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Hobart 60PL20, Operation And Maintenance Manual

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(3) Overload module

The overload module is located inside the generator control box. This overload module

(5, Fig 7)

is a solid-state device designed to interpret a signal from the current transformers and to send a
signal to the protective monitor module

(7, Fig. 7)

when an overload condition exists in any gener-

ator output phase. A pull-apart electrical connector is mounted on the owerload module to provide
quick-disconnect facilities for all wiring to the module. The overload module is equipped with a
hermetically sealed, reed-type relay. Relay contacts are normally open. The solid-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 protective monitor. This signal
“gates” the overload SCR

(silicone-controlled rectifier)

in the protective monitor and interrupts the

load contactor holding circuit, allowing the load contactor to open.

The following is a list of overload module 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 is located inside the generator control box.

(See Fig. 7, item 10)

. This di-

ode-bridge rectifier receives 400-Hz AC from phase C of the generator output an converts it to a
pulsating, direct current for energization of the load contactor coil only. This DC coil-holding circuit
is controlled indirectly be controlling the 400-Hz AC to the rectifier. The ground circuit for the recti-
fier’s AC supply must pass through the relay contacts in the protective monitor module to ground
cable N. Therefore, any time a protective device functions to open the protective monitor relay,
the rectifier’s AC circuit is opened. No DC is then available for the load contactor coil, hence, the
load contactor opens.

OM-2053

December 31/91 Revised

1-1

Page 17

Summary of Contents for 60PL20

Page 1: ...ED PARTS LIST for ENGINE DRIVEN GENERATOR SET SPECIFICATION NUMBER 7009 7009A 7009B For Truck or Trailer Mounting MODEL No 60PL20 60 KVA 400 HZ 115 200 V AC 3 PHASE with PERKINS DIESEL ENGINE TYPE 6 3544 Hobart Brothers Company Airport Systems Group Ground Power Equipment Troy Ohio 45373 U S A ...

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Page 3: ...ounding of Electrically Powered Equipment Equipment driven by electric motors rather than by diesel or gasoline engines must be installed and maintained in accordance with the National Electrical Code ANSI NFPA 70 or other applicable codes A power disconnect switch or circuit breaker must be located at the equipment Check the nameplate for volt age frequency and phase requirements If only 3 phase ...

Page 4: ...it 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 intake ducts of air condition ers E BODILY INJURY PREVENTION Serious injury can result from contact with fans inside some...

Page 5: ...hapter 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 infor mation located in another portion of the manual is referred to its location is identified by a chapter sec tion and paragraph or figure number For example See 2 3 Para B refers to information loca...

Page 6: ...This page intentionally left blank OM 2053 Introduction December 31 91 Revised Page 2 ...

Page 7: ...r 20 89 2 1 13 Mar 20 89 1 1 1 Mar 20 89 2 1 14 Mar 20 89 1 1 2 Mar 20 89 1 1 3 Mar 20 89 2 2 1 Mar 20 89 1 1 4 Mar 20 89 2 2 2 Mar 20 89 1 1 5 Mar 20 89 2 2 3 Mar 20 89 1 1 6 Mar 20 89 2 2 4 Mar 20 89 1 1 7 Mar 20 89 2 2 5 Mar 20 89 1 1 8 Mar 20 89 2 2 6 Mar 20 89 1 1 9 Mar 20 89 1 1 10 Mar 20 89 2 3 1 Mar 20 89 1 1 11 Mar 20 89 2 3 2 Mar 20 89 1 1 12 Mar 20 89 2 3 3 Mar 20 89 1 1 13 Mar 20 89 2 ...

Page 8: ... 3 1 17 Mar 20 89 4 3 22 Mar 20 89 3 1 18 Mar 20 89 4 3 23 Mar 20 89 3 1 19 Mar 20 89 4 3 24 Mar 20 89 3 1 20 Mar 20 89 4 3 25 Mar 20 89 3 1 21 Mar 20 89 4 3 26 Mar 20 89 3 1 22 Mar 20 89 4 3 27 Mar 20 89 3 1 23 Mar 20 89 4 3 28 Mar 20 89 3 1 24 Mar 20 89 4 3 29 Mar 20 89 4 3 30 Mar 20 89 4 1 1 Mar 20 89 4 3 31 Mar 20 89 4 1 2 Mar 20 89 4 3 32 Mar 20 89 4 3 33 Mar 20 89 4 2 1 Mar 20 89 4 3 34 Mar ...

Page 9: ...e devices 1 1 6 a High coolant temperature switch 1 1 6 b Oil pressure switch 1 1 6 4 Air cleaner 1 1 7 5 Exhaust system 1 1 7 6 Radiator 1 1 7 D Generator 1 1 8 E Control Box Assembly 1 1 9 1 Front Panel 1 1 9 a Generator output monitors meters 1 1 9 b Meter and line switches 1 1 9 c Instrument light 1 1 9 d Indicating lights 1 1 9 2 Control box internal components 1 1 9 a Sensing modules 1 1 10 ...

Page 10: ...mers 1 1 15 a Ammeter current transformers 1 1 15 b Line drop current transformers 1 1 15 c Overload current transformers 1 1 15 3 Overload module 1 1 17 4 Rectifier 1 1 17 Section 2 Preparation For Use Storage Or Shipping 1 2 1 1 Preparation for Use 1 2 1 A Inspection Check 1 2 1 B Installing Three phase AC Output Cables 1 2 1 2 Preparation for Storage 1 2 2 A General 1 2 2 B Temporary Storage 1 ...

Page 11: ...pecting the Air Cleaner 2 1 3 B Cleaning Instructions 2 1 4 C Disposal 2 1 4 5 Engine Fuel 2 1 4 A Quality 2 1 4 B Fuel Filter 2 1 4 6 Engine Cooling System 2 1 4 A General 2 1 4 B Radiator Cap 2 1 5 1 General 2 1 5 2 Removal 2 1 5 3 Installation 2 1 5 C Warm Weather Operation 2 1 5 D Cold Weather Operation 2 1 5 1 General 2 1 5 2 Checking coolant solution 2 1 5 3 Preparing the coolant solution 2 ...

Page 12: ...B Generator Exciter 2 1 10 1 Preparation for exciter removal 2 1 10 2 Exciter removal 2 1 10 3 Exciter installation 2 1 10 Section 2 Inspection Check 2 2 1 1 General 2 21 1 2 Engine 2 2 1 A Fuel 2 2 1 B Lubrication 2 2 1 C Coolant 2 2 1 D V Belt 2 2 1 E Exhaust System 2 2 1 3 Electrical System 12 V DC 2 2 2 A Lights 2 2 2 B Fuses 2 2 2 C Wiring and Connections 2 2 3 4 Electrical System 115 V AC 2 ...

