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Hobart 9OC24S, Operation Manual

The Hobart 9OC24S operation manual is a comprehensive guide for users of this outstanding product. With detailed instructions and safety guidelines, this manual can be downloaded free at manualshive.com. Ensure optimal performance and longevity by referring to this manual for assistance with operating your Hobart 9OC24S.

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Page 1: ...ATION MAINTENANCE AND OVERHAUL MANUAL FOR SELF PROPELLED GENERATOR SET MODE L N 0 9OC24S SPECIFICATION NO 5381A AND VARIATIONS 90KVA 115 200 V AC 400 tjZ 3 PHASE Manufactured by MOTOR GENERATOR DIVISION HOBART BROTHERS COMPANY TROY OH IO 45373 U S A ...

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Page 3: ...resistance of the body is decreased when wet thus more easily permitting dangerous currents to flow through it When inspecting or servicing equipment do not work in damp areas without being extremely careful Stand on dry rubber mat or dry wood use insulating gloves that are effective when dampness or sweat cannot be avoided Keep your clothing dry and never work alone 1 Installation and Grounding o...

Page 4: ...nk is not grounded prior to and during fuel transfer Shut unit DOWN before removing fuel tank cap Do not completely fill tank Heat from the equipment may cause fuel expansion overflow Remove all spilled fuel im mediately including any that penetrates the unit After cleanup open equipment doors and blow fumes away with compressed air D TOXIC FUME PREVENTION Carbon Monoxide Engine exhaust fumes can ...

Page 5: ...ith the gearshift in any gear except neutral and the clutch pedal engaged attempt to start the GPU If the GPU starts have qualified maintenance personnel replace the micro switch Hobart part no 403982 and repeat this test procedure prior to returning the GPU to service 3 With the gearshift in any gear except neutral and the clutch pedal engaged switch the GPU to GENERATE mode If the GPU engine doe...

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Page 7: ...3 Ott 30 73 4 June 25 74 5 Ott 30 73 6 act 30 73 7 Ott 30 73 8 act 30 73 1 act 30 73 2 Ott 30 73 3 Ott 30 73 4 Ott 30 73 5 act 30 73 6 Ott 30 73 7 Ott 30 73 8 act 30 73 9 Ott 30 73 10 Ott 30 73 Ju_ne 25 74 Revised Feb 22178 Revised CHAPTER SECTION PAGE l l 11 l l 12 l l 13 l l 14 l l 15 l l 16 l l 17 l l 18 l l 19 l l 20 l l 21 l l 22 l l 23 1 l 24 l l 25 l l 26 l l 27 l l 28 l l 29 1 l 30 1 l 31 ...

Page 8: ...2 act 30 73 2 2 3 act 30 73 2 2 4 act 30 73 2 2 5 act 30 73 2 2 6 act 30 73 2 2 7 act 30 73 2 2 8 act 30 73 2 2 9 act 30 73 2 2 10 act 30 73 2 2 11 act 30 73 2 2 12 act 30 73 2 2 13 act 30 73 2 2 14 act 30 73 2 2 15 act 30 73 2 3 16 act 30 73 2 3 17 act 30 73 2 3 18 act 30 73 2 3 19 act 30 73 2 3 20 act 30 73 2 3 1 Ott 30 73 2 3 2 Ott 30 73 2 3 List bf Effective Pages _ Page2 PAGE DAIE 3 Ott 30 73...

Page 9: ... act 30 73 act 30 73 act 30 73 Ott 30 73 Ott 30 73 Ott 30 73 Ott 30 73 Ott 30 73 Ott 30 73 Ott 30 73 Ott 30 73 act 30 73 act 30 73 Ott 30 73 Ott 30 73 Ott 30 73 Ott 30 73 Ott 30 73 Ott 30 73 act 30 73 act 30 73 act 30 73 Ott 30 73 act 30 73 CHAPTER SECTION 3 l 5 3 l 6 3 l 7 3 l 8 3 l 9 3 l 10 3 l 11 3 l 12 3 l 13 3 l 14 3 2 1 3 2 2 3 2 3 3 2 4 3 2 5 3 2 6 3 2 7 3 2 8 3 2 9 3 2 10 3 2 11 3 2 12 3 2...

Page 10: ... 73 6 Ott 30 73 7 Ott 30 73 8 Ott 30 73 1 Ott 30 73 2 Ott 30 73 1 Ott 30 73 2 Ott 30 73 1 act 30 73 2 Ott 30 73 3 Ott 30 73 4 Ott 30 73 5 Ott 30 73 6 Ott 30 73 List of Effective Pages Page4 CHAPTER SECTION 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 l 6 2 6 2 7 o 7 o 7 o 7 o 7 l 7 l 7 l 7 l 7 2 7 2 7 2 7 2 7 2 7 2 7 2 7 2 7 3 7 3 7 3 7 3 PAGE DATE 7 Ott 30 73 8 act 30 73 ...

Page 11: ...act 30 73 35 Ott 30 73 35A June 25 74 35B June 25 74 35c June 25 74 35D June 25 74 36 Ott 30 73 37 Ott 30 73 38 June 25 74 39 40 June 25 74 act 30 73 41 Aug 13 75 42 June 25 74 June 5 74 Revised Aug 13 75 Revi sed PAGE DAlE CHAP7ER SECTION PAGE DAIE 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 ...

Page 12: ...t 30 73 86 Ott 30 73 87 June 25 74 88 Ott 30 73 89 Ott 30 73 90 Ott 30 73 91 June 25 74 92 June 25 74 1 June 25 74 2 June 25p4 3 June 25 74 4 Ott 30 73 5 June 25 74 6 June 25 74 7 June 25n4 8 June 25 74 9 June 25 74 10 June 25 74 11 June 25 74 12 June 25 74 13 June 25 74 14 June 25 74 15 act 30 73 16 June 25 74 17 June 25 74 18 June 25 74 19 June 25 74 20 June 25 74 21 June 25 74 22 June 25 74 23 ...

Page 13: ...on Chapter Section l l Chapter 1 Section 1 3 Purpose The manual spurposeis to provide information and instructions to experiencedoperators electricians and mechanicswho have never seen or operatedthis generator set It is the intent of the manualto guide and assist operatorsand maintenancepersonnel in the proper useand maintenanceof the equipment 4 Contents Immediatelyfollowing the Introduction is ...

Page 14: ...ow this arrange men t and paragraph ing 1 Control Box A Interior Panel 1 Protective devices a Over loadrelay 2 Contactors B PageN umber ing Pagenumbersdo not run consecutively throughout the manual Each pageis identified by the Chapter Section number in which it appears and by a page numberwithin the Chapter Section Therefore the first pagein each Section is page1 These identifying numbersappearin...

Page 15: ...he Table of Contents For example someadjustment information is needed A quick look at the Table of Contents indicates that Adjustment Test information is located in Chapter Section 2 3 Chapter2 Section 3 If the specific adjustment being sought is not listed in the main Table of Contents turn to Chapter 2 and look in its Table of Con tents under Adiustment Test where eachadjustment is listed with t...

Page 16: ... item numberof the part and the Figure number in which it appearsare given Example Ref 2 Fig 3 f re ers to item number2 which appearsin illustration Figure 3 of the sameChapter Section When the referenced Figure appearsin another Chapter Section the reference will include the Chapter Section number Example Ref 2 3 1 Fig 4 tel Is the user to refer to Chapter Section 2 3 and to see item 1 in Figure ...

Page 17: ...h appearon schematicdiagrams A ampere AC alternating current AR as required C ten tigrade ccw counterclockwise cw clockwise DC direct current de 3 degree F Fahrenheit Fig figure GALS galIons Hz Hertz cycles per second in inch KG kilogram KVA kilovolt ampere KW kilowatt MM millimeter No number Para paragraph PF power factor PSI poundsper square inch Pt pint Qt quart Ref reference refer to RPM revol...

Page 18: ...FOBART z QQ gMOTOR GENERATOR DIVISION a 5 HOBART BROTHERS COMPANY 0 2 B J OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A lntroc ction Ott 30 73 Page 6 ...

Page 19: ...ation SpeciaI Features Optional Equipment and Identification 6 Engine Generator and Control Box 6 Operating Mode Safety Devices 28 Transformer Rectifiers Optional 29 Test Box Optional Additional Variations Preparation for Use l 2 32 1 General Inspection and Checks Lubrication 2 Installing Output Cable Operation l 3 1 1 2 1 GeneraI 1 Moving the Cklit Without Engine Power Operating the Unit Operatin...

Page 20: ...ection Check 2 l 1 GeneraI 1 Maintenance Schedule 1 Inspection Check 5 Maintenance Procedures 2 2 1 General 1 Lubrication 1 Servicing the Air Cleaner 13 Engine FueI 14 Engine Cooling System 18 Battery Service 25 Brake Fluid Check 29 Drive Belts 30 Generator Maintenance 34 Tire Inflation 34 Adjustment Test 2 3 1 GeneraI 1 Testing the Generator Set 1 Engine Generator ComponentsAdjustment Contents Pa...

Page 21: ...oting 3 o 1 Theory of Operation 3 l 1 General 1 Twelve Volt Electrical System 400 Hz Generator System Trouble Shooting Procedures GeneraI Trouble Shooting Chart Equipment for Trouble Shooting Safety Parts Replacement 3 2 Test Values Trouble Shooting Practices Electric Hydraulic Governor Trouble Shooting Engine Trouble Shooting II lustrations Removal Installation 4 o Engine Generator AssemblyRemova...

Page 22: ...ER SECTION 4 l PAGE 10 Individual ComponentsRemovaland Installation General Generator Control Box Trays Power Module Panel Assembly Control Box Repair Electrical Repairs GeneraI Generator Control Box Generator Engine Connection Diagrams Mechanical Repairs Engine Generator CanopyAssembly Overhaul Electrical GeneraI 5 o 5 l 5 2 6 O 1 6 l 1 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 Generator Control Box Assembly...

Page 23: ...chanical 6 2 General Engine Generator IIlustrated Parts List Introduction GeneraI Purpose Arrangement 7 o 7 l 2 1 1 1 1 1 1 1 1 1 Explanation of Parts List 1 Manufacturer s Codes 7 2 1 Explanation of Manufacturer s Vendor Code List 1 Parts List 7 3 1 Explanation of Parts List Arrangement 1 Symbolsand Abbreviations 1 N umericaI Index 7 4 1 Explanation of Numerical Index 1 Manufacturer s Information...

Page 24: ...l 3 l 3 Sheets 1 and 2 2 3 Starting Aid 5 Driver s CompartmentControls Typical 8 Transformer Rectifiers Typical Installation 12 28 5 V DC T R Control Panel 14 28 5 V DC T R Output Voltage Adiustment 14 112 V DC T R Control Panel 16 Test Box Operating Controls 17 Test ReceptacleConnector Typical 18 2 l 2 l 2 l 2 l 1 Maintenance Schedule 2 thru 4 2 Vibration DamperHub 14 3 Lamp Identification Chart ...

Page 25: ...r Grease 9 10 Filler Plugs Air Cleaner Cartridge Replacement Fuel Filter Fuel PumpScreen and Priming Plug Coolant Drains Corrosion Resistor Battery AccessDoors Battery Installation Master BrakeCylinder Belt Deflection Tension Check Chart Belt Deflection Check Alternator Belt Adjustment Fan Belt Adjustment 12 14 16 17 22 24 26 28 29 30 31 33 33 2 Sheets 1 and 2 Terminal Boards Generator andExciter ...

Page 26: ...NUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A LIST OF ILLUSTRATION S CON T D Engine and Generator Controls and Instruments Sheets 1 and 2 6 7 Starter and Solenoid Switch 8 TerminaI Boards 9 Exeitation Resistors 10 End View of Voltage Regulator AmphenolConnector 10 Trouble Shooting Chart 11 thru 30 1 Generator Circuit Connection Diagram 2 2 Engine Circuit Connection Diagram 3 3 Control Bo...

