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Hobart 6824-1 Operation And Maintenance Manual Download Page 187

387617A

20-1

387620A-1

20-18

387621

20-2

387623-1

20-9

387624A-1

20-14

387736B

16-11

387738A

13-8

387748-1

20-23

387881

5-8

387915

21-5

387916

21-4

387947

21-10

388328-49

15-24

388328-52

16-26

388763

4-30, 10-0

388828-1

22-7

389284

2-27

389909

5-5

400059-3

6-7, 18-29

400078

15-6A

400333-1

6-14

400400

15-20

400480-2

13-17

400480-3

13-18, 13-37

400613-4

16-20, 17-3, 18-9

400613-10

2-37, 3-31

400701

13-13, 18-21

400819-1

8-4

400829-5

7A-10

400830-15

13-15

401556

13-11, 16-10

401563-4

16-14, 16-16

401563-5

16-12

401564-4

13-9, 16-28

401564-5

16-29

401566-11

13-10, 16-27

401937-1

12-9, 16-9

401937-2

7A-12, 13-2, 18-20

401937-3

13-1, 13-25, 18-17

401898-2

21-7

FIGURE &

PART NUMBER

ITEM NUMBER

OM-499

May 31/94 Revised

4-4

Page 5

Summary of Contents for 6824-1

Page 1: ...Y Airport Systems Group Troy Ohio 45373 U S A SPECIFICATION MOUNTING VOLTAGE REGULATOR 6824 1 6824A 1 Trailer or Truck 430391C 6824 2 6824A 2 Tractor 430391C 6824 3 6824A 3 Stationary With Fuel Tank B...

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

Page 3: ...is decreased when wet permitting dangerous currents to flow through it When inspecting or servicing equipment do not work in damp areas Stand on a dry rubber mat or dry wood use insulating gloves when...

Page 4: ...b Batteries Batteries may explode and or give off flammable hydrogen gas Acid and arcing from a ruptured battery can cause fires and additional failures When servicing do not smoke cause sparking or...

Page 5: ...ECTRICAL SHOCK turn off power Remove victim if not breathing begin artificial respiration preferably mouth to mouth If no detectable pulse begin external heart massage CALL EMERGENCY RESCUE SQUAD IMME...

Page 6: ...This page intentionally left blank OM 499 Safety Warnings May 31 94 Revised Page 4...

Page 7: ...ers Each chapter is divided into as many sections as required Each new section starts with page 1 Each page is identified by chapter section and page number which are located in the lower outside corn...

Page 8: ...This page intentionally left blank OM 499 Introduction May 31 94 Revised Page 2...

Page 9: ...ipment 1 1 5 a Trailer 1 1 5 b Transformer Rectifier 1 1 5 c Truck 1 1 5 d Second Output and Control Box 1 1 5 e Quick Start Kit 1 1 5 7 Engine Generator and Controls Assembly 1 1 6 a Basic Engine 1 1...

Page 10: ...ne Starting Procedures 1 3 4 d Preparation for Power Delivery Normal Automatic Voltage Control 1 3 4 e Power Delivery Automatic Voltage Control 1 3 5 f Preparation for Power Delivery Manual Voltage Co...

Page 11: ...gine Fuel 2 1 5 Quality 2 1 5 Fuel Filter 2 1 5 7 Engine Cooling System 2 1 6 a General 2 1 6 b Radiator Cap 2 1 6 c Warm Weather Operation 2 1 6 d Cold Weather Operation 2 1 6 e Draining the Cooling...

Page 12: ...5 Trailer and Truck 2 2 4 Section 3 Adjustment Test 2 3 1 1 General 2 3 1 2 Test Panels 2 3 1 a Generator Set Removed from Tractor 2 3 1 b Generator Set in Tow Tractor 2 3 1 3 Generator Set Test 2 3...

Page 13: ...Illustrations 3 1 3 Chapter 4 Illustrated Parts List 4 1 1 Section 1 Introduction 4 1 1 1 General 4 1 1 2 Purpose 4 1 1 3 Arrangement 4 1 1 4 Explanation of Parts List 4 1 1 a Contents 4 1 1 b Parts L...

Page 14: ...This page intentionally left blank OM 499 Table of Contents May 31 94 Revised Page 6...

Page 15: ...rs are not running The engine generator and controls are designed into a compact unit which is easily removable from a tow tractor See Figure 2 for specifications and capabilities 2 Orientation For pu...

Page 16: ...t box manufactured by Hobart Brothers This test circuitry allows electricians to perform as many as twenty four tests and checks from one location conveniently and easily f Electric Governor The engin...

Page 17: ...g frame 2 Lifting eye 7 Engine fan exhaust deflectors 3 Windows 8 Engine exhaust pipe 4 Output receptacle cover 9 Radiator cap access cover 5 Output cable horn Generator Set Figure 1 OM 499 May 31 94...

Page 18: ...425 Hz resets 410 Hz Underfrequency relay Trips 375 Hz to 385 Hz resets 385 Hz Undervoltage time delay 4 to 12 seconds depending upon adjustment Overload relay Trips at 125 rated load in less than 5...

Page 19: ...he right side of the machine is not accessible when mounted on a tow tractor and secondly because the thick doors would not allow mounting in the limited space available on the tractor Panel mounted i...

Page 20: ...l of engine speed and generator output frequency because it provides faster engine response to changes in load conditions This fast response results in very close frequency control Refer to the Barber...