Page 13: ...13 1 General 2 3 13 2 Actuator Linkage Adjustment 2 3 13 3 Magnetic Pick up Inspection Adjustment 2 3 15 4 Governor Controller Adjustment 2 3 16 5 Re checking Actuator Linkage 2 3 16 6 Checking the Actuator 2 3 16 7 Troubleshooting 2 3 18 4 Generator and Exciter Test 2 3 19 5 Diode Test 2 3 19 Chapter 3 Troubleshooting Section 1 Trouble Shooting Procedures 3 1 1 1 General 3 1 1 2 Troubleshooting C...

Page 14: ... 1 2 5 EFF Effective Column 4 1 2 6 UNITS PER ASSEMBLY Column 4 1 2 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 Section 4 Numerical Index 4 4 1 1 Explanation of Numerical Index 4 4 1 Chapter 5 Optional Equipment Chapter 6 Manufacturers Literatur...

Page 15: ...e on board gener ators are not running See Figure 2 for specifications and capabilities 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 3 Spec...

Page 16: ...r control panel window 2 Radiator cap access hole 7 Engine control panel window 3 Canopy 8 Mounting frame 4 Doors attached to canopy 9 Door latches 5 Engine exhaust pipe and cover Generator Set Figure 1 OM 2053 1 1 December 31 91 Revised Page 2 ...

Page 17: ...age 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 112 KVA in less than 5 minutes Undervoltage time delay relay 4 to 12 seconds ENGINE Manufacturer Perkins Diesel Model 6 3544 Type In line 6 cylinder 4 cycle Diesel Displacement 354 cu in 5 8 liters Compression ratio 16 1...

Page 18: ... 1 which prevent excessive door vibration when the unit is running 5 Optional Equipment Two items of optional equipment are presently available for the 7009 7009A units a cold weather start ing aid kit identified as Hobart Part No 488913 and a four wheel trailer with fuel tank identified as Ho bart Part No 280718 7009 or Hobart Part No 281056 7009A Refer to TO 186 in Chapter 5 for information on t...

Page 19: ... control panel 3 Control box assembly 9 Engine assembly assembly 4 Muffler 10 Cooling fan 15 Exhaust pipe assembly 5 Rain cap 11 Radiator assembly 16 Governor actuator 6 90o elbow 12 Mounting frame 17 Load contactor Generator Set Components Figure 3 OM 2053 December 31 91 Revised 1 1 Page 5 ...

Page 20: ...ges in the engine It provides a voltage signal to the actuator which causes the actuator to move the fuel control lever as required to maintain a predetermined engine speed Its power is received from the 12 V DC battery system c Actuator The actuator 16 Fig 3 supplies the force needed to move and position the fuel lever as re quired to maintain a constant engine speed The actuator is operated by a...

Page 21: ... manifold assembly 5 Exhaust system The exhaust system consists of a noise reducing muffler 2 Fig 5 which is connected by a pipe 1 to the exhaust manifold The tail pipe 3 directs exhaust and noise upward 6 Radiator 11 Fig 3 This radiator is a one piece item designed for long periods of operation without servicing Refer to Section 2 1 Para 7 G for servicing procedure Air Cleaner Figure 4 OM 2053 De...

Page 22: ...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 gener ator output is controlled by the amount of DC voltage supplied to exciter fields by the static voltage regulator A centrifugal radial...

Page 23: ...ining 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 5 is a four position rotary type A nameplate 6 located un der the switch knob is marked and lettered to indicate the three functional positions of the me ter switch When the knob is pointing straight DOWN the switch is OFF The line switch 7 ...

Page 24: ...nitor module and performs a function similar to the voltage and frequency sensing modules 1 Instrument panel light 11 Undervoltage indicating light 2 Frequency meter 12 Overfrequency indicating light 3 Voltmeter 13 Underfrequency indicating light 4 AC ammeter 14 Overload indicating light 5 Meter selector rotary switch 15 Hole plug 6 Instruction plate 16 Light test switch 7 Line selector toggle swi...

Page 25: ...oltage circuit to prevent nuisance opening of the contactor under conditions of momen tary undervoltage in the generator output An undervoltage condition which continues uninterrupted for a period of 4 to 12 seconds adjustable will cause the time delay circuit to open the load contactor Each of the five circuits is connected to a corresponding indicating light 10 11 12 13 and 14 which is turned on...

Page 26: ...rd 13 A full and working description of this voltage regulator is provided in Solid State Regulator Manual OM 2020 which is a part of Chapter 6 of this manual l Overload module 5 See Para 6 H 3 for functional description of the overload module m Rectifier 10 See Para 6 H 4 for functional description of the load contactor rectifier F Engine Control Panel See Fig 8 The engine control panel is mounte...

Page 27: ... module 16 Ballast resistor 6 Over underfrequency module 20 ohm 100 watt 7 Memory and time delay module 17 Line drop compensator 8 Fuse interlock relay assembly 9 Auxiliary underfrequency relay 18 Resistor 100 ohm 25 watt 10 Contactor rectifier 19 Line drop burden resistors 11 Overload burden resistors 50 ohm 25 watt 16 6 ohm 25 watt Control Box Internal Components Figure 7 OM 2053 December 31 91 ...

Page 28: ...ch The engine generator control switch 5 also identified as the build up voltage generate idle switch is a three position toggle type It is spring loaded in one position BUILD UP VOLTAGE and will automatically reposition to GENERATE position when released In BUILD UP VOLTS position it performs a dual function First it supplies power to the gover nor control box which allows the engine to operate a...

Page 29: ...sets of contacts The three larger contacts conduct three phase AC generator output A smaller contact set is connected in the protective monitor circuit and supplies 12 V DC power used by sensing relays to signal the protective monitor when a fault occurs Three phase 400 Hz gener ator output power is conducted to the load contactor by 2 0 cables which pass through 3 sets of current transformers 2 C...

Page 30: ...cuit fuse 10 A 4 DC Ammeter 12 Engine ON indicating light 5 Engine generator control switch 13 Engine starter switch 6 Hourmeter 14 Terminal strip behind panel 7 Load contactor control switch 15 Permissive start switch 8 Coolant temperature gage Engine Control Panel Figure 8 OM 2053 1 1 December 31 91 Revised Page 16 ...

Page 31: ...o open The following is a list of overload module 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 ...

Page 32: ...terminal 4 E F terminal Load Contactor Panel Figure 9 1 Bottom of control box 2 Ammeter current transformers 3 Line drop current transformers 4 Overload current transformers Current Transformers Figure 10 OM 2053 1 1 December 31 91 Revised Page 18 ...

Page 33: ...ller neck Allow a capacity for coolant expansion CAUTION Be sure the cooling system antifreeze solution is adequate to protect below lowest temperature expected NOTE For antifreeze protection use a solution of 50 permanent antifreeze Ethylene glycol and 50 clean water c Engine lubricating oil Oil level should be at FULL mark on oil level gage rod See the John Deere Shop Manual for oil recommendati...