Page 27: ...ns 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 1 2 3 4 5 6 7 8 9 10 11 12 12A 13 14 15 16 17 18 19 20 21 Oct30 73 June 25 74Revised LIST OF ILLUSTRATION S CON T D TITLE Self Propelled Generator Set CanopyAssembly Generator Set Without Canopy Control Box Assembly Generator Control Tray Assembly Protective Relay Tray Assembly Voltage Regulator Tray Assembl...

Page 28: ...F ILLUSTRATIONS CON T D 1 FIGURE NUMBER 7 3 22 Transmission Assembly 56 7 3 23 Clutch Group 66 7 3 24 Generator Group 68 7 3 25 Seat and Transformer Rectifier Group 70 7 3 26 Output Terminal Panel Assembly 74 7 3 27 Transformer Rectifier Terminal PaneI Assembly 76 7 3 28 Vehicular Lights Group 78 7 3 29 Bodyand Frame Group 80 7 3 30 Battery Group 84 7 3 31 Axle Group 86 TITLE PAGE NO ...

Page 29: ...ER SECTION PAGE Description l l 1 General 1 Orientation 5 SpeciaI Features 5 Protective Monitor 5 Pull out Trays 5 Voltage Regulator 5 Test Circuitry 5 Electric Hydraulic Governor 5 Optional Equipment and Identification 6 Variation No 1 6 Variation No 2 6 Combinations of Variations 6 Future Variations 6 Engine Generator and Control Box 6 BasicEngine 6 Engine Manufacturer s Equipment 7 Electrical s...

Page 30: ...gine overspeedprotection Engine cooling fan Hobart Installed Engine Equipment Electric hydraulic governor Electric control unit Hydraulic actuator Magnetic pickup Engine safety device Coolant temperatureswitch Air cleaner Mufflers Radiator Generator Control Box Assembly Engine instruments Ammeter Temperaturegage Oi I pressuregage l O_ Page2 CHAPTER SECTION PAGE l l 7 7 7 10 10 10 10 10 11 11 11 11...

Page 31: ...l switch Contactor control switch Lights and light controls Generator control tray Resistors Generator output monitors meters Meter and line switches Receptacleconnector Tray Manual voltage control Protective relay tray Sensing relays Protective monitor module Indicating lights Plug interlock relay Test bank switch Resistor CHAPTER SECTION l l PAGE 14 14 14 14 15 17 17 17 17 17 19 19 19 19 19 20 2...

Page 32: ...ge regulator tray 23 Controls 23 Power modulepanel assembly 24 Capacitors 24 Load contactor 27 Current transformers Overload current transformers 27 27 Line drop current transformers 27 Ammetercurrent transformers 27 Overload module 27 Rectifier 28 Operating Mode Safety Devices 28 Drive Mode Safety Device 28 Generate Mode Safety Device 29 Transformer Rectifiers Optional 29 Test Box Optional 29 Des...

Page 33: ...ation lnstaIIing Output Cable Three phase AC Output Cable lnstaIlation Transformer Rectifier Output Cable Installation 4 Operation GeneraI Moving the Unit Without Engine Power l 3 Operating the Unit 1 Prestart Inspection NormaI Engine Starting Procedures 1 4 Cold WeatherEngine Starting Procedures 5 Mobile Operation 6 General 6 Driving the vehicle 7 Stopping the vehicle 9 Preparation for Power Deli...

Page 34: ...ery Stop 28 5 V DC Power Delivery 112 V DC Power Delivery Stop 112 V DC Power Delivery Operating the Test Box DC and AC Power Delivery CHAPTER FIGURE SECTION NUMBER l l 1 l l 2 l l 3 l l 4 l l 5 l l 6 l l 7 l l 8 l l 9 l l 10 l l 11 LIST OF ILLUSTRATIONS TITLE Self Propelled Generator Set Specifications and Capabilities Sheets 1 and 2 ComponentIdentification Sheets 1 and 2 Air Cleaner and Service ...

Page 35: ...geRod and Filler Cap Output Terminals Typical Opening for Output Cable Typical T R Output Cable Installation T R Cable Plug Boxes Engine and Generator Controls and Instruments Sheets 1 and 2 Starting Aid Driver s CompartmentControls TypicaI Transformer Rectifiers Typical Installation 28 5 V DC T R Control Panel 28 5 V DC T R Output Voltage Adjustment 112 V DC T R Control Panel Test Box Operating C...

Page 36: ...HOBART z 3 QD MOTOR GENERATOR DIVISION i HOBART BROTHERS COMPANY c b B R OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A ...

Page 37: ...elf propelled unit see Fig 1 manufacturedby Motor Generator Division Hobart Brothers Company Troy Ohio 45373 and is identified as Model No 9OC24S Specification No 5381A Instruc tions for optional variations are included The purposeof the generator set is to supply regulated 115 V AC 400 Hz powerto a parkedaircraft for operation of the aircraft s electrical equipmentwhen the on board generators are...

Page 38: ...echanical contract ing band type mountedat the rear of the transmission It operateson a drumattached to the output shaft of the transmission All mobile operation controls are conventional mechanicaltype All units are equippedwith a single seat mountedon the left side This design allows spaceon the right side of the driver for mounting T Rs transformer rectifiers when furnished The engine generator...

Page 39: ...loadcapacity Recommended output cablesize ENGINE 90 KVA 115 200 V 260 A 400 Hz 72 KW 0 8 PF 100 2400 RPM 325 A 2 O Manufacturer CumminsEngine Company Inc Columbus Indiana 47201 CumminsSpecification No 1826 01 Model No V 504 C2 TO Type V 8 Diesel Number of cylinders 8 Bore and stroke 4 5 8 x 3 3 4 inches Displacement 504 cubic inches Brake horsepower 2400 RPM 173 Idle speed High speedlimiting 650 R...

Page 40: ... 304 to 1 4 111 to 1 Final drive Differential Lubricant Capacity 9 472 to 1 5 Q I S Transfer Case Lubricant Capacity l 1 2 PTS Steering Brake service Manual wormand roller type Brake parking 4 Whee I Hydraulic Tires Drive shaft cbntracting bandtype Springs 8 ply 7 00 x 16 IN Semi elliptic Fuel Tank Capacity approx leaf type front and rear 70 GALS Tire Pressure 60 PSI GENERATOR PROTECTIVE SYSTEM Ov...

Page 41: ...loaddevelops PuIl out Trays The control box is equippedwith pull out drawer type trays 14 15 and 16 Fig 5 which provide easy accessto controls andequipment mountedin them Each tray mayberemovedas an assemblyby disconnectinga single quick disconnect connectorand tripping two safety latches Voltage Regulator A solid state adiustable voltage regulator Fig 9 providesautomatic voltage regulation at the...

Page 42: ... The unit is identified as Spec5381A Variation 2 S5381A V2 C Combination of Variations A unit capableof supplying either 28 5 V or 112 V DC in addition to the regular 115 V AC would be identified as Spec 5381A Variations 1 and 2 S5381A Vl and 2 D Future Variations Any additional optional equipmentwhich maybecome available will be coveredby an addendum to this manualor by supplementsinserted in Cha...

Page 43: ...eablecartridge 4 Automatic shut down system This system includes the following a Fuel shut off valve The solenoid operatedfuel shut off valve 9 is mountedon the fuel pump The pumpcan supply fuel to the engine only when the solenoid is energized to hold the valve OPEN The operation of any one of several safety switches will openthe solenoid holding circuit and allow the valve to CLOSE and shut down...

Page 44: ...TOR DIVISION 0 2 HOBART BROTHERS COMPANY I OPERATION MAINTENANCE AND OVERHAUL MAN UAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Fr t to kear View Rear to Front View 6 12 _ Componentldentificaticn figure 3 Sheet 1 of 2 ...

Page 45: ...eratureswitch 7 12 v Alternator 8 Corrosion resistor 9 Fuel shut off valve 10 Overspeedgovernor not used Left Interior Control Box 11 Air cleaner 12 12 V Voltage regulator 13 Exciter 14 Fuel tank valve 15 Clutch 16 Gearshift safety switch 17 Back up light switch 18 Brake master cyIinder 19 Governor electric control box 20 Magnetic pickup Right Side Flywheel Housing ComponentIdentification Figure 3...

Page 46: ...ddition of the following equipment 1 Electric hydraulic governor An electric hydraulic governor kit is installed on the engine to replace a con ventionaI mechan icaI type The electric hydraulic governor system for con trol of engine speed andgenerator output frequency was selected for this application becauseit provides faster engine responseto changesin load con ditions This results in muchcloser...

Page 47: ... the front of the engine in the coolant cross over system It is electrically connectedin series with the fuel shut off valve solenoid and is normally closed The switch will opento stop the engine when internal coolant systemtempera ture reaches205 deg F 3 Air cleaner The diesel engine air cleaner Fig 4 is a dry cartridge type It is equipped with a moisture eliminator and a service indicator The in...

Page 48: ...rs are a special design combiningthe exhaust muffler and exhaust manifold into a welded one piece replaceableunit Mufflers are not interchangeable 5 Radiator The radiator is a tube type with bolted on top and bottomtanks which permit disassemblyfor cleaning and repair D Generator The 400 Hz generator is a brushless revolving field three phase alternating cur rent type The rotor assemblyis mountedb...

Page 49: ...the exciter end and is dischargedat the drive end The completegenerator is bolted to the engine flywheel housing E Control Box Assembly See Fig 5 The control box is a sheet metal enclosure which housesand provides mounting facilities for generator andengine controls and monitoring equipment In addition to instruments and controls which are surface mountedon the left side of the front panel the box...

Page 50: ...START position and must be manually held in this position When released from START it automatically returns to RUN position When held in START position 12 V DC power is supplied directly to the fuel shut off valve solenoid and engine shutdownsafety switches are by passed This direct current is necessaryfor engine starting becausethe low oil pressureswitch is OPEN until the engine is running normal...

Page 51: ...uired and engine speedis controlled by an accelerator and flexible cable arrangement connectedto the governor actuator linkage For mobile operation DRIVE power to the fuel valve must passthrough a micro switch in the output cable plug box see l 2 Fig 3 or a series of switches when the unit is equipped with T Rs see l 2 Fig 5 Output cable plug connectorshold the Micro switches closed when connector...

Page 52: ...ower module 14 Generator control tray 15 Protective relay tray 0 i 0 ii 32 ____ _______ _ ______ _____ _ ___ _ ___ I _ ___ _ _ _ _ __ _ __ _ _ _ _ __ __ 16 17 18 19 20 21 22 23 24 25 26 27 Control Box Figure 5 14 16 Voltage regulator tray Load ccntactor control switch TerminaI board Test receptacle connector Operating mode generate drive control switch Instrument and marker light fuse 20 A HeadIig...

Page 53: ...ant reed type and indicates the frequencyof the generator output alternating current in the range of 380 to 420 Hz cyclesper 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 and C A as selected by the meter selector switch 5 and the line selector switch 4 These switches will be describedbelow The voltmeter has a 3 l 2 in...

Page 54: ...O 5381A 13 14 1 Resistor 25 ohm 100 watt 2 Fastener 3 Instruction plate 4 Line selector toggle switch 5 Meter selector rotary switch 6 AC ammeter 7 Voltmeter 8 Fiequency meter 9 Nylon roller 10 Receptacleconnector 11 Tray 12 Resistor 50 ohm 100 watt 13 Automatic manual switch 14 Manual voltage control rheostat 15 Rectifier Generator Control Tray Figure 6 ...

Page 55: ... DC output of the rectifier is routed to the exciter field through a rheostat 14 The generator output voltage is thereby manually controlled by adjustmentof the rheostat 7 Protective relay tray See Figure 7 The center tray in the control box is identified as the protective relay tray and contains electrical andelectronic safety devices designedto protect the aircraft electrical systemagainst damag...

Page 56: ...d The boardincludes five memorycircuits and a 5 secondtime delay circuit Each memorycircuit is connectedto a correspondingsensing device overloadmodule overvoltage relay etc All of the circuits are connectedto the modulerelay coil and any one of the circuits can energize the coil to openthe relay contacts Thus when a sensing device energizes any one of the modulecircuits the modulerelay is also en...