Page 21: ...e control panel 3 Power module 9 Lifting yoke 15 Cable horn and clamp 4 Control box 10 Engine 16 Radiator 5 Governor control box 11 Engine exhaust pipe 17 Oil pressure switch 6 Starting fluid containe...

Page 22: ...ator and a service indicator 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 p...

Page 23: ...excitation of the generator revolving fields The exciter DC output to the generator fields and consequently the generator output is controlled by the amount of DC voltage supplied to exciter fields b...

Page 24: ...ator output alternating current in the range of 380 to 420 Hz cycles per second The voltmeter indicates the generator output voltage in each phase to neutral A N B N and C N or phase to phase A B B C...

Page 25: ...citer field only when engine speed is being controlled by the electric governor 2 Protective relay tray see Figure 8 The bottom tray in the control box is identified as the protective relay tray and c...

Page 26: ...on relay 11 Automatic manual switch 4 Instruction plate 12 Receptacle connector 5 Line selector toggle switch 13 Manual voltage control rheostat 6 Meter selector rotary switch 14 Manual control rectif...

Page 27: ...e monitor system to function Each of the five lights is connected to an actuating circuit within the memory and time delay module When one of the circuits is activated it turns on the applicable indic...

Page 28: ...indicating light 5 Over undervoltage module 16 Load contactor circuit fuse 2 A 6 Over underfrequency module 17 Protective system fuse 2 A 7 Reset switch 18 Test bank switch 8 Light test switch 19 Rece...

Page 29: ...onnected by a capillary tube to a bulb mounted in the engine cooling system The gage indicates engine coolant temperature in the range of 100o F to 220o F c Oil pressure gage and oil pressure switch T...

Page 30: ...tarting circuit The pushbutton start switch 15 and permissive toggle switch 18 serve to connect power for closing an auxiliary solenoid switch The auxiliary switch then connects power to the starter s...

Page 31: ...truck mounted units or stationary units the regulator is accessible for adjustment by opening rear doors on the right side On tractor mounted units which have a large panel on the right side the regul...

Page 32: ...ter 14 Engine ON indicating light 5 Engine generator control switch 15 Engine starter switch 6 Hourmeter 16 Deleted 7 Load contactor control switch 17 Terminal board 8 Coolant temperature gage 18 Perm...

Page 33: ...ef 2 Fig 7 Transformer loading resistors are located on the power module panel assembly Ref 8 Fig 11 3 Protection Internal circuitry of the welding regulator is protected by a cartridge type 5 ampere...

Page 34: ...t 13 Fuseholder 5 On off switch line drop 14 Receptacle connector compensation 15 Sensing and preamplifier chassis 6 Line drop compensation chassis assembly 16 High phase sensing board assembly 7 Rece...

Page 35: ...Y 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...

Page 36: ...al board 7 Overload module 3 Overload current transformer 8 Line drop resistor 50 ohm 25 watt 4 Ammeter current transformer 9 Line drop current transformer 5 Rectifier 10 Blocking diode Power Module P...

Page 37: ...tor switch is wired in such a manner that for any switch position two pre selected test points in the generator set circuitry are connected for testing The selector switch may be rotated to any one of...

Page 38: ...iewed from the side of the unit See Fig 13 The contactor switch of the second output is located on the control nameplate of th engine control panel See Fig 14 Located beside this switch is the No 2 co...

Page 39: ...No 2 Output Control Figure 14 No 2 Power Module Panel Figure 15 OM 499 May 31 94 Revised 1 1 Page 25...

Page 40: ...This page intentionally left blank OM 499 1 1 May 31 94 Revised Page 26...

Page 41: ...for foreign material such as rags tools shipping papers etc 4 Check fuel coolant and oil hoses and connections for visible leaks Visually inspect the compartment floor and ground surface under the un...

Page 42: ...e control panel see Fig 1 a Open left rear canopy doors and loosen cable clamp screws at cable horn see 1 1 13 Fig 3 b Route cables through cable horn and clamp and upward to terminal board NOTE Condu...

Page 43: ...use where excessive dampness is a problem however the unit must be completely packaged and sealed if moisture absorbing chemicals are to be effective b Temporary Storage When storing the unit for 30 d...

Page 44: ...epare and protect the engine in accordance with instructions in Perkins Diesel Operator s Manual 3 To protect the generator and other electrical components the complete unit should be packaged using m...

Page 45: ...mpartments 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 illustr...

Page 46: ...it fuse 10 A 6 Line switch 17 DC Ammeter 27 Engine protective circuit 7 Reset switch 18 Engine generator indicating light 8 Light test switch control switch 28 Engine starter switch 9 Fault indicating...

Page 47: ...control rheostat switch 39 Cable size compensation 34 Test bank switch rheostat 35 Light test switch 40 Line drop compensation on off 36 Reset switch switch 37 Automatic voltage control 41 Fuse 5 A O...

Page 48: ...seconds This allows the starting aid valve chamber to fill with pressurized ethyl ether b Push the control IN This step sprays starting fluid into the engine intake manifold c Push starter switch 28...

Page 49: ...cate that the load contactor is closed and power is available at the aircraft As soon as the light glows release the switch It will automatically return to the center ON position NOTE If the indicatin...

Page 50: ...y adjusting the rheostat 32 to maintain a steady 115 V AC reading on the voltmeter 2 Turn the rheostat 32 knob CLOCKWISE to INCREASE voltage and COUNTERCLOCKWISE to DECREASE voltage 2 Adjust voltage t...