Page 34: ...t should be prepared for storage as soon as possible after being removed from service 2 The unit should 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 S...

Page 35: ... Operate normal operating controls 2 If weekly operation is not possible prepare and protect the engine in accordance with instructions in the Perkins Diesel Operator s Manual 3 To protect the generator and other electrical components the complete unit should be packaged using moisture proof packaging and sealing material Place containers of moisture absorbing chemi cals such as silica gel in the ...

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Page 37: ...ator 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 13 in ON position NOTE This switch must be ON to check fuel when engine is stopped 2 Hold engine start switch 24 Fig 1 in START po...

Page 38: ... switch 20 Oil pressure gage 8 Fault indicating lights 21 Engine circuit fuse 10 A 9 Load contactor circuit fuse 22 Engine protective circuit 2 A indicating light 10 Protective system fuse 2 A 23 Engine starter switch 11 Instrument panel light 24 Permissive start switch 12 Fuel gage 25 Regulated diagnostic switch 13 Light switch 26 Aircraft test bank switch Operating Controls and Instruments Figur...

Page 39: ... being serviced is equipped with 28 5 V DC interlock relay system If not place in TEST BANK position d Meter switch 4 may be in any position except pointing straight DOWN e Raise engine generator control panel and fasten it as it was previously 2 Connect output cable plug connector to aircraft receptacle Be sure connectors are mated fully and securely 27 Automatic voltage control potentiometer R5 ...

Page 40: ...switch 17 as above 4 It is recommended that the operator check output voltage and current in each of the three phases early in the power delivery run Use the meter switch 4 to select the phase and line to line or line to neutral voltage If the load is changing it is good operating practice to observe the instruments until load conditions stabilize 5 A condition of overvoltage undervoltage underfre...

Page 41: ... 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 Refer also to TO 186 in Chapter 5 of this manual for additional information on the trailer OM 2053 December 31 91 Revi...

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Page 43: ...cation means the use of correct lubricants and adherence to a proper time schedule Frequency of lu brication 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 as semblies which are lubricated and sealed at the factory for lifetime maintenance free operation It is suggested that generator bearings...

Page 44: ...sel Operator s Manual in Chapter 6 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 SAE 30 oil is used Multigrade oils are NOT recommended and should be considered only as a last resort to facili tate engine starting 4 Changing engine oil Change engine lubrica...

Page 45: ...ir Cleaner Check air cleaner periodically and clean or change it as necessary Refer to Para 4 for servicing instructions AC Generator AC generator bearings are sealed and require no periodic lubrication Lubricationand Maintenance Chart Figure 1 4 Air Cleaner Service Refer to Section 1 1 Fig 4 This air cleaner is a dry type which may be cleaned as many as six times be fore replacing it with a new a...

Page 46: ...n 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 is rec ommended for use both summer and winter CAUTION Consult the fuel oil selecting chart in the engine operator s manual before substituting an...

Page 47: ...s 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 CAUTIONS a Do not use methanol or alcohol as an antifreeze and b Do not use two different types of antifreeze Mixed solutions two types make it impossible to dete...

Page 48: ...rkins Diesel Shop Manual for exact locations of engine coolant drain valves NOTE When draining the system for storage remove all drain valves and remove drain plug 3 Allow the system to drain completely NOTE Be sure the drain valves do not plug up during draining 4 When the system is completely drained close all drain valves except when draining for storage F Cleaning the Cooling System Drain and ...

Page 49: ...stem until coolant reaches a level approximately 1 inch below the radiator filler neck NOTE If antifreeze solution is not premixed pour required antifreeze in first Install corrosion inhibitor according to directions on container 3 Start the engine and allow it to idle Add coolant if trapped air escapes from the system and the coolant level falls 4 Continue to check coolant level until the engine ...

Page 50: ... belt to set tle into the grooves of the pulleys and thus show any initial stretching that is going to occur Recheck belt tension after running the engine and adjust as necessary 9 Battery Maintenance A General Two 12 volt batteries supply power for operation of the engine electrical system clearance and panel lights and for flashing the generator exciter field B Battery Location and Accessibility...

Page 51: ...in charge or requires water frequently the reason for the condition must be found and corrected Visually inspect the battery before testing to determine if it has been damaged Moisture on the outside of the case or low fluid level in one or more cells indicates possible battery damage cracked case etc The battery may be tested by two methods A Battery Starter Tester may be used to determine the ba...

Page 52: ...anel The three 1 4 bolts at the bottom on the back of the panel The two 1 4 bolts underneath The three 1 4 bolts on each side holding the side panels The one 1 4 bolt on each side holding the cable rails The one 1 4 bolt on each side underneath holding fenders c Remove main frame rear cross member by removing four attaching bolts see Fig 3 d Remove generator back plate Do this by removing the six ...

Page 53: ...Removable Rear Frame Cross Member Figure 3 OM 2053 December 31 91 Revised 2 1 Page 11 ...

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Page 55: ...Lubrication Chart Ref 2 1 Fig 3 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 7 E F and H 3 Inspect hoses for cracks and deterioration Inspect clamps for tightness D V Belt 1 Inspect V belt for proper tension and adjust if necessary after each 200 hours of operation See 2 1 Para 7 A B and C E Exhaust Sys...

Page 56: ...oltmeter Check all lights Check fuel quantity Weekly Or Every 50 Hours Check crankcase oil level Check all lights Check coolant level Monthly Or Every 200 Hours Check safety switches Clean battery terminals Change engine oil filter element Change engine oil BI MONTHLY OR EVERY 400 HOURS Check cooling system hoses Check exhaust sys tubes fittings clamps Check protective relays Every 6 Months Or 120...

Page 57: ...ontactor CLOSED Engine Control Lamp Industry 1815 Indicating Light Panel Trade No Fault Indicating Control Box Lamp Industry 1815 Lights Trade No Lamp Identification Chart Figure 2 ITEM PROTECTED LOCATION ILLUSTRATION SIZE AND TYPE Instrument panel Engine Sect 1 1 10A Type AGC lights and engine control panel Fig 8 item 11 Protective relay Generator Sect 1 1 2A Type AGC system Control Panel Fig 6 i...

Page 58: ...protective modules to make certain they will function if a fault should occur in the output circuit See 2 3 Para 3 B D Wiring and Connections WARNING Stop operations and stop engine before touching exposed conduc tors or terminals 1 Check all cables leads and wiring for broken worn and damaged insulation 2 Check all connections for tightness 3 Check the output cable plug connector for damaged cont...

Page 59: ...nel light switch 13 in ON position If panel light 11 operates the fuse 21 switch 13 and lamps are good 9 Check fault indicating lights 8 by pressing test switch 7 If lights glow fuse 21 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 CAUTION Engine must not be running when flas...

