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OM-2084 / Operation and Maintenance Manual

90CU24 / Series 500392 / Generator Set

Chapter 4-3

November 27/1997

Page 18

Revised 10/98

Governor Controler

(Left Side of Unit)

Magnetic Pickup

(Right side of Engine)

Governor Kit (Continued)

Figure 8

Summary of Contents for 90CU24

Page 1: ...OM 2084 112797 Revised 10 98 Operation and Maintenance Manual Hobart Brothers Company Ground Power Division Troy OH 45373 U S A Model 90CU24 Generator Sets Series 500392 ...

Page 2: ... this warranty are intended for use exclusively by the buyer and his employees and by no other persons and therefore there shall be no third party beneficiary to this warranty 6 A claim of defects in any PRODUCT covered by this warranty is subject to HOBART factory inspection and judgment HOBART S liability is limited to repair of any defects found by HOBART to exist or at HOBART S option the repl...

Page 3: ...nals in the output circuit or ungrounded electrically live equipment can fatally shock a person Have a certified electrician verify that the equipment is adequately grounded and learn what terminals and parts are electrically HOT Avoid hot spots on machine Use proper safety clothing procedures and test equipment The electrical resistance of the body is decreased when wet permitting dangerous curre...

Page 4: ...ts combustible material near engine exhaust piping misuse of batteries and fuel or unsafe operating or fueling conditions a Electrical Short Circuits and Overloads Overloaded or shorted equipment can become hot enough to cause fires by self destruction or by causing nearby combustibles to ignite For electrically powered equipment provide primary input protection to remove short circuited or heavil...

Page 5: ...ross until medical help arrives IF BREATHING IS DIFFICULT give oxygen if available and have victim lie down FOR ELECTRICAL 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 IMMEDIATELY 8 Equipment Precautionary Labels Inspect all precautionary labels on the equip...

Page 6: ...This page intentionally left blank OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets Safety Warnings November 27 1997 Page 4 ...

Page 7: ...hich are located in the lower outside corner When information located in another portion of the manual is referred to its location is identified by a chapter section and paragraph or figure number For example see Section 2 3 Paragraph 1 a refers to information located in Chapter 2 Section 3 Paragraph 1 a If a chapter and section are not indicated in a reference the referenced material is located i...

Page 8: ...This page intentionally left blank OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets November 27 1997 Introduction Page 2 ...

Page 9: ...ooling Fan 1 1 6 Occasional Engine Faults 1 1 6 Hobart Installed Engine Equipment 1 1 7 Generator 1 1 8 Control Box Assembly 1 1 9 Power Module Panel Assembly 1 1 18 Section 2 Preparation for Use Storage or Shipping 1 2 1 Preparation for Use 1 2 1 Inspection Check 1 2 1 Installing Three phase AC Output Cables 1 2 2 Preparation for Storage 1 2 3 General 1 2 3 Temporary Storage 1 2 3 Long Time Stora...

Page 10: ... Checks and Operations 10 Hours or Daily 2 1 5 B Check and Operations 250 Hours or 3 Months 2 1 7 C Checks and Operations 500 Hours or 6 Months 2 1 7 D Checks and Operations 1000 Hours or 1 Year 2 1 8 E Checks and Operations 1500 Hours or 1 Years 2 1 8 F Checks and Operations 2000 Hours or 2 Years 2 1 10 Seasonal Maintenance Checks Engine 2 1 11 Lamps and Circuit Breakers 2 1 12 Section 2 Maintena...

Page 11: ...m 2 2 15 Cleaning the Radiator Core 2 2 15 Filling the Cooling System 2 2 16 Thermostat 2 2 16 Coolant Filter Removal 2 2 16 Drive Belts 2 2 17 General 2 2 17 Preparation for Belt Check and Adjustment 2 2 17 Check Fan Belt Tension 2 2 17 Generator Maintenance 2 2 18 Cleaning 2 2 18 Adjustment 2 2 18 Section 3 Adjustment Test 2 3 1 General 2 3 1 Testing the Generator Set 2 3 1 Pre operational Test ...

Page 12: ...eads 2 4 2 Electric Governor Troubleshooting 2 4 2 Engine Troubleshooting 2 4 3 Illustrations 2 4 3 Connection and Schematic Diagrams 2 4 3 Engine Controls 2 4 7 Generator Excitation Circuits 2 4 13 No 1 Load Contactor Operating Circuit 2 4 15 No 2 Load Contactor Operating Circuit 2 4 18 Protective Circuit 2 4 20 Generator 2 4 23 Chapter 3 Overhaul Major Repair Section 1 Exciter Armature 3 1 1 Gen...

Page 13: ...3 2 4 Coupling Installation 3 2 5 Cleaning 3 2 5 Assembly 3 2 5 Reassemble Engine and Generator 3 2 10 Run in and Periodic Check 3 2 10 Section 3 Generator Assembly 3 3 1 General 3 3 1 Procedure for Generator Assembly Removal 3 3 1 Procedure for Gaining Access to the Generator 3 3 1 Removing the generator Assembly 3 3 3 Installing a Generator Assembly 3 3 4 Remounting the Generator Assembly 3 3 4 ...

Page 14: ...de List 4 2 1 Section 3 Illustrated Parts List 4 3 1 Explanation of Parts List Arrangement 4 3 1 Symbols and Abbreviations 4 3 1 Section 4 Numerical Index 4 4 1 Explanation of Numerical Index 4 4 1 Numerical Index 4 4 1 Chapter 5 Manufacturer s Literature 5 1 1 Appendix A Options Features Appendix A 1 Unusual Service Conditions Wet Stacking OM 2084 Operation and Maintenance Manual 90CU24 Series 50...

Page 15: ... Orientation For purpose of orientation the radiator is considered to be at the REAR of the unit The generator and controls are at the FRONT RIGHT and LEFT are determined by standing at the REAR end facing the machine Thus the control box is mounted on the LEFT side at the FRONT of the unit 3 Optional Equipment Chapters 1 through 5 of this Operation and Maintenance Manual identifies only the strip...

Page 16: ...Output Cable Clamps 3 Frame 4 Emergency Stop Switch 5 Canopy 6 Radiator Access Door Generator Set Figure 1 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets Chapter 1 1 November 27 1997 Page 2 ...

Page 17: ...Amps 260 Amps Frequency Hz 400 Hz Output kilowatts 72 Power factor 0 8 Duty cycle 100 Operating speed RPM 2400 RPM Overload capacity both outputs 125 rated load Amps 325 Output cable size 2 0 Generator Protective System Over voltage Trips at 126 volts after a 1 second time delay Trips at 140 volts in 160 milliseconds Trips at 180 volts in 50 milliseconds Under voltage Trips at any voltage below 10...

Page 18: ...ounted on the frame just forward of the engine generator combination Figure 3 is an illustration showing the location of all major components and sub assemblies a Basic Engine The basic engine is an in line 6 cylinder diesel rated at 165 horsepower See Fig 2 for general specifications b Engine Manufacturer s Equipment As received from the engine manufacturer the engine includes the following equip...

Page 19: ...Air Cleaner 5 Control Box 6 Output Module Panel 7 Engine Generator Control Panel 8 Mounting Frame 9 Muffler Generator Set Components Figure 3 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets November 27 1997 Chapter 1 1 Page 5 ...

Page 20: ...the engine and turns on the applicable indicating light a Press the engine stop button 20 Fig 5 to turn off the indicating light and reset the protective system b Or use E STOP 4 fig 1 button for immediate reset Low fuel Turns on the low fuel indicating light 27 Fig 5 Depending on the position of JP2 and JP3 on the control PC board a low fuel fault may cause the engine to idle shut down or continu...

Page 21: ...ed position by any normal oil pressure above 12 PSI 83 kPA It is connected in series with the fuel shutoff valve and will open the holding circuit if the oil pressure drops to 12 PSI 83 kPA or below 3 Electric governor system An electric governor kit is installed on the engine to replace a conventional mechanical type The electric governor was selected for control of engine speed and generator out...

Page 22: ...olving field three phase alternating current type The generator set covered by this manual is a dual bearing type The front end of the rotor shaft extends forward beyond the front bearing and is attached to the engine flywheel by a flexible coupling assembly The rear end of the rotor shaft extends rearward beyond the rear bearing and into the exciter stator housing The exciter rotor is mounted on ...

Page 23: ... 5 Engine coolant temperature gage The temperature gage 3 is an electrical type which is connected by a wire to a water temperature sensor installed in the engine cooling system The gage indicates engine coolant temperature in the range of 100 to 240 º F 38 to 116º C 6 Engine start push button switch This push button switch 26 when pressed connects 12 V DC power to the starter solenoid coil which ...