Page 57: ...e sensing relay 17 7 Tray fastener 18 8 Overload indicating light 19 9 Reset switch 20 10 Undervoltage indicating light 21 11 Resistor 100 ohm 25 watt 22 Overvoltage indicating light Underfrequency indicating Iight Interlock relay fuse 2 amp Overfrequency indicating light Test bank switch Receptacleconnector Plug interlock relay Capacitor 6 8 MFD 35 V TerminaI board Diode 400 PRV 1 5 A Load contac...

Page 58: ... attempt is madeto deliver power when the output cable is not connectedto the air craft Twenty eight volt direct current for operation of the relay is supplied from the aircraft either through an on board transformer rectifier or from a twenty eight volt electrical system Connection from the air craft to the interlock relay is madethrough terminals E and F on the cable connectors Test bank switch ...

Page 59: ...lator is designedto provide 1 voltage regulation with 25 secondrecovery time for all loadsup to 100 of rated load on a three phase four wire 115 200 volt 400 Hz brushlessgenerator This regulator provides field excitation power for the rotary exciter and regulates generator output voltage by varying the exciter field poweras required to meetvarying load conditions Thus the generator output is held ...

Page 60: ...ted by the dampingcircuit gain potentiometer 8 Regulator responsetime is adjusted by the dampingcircuit rate potentiometer 10 9 Power modulepanel assembly See Fig 10 The power moduleassembly sometimesreferred to as the contactor panel is locatedon the backpanel of the control box Componentsof the power modulepanel assemblyare as follows a Capacitors The function of the three capacitors 10 Fig lo w...

Page 61: ...hassisassembly 15 Sensing and preamplifier chassis assembly Receptacleconnector 16 High phase sensing boardassembly 17 Reactor Dampingcircuit gain potentiometer 18 Chassis Receptacle connector Dampingcircuit rate potentiometer Static Voltage Regulator ____ Figure 9 Oct30L73 ____ __ _ __ _ _ Ll Page25 _ __ rOBART I z f QD iMOTOR GENERATOR DIVISION i HOBART BROTHERS COMPAN c O OPERATION MAINTENANCE ...

Page 62: ...GENERATOR SET SPEC NO 5381A 8 0 I 6 1 Overload current transformer 6 Load contactor 2 Line drop resistor 50 ohm 25 watt 7 Ammeter current transformer 3 Line drop current transformer 8 Overload device 4 Terminal board 9 Overload resistor 7 5 5 Rectifier 16 6 ohm watt 10 Capacitor Power Module Figure 10 _ _ _ i l l Ott 30 73 Page26 ...

Page 63: ...ansformers The three line drop current transformers 3 in conjunction with the burdenresistors 2 detect the magnitudeand power factor of cur rent flowing from the generator to the load and feed a signal to the voltage regulator which interprets the signal and alters the exciter field current as required to maintain a constant predeterminedvolt ageat the load See Voltage Regulator Manual No TM 232 c...

Page 64: ... function in 4 seconds NOTE All times are plus or minus 25 and are nonadjustable e Rectifier A diode bridge rectifier 5 receives 400 Hz AC from phaseC of the gen erator output and converts it to a pulsating direct current for energization of the loadcontactor holding coil only This DC coil holding circuit is controlled indirectly by controlling the 400 Hz AC to the rectifier The ground circuit for...

Page 65: ...power to an aircraft 7 Transformer Rectifiers Optional See l 3 Fig 4 for illustration The generator set maybeequippedwith one or two T Rs transformer rectifiers depending upon the optional equipmentordered Both the 28 5 V DC T R supplied under Variation 1 and the 112 V DC T R supplied as Variation 2 are coveredby separatemanuals which are included in Chapter 8 when applicable 8 Test Box Optional T...

Page 66: ...TOR DIVISION HOWRT BROTHERS COMPAN OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 1 Test box 2 Cable 3 Plug connector Test BoxAssembly Optional Figure 11 _ ___ A act 30 73 _ ...

Page 67: ...ter After the voltmeter is connectedand selector switch positioned the test circuit is closed by pressing the pushbuttonswitch A voltage value maythen be observed on the voltmeter This arrangementpreventsenergization of test circuitry and equipmentfor extendedperiods and allows the operatorto reset and adjust the voltmeter without disconnecting it from the box For operatinginstructions see Sect l ...

Page 68: ...l l Page32 HOBART 8 z QD MOTOR GENERATOR DlVlSlON 3 HOBART BROTHERS COMPANY B s G OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPE LLED GENERATOR SET SPEC N 0 5381A Ott 30 73 ...

Page 69: ...pect the floor or ground surface under the unit for signs of leakage If leaks are found service by tightening hose clamps tube fittings etc as required D Check the following for sufficient quantity 1 Fuel Check fuel quantity as indicated by fuel gage See l l Fig 5 item 1 Engine control switch 2 must be ON Fill tank as required with No 2 dieseI fueI The fuel tank cap is on the right side of the uni...

Page 70: ...c Check transmission rear axle and transfer case lubricant levels 3 Lubrication Lubricate the equipment in accordancewith instructions in Section 2 2 as required 4 Installing Output Cable Units are generally shippedwithout generator to aircraft cables A Three phase AC Output Cable Installation Typical The output terminal panel is locatedbehind and below the seat on the self propelled unit see Fig ...

Page 71: ...at least a 3 8 inch diametermounting hole Mount ing hole in small leads E and F should be at least l 4 inch diameter 4 Push approximately l 1 2 feet of cable through the hole so that cableends will easily reach the terminal panel 5 Work through the opening behind the seat backto attach the cableterminals to the output terminal panel Each terminal stud is identified by an identifica tion plate Each...

Page 72: ...o damage the cable insulation 7 Removethe woodenblock from the plug box see Fig 3 Coil the cable into the cable box and place the cable plug connector in the plug box NOTE a Plug box maybe locatedoutside the cable box on someunits b When an output cable is not supplied with the generator set a woodenblock is placedin the plug box at the factory to allow the machineto be operatedin DRIVE modeuntil ...

Page 73: ...AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A E F C B A N Output Terminals view from top seat removed Typical Figure 2 I Cable clamps n IT i mP jf i cj 0 CJ 9h h I 1 I s 111 o _ Output cable plug box Opening for Output Cable Typical Figure 3 ...

Page 74: ... BROTHERS COMPw4I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC N 0 5381A T R Output Cable installation Figure 4 112 V DC Plug Box T R Cable Plug Boxes F igure 5 l 2 _ ______ ___ Page6 _ _ ...

Page 75: ...perating the Unit A Prestart Inspection 1 Be sure fuel shutoff valve is OPEN The valve is locatedat the fuel tank outlet see l l Fig 3 item 14 Turn switch Fig 1 item 2 ON and observefuel gage l then turn switch OFF Make certain of sufficient fuel to completethe job to be done The engine will require approximately 6 6 gallons of fuel per hour under full load 2 Be sure the gearshift lever Fig 3 item...

Page 76: ...ting light 13 Power module 14 Generator control tray 15 Protective relay tray 16 17 18 19 20 21 22 23 24 25 26 27 Voltage regulator tray Load contactor control switch TerminaI board Test receptacle connector Operating mode generate drive control switch Instrument and marker light fuse 20 A Headlight fuse Instrument light switch Excitation deenergization relay mountedon rear of panel Capacitor 6 8 ...

Page 77: ...kitch 35y GENERATOR CONTROL TRAY Fault indicating light 5 Load con tactor operating system fuse Protective monitor system fuse Protective monitor system reset switch Test bank switch Rate and gain adjustments Line drop compensation switch Cable size compensation l diustment Cable length compensation adiustment instruct ion plate Voltage adjusting rheostat 28 36 37 38 PROTECTIVE RELAY TRAY VOLTAGE ...

Page 78: ...start switch 2 in START position The green light 9 should glow to indicate power is available to the engine protective circuit and fuel shut off valve 5 Pressstart switch button 5 to crank the engine Release start switch as soon as engine starts Releaseengine control switch 2 as soon as oil pressurereaches 12 poundsor more CAUTION a IF THE ENGINE FAILS TO START WITH IN 30 SECONDS RELEASE THE START...

Page 79: ...aid for use The starting aid is shipped in a safe condition and is not operableuntil assembled Assembleas follows WARN IN G STARTING FLUID IS EXTREMELY FLAMMABLE IT IS UNDER PRESSURE USE CAUTION WHEN HANDLING AVOID CONTACT WITH SKIN AND AVOID BREATHING VAPOR a Loosen clampnuts 1 Fig 2 and slide the cylinder 2 upwardsufficiently to removeprotective cap 3 and plug 4 b Use opener 6 to removecylinder ...

Page 80: ...portion of instructions we shall identify the self propelled unit as a vehicle Operation of the vehicle is similar to operation of a conventional truck with three speed mechanicaltransmission All controls are conveniently located in approximatelythe samepositions that they are found on an ordinary truck or passengercar see Fig 3 The operator should familiarize himself with the steering and perform...

Page 81: ... The gen drive switch Fig 1 item 20 must be in DRIVE position d Depressclutch pedal Fig 3 item 9 fully e Select starting gear with lever 5 An instruction plate with shift pattern is locatedon the left panel abovethe steering column NOTE Becauseof low final gear reduction 9 4 to l it is not necessaryto start the vehicle in 1st gear CAUTION MAKE CERTAIN THE OPERATING AREA IS CLEAR BEFORE MOVING THE ...

Page 82: ...TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 1 Steering wheeI 2 Horn button 3 Spotlight when furnished 4 Control box see Figure 1 5 Gearshift lever 6 Parking brake lever 7 Accelerator pedal 8 Service brake pedal 9 Clutch pedal Driver s CompartmentControls Typical Figure 3 J 3 Page 8 _ _ __ _ Ott 30 73 _ __ _ ...

Page 83: ... in NEUTRAL position and apply parking brake d Place engine control switch in OFF position to stop the engine E Preparation for Power Delivery Normal Automatic Voltage Control The following are power delivery preparation proceduresto be followed after the engine is started 1 Check and position switches and controls see Fig 1 a Loosenfasteners and pull generator control tray 14 outward Place automa...

Page 84: ...ased and no fault lights are ON it indicates that 28 5 V DC holding current is not being supplied from the aircraft to the plug interlock re lay Correct the condition and again operatethe loadcontactor con trol switch 17 as above 5 It is recommended that the operator checkoutput voltage and current in each of the three phasesearly in the power delivery run Use the meter switch 34 to select the pha...

Page 85: ...ions I Discontinue Power Delivery 1 Place the load contactor switch 17 in OFF position Green light 12 should go OFF immediatelyto indicate that the loadcontactor has openedand power is no longer being delivered to the aircraft 2 Disconnect output cable at aircraft Stow cable and place plug connector in plug box WARNING NEVER DISCONNECT THE OUTPUT CABLE WHILE POWER IS BEING DELIVERED 3 Place operat...

Page 86: ...or set for power delivery the sameas preparation for 400 Hz use except DO NOT connect400 Hz output cable to the aircraft _ _ __ _ CAUTION BOTH AC AND DC OiTPUTS MU E OPERATED AT THE SAME TIME REFER TO PARA 6 ___ _ IT _ __ __ 112 V DC Transformer Rectifier 28 5 V DC Transformer Rectifier Transformer Rectifiers Typical Installation Figure 4 __ __ _ __ _ __ ____ _ _ _ _ _____ Ott 30 73 L Rev ised Jun...

Page 87: ...by momentarily holding contactor control switch 8 in top ON position until green light 7 glows Release switch and allow it to return to center ON position 6 Check to be certain fans are running 7 Observevoltmeter 3 If voltage is not 28 5 DC openthe control panel and use rheostat 1 Fig 6 locatedon the line drop and current limiting module 4 to adjust Loosen locknut 2 and turn adjusting screw CLOCK ...

Page 88: ...ent limiting rheostat 12 6 DC ammeter 13 7 Contactor ON indicating light 14 Contactor control switch Current limiting control switch Fuse 2 A 115 V AC circuit Fuse 2 A 12 V DC circuit Light SWitch Hinge PaneI 28 5 V DC T R Control Panel Figure 5 1 Rheostat 3 Screw 2 Nut 4 Line drop and current limiting madule __ 28 5 V DC T R Output Voltage Adjustment _ Figure 6 _ l 3 Ott 30 73 _ ____ _ _ _ _ ___ ...