Page 51: ...oltage value and kind of current AC or DC to be expected at the position and set voltmeter accordingly e Comply with conditions indicated in CONDITIONS column for the particular test being performed f...

Page 52: ...ery If both 28 5 V DC and 115 V AC must be delivered at the same time the following rules and precautions must be observed 1 Place T R current limiting switch in OFF position This will eliminate the s...

Page 53: ...OTE Make sure that No 2 TEST BANK switch 1 1 Fig 15 is positioned properly see para D 1 b for proper position b Discontinue Power Delivery To open the load contactor in the No 2 output circuit place t...

Page 54: ...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 No 2 Output Control Figure 6 OM 499...

Page 55: ...o in SAFETY position 2 Remove two each attaching nuts screws and lockwashers 1 Fig 2 from retaining brackets 2 at the front of the machine 3 Roll the generator set outward carefully until the stop bar...

Page 56: ...are nuts screws and lockwashers 2 Retaining brackets Generator Set Retaining Components Tractor mounted units only Figure 2 Roll out Stop bar For tractor mounted units only Figure 2 OM 499 2 1 May 31...

Page 57: ...ere operating conditions such as low engine temperatures excessively heavy loads and high oil temperatures or intermittent operation However time intervals should not exceed those indicated in the cha...

Page 58: ...ge into the housing Avoid bumping the cartridge tubes against the housing sealing flange Seat the cartridge properly within the housing Press all edges and corners of the cartridge firmly with fingers...

Page 59: ...be clean completely distilled stable and non corrosive Only distillate fuel No 1D is recommended for use both summer and winter Consult the fuel oil selecting chart in the engine operator s manual bef...

Page 60: ...rn When removing cap from a very hot radiator do not turn cap past safety stop until all pressure or steam has escaped Use protective clothing Allow engine to cool before adding coolant 3 Installation...

Page 61: ...ution Before installing antifreeze in the system make the following checks a Check the system for signs of leaks b Inspect all hoses and tighten all hose clamps Install new hoses if necessary c Drain...

Page 62: ...he instructions furnished with the compound 5 After the system has been flushed and thoroughly cleaned of the compound refill the clean coolant Ref Para 7 H g Cleaning the Radiator Core Blow out insec...

Page 63: ...ient operation of the alternator and or the water pump To check belt tension press each belt firmly with the thumb at a point halfway between the alternator pulley and the crankshaft pulley A properly...

Page 64: ...s to support tray as in removal above b Align rails 4 with tracks 5 and slide tray into box Latches will lock automatically c Connect Amphenol connector 3 c Generator Exciter Provisions have been made...

Page 65: ...see Fig 8 On dual output units it will be necessary to dismount the No 2 output control to tilt the panel forward Do not disconnect the wires 1 Tilt out engine control panel a Remove clamp screw whic...

Page 66: ...Engine Control Panel in Tilt out Position Figure 8 OM 499 2 1 May 31 94 Revised Page 12...

Page 67: ...rication Chart Ref 2 1 Fig 3 c 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...

Page 68: ...Drain refill cooling system Change fuel filter elements X Lubricate Check exhaust system X Open fuel tank drain X ELECTRICAL Check all lights X Clean battery terminals X Check wiring X Check connectio...

Page 69: ...ure all controls instruments etc are working properly a Monitoring Instruments Observe operation of voltmeter ammeter and frequency meter each time the unit is started b Indicating Lights Check lamps...

Page 70: ...ers the particular option The manual referred to will provide the appropriate inspection procedure Both manuals cover batteries as when either option is used the batteries are installed within it WARN...

Page 71: ...k Ref Fig 1 2 Provide a source of 12 V DC battery power and connect to DC input terminal Ground NEGATIVE Ref Fig 1 3 Open access doors and remove access panels on right side of unit b Generator Set in...

Page 72: ...switch 16 and lamps are good 9 Check fault indicating lights 9 by pressing test switch 8 If lights glow fuse 11 and indicating lamps are good 10 Make a general inspection of all wiring and terminals I...

Page 73: ...t terminals to make connections 12 Check position of load contactor on off switch 20 Fig 1 and engine generator control switch 18 a Load contactor switch 20 must be in OFF position b Engine generator...

Page 74: ...t fuse 10 A 6 Line switch 17 DC Ammeter 27 Engine protective circuit 7 Reset switch 18 Engine generator indicating light 8 Light test switch control switch 28 Engine starter switch 9 Fault indicating...

Page 75: ...compensation 34 Test bank switch rheostat 35 Light test switch 40 Line drop compensation on off 36 Reset switch switch 37 Automatic voltage control 41 Fuse 5 A For units having a solid state regulator...

Page 76: ...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 k...

Page 77: ...full load and vice versa Use the contactor control switch 20 to apply and remove load several times Frequency drop should be no more than 1 Hz Adjust governor if necessary see Para 4 E 3 26 Follow in...

Page 78: ...tage sensing relay indicating light and time delay Before starting this check let us understand the sequence of events which should happen when voltage is reduced to 103 V or lower At some value betwe...

Page 79: ...overfrequency b If the overfrequency system functions to open the load contactor and turn on the overfrequency light after some frequency between 415 Hz and 425 Hz is reached all components of the sy...

Page 80: ...nd cable size compensation rheostats These two adjustment should be made together Switch 4 Fig 4 must be ON Proceed as follows aa Adjust the rheostat 2 to point to the length in feet of output cable b...