Page 60: ...operly adjusted frequency will be exactly 400 Hz If not adjust engine governed speed in accordance with Para 3 E 3 d 8 Observe voltmeter 2 Use rheostat 27 to adjust voltage to 115 V AC 9 Measure governor actuator input signal See Para 3 E 4 a 10 Measure governor magnetic pickup signal See Para 3 E 4 b 11 Check speed limiting governor Set engine speed limiting governor to 2300 25 RPM See Perkins Di...

Page 61: ...ly 22 Apply 1 3 to 1 2 load at the load bank and allow the unit to run for 15 to 30 minutes Observe op eration of all monitoring instruments 23 Increase load bank resistance to apply a full load 24 Check operation of the governor by observing the frequency meter 1 Fig 1 when generator is switched from no load to full load and vice versa Use the contactor control switch 17 to apply and remove load ...

Page 62: ...lay actuates the protective monitor to open the load contactor and turn on the overvoltage indicating light The overvoltage sensing relay should trip when voltage reaches 130 V to 134 V b Return unit to normal operating conditions by adjusting voltage regulator rheostat and press ing reset switch 6 38 Check operation of undervoltage sensing relay indicating light and time delay Before starting thi...

Page 63: ...anner as the underfrequency circuit except its operating range is from 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...

Page 64: ... switch 20 Oil pressure gage 8 Fault indicating lights 21 Engine circuit fuse 10 A 9 Load contactor circuit fuse 22 Engine protective circuit 2 A indicating light 10 Protective system fuse 2 A 23 Engine starter switch 11 Instrument panel light 24 Permissive start switch 12 Fuel gage 25 Regulated diagnostic switch 13 Light switch 26 Aircraft test bank switch Operating Controls and Instruments Figur...

Page 65: ...ate Regulator Manual OM 2020 which is a part of Chapter 6 of this manual C Basic Engine Adjustments Adjustment procedures applicable to the diesel engine are included in the Perkins Diesel Handbook which accompanies this Hobart manual Specific information for this particular engine is listed in Fig ure 2 27 Automatic voltage control potentiometer R5 30 Cable length compensation rheostat 28 Cable s...

Page 66: ...nd controller have critical adjustments which can affect engine performance and therefore generator output The ad justment 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 followed First Check or adjust actuator linkage Second Check or adjust magnetic pick up Third Check or adjust electr...

Page 67: ... in actuator lever 3 is used to mount ball joint 4 It does not necessarily have to be the same hole as may have been pre viously used Disconnect ball joint 4 from actuator lever 3 b Be sure neither lever the actuator lever 3 or the fuel control lever 7 has 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 attemp...

Page 68: ...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 tighten nut 3 This adjus...

Page 69: ...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 2000 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 cilla...

Page 70: ... Stability adjustment 3 Rated speed adjustment Electric Governor Control Box Woodward Figure 5 Electric Governor Controller Terminal Strip Connections Woodward Governor Figure 6 OM 2053 2 3 December 31 91 Revised Page 12 ...

Page 71: ...ion of the complete system Two definite rules must be followed in making the adjustment Adjust linkage must use the FULL TRAVEL of the actuator output shaft Linkage must move engine speed control lever from FULL IDLE to RATED SPEED posi tion or VERY CLOSE to FULL SPEED position to allow the engine to pull maximum load With the engine stopped refer to Figure 3 and proceed with linkage adjustments a...

Page 72: ...5 turns to force the engine speed control lever downward slightly from the full upward position k Start the engine and set the idle speed to 850 RPM 25 RPM Operate engine at idle speed until it is warmed to operating temperature Then re adjust idle speed set screw if neces sary to obtain the original 850 RPM 25 RPM 2 3 March 10 91 Revised 1 Actuator 2 Actuator shaft 3 Clevis actuator shaft 4 Ball ...

Page 73: ...nd reinstall CAUTION The pickup tip must be directly over a tooth and not between teeth when adjustment is made w c Continue turning pick up CLOCKWISE until it bottoms out it has hit the ring gear teeth d Back the magnetic pick up out 1 4 to 3 4 of a turn COUNTERCLOCKWISE This creates a gap between the magnetic pick up and the ring gear e Disconnect magnetic pick up wires at the terminal strip Fig...

Page 74: ... load and observe the length of time re quired for the engine speed to again stabilize Engine speed should stabilize within 3 to 5 oscilla tions f If engine speed does not stabilize at the above setting continue making slight adjustments to the GAIN control and checking stability and engine speed between no load and full load until the engine speed stabilizes 5 Re checking Actuator Linkage Perform...

Page 75: ...Electric Governor Control Box Barber Colman Governor Figure 9 Electric Governor Controller Terminal Strip Connections Barber Coleman Governor Figure 10 OM 2053 December 31 91 Revised 2 3 Page 17 ...

Page 76: ...r actuator worn internally Magnetic pick up improperly adjusted Engine over speeds when load is applied Magnetic pick up improperly adjusted Friction in throttle linkage Governor improperly adjusted Friction in engine speed control mechanism Springs in engine speed control mechanism opposing governor action Governor actuator worn internally Governor surges at no load Friction in throttle linkage M...

Page 77: ... A Disconnect diode lead s B Use a good quality ohmmeter An instrument which indicates 50 ohms at the center of the scale is preferable NOTE Make certain the battery is in good condition and the pointer is adjusted to zero when the test lead points are shorted together Set the scale selector to RX1 C Hold one ohmmeter lead point on the threaded end of the diode Hold the other lead point on the wir...

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Page 79: ...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 80: ...ation is to re place the complete assembly or the module and send the old assembly or module to stock Assemblies which lend themselves to this concept are Voltage regulator Protective monitor module Governor actuator Over underfrequency module Overload module Electric governor control box Over undervoltage module The above items are in addition to normally replaced items such as fuel pump injector...

Page 81: ... AC input power from magnetic pickup B Assuming other conditions are normal the actuator will go to or remain in IDLE position under the following conditions 1 No 12 V DC power 2 No voltage from control box to actuator C The actuator will surge under the following conditions 1 Stability or gain adjustment set too high 2 Throttle linkage binding Trip PC Board Trip Value Trip Time Within Reset Value...

Page 82: ... switch 20 Oil pressure gage 8 Fault indicating lights 21 Engine circuit fuse 10 A 9 Load contactor circuit fuse 22 Engine protective circuit 2 A indicating light 10 Protective system fuse 2 A 23 Engine starter switch 11 Instrument panel light 24 Permissive start switch 12 Fuel gage 25 Regulated diagnostic switch 13 Light switch 26 Aircraft test bank switch Operating Controls and Instruments Figur...