Page 89: ... loadedconditions the voltmeter should indicate approximately 100 V DC The T R should be loadedto no morethan 400 A for continuous operation The 112 V DC T R doesnot have current limiting nor line drop capability Remember that an overload overvoltage or overheating will causethe load contactor to disconnectthe loadand turn OFF the green indicating light 6 Fig 7 If shut down occurs check for condit...

Page 90: ...B Connect the test prods of an accurate voltmeter at the test jacks 3 and 4 Fig 8 Test iacks are color coded RED indicates POSITIVE BLACK indicates NEGATIVE C Locate the componentor circuit to be tested in the DESCRIPTION column cn the instruction plate and set the selector switch 1 Fig 8 to the number indicated oppositethe description D Note the normal voltage value and kind of current AC or DC t...

Page 91: ...4 Negative test iack black 5 lnstructicn plate Test Box Operating Controls Figure 8 F Press the pushbuttonswitch 2 and observevoltage indicated by the voltmeter Compareto normal voltage indicated in VOLTAGE column G Releasepushbuttonswitch H Repeat steps A thru G for other tests as required J When tests are completed disconnect the test equipment replace test connector cover _ _pet 30 73 __ l 3 __...

Page 92: ...ollowing rules and precautions Place DC current limiting switch in OFF position This will eliminate the soft start feature of the T R but will prevent AC voltage from dropping low enoughto trip the AC loadcontactor Line drop compensation on the T R must be REDUCED or turned DOWN completely to prevent the AC loadcontactor from being openedby an overvoltage condition Readjust AC line drop compensati...

Page 93: ...UBJECT CHAPTER SECTION Maintenance inspection Check 2 l PAGE 1 GeneraI Maintenance Schedule GeneraI 1 Maintenance Schedule Check Sheet Time IntervaIs Identification of Interval Periods Inspection Check GeneraI 5 AR Checksand Operations Electrical system 12 V DC 5 Drive train Brakes A Checksand Operations Check crankcaseoil level 5 5 ...

Page 94: ... indicator Checkexhaust system Electrical 12 V DC system Check all lights Checka Iternator charging rate Electrical 115 V AC system Monitoring instruments Indicating lights Output cable plug connector B Checksand Operations Engine Changecrankcaseoil Changeoil filter elements Checkand record oil pressure Alternator andstarter lubrication Injectors and vaIves Electrical 12 V DC system Battery electr...

Page 95: ...ssis C Checksand Operations Engine Electrical 12 V DC system E lectrical 115 V AC system Brakes Pedal adjustment Brake shoe adjustment CHAPTER SECTION 2 l D Checksand Operations Engine E Checksand Operations Engine Steamclean engine Clean fuel pumpscreen Check vibration damper Adjust injectors and valves Check fuel man ifold pressure act 30 73 _ PAGE 10 10 10 10 10 11 11 11 12 12 12 12 12 12 13 13...

Page 96: ...ER SECTION PAGE Lubricate water pump 2 l 14 Turbocharger 14 Lubricate fan hub 14 Check alternator and cranking motor 15 Drive train 15 Steering 15 Chassis 15 F Checksand Operations 16 Engine 16 SeasonalMaintenance Checks Engine 17 Maintenance Procedures 2 2 1 GeneraI 1 Lubricatipn 1 GeneraI 1 AC Generator 1 Generator Controls 1 Engine Lubrication 1 Lubrication schedule 1 Oil specification 4 Oil vi...

Page 97: ...UBJECT CHAPTER SECTION PAGE Changingoil filter element 2 2 6 Engine Accessories Lubrication 8 Alternator 8 Starter Water pump Fan hub Chassis Lubrication GeneraI CleanIiness Grease application Transmission Rear Axle and Steering Lubrication GeneraI Transmission Rear axle Transfer case Steering gear 13 Servicing the Air Cleaner Cartr idgeRemova I 13 13 Cartridge lnstallation 13 Engine FueI Qua1ity ...

Page 98: ...Changefuel filter elements Fuel PumpService CleanfueI pumpscreen Priming the fueI pump Cold Weather Starting Aid Check fluid content of cylinder Check valve and fuel delivery line Engine Cooling System 18 General 18 Radiator Cap 18 General 18 Remova I Installation Coolant Warm Weather Operation No Antifreeze Cold Weather Operation Using Antifreeze General Selecting antifreeze Checking antifreeze s...

Page 99: ...ning the Cooling System 2 2 PAGE 20 Cleaning the Cooling System 21 Cleaning the Radiator Core 21 Filling the Cooling System 21 GeneraI 21 Inspection Check 21 lnstalI coolant Corrosion Resistor Service Changeperiod 23 Selecting the properelement Changingelement 23 Thermostat 25 Battery Service GeneraI 25 Battery Location andAccessibility Battery Care 25 Liquid LeveI 27 Testing the Battery 27 Test w...

Page 100: ...Adjustment Checking Belt Tension Check and Adjust Alternator Belt Check and Adjust Fan Belts Replace Belts Generator Maintenance Cleaning Adjustment Tire Inflation Adjustment Test GeneraI Testing the Generator Set Preoperational Test Procedures Operational Test Procedures Diode Test Generator andExciter Test CHAPTER SECTION PAGE 2 2 28 29 30 30 30 30 31 32 32 34 34 34 34 1 1 1 1 3 13 14 2 3 Engine...

Page 101: ...ngth and size compensation rheostats Adjust damp and rate potentiometers Basic Engine Adiustmen ts Exhaust valve adjustment Exhaust valve crosshead adiustment Fue I injector timing adiustment Engine idle speed adjustment Engine speed limiting adjustment Engine Accessories Adjustment Electric Hydraulic Governor System Adjustment Governor I in kage adjustment Magnetic pickup adjustment Hydraulic act...

Page 102: ... Brake Adjustment Service Brake Ad justmen t Bleeding Hydraulic Brakes Manua I method Automatic pressure method Gearsh ift Micro Switch Ad justmen t CHAPTER FIGURE SECTION NUMBER 2 l 1 2 l 2 2 l 3 2 l 4 2 2 1 2 2 2 2 2 3 2 2 4 2 2 5 2 2 6 2 2 7 2 c Page 10 LIST OF ILLUSTRATIONS TITLE PAGE NO Maintenance Schedule 2 thru 4 Vibration Damper Hub 14 Lamp Identification Chart 18 Fuse Chart 19 Lubricatio...

Page 103: ... Doors 26 Battery lnstal lation 28 Master Brake Cylinder 29 Belt Deflection Tension Check Chart 30 Be It Deflection Check 31 Alternator Belt Adjustment 33 Fan Belt Adjustment 33 Control Box Interior View Operating Controls and Instruments Sheets 1 and 2 Term ina I Boards Generator and Exciter Stator Test Excitation Resistors Voltage Regulator Adjustments Voltage Regulator Damping Adjustments Engin...

Page 104: ...FOBART I z QD gMOTOR GENERATOR DIVISION p c z HOBART EmOTHERS COMPANY B B OPERATION MAINlENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 2 o Ott 30 73 Page 12 ...

Page 105: ...s a guide for establishment of a schedule to meet the customer s maintenance requirements for his specific operation C Time Intervals 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 may be reached long before the three months calendar period The...

Page 106: ... pressure X Lubricate electrical equipment X Change fuel filter elements X Clean radiator core externa I X Check governor linkage X Check fuel pump seals X Change corrosion resistor element X Check adiust V belt tension X Tighten man ifold nuts X Check turbocharger for leaks X Tighten turbocharger mountings X Check fan hub and drive pulley X Steam clean engine X Clean fue I pump screen and magnet ...

Page 107: ...electric connections Check thermostats and seals Check starting aid ELECTRICAL 12 V DC System Spring and Fall Spring and Fall Spring and Fall Spring and Fal I Fa I I Fall I X X X X Check battery and fluid level X Clean battery terminals X X Check all lights X Check charging rate X Check wiring and connections X 400 Hz System Check output cable and connectors Check voltmeter ammeter and frequency m...

Page 108: ...e universal joints and slip yoke x Lubricate clutch linkage X Check and adjust clutch linkage X X Check universal joints and rear axle x BRAKES Check brake fluid level Check and adjust brakes Lubricate linkage STEER IN G x X X X Check lubricant level in gear box X Lubricate SEE LUBRICATION CHART Adjust steering gear X X CHASSIS Check tire inflation X Check and adjust front wheel bearings X X Inspe...

Page 109: ...serve the indicator when the engine is stopped When the flag is locked in full view change the cartridge See 2 2 Para 3 b Check engine blow by as required if the engine lacks power or uses oil excessively Refer to the Cummins Operation and Maintenance Manual c Tighten manifold muffler and exhaust pipe attaching hardware nuts and capscrews as required d Tighten all attaching hardware as required 2 ...

Page 110: ...ce a Check steering linkage for looseness Correct as required by adjustment or replacement of parts b Check gear box for excessive lash by turning steering wheel while observing front wheels Any movement of the steering wheel should cause a move ment of the front wheels Adjust gear box as required 6 Chassis a Front whee I bearings Check front whee I bearings when the vehicle is raised for service ...

Page 111: ...g l 8 inch pipe plug in side of oil pan Refer to page 2 2 of Cummins Operation and Maintenance Manual b Drain fuel filter The I ife of the fue I pump and in jectors can be extended if the operator drains about a cup of fuel from each of the fuel filter elements to remove water and sediment before starting the engine each day 1 Provide a container for catching drained fuel 2 Remove the hex head pip...

Page 112: ...exhaust system Visually inspect muffler and exhaust pipes for rust and signs of approaching failure Listen for any gasket or joint leaks CAUTION A LEAKING AND DEFECTIVE EXHAUST SYSTEM COULD BE A FIRE HAZARD 2 E lectrical 12 V DC system a Check all lights Check all indicating lights to be sure they will operate when they should Check all vehicular lights If any light fails to operate check both the...

Page 113: ... 2 2 Para 2 D 5 for details c Check and record oil pressure After each oil change check and record oil pressure at idle speed after oil has warmed to approximately 140 deg F Record oil pressure under identical conditions at each oil change interval A comparison of pres sure at idle speed with previous readings will give an indication of pro gressive wear of oil pump bearings shafts etc Investigate...

Page 114: ...ls and clean if necessary in accordance with Para 3 B 2 a above 3 Drive train Check lubricant level in transmission rear axle and transfer case Ref 2 2 Para 2 G Lubricate linkage etc in accordance with instructions under 2 2 Para 2 F and Fig 1 4 Brakes a Check master cylinder fluid level b Lubricate service brake and parking brake linkage See 2 2 Fig 1 5 Steering Lubricate steering linkage and gea...

Page 115: ... plugs are sealed after final pump adjustment Check these seals regularly to detect any tampering or un authorized fuel pump setting as soon as possible 4 Change corrosion resistor element The initial service life of a corrosion resistor element is 100 hours on a new or re bui It engine or after complete change of coolant Change period thereafter is 400 hours See 2 2 Para 5 J for service instructi...

Page 116: ...free trave I of brake pedal Free trave I of the pedal before it starts to move the piston in the master cylinder should be approximately l 4 inch This travel may be checked by moving the pedal with the hand If adjustment is required see 2 3 Para 4 B 1 thru 8 b Brake shoe adiustment Check adjustment by depressing brake pedal with the foot If the pedal can be depressed over halfway to the floorboard...

Page 117: ...TIONS to be observed CAUTION 1 2 WARN IN G 1 DO NOT USE A FLAMMABLE SOLVENT 2 3 IF A CLEANING COMPOUND IS USED SELECT ONE WHICH IS FREE FROM ACID AND WHICH WILL NOT REMOVE PAINT PROTECT OR REMOVE ALL ELECTRICAL ACCESSORIES SUCH AS VOLTAGE REGULATOR ALTERNATOR AND ELECTRICAL WIRING SEAL ALL OPENINGS EXERCISE CARE TO AVOID IN JURY AND DAMAGE TO EYES AND SKIN DO NOT USE MINERAL SPIRITS OR SOLVENTS ON...