Page 81: ...l CLOCKWISE travel ee Turn the rate 2 adjusting screw to near full COUNTERCLOCKWISE position Turn the screw slowly CLOCKWISE until the voltage output abruptly becomes STEADY Continue turning the screw...

Page 82: ...a matched set e Electric Governor System Adjustment 1 General The complete Hobart electric governor kit identified as Hobart Part No 282671 consists of Barber Colman governor parts with brackets and...

Page 83: ...n or VERY CLOSE to FULL SPEED position to allow the engine to pull maximum load With the engine stopped refer to Figure 7 and proceed with linkage adjustments as follows a At the engine speed control...

Page 84: ...ard f Re attach the ball joint to the engine speed control lever with the lockwasher and nut g Tighten the two jam nuts on the threaded rod firmly against their respective ball joints h Check governor...

Page 85: ...kened if the tip of the pick up is too far from the flywheel ring gear or if it becomes damaged If the pick up is removed for any reason or if the signal is weak adjust the magnetic pick up as follows...

Page 86: ...g normal output The controller has two control potentiometers the SPEED control potentiometer and the GAIN potentiometer Make the controller settings as follows NOTE A very small screwdriver is requir...

Page 87: ...peed e Repeat this procedure until generator set operates at proper speeds with and without load 6 Checking the Actuator The actuator does not require any adjustments An actuator malfunction when it o...

Page 88: ...nsidered good 7 Additional Test for Dual Output Unit Perform the tests outlined in para 3 B 16 through 22 substituting the controls and indicators illustrated in Figure 12 TEST CONNECTION NOMINAL RESI...

Page 89: ...Z Plug interlock relay Plug in aircraft 28 V DC 8 D F Exciter input Unit in GEN mode 8 12 VDC 9 V X Regulator output Unit in GEN mode auto man sw in AUTO 50 70 V DC 10 K B Contactor operation Test ba...

Page 90: ...No 2 Output on Dual Output Units Figure 13 OM 499 2 3 May 31 94 Revised Page 20...

Page 91: ...bleshooting Chart 1 A troubleshooting chart is furnished to provide maintenance and repair personnel with a time saving guide for locating trouble To use the chart proceed as follows a Locate the symp...

Page 92: ...way to remedy the situation is to replace the complete tray assembly and send the old tray for repair Assemblies which lend themselves to this concept are Generator control tray Protective relay tray...

Page 93: ...nal from magnetic pickup c The actuator will surge under the following conditions 1 Stability or gain adjustment set too high 2 Throttle linkage binding 9 Engine Trouble Shooting Procedures a General...

Page 94: ...it fuse 10 A 6 Line switch 17 DC Ammeter 27 Engine protective circuit 7 Reset switch 18 Engine generator indicating light 8 Light test switch control switch 28 Engine starter switch 9 Fault indicating...

Page 95: ...compensation 34 Test bank switch rheostat 35 Light test switch 40 Line drop compensation on off 36 Reset switch switch 37 Automatic voltage control 41 Fuse 5 A For units having a solid state regulator...

Page 96: ...al control voltage potential adjusting resistor 2 Exciter field ballast resistors Excitation Resistors Figure 2 End view of Voltage Regulator Amphenol Connector Figure 3 OM 499 3 1 May 31 94 Revised P...

Page 97: ...Test Receptacle Connector Terminals Identification Figure 4 OM 499 May 31 94 Revised 3 1 Page 7...

Page 98: ...This page intentionally left blank OM 499 3 1 May 31 94 Revised Page 8...

Page 99: ...components are good and the starter is unable to crank the engine internal seizure is indicated For repair procedure see Perkins Diesel workshop manual 2 Engine will not start Cranking speed low a Low...

Page 100: ...or damaged pump drive Replace if defective h Defect in injector racks or linkage Refer to Perkins Diesel hand book Make adjustments and or repairs according to instructions therein 4 Engine is hard t...

Page 101: ...ellow blue wires should be connected to N O terminal One Red Yellow wire should be connected to C terminal With wires removed check resistance between terminals C and N C A resistance reading of zero...

Page 102: ...oltage is indicated check pickup adjust ment See 2 3 Para 4 E 2 If pickup is properly adjusted and voltage is still zero replace pickup d Defective actuator Apply 12 V DC to the two actuator input lea...

Page 103: ...uctions 9 Engine is unsteady surges under load a Fault in engine Before condemning the governor system for surging make certain the fault is not in the engine Make certain all cylinders are firing pro...

Page 104: ...B above c Low compression pressure Check compression in accor dance with Para 9 C See causes of low compression listed under ENGINE Trouble 4 B above 12 Engine lacks power a Improper engine adjustment...

Page 105: ...nd Use the test receptacle 31 Fig 1 to connect ungrounded 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...

Page 106: ...wiring from regulator to exciter field Disconnect voltage regulator Amphenol connector see 1 1 14 Fig 10 Using jumper leads with clip and prod terminals connect ungrounded 12 V DC to terminals E and...

Page 107: ...tat R61 32 Fig 1 Connect a jumper across rheostat If maximum manual control voltage is produced replace rheostat No 1 Load Contactor Operating Circuit Trouble Symptom Condition Test or Inspection Corr...

Page 108: ...oad contactor K1 will close when control switch 20 Fig 1 is held in momentary ON position Opens immediately when switch is released to center ON position a 28 5 V DC is not reaching plug interlock rel...

Page 109: ...46 Sect 1 1 21 Fig 9 If the contactor will now remain closed replace fuse interlock relay K17 Sect 1 1 2 Fig 8 or replace the protective relay tray assembly 3 Load contactor opens during power deliver...