Page 24: ...cator Light Red 18 Meter Selector Switch 19 Test Reset Push Button Switch Red 20 Engine Stop Push Button Switch 21 Under Frequency Indicator Light Red 22 No 2 Contactor Push Button Switch Orange 23 Over Frequency Indicator Light Red 24 No 1 Contactor Push Button Switch Yellow 25 Low Oil Pressure Indicator Light Red 26 Engine Start Push Button Switch Green 27 Low Fuel Indicator Light Red 28 Panel L...

Page 25: ...put monitors meters The generator output is monitored by three instruments a frequency meter 9 a voltmeter 13 and an ammeter 12 The frequency meter is an analog type and indicates the frequency of the generator output alternating current in the range of 360 to 440 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 ...

Page 26: ...Panel Lights 2 12 Engine Circuit Breaker 10A 13 Controls Circuit Breaker 5A 14 Marker Light Circuit Breaker 10A 15 Contactors Circuit Breaker 5A 16 Test Bank Aircraft Switch No 2 Output 17 Test Bank Aircraft Switch No 1 Output 18 Regulated Diagnostic Switch 19 Generator Set Control PC Board Control Box Interior Components Dual Output Shown Figure 6 OM 2084 Operation and Maintenance Manual 90CU24 S...

Page 27: ...ed circuit board includes five memory circuits and a time delay circuit Each circuit is connected to a corresponding sensing circuit in the sensing modules All memory circuits are connected to the module circuit relay coil and any one of the circuits can energize the coil to open the circuit relay contacts Thus when a sensing device energizes any one of the module circuits the module circuit is al...

Page 28: ...ngine speed and generator excitation K68 activates to idle the engine and remove excitation from the generator In the RESET state K68 provides a 12 V DC signal to the governor controller causing the engine to attain rated speed 2400 RPM At the same time K68 provides a ground signal to voltage regulator which enables excitation current to the generator When the engine is running K68 changes from OP...

Page 29: ... and Clearance Lights Relay K70 7 No 2 Plug Interlock Relay K202 8 No 1 Plug Interlock Relay K2 9 Bypass Relay K73 10 Low Fuel Fault Relay K65 11 Air Filter Fault Relay K66 12 No 1 Contactor Control Relay K72 Generator Set Control PC Board Figure 7 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets November 27 1997 Chapter 1 1 Page 15 ...

Page 30: ...tarted and the engine is at rated speed the rotary exciter is excited from alternator residual magnetism through the half wave rectifier bridge located on the voltage regulator PC board assembly As the rotary exciter voltage increases alternator excitation increases and the alternator voltage builds up The sensing circuit of the voltage regulator PC board then compares the input voltage to a refer...

Page 31: ...t Course 2 Output Voltage Adjustment Fine 3 Line Drop Compensation Adjustment Voltage Regulator PC Board Figure 8 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets November 27 1997 Chapter 1 1 Page 17 ...

Page 32: ...rd The ammeter is really a voltmeter graduated and numbered in amperes to show current proportional to the voltage signal received This ammeter is so graduated and numbered that when cables running through the current transformers carry a current of 260 amperes rated load 6 67 volts is sent to the ammeter The ammeter will indicate it as 260 amperes c Overload Conditions When an overload condition ...

Page 33: ...ctive device functions to open the protective monitor relay the rectifier s AC circuit is opened No DC is then available for the load contactor holding coil hence the load contactor opens 2 3 4 2 4 5 9 1 7 8 6 3 6 3 6 1 Overload PC Board 2 Resistor 50 ohm 20 watt R16 R17 R18 3 Line Drop Current Transformer T4 T5 T6 4 Resistor 16 6 ohm 20 watt R33 R34 R35 5 Load Contactor 6 Overload Current Transfo...

Page 34: ...e Temperature Sensor ETS switch determines when the System should function When needed the solenoid valve is activated automatically during engine cranking Once activated starting fluid is released from the pressurized cylinder through a flow metering orifice fitting at the bottom of the valve through the nylon tubing and out of an injector nozzle located in the engine s air intake system A reserv...

Page 35: ...enance Manual provided with this Hobart manual OM 2084 b Engine coolant Remove radiator cap to check coolant level Coolant level should be at the bottom of the filler neck See figure 2 for coolant capacities 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...

Page 36: ...es A B C N should be equipped with terminals having at least a 3 8 inch diameter mounting hole Mounting hole in small leads E and F should be at least 1 4 inch diameter To install AC output cables proceed as follows 1 Open the left front canopy door of the generator set 2 Remove plexiglass 3 Remove upper panel below door 4 Loosen screws on cable clamps located on the side panel beneath the left re...

Page 37: ...ou expect your engine to encounter 3 Preparation for Storage When a generator set is to be stored or removed from operation special precautions should be taken to protect the internal and external parts from rust corrosion and gumming in the engine fuel system a General Pull all circuit breakers and or disconnect battery negative terminal 1 The unit should be prepared for storage as soon as possib...

Page 38: ...te under full load until coolant temperature has reached at least 176ºF 80ºC 3 While the engine is running ensure that normal operating controls are in good working condition before shutdown and storage If weekly operation is not possible contact the nearest Cummins Engine Company distributor for instructions d Preparation for Shipment 1 Disconnect battery negative terminal before shipping 2 Durin...

Page 39: ...mal Engine Starting Procedures Engine starting procedures are outlined below Engine operating controls and monitoring instruments are illustrated in Fig 1 Refer to Operating Instructions in the Cummins Operation Manual when starting engine for the first time NOTE The Cummins Operation Manual is provided with this Hobart manual OM 2084 1 If illumination is required press lamps push button switch 28...

Page 40: ...ight red 18 Meter Selector switch 19 Test reset push button switch red 20 Engine stop push button switch red 21 Underfreqency indicator light red 22 No 2 contactor push button switch orange 23 Overfreqency indicator light red 24 No 1 contactor push button switch yellow 25 Low Oil Pressure indicator light red 26 Engine start push button switch green 27 Low Fuel indicator light red 28 Panel light pu...

Page 41: ... lights 10 amp 34 Circuit Breaker control 5 amp 35 Engine circuit breaker 10 amp 36 Output voltage adjustment coarse 37 Output voltage adjustment fine 38 Line drop compensation adjustment Operating Controls and Instruments Dual Output Shown Figure 1 Sheet 2 of 2 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets November 27 1997 Chapter 1 3 Page 3 ...

Page 42: ...omatically Also the green indicating light in the engine start push button 26 switch will glow continuously 2 Observe generator instruments The frequency meter 9 Fig 1 should indicate exactly 400 Hz With voltmeter ammeter selector switch 18 in any line to neutral position A N B N or C N the voltmeter 13 should read 115 volts With voltmeter ammeter selector switch in any line to line position A B B...

Page 43: ... for power delivery This switch is located inside the control box behind the control panel The No 1 and or No 2 output switch 30 or 31 must be set to AIRCRAFT position These switches are located inside the control box behind the control panel See section 2 4 for other No 1 and or No 2 Load Contactor Operating Circuit troubleshooting procedures f Discontinue Power Delivery with Unit Shutdown See Fi...

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Page 45: ... establishment of a schedule to meet the customer s maintenance requirements for his specific operation c Time Intervals See Fig 1 and 2 The schedule is based on both hours of operation and calendar intervals These two intervals are not necessarily the same For example in normal operation the oil change period based on hours of operation will be reached long before the three months calendar period...

Page 46: ...X Clean Radiator Core external X Check Governor Linkage X Change Crankcase Oil X X Change Oil Filter Element X X Check Adjust Drive Belt s Tension X Check Engine and Generator Mounts X X Check Coolant Additive Concentration X Check Fan Hub and Drive Pulley X Check Fuel Prefilter Cartridge X X Check Hose Clamps on Air Intake Side X Service Fuel Cooler X Steam Clean Engine X X Clean fuel system X Ch...

Page 47: ...Fan Mounting Spring Fall Clean Cooling System Spring Fall Check Hoses Spring Fall Clean Electrical Connections Spring Fall Check Thermostats and Seals Fall ELECTRICAL 12 V DC System Check All Lights X Check Charging Rate X Check Battery and Fluid Level X Clean Battery Terminals X X Check Wiring and Connections X ELECTRICAL 400 Hz System Check Output Cable and Connectors X Check Volt Amp Frequency ...

Page 48: ...check battery cable connectors and battery posts If corrosion is observed disconnect cables and clean battery posts and connectors with a wire brush or special battery post and connector cleaning tool Coat posts and connectors with a light film of petroleum lubricant before reconnecting cables c BR Checks and Operations Break In Period Once After 50 150 hrs The following procedures are precautiona...