Page 118: ...ve adjusting instructions Alignment marks Vibration Damper Hub Figure 2 e Check fuel manifold pressure This check is necessary only if there is an apparent or suspected loss of power Refer to Cummins Operation and Maintenance Manual for tools required and test instruct ions f Lubricate water pump See 2 2 Para 2 E 3 for water pump lubrication instructions g Turbocharger Clean turbocharger and check...

Page 119: ...d of the vehicle so the front whee Is are off the floor b Turn the steering wheel while observing the front wheels Any movement of the steering wheel should result in a movement of the front wheels c If fron w ee s t h I do not respond at once to a movement of the steering whee I adjust steering gear 4 Chassis a Front whee I bearings Check front wheel bearings as follows aa Raise front end of vehi...

Page 120: ...vices Complete overhaul facilities should be available If the user performs this operation in his own shop a shop manual should be procured from Cummins Engine Company a Clean and calibrate 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 o...

Page 121: ...ecessary See 2 2 Para 5 G and H for cooling system maintenance 3 Check all hoses In addition to daily checks of hoses for leaks inspect hoses thoroughly each time the cooling system is cleaned and serviced a Inspect for signs of deterioration and collapse b Inspect for cracks and cuts c Inspect for cutting and deformation caused by hose clamps d Replace hoses as required 4 Check and adjust V belts...

Page 122: ... 12 L I Trade No T 3 Lamp Industry 1034 Trade No Lamp Industry 1073 Trade No Clearance Lights Front canopy hous Lamp Industry ing and seat hous Trade N o ing 57 Instrument Panel Control box and Lamp Industry 67 Lights instrument pane I Trade No Engine On Indicat Control box instru Lamp Industry 1815 ing Light ment pane I Trade No Contactor CLOSED Control box instru Lamp Industry NE 51H Indicating ...

Page 123: ...gnal Flasher Contactor Circuit Locat ion Control Box Control Box Rear of Control Box Control Box Protective Relay Tray Voltage Regula tor Flasher Signal Switch Protective Relay Tray Illustration Section l l Fig 5 item 22 Section l l Fig 5 item 21 NONE Section l l Fig 5 item 10 Section l l Fig 7 item 14 Section l l Fig 9 item 12 NONE Section l l Fig 7 item 22 Size 20A 20 A 20A 10 A 2A 5A 14 A 2A AG...

Page 124: ...rOBART 8 t QQ MOTOR GENERATOR DIVISION HOBART BROTHERS COMPANY 0 G B q d OPERATION MAINTENANCE AN D OVERHAUL MAN UAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 2 l Page 20 ...

Page 125: ...cation The rotor is supported by two ball bearings which are lubricated and sealed at the factory for lifetime main tenance free operation It is recommended that bearings be replaced after 5000 hours service Complete replacement instructions are included in Chapter 6 C Generator Controls Generator controls and instruments require no periodic lubrication A few drops of oil may be required on door h...

Page 126: ...teering shaft io ints 61 Clutch brake shaft Bl Clutch shaft bearing Bl Shackle bolt Bl Master cy I B6 Differential B3 Shackle bolt 81 Transfer case 83 82 Bl 83 Bl Shackle bolt 82 El Bl Shackle bolt Fan hub Water pump Steering knuckle Wheel bearing Tie rod end Corrosion resistor i Shackle bolt Oil filter Fuel filter Clutch bearing Clutch shaft Transmission i Brake I inkage i Universal joints j Shac...

Page 127: ...3545 Federa I VV B 680 Lubricants and Fluids Chart Figure 2 Notes Sinclair Litholene Industrial No 2 Mobil Mobilplex 47 or equivalent Must contain ash but no more than 1 85 Texaco Multigear EP 90 Humble Humblegear GP 90 Sinclair Extra Duty Gear Lube 90 or equivalent Whee I bearings Excludes those of sodium or soda soap thickeners Heavy duty brake fluid I I Time lnterva I Symbol Hours AR As Reauire...

Page 128: ... is identified by an API American Petroleum Institute classification designation The man ufacturer does not recommend any specific brand of lubricating oil The use of quality lubricating oil combined with appropriate lubricating oil drain and filter change intervals are important factors in extending engine life Oil recommended for the mode I V 504 C210 engine in this application is API Class CC w...

Page 129: ...l drain readily CAUTION DO NOT USE SOLVENTS AS FLUSHING OILS IN RUNNING ENGINES Change the oil filter element each time the oil is changed Change oil as follows a Provide a container for catching used oil Capacity must be greater than 24 quarts b Remove drain plug located in oil pan c Whileoil is draining proceed to change the oil filter element See Para 2 D 5 bel ow for instructions d Clean the d...

Page 130: ...rod DO NOT OVERFILL 5 Changing oil filter element a Provide a container for catching used oil b Remove drain plug 14 Fig 6 if used in your filter NOTE Oil will drain faster if the center bolt 1 Fig 6 is loosened sufficiently to allow air to enter at the top of the shell 4 c Completely unscrew center bolt 1 and remove the bolt and associated parts 2 through 11 as an assembly d Withdraw filter eleme...

Page 131: ...PROPELLED GENERATOR SET SPEC NO 5381A 1 Center bolt 8 Element support 2 Bolt gasket 9 Spacer 3 Plate 10 Retainer 4 Shell snap ring 11 Element cartridge 5 Sealing ring 12 Head 6 Washer 13 Spring 7 Seal 14 Plug not used on all filters Oil Filter Exploded View Figure 6 _ _ Ott 30 73 __ ___ 2r2_ Page 7 ...

Page 132: ...ell assembly to be sure seals are in place i Install a new element in the shell and on the support 11 i Carefully position a new seal ring 5 in the filter head 12 k Install plug 14 in shell and fill shell with new clean oil same as used in crankcase I Carefully position shell and bolt assembly on head and thread bolt into head Tighten bolt to 25 to 35 foot pounds m Check crankcase oil level n Star...

Page 133: ... remove pipe plug see Fig 7 and replace with a pressure type lubrication fitting Lubricate each 1200 hours with approximately 1 tablespoon of MIL G 3545 or equivalent grease CAUTION DO NOT OVERLUBRICATE PUMP SEALS WILL BE DAMAGED BY OVER LUBR ICATION Fan hub Lubricant in the fan hub should be checked after each 1200 hours of operation or yearly The fan hub on this particular engine is lubricated w...

Page 134: ...of MIL G 3545 or equivalent grease CAUTlON DO NOT OVERLUBRICATE d Remove grease fitting and install pipe plug F Chassis Lubrication 1 General Most chassis lubrication points such as spring shackle bolts tie rod ends etc are equipped with high pressure lubrication fittings 2 Clean I iness It is important that all grease fittings be cleaned before attaching a grease gun or applicator Use a clean clo...

Page 135: ...ion Rear Axle and Steering Gear Lubrication See Fig 9 1 General A common multi purpose gear lubricant is used in each of the above units Since mobileoperation of the self propelled unit is very limited it is unlikely that the lubricant will require changing except after repair or overhaul How ever it is important to check the lubricant level regularly in accordance with Lubrication Chart Figure 1 ...

Page 136: ... UAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Rear axle differential Rear axle transfer case filler plug filler plug Transmission filler plug Magnetic dra n plug Steering gear filler plug Rear Axle Transmission and Steering Gear Grease Filler Plugs II__ _ _ _Figure 9 22 _ Page 12 _ _ Ott 30 73 _ _ I_ ...

Page 137: ...hedule for changing the filter cartridge cannot be determined because of varying operating con ditions Change the filter cartridge when the red indicator flag reaches the top of the viewing chamber and locks in that position see l 1 Fig 4 Change the cartridge as follows A Cartridge Removal See Fig 10 1 Loosen the four wing nuts l unlatch clamps 3 and swing the tee bolts 4 outward away from the moi...

Page 138: ...UMSTANCES SHOULD THE CARTRIDGE BE POUNDED OR STRUCK IN THE CENTER TO EFFECT A SEAL 2 Lock the cartridge in place by installing the moisture eliminator 7 and clamp ing in place with the four tee bolts clamps and wing nuts 3 Wing nuts must be tightened evenly crisscrossing from corner to corner After tightening the nuts as tight as possible by hand tighten them two full turns with a small wrench NOT...

Page 139: ...11 1 Check fuel filter restriction The most accurate method of determining filter change requirement and deter mining change period is by measuring the fuel restriction As foreign material accumulates in filter elements fuel flow becomes more and more restricted and vacuum pressure in the fuel inlet line between the filter and pump rises Check the degree of filter restriction as follows a Connect ...

Page 140: ...H MECHAN ICAL TOOLS MAY DISTORT OR CRACK FILTER HEAD C Fve I Pump Service 1 Clean fue I pump screen The fuel pump should be serviced after each 1200 hours of operation by cleaning the filter screen a Carefully clean the top of the fuel pump so that no dirt may enter the pump when cap 2 Fig 12 is removed b Loosen and remove cap 2 and 0 ring Lift out spring 4 and filter screen 5 assembly Observe spr...

Page 141: ...h hole down Install spring 4 on top of screen assembly f Install cap 2 and 0 ring and tighten to 20 to 25 foot pounds 2 Priming the fue I pump The easiest and best way to prime the fuel system is to prime the fue I pump 4 09 4 4 Thoroughly clean pipe plug 4 Fig 12 and the area around it Remove pipe plug 3 Fill the pump with CLEAN fuel oil CAUTION DO NOT ALLOW DIRT TO ENTER THE PUMP USE CLEAN FUNNE...

Page 142: ...d be delivered to the c 10th WARN ING EXERCISE CARE IN PERFORMING ANY CHECK OF THE STARTING AID SYSTEM STARTING FLUID IS EXTREMELY FLAMMABLE 5 Engine Cooling System A General Cooling system service requires more than maintaining the proper coolant level in the radiator and protecting the system against freezing Water should be clean and free of any corrosive chemicals such as chloride sulphates an...

Page 143: ...olant The preparation and maintenance of the coolant solution is so important to engine life and is so completely covered in the engine manufacturer s manual Operation and Maintenance Manual that we will not attempt to condense or explain it here For information regarding coolant specifications testing equipment anti freeze etc refer to Cummins Operation and Maintenance Manual or consult the local...

Page 144: ... local Cummins Distributor for a list of compatible anti freezes CAUTION DO NOT USE SOLUBLE OIL IN THE COOLING SYSTEM 3 Checking antifreeze solution Check the solution with a reliable tester when in doubt about antifreeze pro tection NOTE a When testing be sure coolant is at operating temperature b Follow manufacturer s instructions cn tester F Draining the Cooling System To drain the cooling syst...

Page 145: ... not to injure the tubes or to break the bond between fins and tubes NOTE Direct the air in a reverse direction to normal air flow Normal flow on this installation is from the engine compartment outward I Filling the Cooling System 1 General The corrosion resistor element should be changed each time coolant is changed Before installing coolant check and inspect the system 2 Inspection Check a Chec...

Page 146: ...E AND OVERHAUL MAN UAi TM 240A SELF PROPEilID GENERATOR SET SPEC NO 5381A 1 RADIATOR DRAIN VALVE COOLANT DRAIN LEFT BANDY BtW JD OIL COOLER END OF OIL COOLER COOLANT DRAINS RIGHT SIDE Coolant Drains Typica I i _ _ __ _ Figcct 13 _ 2 2 I Ott 30 73 j _ _ _ _ _ ___ __ l___ l __ _ _ _ _ _ __ ge22 __ __ I i ...

Page 147: ...ating the cooling system contents and date serviced to the radiator filler neck J Corrosion Resistor Service 1 2 3 Change period The normal change period for the corrosion resistor element is 400 hours how ever the initial service life of an element on a new or rebuilt engine is 100 hours Change the element after the first 100 hours of operation and after each 400 hours of operation thereafter NOT...