Page 110: ...dition is indicated by light DS37 proceed to step B b Defective over under voltage sensing module K26 Use voltage adjusting rheostat 37 Fig 1 to reduce voltage to 110 V AC Observe voltmeter and gradua...

Page 111: ...nd adjust or repair in accordance with ENGINE AND CONTROLS Troubles 8 and 9 d Defective over unde r frequency sensing module K27 If overfrequency nuisance tripping continues after governor system is p...

Page 112: ...or low voltage output a Shorted diode in exciter rectifier CR2 Check diodes in accordance with sect 2 3 Para 6 If diodes are good proceed to step B b Open or shorted exciter rotor winding G2 Use ohmme...

Page 113: ...loose connection Tighten or replace as required b Open or short circuited stator Phase Check stator windings in accordance with Sect 2 3 Para 5 Repair or replace as required c Defective connection in...

Page 114: ...This page intentionally left blank OM 499 3 1 May 31 94 Revised Page 24...

Page 115: ...pt 1 Standard hardware items attaching parts such as nuts screws washers etc which are available commercially 2 Bulk items such as wire cable sleeving tubing etc which are also commercially available...

Page 116: ...ts are shown in this column 4 REC SPARES column When there is an entry in this column it shows the quantity of that item recommended for spares to support ONE end item 5 EFF Effective Column This colu...

Page 117: ...03613 Barber Colman Co 1354 Clifford Ave P O Box 2940 Loves Park IL 61132 2940 03924 StratoFlex Inc 2nd and Piper Sts Baer Field Box 9190 Waynedale Station Ft Wayne IN 46809 04713 Motorola Inc Semico...

Page 118: ...Illinois 60176 50603 H B Electrical Mfg Co Inc 1125 National Pky Mansfield OH 44906 51377 Kysor of Cadilac 1100 Wright St Cadillac MI 49601 51589 ST SEMICON INC 415 N College Ave Bloomington IN 47401...

Page 119: ...Controls Division of Barry Wright Corp 700 Pleasant Street Watertown Massachusetts 02172 82121 Electro Switch Corp 180 King Ave Weymouth MA 02188 82372 Huntington Rubber Company Los Angeles CA 85925...

Page 120: ...Electronics Div of Stewart Warner Corp 1300 N Kostner Chicago IL 60651 98991 Worchester Controls Corp Worchester Valve Division 125 Hartwell Street West Boyleston Massachusetts 01583 No Number Tech P...

Page 121: ...A or AMP ampere AC alternating current AR as required DC direct current Fig Figure hd head hex hexagon Hz Hertz cycles per second I D inside diameter IN inch kVA kilovolt ampere F microfarad No number...

Page 122: ...Generator Set Figure 1 OM 499 4 3 May 31 94 Revised Page 2...

Page 123: ...e Fig 2 D 1 3 No Number GENERATOR SET WITHOUT CANOPY For Details See Fig 4 1 4 No Number FRAME GROUP For Details See Fig 21 1 5 402987 NAMEPLATE HOBART 3 402987 NAMEPLATE HOBART 2 SPECIFICATION MOUNTI...

Page 124: ...Canopy Assembly Figure 2 OM 499 4 3 May 31 94 Revised Page 4...

Page 125: ...482401 COVER PLEXIGLASS GENERATOR CONTROLS 1 13 489030 COVER PLEXIGLASS ENGINE CONTROLS 1 14 481419 SUPPORT MTG REAR CANOPY 1 15 480695 DOOR ASSY ACCESS RECEPTACLE 1 15A 403127 CATCH MAGNETIC V94222 N...

Page 126: ...This page intentionally left blank OM 499 4 3 May 31 94 Revised Page 6...

Page 127: ...MP CABLE AC 2 30 100GH 121 BRACKET MTG CLAMP AC 1 31 482442 HORN ASSEMBLY CABLE ENTRANCE AC 1 32 480701 SPACER LATCH DOOR AC AR 33 403091 8 PLUG PLASTIC 1 3 4 INCH V28520 No DP 1750 AC 6 34 482482 BRA...

Page 128: ...Canopy Assembly Figure 3 OM 499 4 3 May 31 94 Revised Page 8...

Page 129: ...NOPY 1 12 482401 COVER PLEXIGLASS GENERATOR CONTROLS 1 13 489030 COVER PLEXIGLASS ENGINE CONTROLS 1 14 481419 SUPPORT MTG REAR CANOPY 1 15 480695 DOOR ASSY ACCESS RECEPTACLE 1 15A 403127 CATCH MAGNETI...

Page 130: ...This page intentionally left blank OM 499 4 3 May 31 94 Revised Page 10...

Page 131: ...CANOPY ASSEMBLY CONTINUED REF 27 403091 8 PLUG PLASTIC 1 3 4 INCH V28520 No DP 1750 6 28 482482 BRACKET MTG DOOR LATCH 1 29 482507 ROD STOP DOOR 1 30 404101 LIGHT CLEARANCE V75175 No 514 0168 4 31 400...

Page 132: ...Generator Set Without Canopy Figure 4 OM 499 4 3 May 31 94 Revised Page 12...

Page 133: ...T QUICK START V61112 No QS 3267 207 1 8 430391C REGULATOR ASSEMBLY VOLTAGE For Details See Technical Manual TM 759 A E M N 1 489812A REGULATOR ASSEMBLY VOLTAGE For Details See Technical Manual OM 2020...