Page 49: ... oil and dirt to prevent uneven engine cooling hot spots The oil and dirt can also fall into the engine and fuel system when covers are removed during repair work 8 Check Injectors and Valve clearances and adjust if necessary Refer to Cummins Operations manual for details d A Checks and Operations 10 Hours or Daily 1 Check crankcase oil level DO NOT overfill DO NOT operate the engine with oil leve...

Page 50: ...p check for coolant fuel and oil leaks Coolant leaks may be more noticeable when components are cold Observe pumps hoses fittings gasket connections etc for signs of leakage Correct as required 5 Check air cleaner indicator At each daily start up observe the air cleaner indicator light 1 3 6 Fig 1 If this light comes ON it indicates that the air cleaner should be changed 6 Check exhaust system Vis...

Page 51: ...governor linkage Check all attaching hardware Check ball joints for wear and looseness Check linkage for free movement throughout its complete travel range 2 Electrical 12 V DC system NOTE The battery furnished with this generator set is MAINTENANCE FREE a Battery electrolyte level if applicable Battery electrolyte level must be maintained above top of plates Add distilled water as required DO NOT...

Page 52: ... will function if a fault should occur in the output circuit Procedures for testing these relays are contained in the Adjustment Test section of this manual b Wiring and connections Check all cables leads and wiring for broken worn and damaged insulation Check all connections for tightness c Clean and inspect generally g D Checks and Operations 1000 Hours or 1 Year 1 Engine a Change the water cool...

Page 53: ...fuel system See Owner and Operations Manual for instructions c Check vibration damper Fig 4 Check vibration damper for looseness or wobble verifying the hub bolts are tightened to the Cummins specifications d Check adjustment of injectors and valves Injectors and valves must be in correct adjustment at all times for best engine performance Refer to Cummins Operation Manual for injector and valve a...

Page 54: ... shop manual should be procured from Cummins Engine Company a Clean Calibrate Replace injectors Injectors must be cleaned and calibrated regularly to insure proper fuel delivery to combustion chambers Special tools are required It is suggested that the Cummins Distributor be consulted for this operation b Check fuel pump calibration This operation may be performed on an as required basis Pump cali...

Page 55: ...oughly each time the cooling system is cleaned and serviced Inspect for signs of deterioration and collapse a Inspect for cracks and cuts b Inspect for cutting and deformation caused by hose clamps c Replace hoses as required 4 Check and adjust V belts each time the cooling system is cleaned or on an as required basis See 2 2 Para 6 5 Check thermostat and seals each fall when cooling system is ser...

Page 56: ... box Interior 1 1 Figure 6 Item 14 10A Circuit Breaker Load Contactor Circuit Control box Interior 1 1 Figure 6 Item 15 5A Circuit Breaker Circuit Breaker Identification Chart Figure 6 4 Cold Weather Start Servicing and Troubleshooting Many vehicle components can affect cold weather starting The following guide is limited to general troubleshooting of the Dieselmatic System Further details can be ...

Page 57: ...ut 40º F 4º C If either continuity test fails the ETS Switch should be replaced c Check for clogging of flow metering orifice fitting The Dieselmatic s fluid flow rate is controlled by serviceable filtered metering orifice inside the fitting at the bottom of the valve assembly See Figure 7 The following procedure is recommended when checking for clogging 1 Remove system s nozzle from engine 2 If s...

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Page 59: ...aken from the engine manufacturer s Operation and Maintenance Manual and incorporated here to make them more readily available to operators and maintenance personnel 1 Lubrication schedule Time schedules indicated on the Lubrication Chart Fig 4 are approximate They are based on average operating conditions It may be necessary to lubricate more frequently under severe operating conditions such as l...

Page 60: ... 10ºC Arctic Conditions Synthetic Oils See the Cummins Operator s Manual for usable synthetic oils and instructions Fuel Prefilter Drain Filter Daily Change filter element every 250 hours or 3 months of use Coolant Check coolant level daily Service and maintain coolant system according to sect 2 2 para 6 Engine coolant capacity system 28 quarts 26 4 liters Coolant hoses and connections Check coola...

Page 61: ...the engine is at operating temperature Change the oil filter element each time the oil is changed Symbols Time Intervals Hours Calendar AR As Required None A 10 Hours Daily B 200 Hours 3 Months C 400 Hours 6 Months D 800 Hours 1 Year E 1200 Hours 1 Year F 6000 Hours 5 Years S Seasonally Spring and or Fall Symbols and Time Intervals Figure 4 NOTE If lubricating oil is drained immediately after the ...

Page 62: ...es then stop i After the engine has been stopped for about 5 minutes recheck the oil level Add oil if required to bring the level up to the H mark on the gage rod 5 Changing oil filter element a Provide a container for catching oil b Remove the filter and inspect it NOTE The o ring can stick to the filter head Make sure it is removed before installing a new filter If bearing metal particles are fo...

Page 63: ...f Unit Right Side of Unit Changing Oil Filter Figure 6 Fan Hub Alternator Cranking Motor Water Pump Vibration Damper Engine Accessories Figure 7 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets November 27 1997 Chapter 2 2 Page 5 ...

Page 64: ...aced without difficulty on this generator set simply by loosening three metal clamps on each end of the air cleaner it may be inspected either at prescribed service intervals or at any time deemed necessary a Inspecting the Air Cleaner 1 Make periodic checks of air cleaner inlet screen for obstructions If any obstructions are present remove them 2 Check outlet connection for proper seal NOTE DO NO...

Page 65: ...y and performance under most operating conditions Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent misfires and excessive smoke At operating temperatures below 32º F 0º C use a blend of No 1D and No 2D fuels also known as winterized No 2D NOTE No 1D fuels can be used but fuel economy will be reduced b Fuel Filter Fig 8 A doub...

Page 66: ...as chloride sulphate and acids It should be kept slightly alkaline with a pH value in the range of 8 0 to 9 5 Any water which is suitable for drinking can be used in the engine when properly treated as described in Cummins Operation and Maintenance Manual The Cummins Distributor should be consulted regarding the selection of satisfactory brand permanent type antifreeze for use in the cooling syste...

Page 67: ...ling system For complete information regarding coolant specifications temperature ranges testing equipment antifreeze etc refer to Cummins Operation and Maintenance Manual 1 General A permanent type antifreeze is recommended for use in the cooling system in any climate 1 Do not use methanol or alcohol as an antifreeze 2 Do no mix brands or type of antifreeze A solution containing two or more types...

Page 68: ...ater pump belts Replace belts if necessary 2 Install coolant a Remove radiator cap Be sure the drain valve is closed Make sure the vent in the water manifold is open to allow air to escape when filling b Pour coolant anti freeze water into radiator very slowly until it reaches level of top drain valve Close valve and continue filling until coolant reaches a level approximately 1 inch below top of ...

Page 69: ...ive The belt can then be slid off the water pump pulley and worked off the other pulleys and around the fan 3 Inspect the belt for damage a Traverse across the belt width cracks are acceptable b Longitudinal direction of belt length cracks that intersect with transverse cracks are unacceptable 4 Replace the belt if it has unacceptable cracks is frayed or has pieces of material missing 5 Check the ...

Page 70: ...Checking Belt Tension Figure 9 Removing and Inspecting Drive Belts Figure 10 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets Chapter 2 2 November 27 1997 Page 12 ...

Page 71: ...rvicing and Troubleshooting When servicing or troubleshooting the cold weather starting kit make certain that this work is done in a well ventilated area Goggles should be worn to protect eyes when servicing this kit Many vehicle components can affect cold weather starting The following instructions are limited to troubleshooting of the Dieselmatic System The most common problems are 1 an empty fl...

Page 72: ... Goggles should be worn to protect eyes when servicing this kit The Dieselmatic s fluid flow rate is controlled by serviceable filtered metering orifice inside the fitting at the bottom of the valve assembly See Figure 2 The following procedure is recommended when checking for clogging 1 Remove system s nozzle from engine 2 If starting fluid does not spray from nozzle when the system is activated ...

Page 73: ...he engine is started Refer to Paragraph 3 e 1 and see Figure 3 6 Inspect for oil fuel and coolant leaks 7 If the setting of the output voltage coarse adjustment potentiometer 36 Fig 1 on the voltage regulator has been disturbed set it at CENTER position halfway between full clockwise position and full counterclockwise position 8 Check marker lights circuit breaker 33 Fig 1 by pressing panel light ...

Page 74: ...ight red 18 Meter Selector switch 19 Test reset push button switch red 20 Engine stop push button switch red 21 Underfreqency indicator light red 22 No 2 contactor push button switch orange 23 Overfreqency indicator light red 24 No 1 contactor push button switch yellow 25 Low Oil Pressure indicator light red 26 Engine start push button switch green 27 Low Fuel indicator light red 28 Panel light pu...