Page 148: ...kwasher 8 Spring 3 Cover 9 Sump plate 4 Gasket 10 Body 5 Upper plate 11 Plug 6 Element Corrosion Resistor Figure 14 e Remove and discard element 6 f Remove magnesium plate 7 and lift spring 8 from housing g Polish plates If less than half of metal surface can be exposed by polishing install new plates h Clean housing 10 r __ __ _ 2 2 ___ __ ___ _ act 30 73 P g 24 __ ...

Page 149: ...r recommended test instructions 6 Battery Service A General Twelve volt DC power is supplied by two pairs of 6 V batteries four batteries used Each pair is connected in series to produce 12 V DC The two pairs are connected in parallel to provide maximum amperage for engine cranking The 12 V DC system provides power for operation of the engine electrical system governor system 400 Hz generator prot...

Page 150: ...ain stored batteries in a charged Be sure batteries are fastened securely vibration FASTENER 15 condition in the vehicle to avoid damage from Maintain battery fluid at proper level Keep battery terminal posts and lead connectors clean WARNING a BATTERIES GIVE OFF HIGHLY INFLAMMABLE GAS NEVER ALLOW SPARKS OR OPEN FLAME NEAR THE BATTERIES b AVOID SPILLING ELECTROLYTE ON HANDS OR CLOTHING 2 2 __ __ a...

Page 151: ...ral Tests are made on a battery to determine the state of charge and also the con dition The results of these tests show that the battery is good needs recharg ing ar must be replaced If a battery has failed is low in charge or requires water frequently the reason for the condition must be found and corrected Visually inspect the battery before testing to determine if it has been damaged The prese...

Page 152: ...the acceptacle voltage value test each cell with the hydrometer If the difference in specific gravity readings between any two cells is 50 points 0 050 or more the battery is not satisfactory for service and should be replaced F Cleaning the Battery see Fig 16 Disconnect battery lead connectors from battery posts Brighten terminal and post surfaces with steel wool a wire brush or special terminal ...

Page 153: ...r cap Remove cap D Visually check brake fluid level The proper level of fluid in the reservoir is approximately 3 8 inch below the bottom edge of the filler hole This space is required to prevent surge losses through the air vent in the filler cap E Add only clean good quality heavy duty brake fluid Specification Federal VV B 680 or equiva lent is recommended CAUTION EXERCISE CARE TO PREVENT DIRT ...

Page 154: ...in operating position before checking be It tension C Checking Belt Tension Check belt tension every 400 hours or each 6 months whichever comes first A belt which is too tight is destructive to bearings of the driven part A loose belt will slip and cause inefficient operation of the part being driven as well as wear to the belt Deflection per foot Belt Width 0 3048 m of span l 2 in 12 700 mm Gener...

Page 155: ...ed manually by depressing a belt with the index finger to determine the amount of belt deflection obtained when a force of approximately 13 pounds is applied at a point halfway between pulleys see Fig 19 See Fig 18 for belt deflection tension checkchart Check and Adjust Alternator Belt 1 Check belt tension see Para 8 C above 2 If belt requires adjustment loosen adjusting bracket capscrew 3 Fig 20 ...

Page 156: ...rews and recheck belt tension 5 Repeat steps 2 through 4 as required until belt tension is correctly adjusted F Replace Belts 1 2 3 4 2 2 Page 32 Always shorten the distance between pulley centers so belt s can be installed without force CAUTION NEVER ROLL A BELT ON OVER A PULLEY AND NEVER USE A PRY BAR TO IN STALL A BELT When two or more belts are used to drive a component replace belts with a ma...

Page 157: ... UAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A n I f Alternator Be It Adiustment Figure 20 1 Adjusting screw 2 Fan pulley 1 Alternator 2 Adjusting bracket 3 Capscrew Fan Belt Adjustment _ _ _ ______ Figure 21 _ __ __ _I _ ioc 30 z3 _ _ ____ _ _ _ _ ____ 2 2 Page 33 ____ _ _ ...

Page 158: ...The unit is brushless and bearings are permanently lubricated and sealed A Cleaning The generator may be cleaned by careful use of compressed air and or a good SAFE commercia I cleaner Steam cleaning of the generator is no longer recommended because the use of steam and harsh chemical compounds may result in damage to insulation and generator components CAUTION BE SURE THE UN IT IS COMPLETELY DRY ...

Page 159: ...l boards which may be used for testing are located in this area Ref Fig 3 2 Connect cables from the generator output terminals to a load bank Use cables of the same size and length as those to be used in service see l 2 Para 4 A Be certain that all connections are secure and the generator N cable is grounded 3 Check engine oil level Oil should be at or near H mark on gage rod 4 Check I b u ricant ...

Page 160: ...5 by pressing lens holders If lights glow fuse 36 and indicating lamps are good 13 Check operation of all vehicular lights 14 Make a general inspection of all wiring and terminals Inspect the equipment to be certain no damage will result from starting the engine 15 At initial start up after generator overhaul or repair flash the exciter field by momentarily applying 12 V DC to the field windings a...

Page 161: ... 3 and identify terminals E 1 and E 2 NOTE Figure 3 illustrates terminal boards and explains method of identifying terminals bb Connect a jumper lead with alligator clips between terminals E 2 and D 14 ground cc Connect another jumper lead to terminal E 8 and MOMENTARILY touch the other end to terminal E l to flash the exciter field CAUTION VERY HIGH AMPERAGE IS AVAILABLE AT TERMINAL E 8 HANDLE WI...

Page 162: ...ight 13 Power module 14 Generator control tray 15 Protective re lay tray 16 17 18 19 20 21 22 23 24 25 26 27 Voltage regulator tray Load contactor control switch Terminal board Test receptacle connector Operating mode generate drive control switch Instrument and marker light fuse 20 A Head I ig ht fuse Instrument light switch Excitation deenergization relay mounted on rear of panel Capacitor 6 8 M...

Page 163: ... 36 Fault indicating light 5 37 Load contactor operating system fuse 38 Protective monitor system fuse 39 Protective monitor system reset switch 40 Test bank switch 41 Rate and gain adjustments 42 Line drop compensation switch 43 Cable siie compensation adjustment 44 Cable length compensation adjustment 45 Instruction plate 46 Voltage adjusting rheostat 28 36 37 38 39 PffOTECTlVE RELAY TRAY 43 4 4...

Page 164: ...ified by a number 1 2 3 etc Terminals are numbered from LEFT to RIGHT on horizontally mounted boards and from BOTTOM to TOP on vertically mounted boards Number 1 terminal on each board is indicated on the illustration Any individual terminal may be identified by combining the board identification letter with the terminal number Example Terminal A 8 is the eighth terminal from the LEFT on board A T...

Page 165: ...mid range position Bring the engine up to governed speed and also energize the generator by placing the operating mode switch 20 in GEN position If the engine comes up to governed speed indicated by a near 400 Hz reading on the frequency meter 6 and voltage value appears on the voltmeter 30 it proves that the electric hydraulic governor and excitation deenergization relay circuits are functioning ...

Page 166: ...30 and turn manual control rheostat 31 CLOCKWISE to full clockwise position Maximum voltage should be at least 160 V AC c Observe voltmeter and turn rheostat 31 to full COUNTERCLOCKWISE position Minimum voltage should be 95 V AC or less d Adjust voltage to 115 V AC then return the automatic manual switch to AUTOMATIC position 15 Position load bank switches etc to apply a light load to the generato...

Page 167: ...on This indicates that the load contactor is closed and the plug interlock relay is functioning properly Place test bank switch in ON position and disconnect 24 V DC power source connected in step 21 above Apply l 3 to l 2 90 A to 130 A load at the load bank and allow the unit to run for 15 to 30 minutes Observe operation of all monitoring instruments Increase load bank resistance to apply a full ...

Page 168: ...tion Check operation of the line switch 35 A normal voltage of 115 V AC should be indicated when the switch is in LINE TO NEUTRAL position A voltage of approximately 200 V AC should be indicated when the switch is placed in LINE TO LINE position Check accuracy of frequency meter a Connect a master frequency meter of known accuracy to the frequency meter 29 terminals b Compare meter readings Error ...

Page 169: ...tor rheostat and pressing reset switch 39 39 Check operation of undervoltage 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 between 103 V and 93 V the undervoltage sensing relay Ref l 1 Fig 7 item 5 should function to activate the undervoltage time delay ci...

Page 170: ...rating normally under load reduce generator output frequency by reducing engine speed Use the governed speed setting potentiometer Ref Fig 12 Turn adiusting screw COUNTERCLOCKWISE gradually to reduce engine speed until frequency meter indicates 386 Hz bderfrequency protective relay should not function to open the load con tactor at this frequency Reduce frequency in steps of 1 Hz b If the protecti...

Page 171: ...ibration and for any parts which may have become loosened during the above checks CAUTION S fOP OPERATIONS BEFORE ATTEMPTING TO TIGHTEN PARTS 45 Check 400 H z generator bearings Use a stethoscope or metal sounding rod to listen for unusual noises If using a metal rod place one end on the gen erator housing and hold the other end near the ear Hold the rod with three fingers and use the index finger...

Page 172: ...erator fields may be tested with a Kelvin bridge This is a double bridge type instrument required for the very low resistances encountered in this test It is understood that 0 resistance indicates a SHORT CIRCUITED condition An infinite resistance reading indicates an OPEN CIRCUITED condition See Fig 4 below for resistance values NOTE The equipment should be COLD or at normal ambient temperature w...

Page 173: ...d C of theresistor to increase voltage potential Move the band toward the double wire end E two wires connected to decrease voltage potential c Tighten slider band clamping screw when adjustment is completed 2 Adjust 115 V AC voltage regulator When a voltage regulator is first put into service or when output generator to aircraft cables are changed the regulator may require up to five separate adj...

Page 174: ...e together Switch 4 Fig 6 must be ON Proceed as follows aa Adjust the rheostat 2 to point to the length in feet of output cable being used Various cable lengths are indicated on a plate mounted behind the rheostat knob bb Adj t h us r eostat 3 to point to the size of cable being used Various cable sizes are also indicated on a plate behind the rheostat knob cc With generator running no load check ...

Page 175: ...eostats 2 and 3 slightly to obtain a voltage of 115 V AC or as close to this value as possible Turn knobs CLOCKWISE to INCREASE voltage and COUNTERCLOCKWISE to DECREASE Turn each knob a small amount at a time to determine which rheostat is having the most effect on output voltage and re quires adjustment c Adjust damp and rate potentiometers see Figure 7 See 7 Fig 6 for potentiometers location in ...

Page 176: ...amp 1 Fig 7 adjusting screw CLOCKWISE to improve response Turn COUNTERCLOCKWISE to improve STABILITY Gen erally the best adjustment is approximately 3 4 of full CLOCKWISE travel ee Turn the rate 2 adjusting screw to near full COUN IERCLOCKWISE position Turn the screw slowly CLOCKWISE until the voltage output abruptly becomes STEADY Continue turning the screw CLOCKWISE 5 deg to 10 deg past this poi...

Page 177: ...OCKWISE RATE Affects stability ADJUSTING SCREW DIRECTION OF ROTAT ION Regulator will likely be UNSTABLE if adjusting screw is at either limit of adjustment CLOCKWISE or COUNTERCLOCKWISE From a point near full COUNTERCLOCK WISE position turn the screw CLOCKWISE until a point is reached where the voltage regula tor abruptly becomes STEADY Best adjustment for the system is usual ly 5 deg to 10 deg be...

Page 178: ...C2 10 1826 01 2400 RPM 625 to 675 RPM approximately 2640 RPM 1 5 4 8 6 3 7 2 Type PTG Automotive type 45 to 75 PSI 165 to 195 deg F 73 9 to 90 6 deg C Engine Specifications Figure 8 5 Engine speed limiting adjustment The speed limiting adjustment is also set and sealed at the factory Speed should be limited to approximately 2640 RPM If adjustment is required contact your local Cummins Distributor ...

Page 179: ...ber that the weight of the levers 4 and 8 Fig 9 and rod assembly will automatically hold the linkage in FULL SPEED fuel on position when the engine is stopped Check and adjust linkage as follows 4 b 4 4 before adjusting the actuator linkage remove two attaching bolts from the accelerator I inkage Ref Fig 13 and move it away from the actuator so that it cannot possibly interfere with actuator linka...