Page 134: ...This page intentionally left blank OM 499 4 3 May 31 94 Revised Page 14...

Page 135: ...2 26 HF 2752 MOUNT RUBBER For mounting electrical panels on control box support panel V16238 No 4624 105 12 27 482305 HARNESS WIRE VOLTAGE REGULATOR 1 28 488702 LINES FUEL ASSEMBLY For Details See Fi...

Page 136: ...Radiator and Cooling System Group Figure 5 OM 499 4 3 May 31 94 Revised Page 16...

Page 137: ...HROUD RADIATOR 1 10 402958 CORE RADIATOR V41197 SIZE 26 X 28 X 2 11 32 1 11 387313 RAIL SIDE RADIATOR ASSY 2 12 50GHP 89 STRIP REINFORCING 4 13 50GHP 82 GASKET RADIATOR 2 14 488538 BASE RADIATOR ASSY...

Page 138: ...Air Cleaner Assembly Figure 6 OM 499 4 3 May 31 94 Revised Page 18...

Page 139: ...o HS 32 3 7 400059 3 CONNECTOR FEMALE SAE 45 V79470 No 46 X 4 1 8 W 10893 2 FITTING HOSE SWIVEL FEMALE V30327 No KA04 04NS 2 9 56534 HOSE LOW PRESSURE 1 4 ID 48 10 84A 1006 REDUCER RUBBER V82372 NO 40...

Page 140: ...Electric Governor Assembly Woodward Governor Kit Part No 488701 Figure 7 OM 499 4 3 May 31 94 Revised Page 20...

Page 141: ...7 1 4 84A 1091 ARM THROTTLE GOVERNOR V31361 No 3952027 1 5 402908 JOINT BALL GOVERNOR LINKAGE 2 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...

Page 142: ...Fuel Lines Assembly Figure 8 OM 499 4 3 May 31 94 Revised Page 22...

Page 143: ...CONNECTION AC 4 12 78A 1021 FITTING CONNECTION BANJO AC 2 13 W 10905 6 SLEEVE COMPRESSION BRASS V79470 No 60 X 5 AC 3 14 W 10901 3 NUT COMPRESSION BRASS V79470 No 61 X 5 AC 2 15 30523 COPPER BARE TUBI...

Page 144: ...Oil Line Assembly Figure 9 OM 499 4 3 May 31 94 Revised Page 24...

Page 145: ...See Fig 4 REF 1 403809 1 SWITCH LOW OIL PRESSURE V51377 No C 25900 10 1 2 W 10909 1 TEE STREET BRASS V79470 No 3750 X 2 1 3 W 10886 1 CONNECTOR MALE WEATHERHEAD V79470 No 48 X 4 1 4 403590 1 SWIVEL FE...

Page 146: ...Fuel Oil Lines Figure 10 OM 499 4 3 May 31 94 Revised Page 26...

Page 147: ...Fig 4 B REF 1 W 10891 8 ELBOW MALE V79470 49 X 8 B 1 2 403590 4 FITTING SWIVEL FEMALE 3 4 SAE THD V03924 B 2 3 56551 HOSE 8 13 32 I D B 46 4 W 10891 11 ELBOW MALE V79470 49 X 10 B 1 5 403590 5 FITTING...

Page 148: ...Fuel Oil Lines Figure 11 OM 499 4 3 May 31 94 Revised Page 28...

Page 149: ...V79470 No 60 X 5 B 3 8 78B 1022 BOLT BANJO CONNECTION B 2 9 78A 1023 WASHER BANJO CONNECTION B 4 10 78B 1021 FITTING BANJO CONNECTION B 2 11 30523 COPPER BARE TUBING B 25 12 W 10900 3 NUT INVERTED FL...

Page 150: ...Stator Terminal Panel Assembly Figure 12 OM 499 4 3 May 31 94 Revised Page 30...

Page 151: ...FLAT 3 8 IN 9 4 482446 RETAINER CABLE 6 5 482443 BAR BUS 3 6 W 10854 4 CAPACITOR 0 1 MFD 500 V V90201 No B 206143 3 7 482471 STRAP CONNECTING CAPACITORS 1 8 482449 BRACKET MOUNTING BOARD 2 9 401937 1...

Page 152: ...Power Module Panel Assembly Figure 13 OM 499 4 3 May 31 94 Revised Page 32...

Page 153: ...NG SOCKET CONNECTOR V89110 No 1 480287 0 1 10 401566 11 TERMINAL SOCKET V89110 No 60619 1 10 11 401556 MOUNT SHOCK RUBBER V81860 No SS 01 4 12 363136 2 TRANSFORMER CURRENT AMMETER 3 13 400701 CONNECTO...

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Page 155: ...NEL ASSEMBLY POWER MODULE For NHA See Fig 4 D REF 24 482069 PANEL POWER MODULE ASSY D 25 401937 3 STRIP TERMINAL V98410 NO 35012 3526 D 1 26 404065 2 RECTIFIER SILICON V04713 NO SDA10270 2 D 1 27 16DA...

Page 156: ...Control Box Assembly Figure 14 OM 499 4 3 May 31 94 Revised Page 36...

Page 157: ...REF 1 482278 2 TRAY ASSY GENERATOR CONTROLS For Details see Fig 15 1 2 482285 1 TRAY ASSEMBLY PROTECTIVE RELAYS For Details see Fig 16 1 3 No Number CONTROL BOX AND INTERNAL COMPONENTS GROUP For Deta...

