6311 C EF 1 11 80A 1054 CAP GREASE V22938 No 6312 C EF 1 12 85A 1024 NUT HEX V22938 No 4603 1 C EF 8 13 80A 1050 WASHER SPINDLE V22938 No 4702 2 C EF 1 14 80A 1051 NUT SPINDLE V22938 No 4600 2 C EF 1 15 76A 1189 PIN COTTER V22938 No 4800 5 C EF 1 16 76A 1266 CLAMP...

Page 156: ...This page intentionally left blank 4 3 March 16 90 Page 32 OM 2029 ...

Page 157: ...EEL V22938 No 6251 1 C EF 1 29 404553 CUP BEARING INNER V22938 No 6152 C EF 2 30 404554 CUP BEARING OUTER V22938 No 6151 C EF 1 31 80A 1056 CONE BEARING INNER V22938 No 6057 C EF 1 32 80A 1055 CONE BEARING OUTER V22938 No 6058 C EF 1 33 80A 1057 SEAL GREASE V22938 No 6311 C EF 1 34 80A 1050 WASHER SPINDLE V22938 No 4702 2 C EF 1 35 80A 1051 NUT SPINDLE V22938 No 4600 2 C EF 1 36 76A 1189 PIN COTTE...

Page 158: ...This page intentionally left blank 4 3 March 16 90 Page 34 OM 2029 ...

Page 159: ... LABEL TONGUE C EF 1 48 76A 1244 CABLE CONDUIT V22938 11 8318 C EF 2 49 284399 21 LATCH PETAL V22938 No 3853 2 C EF 1 50 284399 25 BOLT V22938 No 4901 1 C EF 1 51 181840 LATCH SPRING V22938 No 4006 C EF 1 52 284399 23 BOLT V22938 No 4601 11 C EF 1 53 284399 37 NYLON ROLLER V22938 No 5929 4 C EF 1 54 181843 BOLT V22938 No 4901 58 C EF 1 55 181844 LOCKNUT V22938 No 4601 40 C EF 1 56 284399 8 BRAKELE...

Page 160: ...Brake Kit Assembly Figure 14 4 3 March 16 90 Page OM 2029 ...

Page 161: ...NING PRIMARY V14892 No 3202045 C EF 1 2 76A 1335 SHOE LINING SECONDARY V14892 No 3202049 C EF 1 3 76A 1336 SCREW ADJUSTING PIVOT NUT V14892 No 302058 C EF 1 4 76A 1337 SOCKET ADJUSTING SCREW V14892 No 48032 C EF 1 5 76A 1338 LEVER PARKING BRAKE PIN Left V14892 No 48834 C EF 1 76A 1339 LEVER PARKING BRAKE PIN Right V14892 No 48835 C EF 1 76A 1340 CYLINDER ASSEMBLY WHEEL LEFT V14892 No 616200 C EF 1...

Page 162: ...This page intentionally left blank 4 3 March 16 90 Page 38 OM 2029 ...

Page 163: ...3 C EF 1 11 76A 1348 PIN ANCHOR V14892 No 310574 C EF 1 12 76A 1349 PLATE SHOE GUIDE V14892 No 32594 C EF 1 13 76A 1350 SPRING ANCHOR V14892 No 33786 C EF 2 14 76A 1351 SPRING STRUT TO SHOE V14892 No 41199 C EF 1 15 76A 1352 PIN SHOE HOLDDOWN SPRING V14892 No 26320 C EF 2 16 76A 1353 CUP V14892 No 23969 C EF 2 July 27 90 Revised 4 3 Page 39 OM 2029 ...

Page 164: ...Solid State Voltage Regulator Assembly Part No 489812A Figure 15 4 3 July 27 90 Page 40 OM 2029 ...

Page 165: ...EOSTAT TRIPLE TANDEM V44655 NO 6610 1 10 370141 BRACKET MOUNTING PLUG 1 11 402376 RECEPTACLE V02660 NO MS 1302A 22 14P 1 12 401911 3 TERMINAL BOARD V88223 NO 441 3 1 13 281281 NAMEPLATE MODEL SERIAL NO A B 1 14 181419 BOX P C BOARD ASSEMBLY A B 1 15 406003 2 STRIP TERMINAL 12 STATION A B 1 16 489811 BOARD PC VOLTAGE REGULATOR A B 1 17 404460 1 SUPPORT PC BOARD LOCKING V52238 NO LCBS 10 A B 4 18 40...