Page 83: ... compression pressure The injection of the proper amount of fuel at the right time Lack of power uneven running excessive vibration stalling and hard starting may be caused by low com pression faulty injection in one or more cylinders or lack of sufficient air Refer to Perkins Handbook for trouble shooting and repair procedures 10 Illustrations Illustrations in Figure 1 are referred to throughout ...

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Page 85: ... 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 Rplace D Internal seizure D If all engine starting com ponents are good and the starter is unable to crank the engine internal seizure i...

Page 86: ...ollows 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 fuel connections Replace any lines between tank and damaged hoses or fuel fuel pump links 4 Plugged or defective 4 Do not overlook the fuel filter possibility of restricted flow through the fuel filters Also check gaskets for leaki...

Page 87: ...instructions in Perkins Handbook 3 Cylinder head 3 Check gasket in accor gasket leaking dance with instructions in Perkins Handbook 4 Improper valve 4 Check and adjust valve clearance adjust clearance in accordance ment with instructions in John Deere Handbook 5 Engine starts Stops A The shut down circuit A Restart the engine hold after a few seconds may have functioned permissive start switch in ...

Page 88: ...overnor controller s mode controller due to terminal strip If engine comes up defective operating to speed check following mode switch 15 Fig 1 B Governor linkage B Check governor linkage and binding or governor throttle shaft for binding throttle sticking and sticking Repair as required C Defective or mis C The controller may not be adjusted magnetic receiving a signal from the mag pickup 2 Fig 4...

Page 89: ...w several turns clockwise to be sure speed setting is not too low because of tampering If voltage remains low or at zero replace controller Refer to governor instruction booklet in Chapter 6 for controller bench tests and adjustments 8 Engine goes to A Governed speed con A Turn speed control adjust overspeed when con trol adjustment set ing screw fully counterclock trol switch 15 too high see 2 3 ...

Page 90: ...er controls on controller in accordance Colman controller with Section 2 3 Para 4 F 4 3 Magnetic pickup 3 Check and adjust pickup as per signal weak Section 2 3 Para 4 E 3 for ungrounded magnetic pickup or Para 4 F 3 for grounded magnetic pickup 10 Engine has slow A Governor controller A Adjust See 2 3 Para 4 E 4 response time improperly adjusted B Actuator linkage binding B Inspect and repair as ...

Page 91: ... switch 25 Fig 1 in age in all phases circuit DIAGNOSTIC position This Generator operating applies 12 V DC from the at 400 Hz battery to the exciter field which should produce an indicated output voltage of 55 V DC 5 V DC If the voltage produced is within this range the generator is good and the trouble is in the voltage regulator circuit Proceed to step B B Defect in VOLTAGE B Check as follows RE...

Page 92: ...nect plug from connector at voltage regulator PC voltage regu board Using jumper lator or defec leads with clip and prod tive wiring from terminals connect 12 V regulator to DC to terminals 4 and 5 exciter field in loose plug Connect NEGATIVE to terminal 5 Connect POSITIVE lead to terminal 4 see Sche matic Connection Diagram in Chapter 6 If the generator will NOT pro duce at least 50 V AC replace ...

Page 93: ... 1 1 known to be operating 4 Fig 8 properly If contactor still doesn t close proceed to step 3 3 Defective load 3 Set Regulated Diagnos contactor control tic switch S1 in switch S5 20 REGULATED position Fig 1 Check AC voltage input to contactor rectifier CR6 If voltage isn t approximately 115 V AC contactor control switch is defective and must be replaced 4 Defective recti 4 After making certain f...

Page 94: ... protective B Press the lens housing of relay fuse F2 fault indicating lights If lamps 1 1 8 Fig 6 do not glow replace fuse F2 C Defective plug C Place test bank switch S2 interlock relay K2 34 Fig 1 in ON position If load contactor will now remain closed replace the plug interlock relay K2 Sect 1 1 2 Fig 7 D Small contacts in D Connect a jumper lead be load contactor K1 tween small terminal no 1 ...

Page 95: ...ouble shooting the protective circuits To avoid repetition it will be assumed that the reset switch 6 Fig 1 has been pushed and theload contactor has been closed before commencing each test 1 Load contactor A The overvoltage con A Press reset switch 6 opens during power dition may have been Fig 1 and resume power delivery Over the result of a sud delivery Observe voltmeter voltage indicating den d...

Page 96: ...the under voltage relay is defective Replace the module K26 C Defective protective C With unit running normally monitor module K14 use potentiometer 27 Fig 1 to reduce voltage quickly to 90 V If the undervoltage indicating light DS38 is turned ON immediately the protective monitor circuitry is defective Replace protective monitor K14 3 Load contactor opens A Electric governor A Proceed as follows ...

Page 97: ... replace over under frequency relay 5 Load contactor A There may have been A Observe ammeter 3 Fig 1 opens during power an overload condition Check for abnormal overload delivery Over which caused the condition and correct If frequency indi overload device K4 overload device functions to cating light ON to function normally open the load contactor when an overload does not exist proceed to step B ...

Page 98: ...oose connection A Check all output connec overheats causing high resis tions Look for discolora tance tion caused by heat Tighten or replace as required B Improper or blocked B Check for foreign material ventilation rags etc blocking air flow Provide adequate ventilation C Generator stator C Check stator windings See windings short circuited Sect 2 3 Fig 6 4 Unbalanced output A Loose connection in...

Page 99: ...ng 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 1 St...

Page 100: ...ATURE column 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 relationship Thus components of an assembly are listed directly below the assembly and in dented one space Vendor codes and part numbers for purchased parts are shown in this c...

Page 101: ...Marketing 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 03613 Barber Colman Co 1354 Clifford Ave Loves Park IL 61132 03924 StratoFlex Inc 2nd and Piper Sts Baer Field Box 9190 Waynedale Station Ft Wayne IN...

Page 102: ...th 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 31337 Parker Metal Corp 85 Prescott Street Worchester MA 01605 31356 J B T Instruments Incorporated 394 East Street P O Box 1818 New Haven Connecticut 06508 31361 Woodward Governor Company 1000 E Drake Road P O Box ...

Page 103: ...hicago 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 73559 Carlingswitch Inc 505 New Park Ave West Hartford Connecticut 06110 74400 Stewart Warner Corp Hobbs Div Ash Street Yale Boulevard Springfield Illinois 62705 75175 K D Lamp Com...

Page 104: ...ka 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 Company Inc Bearing Divisi...

Page 105: ... 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 uF 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 106: ...Generator Set Figure 1 OM 2053 4 3 December 31 91 Revised Page 2 ...