Page 75: ... lights 10 amp 34 Circuit Breaker control 5 amp 35 Engine circuit breaker 10 amp 36 Output voltage adjustment coarse 37 Output voltage adjustment fine 38 Line drop compensation adjustment Operating Controls and Instruments Dual Output Shown Figure 1 Sheet 2 of 2 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets November 27 1997 Chapter 2 3 Page 3 ...

Page 76: ...gnostic switch 29 Fig 1 must be placed in the DIAGNOSTIC position for 3 to 5 seconds to remagnetize the exciter Then return the switch to the REGULATED position after voltage has built up 8 Observe frequency meter 9 If engine speed is properly adjusted frequency will be exactly 400 Hz If not adjust engine governed speed in accordance with Para 3 E 3 See Fig 6 9 Observe voltmeter 13 Use output volt...

Page 77: ...s to terminal N 7 With test bank switch in AIRCRAFT position press the No 1 contactor operating push button switch 24 The No 1 contactor power ON indicating light within the push button switch should glow and remain on when the push button switch is released This indicates that the load contactor is closed and the plug interlock circuit is functioning properly 8 Apply 1 3 to 1 2 load 30 to 45 KVA ...

Page 78: ...ioning to bypass the plug interlock circuit 5 Return the No 2 test bank switch 31 to AIRCRAFT position The No 2 load contactor should open at once and the orange indicating light within the No 2 load contactor push button switch 22 should go OFF 6 Connect a source of 24 V DC power two twelve volt batteries connected in series to terminals N and F or E at the output terminal panel Connection polari...

Page 79: ...ht At 126 volts the circuit will trip after a 1 second time delay At higher values of voltage time delays for over voltage trips are as follow At 140 volts the circuit will trip within 160 milliseconds At 180 volts the circuit will trip within 50 milliseconds b If the load contactor does not open under the conditions described in step a refer to the Troubleshooting Chart in Section 2 4 c Return un...

Page 80: ...8 Check over frequency sensing circuit protective monitor and indicating light At some frequency value from 420 Hz to 480 Hz after 7 seconds the over frequency sensing circuit should signal the over frequency circuit in the protective monitor module to OPEN the load contactor holding circuit thus OPENING the load contactor At any frequency value exceeding 480 Hz the over frequency sensing circuit ...

Page 81: ...ments of any kind b Adjust 400 Hz voltage regulator When a voltage regulator is first put into service or when output generator to aircraft cables are changed the regulator may require adjustments of output voltage value and line drop compen sation For making these adjustments the voltage regulator has three potentiometers Coarse output voltage potentiometer Fine output voltage potentiometer Line ...

Page 82: ... end of the cables from voltage under no load c Basic Engine Adjustments Adjustment procedures applicable to the diesel engine are included in the Cummins Operation Manual which is located in Chapter 5 Specific information for these engines is listed in Figure 2 Refer to the Cummins Operation and Manual for detailed information on the following engine adjustments 1 Exhaust valve adjustment 2 Fuel ...

Page 83: ...ol box NOTE When making governor system adjustments an important factor in such adjustments is the type of fuel used in the generator set For the engine of this generator set carefully follow the engine fuel guidelines referenced in 2 2 4 a 1 Actuator linkage adjustment See Fig 3 The proper adjustment of the mechanical linkage between the electric actuator and engine speed control lever is importa...

Page 84: ...uator 2 Stop Lever 3 Stop Lever Bracket 4 Ball Joint 5 Nuts 6 Actuator Rod Governor Actuator Linkage Figure 3 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets Chapter 2 3 November 27 1997 Page 12 ...

Page 85: ...another place in the oval hole in the engine stop lever and readjust the rod length f When proper adjustment has been completed tighten the jam nut 5 on the threaded rod 2 firmly against the ball joint 4 g Check governor linkage for freedom of travel Move the rod assembly manually to see that there isn t any binding or lost motion in linkage Make corrections if and as required At NO FUEL position ...

Page 86: ...igh as 25 30 V AC without damage to the internal electronics of the control box 3 Governor control box adjustment See fig 5 The control box has three control potentiometers pot for setting the response characteristics of the governor system They are I D and GAIN There is a forth potentiometer named DROOP which is not used in this installation It is set to zero of minimum There are two potentiomete...

Page 87: ...the rated speed 2400 RPM Turn the GAIN potentiometer 4 full CLOCKWISE The frequency meter gage and governor should become unstable and oscillate If it does not manually bump the linkage to cause it to oscillate Slowly turn the GAIN potentiometer 3 COUNTER CLOCKWISE until the oscillations stop Turn the GAIN potentiometer an increment past a point where the oscillations stop Turn the D potentiometer...

Page 88: ...several times to optimize performance b Adjust for RATED speed operation fig 5 The function of the speed adjust p c board is to set the rated engine speed To check for proper adjustment proceed with the following steps With the engine running and properly adjusted for IDLE speed press engine start switch 26 to increase RPMs to RATED SPEED The engine should be running at 2400 RPM and have an output...

Page 89: ...eld L2 26 5 A B B C C A Exciter Armature G2 0 1 Generator Revolving Field L1 2 1 NOTE The two leads of a phase must be connected when test is made Take readings when unit is cold and in an ambient temperature of 70º F 21º C Generator and Exciter Stator Tests Figure 6 5 Diode Test Test values for diodes are not given here because they could be misleading Test values may vary even between diodes of ...

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Page 91: ... voltage leads and components High voltage can kill Maintenance personnel must be very careful when performing terminal to terminal checks to be certain the proper terminals are being used especially when using jumper leads Damage to electrical components may result from the application of improper voltage and current A good quality multi scale volt ohmmeter is the only instrument required for tro...

Page 92: ...oad Engine oil pressure warm and at rated speed 2400 RPM 45 to 90 PSI 445 to 621 kPa Engine coolant temperature normal operation 160 to 200º F 71 to 93º C 5 Check Connections and Leads ALWAYS make a check of connections and leads to a component suspected of being faulty With the exception of a few instances we will assume that connections and wiring have always been checked first and that power ha...

Page 93: ...h pressure 4 The injection of the correct amount of clean fuel at the proper time NOTE When troubleshooting the engine keep the above requirements in mind 8 Illustrations Illustrations Figures 1 2 and 3 are referred to throughout the Troubleshooting Chart 9 Connection and Schematic Diagrams All connection and schematic diagrams for generator engine lights and all controls are located in chapter 5 ...

Page 94: ...t red 8 Engine ammeter 22 No 2 contactor push button switch orange 9 Frequency meter 23 Overfreqency indicator light red 10 Control Box label 24 No 1 contactor push button switch yellow 11 Strip lights 3 25 Low Oil Pressure indicator light red 12 Generator ammeter 26 Engine start push button switch green 13 Voltmeter 27 Low Fuel indicator light red 14 Overload indicator light red 28 Panel light pu...

Page 95: ... Engine circuit breaker 10 amp No 1 output 36 Output voltage adjustment coarse 31 Test bank aircraft switch No 2 37 Output voltage adjustment fine 32 Circuit Breaker contactors 5 amp 38 Line drop compensation adjustment 33 Circuit Breaker marker lights 10 amp OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets November 27 1997 Chapter 2 4 Page 5 ...

Page 96: ... and Clearance Lights Relay K70 7 No 2 Plug Interlock Relay K202 8 No 1 Plug Interlock Relay K2 9 Bypass Relay K73 10 Low Fuel Fault Relay K65 11 Air Filter Fault Relay K66 12 No 1 Contactor Control Relay K72 Generator Set Control PC Board Figure 3 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets Chapter 2 4 November 27 1997 Page 6 ...

Page 97: ...doesn t operate it is defective Replace it If starter motor does operate proceed to step d d Internal seizure If battery and starter are good and starter is unable to crank engine internal seizure is indicated Attempt to hand crank engine with a 3 4 inch square drive on a long flex handle on crankshaft pulley If engine cannot be turned one complete revolution internal seizure is indicated Remove e...

Page 98: ...l PC board 2 Engine will not start Cranking speed low a Low battery output Check battery Recharge or replace b Loose starting circuit connections or faulty cables Check all connections and cables Tighten or replace as required c Improper lubricating oil viscosity Check oil See Chapter 1 2 1 c Remove and replace oil if as necessary 3 Engine WILL NOT start Cranking speed normal LOW OIL indicating la...

Page 99: ...ated check pickup adjustment see 2 3 Para 3 e 2 If pickup is properly adjusted and voltage is still zero replace pickup c Defective actuator Apply 12 V DC to two actuator input leads terminals 4 and 5 on terminal strip Actuator lever should move immediately to full speed position If lever does not move replace actuator d Faulty controller Connect a DC voltmeter to terminals 4 and 5 on the controll...