Page 166: ...Magnetic Amplifier Voltage Regulator Assembly Part No 281407 Figure 16 4 3 July 27 90 Page 42 OM 2029 ...

Page 167: ... C F 1 9 16DA 2162 KNOB RHEOSTAT C F 1 10 281401 BRACKET MOUNTING RHEOSTAT C F 1 11 401564 3 HOUSING CONNECTOR C F 2 12 430340 CHASSIS LINE DROP COMPENSATOR 1 13 401564 2 HOUSING CONNECTOR C F 1 14 370141 BRACKET MOUNTING PLUG 1 15 HF 2407 FUSEHOLDER V71400 No HKP C F 1 16 400782 1 FUSE 5 AMP TYPE MTH C F 1 17 402376 RECEPTACLE AMPHENOL 19 CONTACT V02660 No MS 1302A 22 14P 1 18 480725 LABEL INSTRU...

Page 168: ...This page intentionally left blank 4 3 July 27 90 Page 44 OM 2029 ...

Page 169: ...tly opposite the part If the part is used in more than one place each lo cation is listed commencing with the first location the part is listed A 25 9 4 DATA 3169 11 14 DDW 155 1 3 3 18 DDW 495 4 3 8 DW 1704 9 5 FW 2267 A 4 2 HF 1459 8 17 HJ 129A 2 11 W 10072 1 11 19 W 10072 48 11 18 W 10119 1 4 26 W 10750 1 7 19 W 10750 2 4 25 W 10760 1 4 29 W 10854 4 10 6 W 10869 14 12 7 W 10869 17 5 8 W 10869 2...

Page 170: ... 100GH 117 2 15 100GHP 190 11 6 100NH 2 11 12 100NH 3 11 13 12CW 1320A 5 1A 5 12CW 2077 4 4 27 16DA 4004A 10 8 2 16DA 4004A 3 8 3 16DA 4249 11 11 17 16DA 4253 1 8 8 16DA 5082 8 46 180189 1 8 24 180189 2 7 9 180329 1 8 4 180420 2 20 180441 4 3 180447 1 4 1A 18 180474 3 39 180462 10 1 180463A 1 3 22 10 0 180463A 2 3 0 10 0 180466 1 5 1A 7 180467 1 6 1A 15 180477 1 19 1A 26 180486 2 5 180487 2 13 180...

Page 171: ... 3 181834 13 3 181835 13 3 181836 13 25 181837 13 43 181838 13 49 181839 13 50 181840 13 51 181841 13 52 181842 13 53 181843 13 54 181844 13 55 181845 13 56 1CZ 148 10 3 280038 1 11 280103 5 0 3 16 280105 3 19 280110 3 17 280134 1 1 2 0 280144 2 1 280145 2 17 280146 2 3 280147 2 4 280149 2 6 280150 2 7 280156 3 25 280157 3 24 280158 3 27 280164 4 1 FIGURE AND PART NUMBER ITEM NUMBER March 16 90 Re...

Page 172: ...3 3 280589 2 18 280763 13 44 280951 1A 22 281271 3 34 281272 3 35 281349 3 42 281350 13 45 281359 1A 9 13 0 281363 13 0 281391 3 38 281392 3 37 281407 8 44 281744 1A 30 281799 1A 11 281813 1A 7 281824 1A 8 281834 1A 16 281841 1A 19 281842 1A 27 281870 1A 17 281871 1 1A 21 282101 1A 28 282116 1A 6 282117 1A 29 282130 1 10 5 35141 4 19 356250 12 5 FIGURE AND PART NUMBER ITEM NUMBER 4 4 April 8 93 Re...

Page 173: ...789 5 6 389685 3 2 389824 1A 31 400059 3 5 13 400078 8 36 400333 1 5 14 400400 8 18 400613 10 1 9 400646 2 8 32 400698 5 8 13 400701 8 38 10 16 400818 2 12 1 400819 1 12 2 400902 4 12 401556 8 5 10 12 401564 3 8 42 401564 4 8 41 10 10 401564 5 8 43 401937 1 10 13 401937 2 7 7 401937 3 7 17 401937 4 10 15 401937 5 8 31 401937 8 8 28 402037 13 8 25 402247 4 8 402257 4 4 402377 8 45 FIGURE AND PART N...