Page 107: ...LER OR TRUCK MOUNTING C 1 1 No Number CANOPY ASSEMBLY For Details See Fig 2 A 1 No Number CANOPY ASSEMBLY For Details See Fig 2 BC 1 2 No Number GENERATOR SET WITHOUT CANOPY For Details See Fig 3 1 3 No Number FRAME GROUP For Details See Fig 3 1 4 402987 LABEL HOBART 3 5 280718 TRAILER FENDERS FUEL TANK OPTION A 1 281056 TRAILER FENDERS FUEL TANK OPTION BC 1 NOT ILLUSTRATED OM 2053 July 16 96 Revi...

Page 108: ...Canopy Assembly Figure 2 OM 2053 4 3 December 31 91 Revised Page 4 ...

Page 109: ...6 280575 DOOR CANOPY ASSY A 3 281071 DOOR CANOPY ASSY BC 2 7 280579 DOOR CANOPY L R A 1 281096 DOOR CANOPY L R BC 1 8 482401 COVER GENERATOR CONTROL A 1 281093 COVER GENERATOR CONTROL BC 1 9 489030 COVER ENGINE CONTROLS A 1 281574 COVER ENGINE CONTROLS BC 1 10 281109 DOOR CANOPY R R BC 1 11 181125 LATCH DOOR A 7 181125 LATCH DOOR BC 8 12 280646 BAFFLE HEAT A 1 13 281102 BAFFLE HEAT BC 1 14 403153 ...

Page 110: ...Generator Set Without Canopy Specification 7009B 1 Illustrated Figure 3 OM 2053 4 3 December 31 91 Revised Page 6 ...

Page 111: ...6 3544 1 9 No Number RADIATOR AND COOLING SYSTEM GROUP For Details See Fig 4 1 10 281050 MUFFLER ASSEMBLY 1 11 281041 1 PIPE EXHAUST ASSY 1 12 180404 SUPPORT MUFFLER LH 1 13 180405 SUPPORT MUFFLER RH 1 14 DDW 495 1 CAP RAIN 1 15 488908 FAN FLEX COUPLING ASSY 1 16 404154 15 CLAMP FULL CIRCLE 1 17 280542 1 PANEL ASSEMBLY CONTROL ENGINE For Details See Fig 11 1 18 281118 PANEL SUPPORT CONTROL BOX 1 1...

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Page 113: ...PART NO 1234567 EFF ASSY 3 CONTINUED 25 280722B PANEL CONTACTOR ASSY For Details See Fig 12 1 26 281117 LEG SUPPORT CONTROL BOX BC 1 27 280914 SHROUD AIR ASSY 1 28 84A 1101 KIT STARTER SPACER 1 NOT ILLUSTRATED OM 2053 July 16 96 Revised 4 3 Page 9 ...

Page 114: ...Radiator and Cooling System Group Figure 4 OM 2053 4 3 December 31 91 Revised Page 10 ...

Page 115: ...4018 1 4 281031 SHROUD FAN ASSEMBLY 1 5 280942 GUARD FAN LEFT 1 6 280941 GUARD FAN RIGHT 1 7 W 10869 3 CLAMP HOSE 2 8 W 10869 7 CLAMP HOSE V35708 NO HS 12 2 9 56531 HOSE RADIATOR OUTLET 46 10 56532 HOSE RADIATOR INLET 17 11 386751 CLAMP OVERFLOW HOSE 2 12 402433 CLAMP HOSE 1 13 403782 2 SWITCH SHUTDOWN TEMPERATURE V51377 NO 1002 04880 34 1 14 W 7814 4 BUSHING PIPE STEEL 1 NOT ILLUSTRATED OM 2053 J...

Page 116: ...Air Cleaner Assembly Figure 5 OM 2053 4 3 December 31 91 Revised Page 12 ...

Page 117: ...SE 2 3 281036 PIPE AIR INTAKE ASSY 1 4 85A 1045 REDUCER RUBBER 1 5 W 10869 6 CLAMP HOSE 1 6 181129 CLAMP AIR CLEANER 2 7 281034 BRACKET MTG AIR CLEANER 2 8 402321 1 SCREW 1 4 20 X 1 2 HWH TAP TITE 3 9 402119 2 SCREW 1 4 20 X 1 2 HHC ST 2 10 W 11254 4 WASHER LK STD 1 4 2 11 W 11278 7 NUT 1 4 20 HEX FULL ST 2 Not Illustrated OM 2053 July 16 96 Revised 4 3 Page 13 ...

Page 118: ...Electric Governor Kit Woodward Governor Figure 6 OM 2053 4 3 December 31 91 Revised Page 14 ...

Page 119: ...361 No 8256 017 1 4 84A 1091 ARM THROTTLE GOVERNOR V31361 No 3952027 1 5 DELETED 6 W 9476 11 ROD THREADED 1 4 28 x 4 3 4 1 7 W 11280 3 NUT JAM HEX 1 4 28 5 8 488692 BRACKET MTG ACTUATOR 1 9 285202 PLATE MOUNTING LINKAGE 1 10 84A 1075 MOUNT SHOCK RUBBER 4 11 482989 STRAP WIRE GROUND 2 12 50MS 732 0 NUT 1 4 20 HEX KEPS ST 1 13 405071 1 SCREW CAP HEX HEAD M8 1 NOT ILLUSTRATED This governor assembly u...

Page 120: ...Electric Governor Kit Barber Colman Governor Figure 6A OM 2053 4 3 December 31 91 Revised Page 16 ...

Page 121: ... BRACKET MTG ACTUATOR 1 4 282674 BRACKET MTG ACTUATOR 1 5 281776 JOINT BALL GOVERNOR LINKAGE 2 6 281775 CLEVIS ACTUATOR ROD 1 7 281774 2 SENSOR MAGNETIC GOVERNOR 1 8 W 9476 11 ROD THREADED 1 4 28 x 4 3 4 1 9 401937 2 BLOCK TERMINAL 1 10 W 11280 3 NUT JAM HEX 1 4 28 3 11 84A 1075 MOUNT SHOCK RUBBER 4 12 482989 STRAP WIRE GROUND 2 Not Illustrated This governor assembly used on units manufactured aft...

Page 122: ...Fuel Lines Assembly Figure 7 OM 2053 4 3 December 31 91 Revised Page 18 ...

Page 123: ... RIGID HOSE END 1 8 84A 1007 1 FITTING HOSE MALE 1 9 W 10869 14 CLAMP HOSE BC 1 10 W 10051 6 CLAMP HOSE BC 2 11 56587 HOSE RUBBER BC 40 12 78B 1019 3 TUBE RIGID HOSE END 1 13 W 10886 2 CONNECTOR MALE SAE 45 FLARED BRASS 1 14 W 7814 3 BUSHING PIPE STEEL 1 15 W 7814 10 BUSHING PIPE STEEL 3 4 X 1 8 A 1 16 W 10901 3 NUT COMPRESSION BRASS A 2 17 W 10905 6 SLEEVE COMPRESSION BRASS A 2 18 79B 1022 BOLT B...