Page 100: ...indicating lamp comes ON immediately a Defective or incorrectly wired high temperature switch S49 located on engine block on right side Check wiring to high tem perature switch according to connection diagram in Chapter 6 and see that wiring is correct If wiring is correct remove wires and check resistance between terminals C and N O A resistance of less than 10 ohms indicates a defective switch R...

Page 101: ...ay and the generator control PC board itself 9 All panel and clearance lights are either always ON or always OFF a Marker lights circuit breaker CB11 33 Fig 2 won t close Replace marker lights circuit breaker CB11 if defective b Clearance panel lights relay K70 6 Fig 3 could be defective or the PC board itself could have developed a malfunction Replace relay K70 in attempt to make the lights funct...

Page 102: ...ressure Check compression in accordance with Cummins Operation Manual See causes of low compression listed under ENGINE CONTROLS 13 Engine lacks power a Improper engine adjustments and gear train timing Tune up engine in accordance with Cummins Operation Manual b Insufficient fuel See ENGINE CONTROLS c Insufficient inlet air due to damaged air cleaner Check air cleaner for plugging and or damage d...

Page 103: ...uced is within this range generator is good and trouble is in voltage regulator circuit Proceed to step B c Defective voltage regulator Disconnect rectangular plug connector of regulator wiring assembly from suspect PC board and connect a properly working PC board to regulator wiring assembly while avoiding short circuiting bottom of properly working PC board to installed PC board Then start gener...

Page 104: ...rom voltage regulator PC board Using jumper leads with clip and prod terminals connect 12 V DC to terminals 1 and 4 in loose plug Connect NEGATIVE to terminal 4 Connect POSITIVE lead to terminal 1 see Schematic and Connection Diagrams in Chapter 5 If generator will NOT produce at least 80 V AC replace or repair connector and wiring between voltage regulator and exciter field as required OM 2084 Op...

Page 105: ... connections in AC and DC load contactor actuating circuits load contactor may be prevented from closing for any one of following reasons Check all wiring and connec tions in load contactor circuits Then check components as follows c Defective open relay in memory and time delay PC board 1 1 4 Fig 6 Replace memory and time delay PC board with a board known to be operating properly If contactor sti...

Page 106: ...ately when switch is released a No 1 plug interlock relay K2 8 Fig 3 on generator control PC board could be defective Place test bank aircraft switch No 1 output S2 30 Fig 2 in TEST BANK position If load contactor will now remain closed replace plug interlock relay K2 If not proceed to step b b No 1 load contactor relay K72 12 Fig 3 on generator control PC board or the board itself could be defect...

Page 107: ...3 Load contactor opens during power delivery NO fault indicating lights on a No 1 load contactor relay K72 12 Fig 3 on generator control PC board or the PC board itself could be defective Replace relay K72 and again close contactor If contactor still opens try replacing the PC board to correct this malfunc tion Proceed with trouble shooting as follows if malfunction is not corrected b A fault has ...

Page 108: ...time delay PC board 1 1 4 Fig 6 Replace memory and time delay PC board with a board known to be operating properly If contactor still doesn t close proceed to step d d Defective output No 2 push button switch S275 22 Fig 2 Check AC voltage input to contactor rectifier CR206 1 1 13 Fig 9 If voltage isn t approximately 115 V AC contactor output No 2 push button switch is defective and must be replac...

Page 109: ...is not reaching No 2 plug interlock relay K202 from aircraft for following reasons Proceed as follows to find cause of this malfunction d Generator to aircraft cable connector defective or not plugged into aircraft receptacle connector Inspect cable connector plug thoroughly for damaged E and F terminals Be sure plug is fully mated with aircraft receptacle connector and making good contact e Aircr...

Page 110: ...ircuit Trouble Symptom Test Check And or and Condition Probable Cause Remedy NOTE Protective relays and protective monitor are not completely functional until load contactor is CLOSED Since it is not advisable to vary voltages for test purposes while delivering power to an aircraft generator should be connected to a load bank for trouble shooting protective circuits To avoid repetition it will be ...

Page 111: ...s again and an under voltage condition is indicated by UV indicating light proceed to step B b Defective over under voltage PC board K26 Use course voltage potentiometer 36 Fig 2 to reduce voltage to 95 V Under voltage indicating light should NOT come on during a time delay of 4 to 12 seconds If light comes on before a delay of 4 to 12 seconds under voltage relay is defective Replace over under vo...

Page 112: ...hapter under ENGINE AND CONTROLS d Defective over under frequency PC board K27 If under frequency tripping continues after governor system is proven to be good and an under frequency condition does not exist replace over under frequency PC board 6 Load contactor opens during power delivery Overload indicating light ON a There may have been an overload condition which caused overload device K4 Obse...

Page 113: ...normal values d Open or shorted generator rotor windings L1 Check resistance with ohmmeter to determine if open or short circuited 2 Generator operates single phase a Open or short circuited winding in generator stator G1 Check stator winding resistances See Sect 2 3 Fig 6 for normal values 3 Generator overheats a Loose connection causing high resistance Check all output connections Look for disco...

Page 114: ...rcuit Check plug and receptacle connectors at aircraft Tighten repair or replace as required b Break or cut in output cable assembly Inspect Repair or replace as required c Unbalanced load Check aircraft 400 Hz components OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets Chapter 2 4 November 27 1997 Page 24 ...

Page 115: ... The name exciter armature refers to the shaft mounted revolving three phase windings of the exciter 1 Coupling Key 2 Flex Coupling Assembly 3 Generator Housing Stator Assembly 4 Armature Assembly 5 Exciter Housing Coils Assembly 6 Exciter Cover 7 Rear Bearing Retainer 8 Exciter Armature Assembly 9 Exciter Key 10 Not Used 11 Mounting Bracket 12 Front Bearing Retainer 13 Front Bearing Generator Top...

Page 116: ...consists of a revolving winding assembly on a laminated core a rectifier assembly diode mounting plate with diodes and a mounting flange The flange core and diode mounting plate are bolted together to make the complete exciter armature The exciter armature is mounted on the main generator armature shaft with a 3 8 inch square machine key and is held in place by a 1 2 13 hex head cap screw in the c...

Page 117: ...moving the exciter from the generator shaft This can be done using two 3 8 16 X 5 inch fully threaded hex head bolts Instructions for doing this are provided in Paragraph e 2 c Conditions for Exciter Removal The mechanics performing the work must decide upon the best and most convenient method of removing the exciter armature If the exciter armature is being replaced then the work may be performed...

Page 118: ...of the assembly make threading the 1 4 inch stud into the key rather clumsy This could result in cross threading and damage to key and stud It is safer and easier to attach as follows a Thread stud 1 Fig 4 into adapter 2 until it bottoms then thread this assembly 1 and 2 into key until stud bottoms in key threads Tighten securely b If hammer 5 and rod 4 are not already assembled thread one nut 3 o...

Page 119: ...d from the shaft to be removed from it by hand Remove it slowly from the shaft and at the same time observe the following CAUTION Pay close attention to field leads while pulling exciter armature from shaft Make CERTAIN that the leads stay in the 1 2 keyway One mechanic should watch them constantly while another operates the puller Make certain that leads do not catch and be sure that they slide s...

Page 120: ...ate contacts the end of the generator shaft If the exciter armature cannot be pushed on by hand use a 1 2 13 X 5 inch hex head bolt and 1 2 13 nut as shown in Figure 6 to pull the exciter armature onto the generator shaft Put the exciter armature on slowly and at the same time pull field leads through hole B Fig 2 in the diode mounting plate Screw the nut onto the bolt until it is near the head of...

Page 121: ...its are involved the correct grade of LOCTITE is included in the Kit The application of NEVER SEEZ to the shaft and armature bore is NOT recommended because there is a danger that it may mix with and contaminate the LOCTITE Application of NEVER SEEZ will be at the customer s risk LOCTITE can lose its adhesive and tightening properties if contaminated by rust preventatives oil or other lubricants a...

Page 122: ...Installing the Exciter Armature Figure 6 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets Chapter 3 1 November 27 1997 Page 8 ...

Page 123: ...be equally spaced There is NO ACCEPTABLE SUBSTITUTE for these bolts Hobart Brothers stocks these bolts as Part Number W 11102 18 2 Disassembly Removal of the flexible coupling is required for servicing the generator armature generator bearings or the coupling itself To remove the coupling for any reason it is necessary to separate the engine and generator On self propelled units many mechanics pre...

Page 124: ...ing out of the hub 5 Slide the coupling assembly off the shaft and remove the key 5 6 Inspect the coupling assembly components carefully as follows a Check for deformed fan blades and damage to the disk b Check the rubber exposed at both ends of the bushings for signs of deterioration c Check hub and split bushing for cracks evidence of galling and rust pits Light rust is permissible on the split ...