Page 158: ...Generator Controls Tray Assembly Figure 15 OM 499 4 3 May 31 94 Revised Page 38...

Page 159: ...9 16DA 4004A 10 RELAY EXCITATION DEENERGIZATION 12V V77342 No KAP 14D G 12 1 10 16DA 4052 0 SOCKET RELAY V02660 No 77 MIP 11 1 11 363771 5 SLEEVING PLASTIC 8 IN I D 6 12 363770 1 SLEEVING PLASTIC 3 16...

Page 160: ...This page intentionally left blank OM 499 4 3 May 31 94 Revised Page 40...

Page 161: ...BLY GENERATOR CONTROL 1 25 370382A HANDLE TRAY 1 26 404028 NAMEPLATE HOBART 1 27 76A 1115 LATCH ADJUSTABLE GRIP V94222 No 48 99 126 11 1 28 402383 SLIDE ASSEMBLY TRAY Consists of four parts marked CR...

Page 162: ...Protective Relays Tray Assembly Figure 16 OM 499 4 3 May 31 94 Revised Page 42...

Page 163: ...MEMORY AND TIME DELAY 1 12 401563 5 HOUSING PIN CONNECTOR 1 13 482038 BOARD ASSEMBLY OVER UNDERVOLTAGE 1 14 401563 4 HOUSING PIN CONNECTOR 1 15 482039 BOARD ASSEMBLY OVER UNDERFREQUENCY 1 16 401563 4...

Page 164: ...This page intentionally left blank OM 499 4 3 May 31 94 Revised Page 44...

Page 165: ...M 1 482286 TRAY ASSEMBLY PROTECTIVE RELAYS 1 31 402383 SLIDE ASSEMBLY TRAY Consists of four parts marked CR CL DR DL V75358 No 1336 12 1set 32 404028 NAMEPLATE HOBART 1 33 370382A HANDLE TRAY 1 34 76A...

Page 166: ...Control Box and Internal Components Group Figure 17 OM 499 4 3 May 31 94 Revised Page 46...

Page 167: ...GROMMET RUBBER V02231 No AGW 4211 2 2 82B 1047 LIGHT PANEL V74400 No MI 3216 1 3 400613 4 BULB V74400 No 3271 1 4 W 10051 10 CLAMP WIRE PLASTIC V81074 No EC 10 2 5 W 10051 13 CLAMP WIRE PLASTIC V81074...

Page 168: ...Engine Control Panel Assembly Figure 18 OM 499 4 3 May 31 94 Revised Page 48...

Page 169: ...8 DW 4304 GAUGE TEMPERATURE WATER V57733 No 2100 1 9 HF 2518 8 LIGHT PILOT ENGINE GENERATOR GREEN A C 2 HF 2518 8 LIGHT PILOT ENGINE GENERATOR GREEN D 3 400613 4 BULB V74400 No 3271 1 10 DW 6080 GAUGE...

Page 170: ...This page intentionally left blank OM 499 4 3 May 31 94 Revised Page 50...

Page 171: ...Number NAMEPLATE START RUN STOP Furnished with Engine 1 24 403380 CAP CHAIN ASSEMBLY V02660 No 9760 28 1 25 482304 HARNESS WIRE TEST RECEPTACLE ASSY A 1 26 W 10051 13 CLAMP WIRE PLASTIC 1 27 482298 NA...

Page 172: ...Output Terminal Board Assembly Figure 19 OM 499 4 3 May 31 94 Revised Page 52...

Page 173: ...X 3 4 A 8 6 W 11254 6 WASHER LOCK STEEL 3 8 IN A 8 7 W 11242 10 WASHER FLAT STEEL 3 8 IN A 8 8 482446 RETAINER CABLE A 4 9 482443 BAR BUS PHASE A 4 10 W 11112 3 SCREW RD HD MH STEEL 10 24 X 3 4 A 4 11...

Page 174: ...Generator Group Figure 20 OM 499 4 3 May 31 94 Revised Page 54...

Page 175: ...UPLING 1 13 481379 KEY EXCITER 1 14 387624A 1 HOUSING EXCITER 1 15 100NH 2 POLEPIECE 4 16 100NH 3 INSULATION EXCITER 4 17 Data 3190 COIL FIELD EXCITER 1 SET 18 387620A 1 HOUSING FAN ASSEMBLY Series 68...

Page 176: ...Mounting Frame and Lifting Yoke Assembly Figure 21 OM 499 4 3 May 31 94 Revised Page 56...

Page 177: ...5 387915 TRACK ROLL OUT LEFT B 1 6 488689 FRAME MOUNTING 1 7 401898 2 CAM FOLLOWER V92563 No CF 1 1 2 B 10 8 402194 FITTING GREASE V95879 No 1728 J B 10 9 481113 PLATE END REAR Part of Item 6 Assy 1...

Page 178: ...Auxiliary Frame and Components Group Figure 22 OM 499 4 3 May 31 94 Revised Page 58...

Page 179: ...BOX BATTERY SUB ASSEMBLY C 1 6 100GH 664 CABLE BATTERY CONNECTIONS C 1 7 388828 1 CABLE BATTERY NEGATIVE C 1 8 357177 3 CABLE BATTERY POSITIVE C 1 9 480733 CLAMP BATTERY C 1 10 483203 FRAME MTG ASSEM...

Page 180: ...Electric Governor Assembly OM 499 4 3 May 31 94 Revised Page 60...