Page 180: ...ing or interference Re install accelerator linkage removed in step a above and adjust if necessary in accordance with Para 3 F 2 Magnetic pickup adjustment The strength of the magnetic pickup signal to the control box can be weakened if the tip of the pickup is too far from the flywheel ring gear If the pickup is to be removed for any reason or if the signal is weak as indicated by test in Para 2 ...

Page 181: ...5 Ball joint 6 Nut 7 Rod 8 Fuel pump lever I Governor Linkage Adjustment Figure 9 f Back the pickup outward counterclockwise l 2 turn Hold the pickup securely in this position and tighten nut 3 This adjustment will result in a clearance of approximately 0 028 inch between the pickup tip and the flywheel teeth and give an operating AC voltage of 4 V to 8 V at the control box terminals 5 and 6 when ...

Page 182: ... bench test The actuator has one adjustment which determines the voltage values required to correctly position the output shaft and lever throughout its operating range This adjustment is controlled by an adjusting screw 3 Fig ll located in the bottom of the actuator body To test and adjust the actuator on the engine proceed as follows a If accelerator I inkage is not already taken off remove as i...

Page 183: ...ing 5 from turning while loosening or tightening nut 4 or adjusting screw 3 by placing an open end wrench across flats on the bushing 2 If fuel oil pressure and actuator are normal l 4 turn of screw 3 will cause the lever 4 Fig 9 to move from one limit of its ful I trave I range 30 degrees to the other Turning the screw 3 Fig 11 CLOCKWISE in will cause the lever to move downward to FULL FUEL posit...

Page 184: ...ll joint 5 Fig 9 and rod assembly to actuator lever 4 i Connect a voltmeter to actuator input terminals 1 and 2 Fig 11 k Operate the engine at normal governed speed 400 Hz indicated on frequency meter The voltmeter should indicate a voltage of 2 V to 4 V DC on the 12 V DCscale If voltage is not within this range loosen locknut 4 Fig 11 and readjust screw 3 very slightly to obtain a volt age value ...

Page 185: ...ition c Use the adjusting screw in the speed setting potentiometer Fig 12 to adjust engine speed to produce a generator output of exactly 400 Hz 2400 R PM NOTE 1 A very small screwdriver is required for this adjustment Turn the screw CLOCKWISE to IN aEASE engine speed and COUNTERCLOCKWISE to DECREASEspeed 2 This is a 24 turn potentiometer with no stops The adjusting screw is designed to slip when ...

Page 186: ...T SPEC NO 5381A 0 0 HOBART BROTHERS NO 389870 GAIN lo 4 5 6 7 8 RESET DROOP r l I z IO POT C daJ I l d frequency Power Source Jpru U A U31 lrly screw C W Increase C C W Decrease Shie Id ing Ground Governor Electric Control Box and Potentiometer Figure 12 __ 2 3 ____ __ Ott 30 73 _ _ ___ _____ __ ___ __ Page 28 b __ __ _ ...

Page 187: ...chanical operation of the hydraulic actuator Linkage components are shown in IDLE position Dotted lines represent full drive speed position which is somewhat less than the full speed position attainable by the actuator arm 1 Engine speed is limited to 2640 RPM in DRIVE mode by a speed limiting governor in the engine fuel pump Top speed is also limited by the same device in GEN mode The end not ill...

Page 188: ...Nut 6 must be tight against finger 2 when checking clearance 4 Operate arm 1 throughout its full travel to make certain it will not touch any component inc Iuding finger 2 5 Check security of all components 4 Chassis Comoonents Adiustment Since mobile operation is limited mileagewise for this unit wear and adjustment of chassis parts should be minimal Adjustments most like ly to be required are co...

Page 189: ...R SET SPEC NO 5381A 1 inch free travel ___ _ Lengtkn to decrease pedal travel Shorten to increase pedal travel 1 Clutch pedal 2 Return spring 3 Pedal stop screw 4 Clutch rod 5 Nut Clutch Pedal Figure _ _ _ __ _ __ _ _ act 30 73 2 3 6 Top adjuster not threaded 7 Swivel 8 Clutch throwout shaft 9 Bottom adjuster threaded Ad justmen t 14 _ _ I __ _ _ Page 31 ...

Page 190: ... bottom adjuster 9 from the swivel 7 Thread bottom adjuster 9 ONTO rod 4 to increase pedal trave I Thread the adjuster in the OFF direc tion to decrease pedal travel The top adjuster 6 is not threaded Be certain adjusters 6 and 9 are seated on swivel 7 then tighten nut 5 Check pedal travel Repeat steps b and c if necessary until a satisfactory adjustment has been completed B Brake Pedal Adjustment...

Page 191: ... not subject to wear imposed by stopping the vehicle Adjustment by use of the adjusting knob located on the end of the parking brake lever should be sufficient for a long period of time If adjustment of the brake band is required proceed as follows See Figure 16 1 Raise the rear of the vehicle and position safety stands 2 Make certain the parking brake lever is in OFF position 3 Inspect brake lini...

Page 192: ...T SPEC N0 5381A 1 Anchor screw 2 Safety wire 3 Band mounting bracket 4 Mounting arm 5 Brake band 6 Brake Iin ing 7 Nut 8 Screw 9 Adjusting nut 10 Cotter pin 11 Brake drum 12 Spring 13 Cotter pin 14 Brake rod 15 Cam lever 16 Rod attaching eye 17 Lever Parking Brake Adjustment _ ___ __ Figure 16 _ ___ _ _ 2 3 Ott 30 73 Page 34 _ _ _ ____ __ __ _ __ __ _ ...

Page 193: ...pply pressure as required in locked position 10 Release brake lever and recheck adjustment to make certain the band is fully released and lining is not touching brake drum CAUTION IF THE BRAKE DRUM RUBS THE LINING AT ANY POINT THE LIN IN G CAN BE DESTROYED BY FRICTION IN A SHORT TIME 11 Install new safety wire 2 Tighten nut 7 Install new cotter pin 10 D Service Brake Adjustment Service brakes shou...

Page 194: ... system if the master cylinder reservoir is allowed to become empty or if the system is opened for any reason A leaking condition may also allow air to enter To remedy the condition the system must be bled to expel the air The system may be bled manually or with pressure bleeding equipment 1 Manual method This bleeding method can best be accomplished by two mechanics one to operate the bleeder val...

Page 195: ...s cease to appear at the submerged end of the bleeder tube NOTE Be sure the reservoir ALWAYS contains fluid during the bleeding operation Close the bleeder valve and remove bleeder hose Repeat the bleeding procedures at each wheel cylinder in the following sequence left front right rear and left rear Fill the master cylinder Fluid level should be 3 8 inch below the bottom edge of the filler hole I...

Page 196: ... the center of a proper size cap and soldering a tube fitting in the hole c Position a 3 8 inch box end wrench on the right front wheel cylinder valve see Figure 18 Attach a bleeder tube to the end of the bleeder valve and submerge the free end of the tube in a clear glass container partially filled with clean brake fluid d Open the valve on the bleeder tank or hose to admit pressurized brake flui...

Page 197: ...RAL position and check the relative positions of Micro switch button 6 and trip arm 1 The switch actuating button 6 should extend from the switch 4 to its full ON position and be located in the trip arm notch 7 If the switch is out of position proceed to step 3 3 Loosen nuts 5 and screws 3 sufficiently to allow screws to move in adjusting slots provided in the mounting bracket 8 4 Move the switch ...

Page 198: ...ED GENERATOR SET SPEC NO 5381A I I I _ I I 1 I I I aI J __________ al 11 I _ __ _ L s _ 1 Trip arm 2 Gearshift lever 3 Screw 4 Micro switch 5 Nut 6 Switch button 7 Notch 8 Bracket Top View Gearshift Micro Switch Adjustment Figure 19 _I_ _ ____ _____ __ i 2 T3 L __ ____ _ _ _ ___ _ _ gct30 73 j Page 40 __ __ _____ ...

Page 199: ...l System Engine Shut Down System Safety Switch By Pass Operating Mode Control System Electric hydraulic governor system General Theory of operaton Excitation deenergization circuit Lighting System Protective Monitor System 12 V DC 400 Hz Generator System Generator General Theory of generator operation Voltage Regulator Automatic voltage regulation Genera I Theory of operation CHAPTER SECTION 3 l P...

Page 200: ...tem 3 l Genera I Theory of operation Protective Monitor System Genera I Fault sensing devices Fault sensing relays Over load sensing device Protective monitor module Generator Monitoring System Trouble Shooting Procedures Genera I Trouble Shooting Chart Description Use of the Trouble Shooting Chart Equipment for Trouble Shooting Safety Parts Replacement 3 2 Test Values Trouble Shooting Practices P...

Page 201: ...I lustrations LIST OF ILLUSTRATIONS CHAPTER FIGURE SECTION NUMBER 3 1 3 1 3 l 3 l 3 l 3 2 3 2 3 2 3 2 3 2 1 Operating Controls and Instruments Sheets 1 2 3 4 5 TITLE Engine Circuit Schematic Diagram Generator Circuit Schematic Diagram Governor Speed Setting Potentiometer Schematic Governor Actuator Cross Section Electric Governor Voltage Values and 2 Starter and Solenoid Switch Terminal Boards Exe...

Page 202: ...GENERATOR DIVISION HOBART BROTHERS COMPANY OPERATION MAINIENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 3 o Ott 30 73 Page 4 ...

Page 203: ...B Some components of the engine shut down system are identified in Fig 1 by name rather than by symbol Example FUEL VALVE SOLENOID 2 Twelve Volt Electrical System See Fig 1 In addition to supplying the electrical requirements of engine accessories and shut down devices the 12 V DC system supplies power for the main generator output protective system Warning and illuminating lights are also served ...

Page 204: ...ION HOB mT BROTHERS COMPANY OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 480115 with latest change 7 25 73 Engine Circuit Schematic Diagram Figure 1 3 1 Page 2 Ott 30 73 ...

Page 205: ...ient ly 12 PSI to close the OIL PRESSURE SWITCH Output cable plugs must be properly stored in plug boxes PBMS to make the by pass circuit functional C Operating Mode Control System This system provides 12 V DC power for operation of the electric governor control box and the AC generator excitation deenergization relay EDR The system is protected by a 10 ampere fuse 1FU An hourmeter RTM is connecte...

Page 206: ...ION z HOBART BROTHERS COMPANY c 2 B B k OPERATION MAIN IENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 388375A with latest change 10 26 72 3 l Page 4 Generator Circuit Schematic Diagram Figure 2 Ott 30 73 ...

Page 207: ...r 2RH deter mines the governed speed of the engine The potentiometer signa I enters the box through terminals 9 and 10 The value of this signal may be varied from 0 V DC minimum engine speed to 1 5 V DC maximum engine speed Voltage and engine speed is increased by turning the pot ad justing screw CLOCKWISE It is decreased by turning the screw COUNTER CLOCKWISE Ref 2 3 Fig 12 Twenty four complete t...

Page 208: ...en the pilot valve moves upward oil is released from beneath the piston allowing it to move downward and reduce engine speed The actuator pilot valve is attached to a permanent magnet in a transducer The output signal from the control box passes through the transducer coil and tends to push the magnet and pilot valve plunger downward A feedback spring and a top centering spring add to this downwar...

Page 209: ...2 Adiustment of these controls is covered in 2 3 Para 3 E 4 Electric governor voltage values are contained in Figure 5 2 Excitation deenergization circuit The purpose of this circuit is to supply 12 V DC power through the two position switch 3s for closing the excitation deenergization relay EDR and maintain ing it in closed position to supply AC power to the voltage regulator REG and DC power to ...

Page 210: ...OTHERS COMPANY c z 4 I OPERATION MAINTENANCE AND 0VERHAL L MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Dee Inc Pilot Valve Plunger AdjustingScrew Governor Actuator Cross Section _ _ _ _ L_ _ _ Figure 4 3 l act 30 73 _ _ _ _ _ __ I_ _ _ _ ...