Page 125: ...ct our Service Department by mail telephone or FAX Write Hobart Brother Company Ground Power Division Service Department 1177 Trade Square East Troy Ohio 45373 U S A In U S A Call 800 422 4166 Parts 800 422 4177 Service From Foreign Countries Call 937 332 5050 Parts 937 332 5060 Service FAX 937 332 5121 800 367 4945 Toll Free in U S A Access to Coupling Bolts for removal or installation Figure 2 O...

Page 126: ... of lubrication and installation instructions c Bushing Replacement To replace bushings only proceed as follows 1 Press out ALL old bushings 2 Refer to Figure 5 Clean each bushing socket thoroughly removing all traces of old rubber DO NOT scratch or deform the bore of the bushing socket 3 Shake the container of lubricant vigorously and poor it into a small shallow dish 4 Roll a bushing in the lubr...

Page 127: ...it 2 Refer to Figure 3 Assemble the split bushing 2 into the hub 3 Make certain that only the bolts are lubricated and that no lubricant is permitted to get inside the bushing where the armature shaft will enter the bushing 3 Lubricate the three 3 8 16 bolts SPARINGLY and start them into the three unthreaded holes finger tight 4 Slide the generator armature as far as it will go toward the fan hous...

Page 128: ...ly and evenly as follows a Set a torque wrench to 30 foot pounds 41 N m and tighten all three 3 8 16 bolts to that value Block the coupling against clockwise rotation with a bar as illustrated in Figure 10 Observe the CAUTION above when it is necessary to rotate the shaft b Repeat step a above until 3 8 16 bolts can no longer be tightened c Recheck the dimension in Figure 9 to be sure it is the sa...

Page 129: ...Bushing Installation Figure 5 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets November 27 1997 Chapter 3 2 Page 7 ...

Page 130: ...Flywheel Adapter Figure 7 Assembly Procedure Figure 6 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets Chapter 3 2 November 27 1997 Page 8 ...

Page 131: ...Measuring from Mounting Face to Bushing Figure 9 Engine Measurement Figure 8 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets November 27 1997 Chapter 3 2 Page 9 ...

Page 132: ... with a wrench d Insert all remaining attaching bolts two installed in Step B above through the generator flange engaging the tapped holes in the flywheel housing and tighten them all securely e Refer to Figure 2 Insert a long piece of wood through the fan housing to block the armature against clockwise rotation Torque all of the coupling bolts to 85 foot pounds 115 N m 6 Run in and Periodic Check...

Page 133: ...lower panel 16 left front top panel 13 and the left front lower panel 12 Remove the clear power module cover 8 and loosen cable clamps to so that the aircraft cables can be disconnected from the load contactors on the power module 9 8 Disconnect plug connectors from the back of the control box 4 and remove wires going to TB 5 Disconnect plug from power module 9 9 Remove the control box 4 10 Remove...

Page 134: ...Module Cover 9 Power Module 10 Generator Assembly 11 Generator Wrapper 12 Front Left Bottom Panel and Cable Clamps 13 Front Left Top Panel 14 Control Box Door 15 Air Cleaner 16 Right Front Lower Panel Assembly Removal Required for Access to Generator Figure 1 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Sets Chapter 3 3 November 27 1997 Page 2 ...

Page 135: ...drilled in the top of the generator housing Insert a 1 2 13 eye bolt in the hole and attach the hoist chain to the eye bolt as shown in Figure 2 4 Remove the 5 8 11 x 4 1 2 bolts generator to flywheel coupling bolts 5 Detach the generator housing from the engine Do this by removing the six M10 1 5 x 35 metric bolts 6 Carefully lift and separate the generator from the engine Generator Lifting Arran...

Page 136: ...it carefully and slowly into position for attachment to the engine 3 While still supporting the generator assembly with the hoist attach the generator housing to the engine using the six M10 1 5 x 35 metric bolts 4 Attach the generator to the flywheel coupling using the six 5 8 11 x 4 1 2 bolts 5 Mount the generator housing to the frame of the generator set using the four 5 8 11 x 4 1 2 bolts 6 In...

Page 137: ...e available commercially 2 Bulk items such as wire cable sleeving tubing etc which are also commercially available 3 Permanently attached parts which lose their identity by being welded soldered riveted etc to other parts weldments or assemblies b Parts List Form This form is divided into six columns Beginning at the left side of the form and proceeding to the right columns are identified as follo...

Page 138: ... space Vendor codes and part numbers for purchased parts are also listed in this column when applicable Hobart modification to vendor items is also noted in this column 5 EFF Effective Column This column is used to indicate the applicability of parts to different models of equipment When more than one model of equipment is covered by a parts list there are some parts which are used on only one mod...

Page 139: ...g PA 17520 18265 Donaldson Co Inc 1400 W 94th St P O Box 1299 Minneaplis MN 55440 1299 1DG36 E M Products Inc 220 W 90th St Minneapolis MN 55420 25710 Deka Plastics Inc 914 Westfield Ave Elizabeth NJ 07208 1222 28520 Heyco Molded Products 750 Boulevard P O Box 160 Kenilworth New Jersey 07033 1721 2B928 Barber Colman Co Pasadena TX 77501 Section 2 Manufacturer s Codes 1 Explanation of Manufacturer ...

Page 140: ...7733 Stewart Warner Corporation 1826 Diversey Parkway Chicago Illinois 60614 Code Vendor s Name Address 61706 EAO Switch Corp 198 Pepes Farm Rd P O Box 552 M O Milford CT 06460 3670 66180 Automatic Timing and Controls 3312 Bloomingdale Melrose Park IL 60160 1030 7M613 Wright F B Co of Cincinnati 4689 Ashley Dr Hamilton Oh 45011 9706 72582 Detroit Diesel Corp 13400 W Outer Dr Redford MI 48239 4001 ...

Page 141: ...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 PRV Peak reverse voltage PSI Pounds per square inch Ref Reference the item has been listed previously TM Technical Manual T R Transformer rectifier V Volt when used as a prefix to a five digit number indicates ve...

Page 142: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 2 Revised 10 98 Generator Set Figure 1 ...

Page 143: ...ENCY STOP 1 285125 GUARD MUSHROOM BUTTON V14799 K564M 1 1 5 Not Used 1 6 287048 LABEL TERMINAL BLOCK 1 1 7 402987 LABEL HOBART 3 1 8 78A 1000 LABEL I D 1 1 9 287459 LABEL GENERAL WARNING 1 1 10 79A 1110 LABEL OPTIONS 1 1 11 76B 1148 LABEL DIESEL FUEL 1 1 12 430077 002 LABEL HANDLING 1 1 13 282562 CAP FUEL V49234 1275 0003 1 1 14 287460 LABEL HIGH VOLTAGE 1 1 15 287461 LABEL FUEL 1 1 16 287462 LABE...

Page 144: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 4 Revised 10 98 Frame Assembly Figure 2 ...

Page 145: ...UVERED ASSEMBLY 1 2 10 402037 028 GROMMET RUBBER V7M613 HW 2036 1 2 11 283506 COVER POWER MODULE 1 2 12 76A 1131 TUBING Z FLEX 12 2 13 287413 FRAME MOUNTING ASSEMBLY 1 2 14 287437 COVER FUEL COOLER 1 2 15 287423 PANEL BOTTOM 1 287436 004 INSULATION BOTTOM PANEL 1 2 16 287421 YOKE ASSEMBLY 1 2 17 287424 SUPPORT ENGINE FRONT 1 2 18 286915 TANK FUEL ASSEMBLY 65 GALLON 1 2 19 DELETED 2 20 287506 COVER...

Page 146: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 6 Revised 10 98 Canopy Assembly Figure 3 ...

Page 147: ... PLUG 1 3 14 403091 017 PLUG HOLE PLASTIC V28520 DP 2 5 2 3 15 403091 008 PLUG HOLE PLASTIC V28520 DP 1750 2 3 16 283641 PANEL SIDE LEFT FRONT 1 3 17 Not Used 3 18 283642 PANEL SIDE LEFT FRONT 1 3 19 287534 DOOR LEFT FRONT ASSEMBLY 1 287542 001 HEX RECESS DOOR LATCH 1 287526 002 DOOR LATCH PULL TAB 1 3 20 286834 COVER CONTROLS 1 3 21 287537 DOOR LEFT REAR ASSEMBLY 1 287542 001 HEX RECESS DOOR LATC...

Page 148: ...n and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 8 Revised 10 98 3 2 1 4 Interior Components Left Side Figure 4A 6 7 8 5 10 9 12 11 Interior Components Right Side Figure 4B ...