Page 174: ... 13 29 404554 13 6 13 30 404595 6 1 406006 8 39 406768 3 7 14 408544 1 8 16 408544 2 7 8 408590 5 4 408591 5 5 408592 5 1 408593 5 2 408595 1 20 408664 3 6 408670 1 1 10 408671 3 10 408781 1 13 46 430278 1A 12 4303401 8 26 480126A 1 11 16 480127A 11 2 480603 1 3 26 480628 11 26 480646 11 4 480669 11 25 481209 2 1 13 1A 24 481379 11 11 481940 11 22 482038 8 33 482039 8 30 FIGURE AND PART NUMBER ITE...

Page 175: ...5 9 9 5CW 976A 9 14 76A 1115 8 23 76A 1147 13 1 76A 1171 13 42 76A 1189 13 15 13 36 76A 1241 13 41 76A 1244 13 48 76A 1251 13 3 76A 1252 13 3 76A 1254 13 7 13 28 76A 1255 13 12 13 39 76A 1256 13 2 76A 1258 13 19 76A 1259 13 23 76A 1261 13 23 13 24 76A 1262 13 24 76A 1263 13 20 76A 1266 13 16 76A 1268 13 17 76A 1269 13 18 76A 1270 13 19 76A 1273 13 25 76A 1274 13 25 76A 1275 13 4 76A 1277 13 27 FIG...

Page 176: ...7 14 10 76A 1348 14 11 76A 1349 14 12 76A 1350 14 13 76A 1351 14 14 76A 1352 14 15 76A 1353 14 16 78A 1115 1 7 3 78A 1116 1 7 5 78A 1117 1 7 4 78A 1120 1 7 6 78B 1019 2 12 12 78B 1118 1 3 28 78B 1119 1 3 33 4 14 79A 1018 13 39 79A 1019 13 40 79A 1022 13 21 79B 1138 8 7 80A 1050 13 13 13 34 80A 1051 13 14 13 35 80A 1054 13 11 13 37 80A 1055 13 9 13 32 80A 1056 13 8 13 31 80A 1057 13 10 13 33 81B 10...

Page 177: ...84A 1006 5 3 84A 1008 1 7 15 84A 1009 3 23 6 2 84A 1020 6 3 84A 1075 6 9 84A 1091 6 4 84B 1003 7 2 8 14 FIGURE AND PART NUMBER ITEM NUMBER OM 2029 September 30 89 Revised 4 4 Page 9 ...

Page 178: ...This page intentionally left blank OM 2029 4 4 September 30 89 Revised Page 10 ...

Page 179: ...ck Ford Std Ford Shop Manual 77B 1103 Quick Start Kit OM 2029 180952 Third Output TO 128 481428B 11 Kit Mounting Transformer Rectifier Assembly OM 2029 281883 Consists of No 402096 Quick Start Assembly and No W 7814 1 Bushing This transformer rectifier T R mounting kit is for use with the Specification 6906 6 generator set The kit consists mainly of one or two supports depending on the number of T...

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Page 181: ...any Electrically Powered Governor Engine John Deere Operators Manual No 6466A Flexible Coupling Hobart Brothers Company Coupling Manual TM 736 Exciter Rotor Hobart Brothers Company Rotor Manual TM 360 Hobart Diagrams 280170 Diagram Connection Schematic 6906 1 6906 2 281403 Diagram connection Schematic 6906 3 6906 4 6906 5 and 6906 6 408671 Engine John Deere Diesel Model 6466T 408595 Four Wheel Tra...

Page 182: ...This page intentionally left blank OM 2029 6 0 September 30 89 Revised Page 2 ...

Page 183: ...r oil vapor F Damp or very dry locations radiant heat vermin infestation or atmospheres conducive to fungus growth G Abnormal shock vibration or mechanical loading from external sources during equipment opera tion H Abnormal axial or side thrust imposed on rotating equipment shafts I Low and or high ambient temperatures 2 Operation at A Voltages above or below rated voltage B Speeds other than rat...

Page 184: ...This page intentionally left blank OM 2029 Unusual Service Conditions September 30 89 Page 2 ...

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