Page 181: ...MINAL QUICK CONNECT 1 4 3 11 W 9476 43 ROD THREADED 1 4 28 x 3 1 4 1 12 401937 2 BLOCK TERMINAL 1 13 W 11111 8 SCREW 8 32 X 3 4 RDHD ST 2 14 W 11254 10 WASHER 8 LOCK ST 10 15 W 11287 3 NUT 8 32 HEX ST...

Page 182: ...This page intentionally left blank 4 3 March 31 74 Revised Page 21A OM 499...

Page 183: ...used in more than one place each location is listed commencing with the first location the part is listed A 25 21 14 AW 626 21 15 AUXILIARY FRAME COMPONENTS 4 32 21 13 22 0 CONTROL BOX AND INTERNAL C...

Page 184: ...10893 0 8 26 W 10893 2 6 8 8 7 11 3 W 10900 3 8 16 11 12 W 10901 1 8 18 11 14 W 10901 3 8 14 11 6 W 10905 1 8 17 11 13 W 10905 6 8 13 11 7 W 10909 1 9 2 W 11093 2 7A 21 W 11097 18 12 1 19 5 W 11111 8...

Page 185: ...15 21 W 8105A 4 15 22 W 9360 211 13 22 W 9360 278 13 23 W 9360 279 13 21 W 9476 11 7 6 W 9476 43 7A 11 W 9549 19 19 3 W 9746 1 13 3 W 9746 3 13 35 16 8 W 9916 10 15 23 W 9917 18 18 7 1CZ 93B 4 38 13 1...

Page 186: ...81343 20 22 281772 7A 1 281774 2 7 1 281774 2 7A 9 281775 7A 6 281776 7A 5 282501 7A 2 282671 7A 0 282673 7A 3 282674 7A 4 282761 4 5 30GH 417 4 25 30523 8 15 11 11 351541 5 21 355194 5 18 357177 3 22...

Page 187: ...7 18 29 400078 15 6A 400333 1 6 14 400400 15 20 400480 2 13 17 400480 3 13 18 13 37 400613 4 16 20 17 3 18 9 400613 10 2 37 3 31 400701 13 13 18 21 400819 1 8 4 400829 5 7A 10 400830 15 13 15 401556...

Page 188: ...2908 7 5 7A 23 402958 5 10 402987 1 5 40303 5 1 403091 8 2 33 403091 8 3 27 403127 2 15A 403127 3 15A 403189 18 6 403336 16 18 403380 18 24 403483 6 5 403492 1 22 1 403590 1 9 4 403590 4 10 2 403590 5...

Page 189: ...5 480674 22 1 480675 22 2 480676 22 5 480695 2 15 3 15 480701 2 32 3 26 480711 22 13 480733 22 9 481032 22 16 481113 21 9 481379 20 13 481416 2 1 3 1 481419 2 14 3 14 481940 20 24 482075 2 4 3 13 0 4...

Page 190: ...36 482311 21 3 482315 21 2 482316 21 1 482317 4 20 19 0 482318 4 21 482319 4 2 12 0 482320 2 6 3 6 482321 2 18 482322 2 19 482323 2 20 482325 4 19 482326 2 28 482327 2 21 482328 2 23 482333 2 22 4823...

Page 191: ...2 34 3 28 482471 12 7 482483 20 4 482507 2 35 3 29 482706 22 14 482918 4 15 482989 7 11 482989 7A 8 483203 22 10 484016 18 1 484067 4 3 484071 19 14 484265 3 4 40 485380 3 23 488538 5 14 488539 5 7 48...

Page 192: ...29 2 17 489030 2 13 3 13 489032 2 11 3 11 489047 20 22 489052 2 8 3 8 489112 1 2 2 0 489291 6 4 489812A 4 8 489860 1 2 2 0 489861 1 2 2 0 3 0 5CW 1932 0 5 15 5CW 2048 22 11 5CW 3884 2 7A 25 50GHP 82 5...

Page 193: ...78B 1010 4 33 78B 1019 1 8 19 11 15 78B 1019 2 8 9 11 5 78B 1021 11 10 78B 1022 8 10 11 8 82B 1047 17 2 18 2 83A 1026 6 11 18 13 83A 1029 6 13 84A 1006 6 10 84A 1009 7 2 84A 1010 6 2 84A 1011 6 1 84A...

Page 194: ...This page intentionally left blank OM 499 4 4 May 31 94 Revised Page 12...

Page 195: ...ifier 28 5 V DC OM 433 487750 1 Transformer Rectifier Mounting Kit TO 105 481387 Truck Body Package TO 109 481386 Truck Chevrolet TO 109 404137 Truck Ford Std TO 109 403757 Truck GMC TO 109 404238 Sec...

Page 196: ...This page intentionally left blank OM 499 5 0 May 31 94 Revised Page 2...

Page 197: ...ns Engines Inc Handbook for Diesel Engines T6 3544 and 6 3544 Flexible Coupling Hobart Brothers Company Coupling Manual OM 2019 Exciter Rotor Hobart Brothers Company Rotor Manual TM 360 Hobart Diagram...

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Page 211: ...oil vapor 6 Damp or very dry locations radiant heat vermin infestation or atmospheres conducive to fungus growth 7 Abnormal shock vibration or mechanical loading from external sources during equipmen...

Page 212: ...This page intentionally left blank OM 499 Unusual Service Conditions May 31 94 Revised Page 2...

Page 213: ...do not allow the engine to reach most efficient operating temperature for complete combustion of fuel The unburned fuel collects in the exhaust system to cre ate the wet condition known as wet stackin...

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