Page 149: ... DIODE ASSEMBLY 1 4B No Number INTERIOR COMPONENTS RIGHT SIDE REF 4B 5 No Number COOLING SYSTEM COMPONENTS See Fig 10 REF 4B 6 287532 002 KIT GOVERNOR ASSY See Fig 7 and 8 REF 4B 7 No Number COLD WEATHER START COMPONENTS See Fig 19 REF 4B 8 No Number AIR INTAKE COMPONENTS See Fig 15 REF 4B 9 No Number ENGINE COMPONENTS See Fig 13 REF 4B 10 No Number FUEL SYSTEM COMPONENTS See Fig 9 REF 4B 11 No Nu...

Page 150: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 10 Revised 10 98 Control Box Door Assembly Figure 5 ...

Page 151: ...able Below SWITCH ENGINE STOP Items A F I J 1 set 5 18 287038 001 HOLE PLUG 1 5 19 See Table Below SWITCH OUTPUT CONTACTOR No 1 Items A C F I J K 1 set 5 20 See Table Below SWITCH ENGINE START Items A C F H J 1 set 5 21 See Table Below SWITCH LAMPS Items A B F K 1 set 5 22 W 10051 010 CLAMP WIRE 5 8 2 5 23 DELETED 2 24 494134 001 GAUGE FUEL LEVEL 1 2 25 284486 001 LIGHT GAUGE 4 ITEM PART No PUSH B...

Page 152: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 12 Revised 10 98 Control Box Interior Components Figure 6 ...

Page 153: ...37 BRACKET MOUNTING SWITCHES 1 6 18 283978 002 CIRCUIT BREAKER 10A V77342 W23 X1A16 10 2 6 19 283978 001 CIRCUIT BREAKER 5A V77342 W23 X1A16 5 2 6 20 400292 004 SWITCH TOGGLE SPDT 1 6 21 400292 006 SWITCH TOGGLE 4PDT 1 6 22 40201 INSULATION STRIP NEOPRENE 1 8 X 1 2 58 6 23 30GH 1262 SOCKET LIGHT PANEL V13445 DL 21 2 6 24 50GHP 206 LAMP PILOT LIGHT 2 6 25 284908A BOARD PC GENERATOR SET CONTROL ASSY...

Page 154: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 14 Revised 10 98 Control Box Dual Output Kit Figure 6a ...

Page 155: ... 001 ACTUATOR SLEEVE V61706 704 731 0 B D 1 6a 4 285033 FLANGE MOUNTING V61706 704 950 5 B D 1 6a 5 284475 001 BLOCK CONTACT NC V61706 704 900 3 B D 1 6a 6 285034 001 LAMP HOLDER V61706 704 950 0 B D 1 6a 7 400613 004 BULB TYPE 1815 B D 1 6a 8 285030 004 LENS ORANGE V61706 704 702 3 B D 1 6a 9 402662 SWITCH TOGGLE B D 1 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set No...

Page 156: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 16 Revised 10 98 4 2 5 2 7 8 6 Governor Kit Figure 7 2 1 3 ...

Page 157: ...AGE V2B928 DYNZ 7 1 3 7 3 285436 BRACKET LEVER STOP 1 7 4 287649 LEVER FUEL PUMP STOP 1 7 5 287717 007 ARM THROTTLE LINKAGE 1 7 6 281775 CLEVIS ACTUATOR ROD V2B928 DYNK 218 1 1 7 7 284223 BRACKET GOVERNOR ACT MTG 1 7 8 281772 ELECTRIC GOVERNOR ACTUATOR V2B928 DYNC 10502 000 0 12 1 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set November 27 1997 Chapter 4 3 Revised 10 28...

Page 158: ...aintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 18 Revised 10 98 3 5 2 1 4 Governor Controler Left Side of Unit Magnetic Pickup Right side of Engine 7 6 8 Governor Kit Continued Figure 8 ...

Page 159: ...12 1 8 2 84A 1075 MOUNT RUBBER 4 8 3 482989 STRAP CONTROLLER 2 8 4 181891 003 BOARD PC SPEED ADJUST 1 8 5 285141 BRACKET CONTROLLER MTG 1 8 6 285062 001 SENSOR MAGNETIC PICKUP V2B928 3040AN25 1 8 7 281751 003 ADAPTER MAGNETIC PICKUP 1 8 8 285063A 003 CABLE ASSEMBLY 1 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set November 27 1997 Chapter 4 3 Revised 10 28 Page 19 ...

Page 160: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 20 Revised 10 98 Fuel System Components Figure 9 1 2 8 12 11 9 10 3 4 5 6 7 ...

Page 161: ...44 HOSE LOW PRESSURE 21 W10869 014 HOSE CLAMP 1 9 5 400819 003 VALVE BALL 1 2 1 9 6 12CW2077 003 ELBOW NPT ST 90 DEG 1 9 7 W10760 001 NIPPLE PIPE 1 X 1 9 8 056544 LINE FUEL RETURN 28 W10869 014 HOSE CLAMP 2 9 9 286851 FITTING HOSE BARBED BRASS 1 9 10 12CW2077 003 ELBOW 90 DEG 1 9 11 286915 FUEL TANK 65 GAL 1 9 12 486719 009 FUEL SENDER 1 9 13 286897 004 PRIMARY FUEL FILTER REF 9 14 286897 005 SECO...

Page 162: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 22 Revised 10 98 Cooling System Components Figure 10 5 4 3 2 1 6 7 8 9 10 ...

Page 163: ...287659 HOSE RADIATOR UPPER 1 W10869 003 CLAMP HOSE 2 287660 HOSE RADIATOR LOWER 1 W10869 005 CLAMP HOSE 2 10 4 287453 GUARD FAN PUMP SIDE 1 287656 GUARD FAN EXHAUST SIDE 1 10 5 287612 GUARD FAN WIRE SPIRALED 1 10 6 287619 SHROUD TOP 1 10 7 287620 SHROUD BOTTOM 1 10 8 286654 FAN COOLING V75418 4035 41296 80 1 10 9 283873 DRAIN RADIATOR 2 56535 HOSE DRAIN 3 8 38 W10869 014 CLAMP HOSE 2 10 10 287333 ...

Page 164: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 24 Revised 10 98 Power Module Assembly Single Output Figure 11 ...

Page 165: ...LOAD ASSEMBLY 1 11 13 401564 004 HOUSING SOCKET V00779 1 480287 0 1 11 14 180593 002 CAPACITOR 0 1 MFD 500 VAC ASSEMBLY 3 11 15 286084 RECEPTACLE ASSEMBLY HARNESS 1 11 16 401911 020 BLOCK TERMINAL V30430 0220081 1 11 17 AW 626 BUSHING INSULATING A B C 3 11 18 76A 1132 TUBING Z FLEX 3 4 DIA 3 9 pieces 27 11 19 282089 009 DIODE FLYBACK 1 11 20 W 9746 003 RESISTOR 100 OHM 25 W V91637 HL 25 062 100 5 ...

Page 166: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 26 Revised 10 98 3 2 1 Grounding Plate and Cables Figure 12 ...

Page 167: ...o Number GROUND PLATE COMPONENTS REF 12 1 W 9360 289 CABLE 111 POWER MOD TO GROUND 1 12 2 W 9407 446 CABLE ENGINE TO GROUND 1 12 3 287735 PLATE GROUND 1 NOT ILLUSTRATED OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set November 27 1997 Chapter 4 3 Revised 10 28 Page 27 ...

Page 168: ...4 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 28 Revised 10 98 1 2 3 5 6 4 Right Side of Engine Top Front of Engine 7 8 9 Engine Components Figure 13 ...

Page 169: ...SS 1 13 5 403782 002 SWITCH SHUT DOWN 1 W 7814 004 ADAPTER 3 8 X 1 2 1 13 6 287611 ENGINE CUMMINS 1 287438 VALVE OIL DRAIN 1 13 7 282852 MOUNT ENGINE 2 13 8 480603 002 SHOCK MOUNT GREEN 2 480628 WASHER SHOCK MOUNT 2 13 9 78B 1119 1 SENDER WATER TEMP V16476 02019 1 W 7814 004 ADAPTER 3 8 X 1 2 1 13 10 286897 006 OIL FILTER 1 13 11 286897 004 PRIMARY FUEL FILTER 1 13 12 286897 005 SECONDARY FUEL FIL...

Page 170: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 30 Revised 10 98 4 1 3 5 2 Battery Components Figure 14 ...

Page 171: ...EF 14 1 287741 NEGATIVE BATTERY CABLE ASSY 1 14 2 281881 001 BATTERY 12V V25710 724DT 2 14 3 287740 POSITIVE BATTERY CABLE ASSY 1 14 4 286219 BATTERY HOLD DOWN 1 14 5 5CW 2048 BATTERY SUPPORT ROD 2 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set November 27 1997 Chapter 4 3 Revised 10 28 Page 31 ...