Page 124: ...Oil Line Assembly Figure 8 OM 2053 4 3 December 31 91 Revised Page 20 ...

Page 125: ...e Fig 3 REF 1 403809 1 SWITCH LOW OIL PRESSURE V51377 No C 25900 10 1 2 W 10909 1 TEE STREET BRASS V79470 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 51 NOT ILLUSTRATED OM 2053 July 16 96 Revised 4 3 Page 21 ...

Page 126: ...Battery Installation For units having TWO batteries Figure 9 Battery Installation For units having ONE battery Figure 9A OM 2053 4 3 December 31 91 Revised Page 22 ...

Page 127: ...96 1 CLAMP HARNESS WIRE 1 8 W 9407 138 CABLE ENGINE TO GROUND 1 NOT ILLUSTRATED NOMENCLATURE UNITS FIGURE HOBART PER ITEM NO PART NO 1234567 EFF ASSY 9A NO MUMBER BATTERY INSTALLATION For NHA See Fig 3 For units having ONE battery BC REF 1 281871 1 BATTERY 12 VOLTS 1 2 181825 TRAY BATTERY 1 2A A 25 SPACER BATTERY TRAY 8 3 181831 FRAME HOLD DOWN BATTERY 1 4 388827 14 CABLE POSITIVE 1 5 388828 9 CAB...

Page 128: ...Control Box Assembly Figure 10 OM 2053 4 3 December 31 91 Revised Page 24 ...

Page 129: ...05277 No IN4820 4 14 400030 1 CAPACITOR TANTALUM 6 8 MFD 35 V V80183 No 150D685X9035B2 1 15 16DA 4004A 3 RELAY PLUG IN 24 VOLT D C V77342 No K10 14DG 24 1 16 280534 BOTTOM CONTROL BOX 1 17 482038 BOARD PC OVER UNDERVOLTAGE ASSY 1 18 401556 MOUNT SHOCK RUBBER V81860 No SS 01 16 19 387738A BOARD PC OVERLOAD 12 VOLT ASSY 1 20 404460 1 SUPPORT LOCKING PC BOARD 4 21 482039 BOARD PC OVER UNDERFREQUENCY ...

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Page 131: ...INE DROP BURDEN 50 OHM 25 W V44655 No 0200D 3 40 363136 2 TRANSFORMER CURRENT AMMETER 3 41 402037 9 GROMMET RUBBER V02231 No AGW 4211 1 42 402658 HOLDER FUSE V71400 No HKP HH 2 43 W 11166 1 FUSE AGC 2 AMP 2 44 82B 1047 LIGHT PANEL V74400 No MI 3216 1 400613 4 BULB V74400 No 3271 1 45 402662 SWITCH AIRCRAFT TEST BANK DPST V73559 No 2GK71 73 1 46 402826 SWITCH REGULATOR DIAGNOSTIC 4PDT V15605 No 892...

Page 132: ...Engine Control Panel Assembly Figure 11 OM 2053 4 3 December 31 91 Revised Page 28 ...

Page 133: ...64 GAUGE TEMPERATURE WATER 1 9 180913 1 LIGHT PILOT ENGINE GENERATOR GREEN 12 VOLT 2 10 82A 1030 GAUGE PRESSURE OIL 1 11 403091 5 BUTTON PLUG HOLE 1 12 400701 CONNECTOR RIGHT ANGLE 2 13 401937 2 STRIP TERMINAL V98410 No 35008 3526 1 14 404100 SWITCH PUSHBUTTON STARTER V70040 No 1996097 1 15 25MS 156 BUS JUMPER 1 16 20RT 353 1 DIODE NEGATIVE BASE 16 AMP 1 17 W 11166 3 FUSE AGC 10 AMP 1 18 402658 HO...

Page 134: ...4 3 Revised Page 30 March 30 93 Contactor Panel Assembly Figure 12 OM 2053 ...

Page 135: ...TOR 3 POLE 1 4 402119 8 SCREW 1 4 20 x 1 1 2 HHC ST 1 5 A 25 WASHER INSULATING 2 6 DW 1704 BUSHING 1 7 W11242 5 WASHER FLAT ST 1 4 5 8 W 11254 4 WASHER LOCK 1 4 ST 5 9 W 11280 2 NUT HEX 1 4 20 ST 2 10 W 11097 8 SCREW 3 8 16 x 2 HHC ST 1 11 W 11242 10 WASHER FLAT ST 3 8 1 12 W 11254 8 WASHER LOCK ST 3 8 1 13 W 11278 5 NUT HEX 3 8 16 2 14 W 11263 6 WASHER LOCK IET ST 3 8 2 Revised 4 3 March 25 93 Pa...

Page 136: ...Generator Group Figure 13 OM 2053 4 3 December 31 91 Revised Page 32 ...

Page 137: ...SPACER COUPLING 1 12A 402789 3 SCREW SPACER RING 8 13 481379 KEY EXCITER 1 14 387624A 1 HOUSING EXCITER 1 15 100NH 2 POLEPIECE EXCITER 4 16 100NH 3 INSULATION EXCITER WRAPPER 4 17 489180 COIL FIELD EXCITER 1 SET 18 387620A 1 HOUSING FAN ASSEMBLY 1 19 85B 1039 KEY FLEXIBLE COUPLING 1 20 W 10072 48 BEARING FRONT V53035 6314DDUG3E1SR1S 1 21 W 10072 1 BEARING REAR V53035 6310DDUC3ESR1S 1 22 181346 ARM...

Page 138: ...Trailer Assembly Figure 14 OM 2053 4 3 December 31 91 Revised Page 34 ...

Page 139: ...SY A 1 281058 TANK FUEL ASSY B 1 19 280611 CAP TANK FUEL A 1 76A 1152 CAP TANK FUEL B 1 20 280564 STRAP MTG FUEL TANK 2 21 280608 INSULATOR FUEL TANK 2 22 280585 PANEL SIDE A 3 23 280724 PANEL SIDE LEFT REAR A 1 24 280727 BUMBER REAR 1 25 79A 1075 DRAWBAR ASSY V22938 No 19 3500 1 26 79A 1057 PIN HINGE V22938 No 5416 1 27 76A 1171 PIN COTTER V22938 No 4800 6 2 79A 1045 CENTER ARM ASSY V22938 No 15 ...

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Page 141: ... 5401 2 52 84A 1082 PIN ROLL V22938 No 5000 6 2 85A 1026 HUB ASSY FRONT AXLE V22938 No 7 3601 2 53 85A 1020 CAP GREASE V22938 No 6301 2 54 85A 1022 BEARING CONE OUTER V22938 No 6051 1 55 85A 1021 BEARING CONE INNER V22938 No 6050 1 56 85A 1023 SEAL GREASE V22938 No 6300 1 57 85A 1024 NUT STUD V22938 No 4603 1 10 58 LOCKWASHER 5 85A 1019 HUB STUD CUP ASSY V22938 No 7 3601 2 59 85A 1025 HUB V22938 N...

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Page 143: ... one place each lo cation is listed commencing with the first location the part is listed A 25 9 2A 9A 2A 12 5 BATTERY INSTALLATION 9 0 9A 0 CANOPY ASSEMBLY 1 1 2 0 DW 1704 12 6 DDW 495 1 3 14 FRAME GROUP 1 3 FW 1312 11 4 GENERATOR GROUP 3 1 GENERATOR SET WITHOUT CANOPY 1 2 3 0 HF 1459 10 29 HF 2752 3 20 RADIATOR AND COOLING SYSTEM GROUP 3 9 4 0 W 10051 6 7 10 W 10072 1 13 21 W 10072 48 13 20 W 10...

Page 144: ...1 6 6 6A 8 ICZ 93B 10 13 ICZ 148 10 34 W 9746 1 10 39 W 9746 3 10 38 W 9916 10 10 25 W 9917 18 11 7 Y 680 11 5 100GHP 66 13 8 100NH 2 13 15 100NH 3 13 16 12CW 1320A 5 11 19 12CW 2125 11 21 12CW 2146 6A 6 15GH 433 10 28 16DA 4004A 3 10 15 16DA 4004A 10 10 6 16DA 4052 0 10 7 16DA 4253 1 10 9 180404 3 12 180405 3 13 180913 1 11 9 180913 4 10 31 180927 13 12 180954 4 1 181077A 14 1 181079 14 3 181125 ...

Page 145: ...0579 2 7 280581 14 14 280582 14 15 280583 2 1 280585 14 22 280587 14 17 280588 14 16 280590 10 47 280591 2 5 280597 14 4 280602 14 5 280604 14 10 280605 14 11 280606 2 19 280607 14 6 280608 14 21 280611 14 19 280612 11 2 280618 1 9 5 280619 1 9 4 280635 2 2 280646 2 12 280718 1 5 280718 14 0 280722B 3 25 280722C 12 0 280723C 12 1 280724 14 23 280725 14 11A Revised 4 4 March 25 93 Page 3 FIGURE ITE...

Page 146: ...0 281058 14 18 281071 2 6 281074 2 1 281093 2 9 281096 2 7 281102 2 13 281104 2 4 281109 2 10 281114 2 3 281115 2 2 281116 3 19 281117 3 26 281118 3 18 281574 2 9 281774 2 6A 7 281776 6A 5 281871 1 3 2 9A 1 282130 1 12 3 282671 3 4 6A 0 282500 6A 1 282501 6A 2 282673 6A 3 282674 6A 4 284399 1 14 47 284399 2 14 48 284399 4 14 33 284399 5 14 25 284399 6 14 27 4 4 Revised Page 4 May 6 93 FIGURE ITEM ...

Page 147: ...48 400400 10 30 400613 4 10 31 10 44 400701 11 12 400785 7 10 10 400818 1 7 1 400819 2 7 2 400954 14 7 401468 14 8 401556 10 18 401564 3 10 37 401564 4 10 2 401564 5 10 23 401937 2 6A 9 11 13 401937 3 10 1 402037 9 10 41 402086 2 3 2 9 1 402119 2 5 9 402119 4 12 2 402119 8 12 4 402321 1 5 8 402433 4 12 402658 10 42 11 18 402662 10 45 402665 1 10 51 402789 3 13 12A 402826 10 46 402908 6 5 Revised 4...

Page 148: ... 404530 14 30 04595 6 1 405071 1 6 13 405154 5 10 35 405743 4 3 430077 2 2 18 430340 10 36 480603 1 13 26 480628 13 27 480669 13 5 481379 13 13 481940 13 24 482038 10 17 482039 10 21 482291 10 33 482401 2 8 482483 13 4 482496 1 9 7 9A 7 484634 14 12 484689 1 10 11 484690 2 10 12 486270 10 14 13 488692 6 8 488693 6 9 488695 3 24 8 0 488735 1 3 21 488735 2 3 22 488701 3 4 6 0 4 4 Revised Page 6 May ...

Page 149: ... 76A 1171 14 27 76A 1183 14 72 78A 1000 2 15 78A 1023 7 19 78B 1019 2 7 7 78B 1019 3 7 12 78B 1021 7 20 79A 1035 14 71 79A 1045 14 27 79A 1046 14 28 79A 1047 14 32 79A 1048 14 33 79A 1051 14 67 79A 1052 14 68 79A 1053 14 69 79A 1054 14 70 79A 1057 14 26 79A 1077 14 66 79A 1078 14 34 79A 1110 2 16 79A 1144 13 28 79B 1022 7 18 80A 1052 14 47 14 65 80B 1107 3 8 82A 1030 11 10 82B 1047 10 44 11 3 Revi...

Page 150: ...37 14 55 85A 1022 14 36 14 54 85A 1023 14 38 14 56 85A 1024 14 39 14 57 85A 1025 14 41 14 59 85A 1026 15 52 85A 1027 14 42 14 60 85A 1028 14 43 14 61 85A 1029 14 44 14 62 85A 1030 14 45 14 63 85A 1031 14 46 14 64 85A 1034 14 49 85A 1035 14 50 85A 1037 14 65 85A 1045 5 4 85B 1013 14 2 85B 1039 13 19 4 4 Revised Page 8 Mar 6 93 FIGURE ITEM PART NUMBER NUMBER OM 2053 ...

Page 151: ...furnished with your generator Available options are listed below OPTION NAME MANUAL HOBART NO 7009 Trailer Fenders Fuel Tank and Parts OM 2053 280718 7009A Trailer Fenders Fuel Tank and Parts OM 2053 281056 Quick Start Kit OM 2053 181867 Kit Water Heater TO 192 181714 OM 2053 March 20 89 5 0 Page 1 ...

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Page 153: ...mpany for Specification 7009B units Electrically Powered Governor Instruction Manual Engine Perkins Diesel Engine Operators Manual No 6 3544 Flexible Coupling Hobart Brothers Company Coupling Manual OM 2019 Exciter Rotor Hobart Brothers Company Rotor Manual TM 360 HOBART DIAGRAMS 281025 Schematic and Connection Engine and Generator Specifications 7009 and 7009A 5 sheets 282682 Schematic and Connec...

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Page 175: ...il 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 rated ...

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Page 177: ...to reach most efficient operating temperature for complete combustion of fuel The unburned fuel collects in the exhaust system to create the wet condition known as wet stacking To alleviate wet stacking in lightly loaded engines it is recommended that the ma chine be connected to a load bank after each 200 hours of use and operated un der full rated load for one hour This will burn away and evapor...

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