Page 172: ...4 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 32 Revised 10 98 4 2 1 2 9 6 8 7 5 3 Air Cleaner Components Viewed from the top front of unit Figure 15 ...

Page 173: ...1 15 4 282918 ELECTRIC RESTRICTION INDICATOR V18265 REX77 0062 1 15 5 280732 007 CLAMP T BOLT 1 15 6 287548 AIR CLEANER REPLACEMENT REF 15 7 284923 MOUNT AIR CLEANER BAND V18265 AAH00 0349 2 15 8 286061 CLEANER AIR V18265 EBB12 0271 1 15 9 287371 ELBOW 4 I D 2 15 10 284461 CONNECTOR SHORT PIPE 1 NOT ILLUSTRATED OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set November 27...

Page 174: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 34 Revised 10 98 1 2 3 Muffler and Exhaust Components Figure 16 ...

Page 175: ...ST COMPONENTS REF 16 1 287596 MUFFLER EXHAUST 1 16 2 287597 MUFFLER WRAPPER 1 16 3 287624 PIPE EXHAUST TURBO TO SILENCER 1 404154 013 CLAMP PIPE 1 16 4 DDW 495 001 CAP RAIN 1 NOT ILLUSTRATED OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set November 27 1997 Chapter 4 3 Revised 10 28 Page 35 ...

Page 176: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 36 Revised 10 98 Generator Assembly Figure 17 ...

Page 177: ...TOR ASSY 120kVA S B 1 17 19 W 11236 007 SCREW 1 4 20 x 3 4 HWH SF TAP TYPE F 3 17 20 281699 COVER GENERATOR 1 17 21 281701 KIT FLEX COUPLING ASSY 1 17 22 W 11097 033 SCREW 3 8 16 x 1 3 4 HHC ST GRADE 5 3 17 23 85B 1039 KEY COUPLING 1 17 24 W 11102 018 SCREW 5 8 11 x 2 3 4 HD 6 17 25 283546 SHROUD FAN 1 17 26 283560 BRACKET MTG SHROUD FAN 3 17 27 42517 SLEEVING NEG EXC LEAD 0 3 17 28 41507 SLEEVING...

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Page 179: ...5787 008 NUT HEX FULL M10 1 5 4 No Number HARDWARE GENERATOR HOUSING TO SHOCK MOUNTS 17 39 284312 003 SCREW HHC M16 2 0 X 90 2 17 40 281929 016 WASHER FLAT M16 2 17 41 281930 011 WASHER LOCK M16 2 17 42 405787 011 NUT HEX M16 2 0 2 No Number HARDWARE GENERATOR HOUSING TO ENGINE 17 43 405061 005 SCREW M10 1 5 X 35 6 17 44 84A 1034 WASHER LOCK 6 NOT ILLUSTRATED OM 2084 Operation and Maintenance Manu...

Page 180: ...OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 40 Revised 10 98 2 6 5 4 3 1 Power Module Second Output Kit Figure 18 ...

Page 181: ...TOR LINE 3 POLE V11641 421F109137R B D 1 18 3 A 25 WASHER INSULATING B D 4 18 4 DW 1704 BUSHING INSULATING E F B D 2 18 5 404065 002 RECTIFIER SILICON V14552 MB354CA B D 1 18 6 W 9746 003 RESISTOR 100 OHM 25W V91637 HL 25 062 100 5 B D 1 18 7 W 9350 313 CABLE 1 0 B D 1 NOT ILLUSTRATED OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set November 27 1997 Chapter 4 3 Revised 1...

Page 182: ...and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 42 Revised 10 98 1 2 3 Quick start temperature sensor Quick Start fuel line into head of engine Quick Start Components Figure 19 ...

Page 183: ...9 No Number COLD WEATER START COMPONENTS REF 19 1 408506 COLD WEATER START KIT 1 18 2 282196 CIRCUIT BREAKER MOUNTING BRACKET 1 18 3 409527 003 CIRCUIT BREAKER 15A 1 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set November 27 1997 Chapter 4 3 Revised 10 28 Page 43 ...

Page 184: ...This page intentionally left blank OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Chapter 4 3 November 27 1997 Page 44 Revised 10 98 ...

Page 185: ...22 283633 2 1 283634 3 12 283638 3 16 283641 3 18 283642 3 7 283647 10 9 283873 6 19 283978 001 6 18 283978 002 8 1 283990 001 7 7 284223 18 284244 4A 3 284244 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set November 27 1997 Chapter 4 4 Page 45 Section 4 Numerical Index 1 Explanation of Numerical Index The purpose of this index is to assist the user in finding the illus...

Page 186: ...6017 15 8 286061 11 24 286082 11 15 286084 14 4 286219 10 8 286654 3 20 286834 9 9 286851 3 11 286852 2 8 286853 3 23 286858 2 3 286866 3 5 286868 13 11 286897 004 9 13 286897 004 13 12 286897 005 9 14 286897 005 13 10 286897 006 2 18 286915 9 11 286915 4A 1 286968 003 5 286968 003 6 286968 003 5 1 286969 003 4B 14 287001 2 7 287014 4B 13 287027 5 18 287038 001 1 6 287048 6 37 287075 001 4A 1 2870...

Page 187: ... 287717 005 7 5 287717 007 12 3 287735 14 3 287740 14 1 287741 6 23 30GH 1262 1 20 351541 6 9 375426 003 17 32 386612 3 24 386751 6 8 387736C 11 12 387738A 3 25 387859 6 20 400292 004 6 21 400292 006 5 5 400613 004 6a 7 400613 004 9 5 400819 003 6 33 400826 001 6 35 400828 001 6 26 401564 003 11 13 401564 004 6 11 401564 004 6 7 401564 005 11 16 401911 020 4B 15 401911 020 6 16 401911 020 6 30 401...

Page 188: ...78A 1116 1 5 7 78A 1117 2 13 1 78B 1118 2 13 9 78B 1119 1 1 10 79A 1110 6 5 79A 1164 6 3 79B 1159 1 6 4 79B 1159 2 6 6 79B 1159 6 5 15 79C 1158 3 27 7J 422 0 3 27 7J 422 0 17 44 84A 1034 11 10 84A 1075 8 2 84A 1075 17 23 85B 1039 11 7 A 25 18 3 A 25 11 17 AW 626 11 8 AW 626 1 26 DDW 495 001 16 4 DDW 495 001 11 9 DW 1704 18 4 DW 1704 5 5 HF 2518 2 11 23 HF 2752 11 4 HF 2752 4A 1 HF 2752 4A 3 HF 275...

Page 189: ... 000 13 5 W7814 004 13 9 W7814 004 10 1 W7814 011 5 13 W8105A 004 11 21 W9350 301 11 21 W9350 302 11 21 W9350 312 11 21 W9350 313 18 7 W9350 313 12 1 W9360 289 12 2 W9407 446 11 20 W9746 003 18 6 W9746 003 5 6 W9917 018 OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set November 27 1997 Chapter 4 4 Page 49 Figure Item Number Part Number Figure Item Number Part Number ...

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Page 191: ...Manual HOBART DIAGRAMS Part No 500392 DIAGRAM DIAGRAM 287655 Schematic and Connection Engine Generator and Options 286998 Connection Control Box 285986 Connection Power Module OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set November 27 1997 Chapter 5 1 Page 1 ...

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Page 209: ...r TO 241 Kit Noise Reduction 287497 Transformer Rectifier Assembly 28 5V 487750 1 OM 433 Kit Unit Operating Clearance Lights 287173 1 Kit Spotlight 287061 Kit Block Heater 120V 287528 1 TO 256 Kit Block Heater 240V 287528 2 TO 256 Kit Fire Extinguisher 283012 TO 252 Kit Pin Hitch 500392 1 2 and 5 only 381441 Kit Pintle Hitch 500392 1 2 and 5 only 76A 1361 Kit Fixed Mounting 500392 3 and 4 only 283...

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Page 211: ...ry locations radiant heat vermin infestation or atmospheres conducive to fungus growth Abnormal shock vibration or mechanical loading from external sources during equipment operation Abnormal axial or side thrust imposed on rotating equipment shafts Low and or high ambient temperatures 2 Operation at Voltages above or below rated voltage Speeds other than rated speed Frequency other than rated fre...

Page 212: ...This page intentionally left blank OM 2084 Operation and Maintenance Manual 90CU24 Series 500392 Generator Set Unusual Service Conditions November 27 1997 Page 2 ...

Page 213: ...ing 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 machine be connected to a load bank after each 200 hours of use and operated under full rated load for one hour This will burn away and evaporate the accumulation of fuel in ...

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