Page 211: ...NE IS RUNNING AT GOVERNED SPEED _ Electric Governor Voltage Values Figure 5 D Lighting System Instrument panel lights lW 2W and 3W are operated by the 12 V DC system and controlled by a toggle switch 4s Th IS system is also protected by a 20 ampere fuse 4FU Headlights are controlled by another toggle switch 7s and protected by a 20 ampere fuse 5FU E Protective Monitor System 12 V DC The AC generat...

Page 212: ... second output power The main purpose of the electric hydraulic governor described above is to main tain this generator speed under all operating conditions At initial start up of the generator the exciter field 2FLD must be polarized by momentarily apply ing 12 V DC across the input terminals Ref 2 3 Para 2 A 15 To make the generator functional after a start up the operating mode switch 3s must b...

Page 213: ...by passed by the automatic manual switch 1s and DC power is supplied to the exciter field 2FLD through a rectifier 2REC and a rheostat IRH The rectifier converts AC generator output to DC for excitation of the exciter field 2FLD E xcitation is controlled as required by manually adjusting the rheostat 1RH C Generator Output Control System 1 General The generator output control system consists of th...

Page 214: ...t cable plug is properly connected to the aircraft the 1PIR contacts should be closed and allow current to pass to the fuse interlock relay FIR contacts The function of the FIR is to cause the load contactor to open in the event the pro tective system fuse 2FU should bl ow and disable the protective relay system The FIR contactsare closed when the small contacts in the load contactor 1 LC close an...

Page 215: ...esponse becomes much faster so that a load of 150 will cause the device to function in approximately 16 seconds When the solid state circuitry closes the relay a signal is sent to the protective monitor module The signal causes the module to interrupt the load contactor holding circuit and disconnect the output load 3 Protective monitor module Ott 30 73 The function of the protective monitor modul...

Page 216: ...dicated by three instruments a frequency meter FM a voltmeter VM and an ammeter 2AM The reed type frequency meter FM indicates cycles per second Hz in phase A The voltmeter VM will indicate generator output voltage in each of three phases as selected by the rotary switch SS Output amperage is indicated by the ammeter 2AM Current sensing transformers lCT 2CT and 3CT supply the operating signa Is to...

Page 217: ...Trouble symptom and condition 2 Probable cause 3 Test check and remedy B Use of the Trouble Shooting Chart Read the trouble symptoms and conditions before proceeding to causes and reme dies For example at the beginning of the trouble shooting chart under ENGINE the first trouble listed is Engine will not start Starter will NOT crank engine If the starter WILL crank the engine then obviously this i...

Page 218: ...o this concept are Generator control tray Protective relay tray Voltage regulator Over load module Protective monitor module Electric governor control box Hydraulic governor actuator The above items are in addition to normally replaced items such as injectors relays etc 6 Test Values Although test values are provided throughout the trouble shooting chart where applicable additional information and...

Page 219: ...ntrol box are shown on separate illustrations with the component of which they are a part CAUTION 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 B Identification of Terminals Each...

Page 220: ...f troubles A The system requires three sources of power to operate normally 1 12 V DC input power from engine electrical system 2 4 V to 6 V AC input power from magnetic pickup 3 20 psi or more oil pressure from engine fuel oil system NOTE Low oil pressure wil I result in sluggish actuator operation B Assuming other conditions are normal the actuator will go to or remain in IDLE position under the...

Page 221: ...Sufficient 12 V DC power reaching the fuel shut off solenoid valve C An adequate supply of air compressed to a sufficiently high compression pressure D The injection of the correct amount of clean fue I at the proper time When trouble shooting the engine keep these requirements in mind 10 Illustrations Illustrations Figure 1 through 5 are referred to throughout the Trouble Shooting Chart Figure 6 ...

Page 222: ...tact or closed indicating light 13 Power module 14 Generator control tray 15 Protective relay tray 16 Voltage regulator tray 17 Load ccntactor control switch 18 Terminal board 19 Test receptacle connector 20 Operating mode generate drive control switch 21 Instrument and marker light fuse 20 A 22 Headlight fuse 23 Instrument light switch 24 Excitation deenergization relay mounted on rear of panel 2...

Page 223: ... light 5 37 Load contactor operating system fuse 38 Protective monitor system fuse 39 Protective monitor system reset switch 40 Test bank switch 41 Rate and gain adjustments 42 Line drop compensation switch 43 Cable siie compensation adjustment 44 Cable length compensation adjustment 45 instruction plate 46 Vojtoge adjusting rheostat Operating Controls _ _ 28 29 31 32 35y GENERATOR CONTROL TRAY 28...

Page 224: ...MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 5 1 Starter 2 Starter terminal 3 Solenoid ground terminal 4 Switch to starter terminal 5 Solenoid switch 6 Solenoid switch input terminal 7 Solenoid input signal terminal Starter and Solenoid Switch Front View Figure 2 ...

Page 225: ...nalon a board is identified by a number 1 2 3 etc Terminals are numbered from LEFT to RIGHT on horizontally mounted boards and from BOTTOM to TOP on vertically mounted boards Number 1 termir ai on each board is indicated on the illustration Any individual terminal may be identified by combining the board identification letter with the terminal number Example Terminal A 8 is the eighth terminal fro...

Page 226: ...ANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 1 Manual control voltage potential adiusting resistor 2 Exciter field ballast resistors Excitation Resistors Figure 4 To exciter field To exciter field End View of Voltage Regulator Amphenol Connector Page lO _ _ _ _ _ _ MI ...

Page 227: ...nnections grounded D Defective start switch D Check voltage at terminal E9 W B Fig 3 while pressing start switch button 5 Fig 1 If no volt age is indicated replace switch E e Defective starter sole E Momentarily connect a large size noid or starter l O min cable between termi nals 6 and 4 Fig 2 If the starter cranks the engine the solenoid 5 Fig 2 is defective If the starter does not crank the eng...

Page 228: ... not A Defective fuse 10 Fig 1 A Remove fuse and visually inspect start Cranking Replace if blown and check speed normal In for cause of fuse blowing dicating light 9 Fig 1 dcjes NOT B Defective switch 2 Fig B If fuse 10 Fig 1 and lamp glow when switch 1 9 Fig 1 are good the engine 2 Fig 1 is in control switch 2 Fig 1 is RUN position 0 defective e Replace switch Lamp is GOOD 4 Engine will not NOTE...

Page 229: ... below If no voltage is observed continue checking circuit as follows 1 Check voltage at terminal E4 Fig 3 while holding switch 2 Fig 1 in START position 0 If no voltage is indicated re place switch If approximatei 12 V DC is indicated proceec to step 2 2 Check circuitry and Micro switch Repair or replace as required e B Operation of the fuel valve may be checked in at least two ways 1 Operation o...

Page 230: ...e the pump see 2 2 Fig t 12 before attempting to find the cause of no fuel Fill the pump with clean fuel oil If the engine will not start after priming mechanical pump trouble is indicated If the engine starts and then stops after o short time trouble between the fuel source and the suction side of the pump is indicated Check and or remedy as follows 1 Insufficient fuel in tank l The fuel tank sho...

Page 231: ...not a An open relief valve will position Cont d seating cause low output pressure b Worn pump gears b Check pump for normal or damaged pump operation Replace if drive defective D Low ambient temperature D Check causes and remedies under or limited fuel ENGINE Trouble 3 A and B above E Low compression which E Check compression may be caused by any one of the following 1 Sticking or burned l Cylinde...

Page 232: ...E Do not overlook the possibility of a defec tive engine control switch 2 Fig 1 5 Engine runs at idle A The 12 V DC input circuit A To determine which system or speed Engine will to the electric governor circuit is defective use a jumper not come up to control box is defective lead to connect 12 V DC to governed speed or the governor control terminal No 1 on the governor when operating mode box is...

Page 233: ... defective Check and replace if required c Excitation deener gization relay EDR defective 2 Defective governor control box Ref 3 1 Fig 1 c Check EDR coil and con tacts Replace EDR if defective 2 Replace control box if defec tive Do not attempt to repair 7 Engine misses A Low coolant temperature A If indicated temperature stays Runs unevenly below 65 deg F remove inspect and test the thermostat Rep...

Page 234: ...s follows 1 Damaged air cleaner 1 Check air cleaner for plugging and or damage GENERATOR AND tX CITATION CIRCUIT 1 No or low gen NOTE No or low g enerator output may be caused by a defective erator output volt generator or lack of excitation to the exciter field The age in all phases first test should determine whether the defect is in the Generator operat generator or in the excitation circuit in...

Page 235: ... and B Fig 4 If a normal voltag is now produced check each resistor and replace defective one or both 2 Defective automatic manual sw itch IS 33 Fig 1 2 With generator running at nor mal speed and automatic manual speed in AUTOMATIC position check voltage at terminal Al5 and also at A16 If no voltage at either of these terminals replace the auto matic manual switch If a voltage can be read proceed...

Page 236: ...uce a normal voltage replace the excitation deenergization relay EDR 5 Defective plug con nectar at voltage reg ulator or defective wiring from regulator to exe iter fie Id 5 Before condemning the volt age regulator as the defec tive component eliminate the plug connector and wir ing as a possible trouble source as follows a Disconnect Amphenol connector l l Fig 9 item 14 Insert a short piece of w...

Page 237: ...lator LOAD CON TACTOR OPERATING CIRCUIT 1 Load contactor A In addition to defective A Check wiring and connections in 1LC will not wiring and connections the load contactor circuits on the close when load in the AC and DC load engine control pane I protective con tactor control contactor actuating cir switch 17 Fig relay tray and power module cuits the load con tactor Check components as follows 1...

Page 238: ...ad con tactor 1LC coil 5 Disconnect leads at the loac contactor terminals Xl and X2 Use ohmmeter to check coil resistance between terminals Xl and X2 Re sistance should be approxi mately 60 ohms If coil is defective I replace the load con tactor Load contactor will A 28 5 V DC is not reaching A Check voltage at terminal B9 close when contact plug interlock relay 1PIR Fig 3 Voltage should be 28 or ...

Page 239: ...erlock relay 1PIR l l Fig 7 item 18 or the complete protective relay tray D Small ccntacts in load D Connect a jumper lead between contactor 1 LC defective terminals 815 and 816 Fig 3 If load contactor will now remain closed replace the load con tactor 1LC l 1 Fig 10 item 6 E Defective fuse interlock E Open protective relay tray and relay FIR or resistor connect a jumper across the re 4RE S sistor...

Page 240: ... control switch 5s is released check for trouble under Trouble 2 above IOTE The protective relays and protective monitor are not completely functional unless the load contactor is CLOSED Since it is not advisable to vary voltages for test purposes while delivering power to an aircraft the generator set should be con nected to a load bank for trouble shooting the protective circuits If a load bank ...

Page 241: ...et switch 39 Fig 1 and resume power delivery Ob serve voltmeter and gradually in crease voltage with rheostat If the overvoltage sensing relay OV functions to open the load con tactor at any value less than 134 V AC it is defective Remove pro tective relay tray and replace 2 Load contactor A An undervoltage condition opens during A Observe generator voltage on caused the undervoltage power de I iv...

Page 242: ...lectric governor im A Proceed as follows opens during properly adjusted or power de I ivery malfunctioning Overfrequency light ON a 1 Governor improperly 1 Adjust in accordance with adiusted 2 3 Para 3 E 4 2 Electric governor 2 Check and adjust or repair system maIfunction ing in accordance with ENG INE AND CONTROLS Trouble no 8 in the Trouble Shoot ing Chart 0 B If overfrequency nuisance trip B D...

Page 243: ...n which power de I ivery and resume power delivery caused the overload de Observe ammeter 32 Fig 1 Overload indicat vice OL to function Check for abnormal overload ing light ON normally condition and correct If over load device functions to open the load contactor when an overload does not exist proceed to step B B One of the resistors B An open resistor will cause a 8RES 9RES or IORES higher than...

Page 244: ...pen or short circuited e Check stator winding resistances See 2 3 Fig 4 for normal values A Loose connection causing high resistance Check all output connections for looseness Look for discoloration caused by heat highten or re place as required B Improper or blocked venti B Check for foreign materials rags lation etc blocking air flow Provide adequate ventilation C Generator stator windings 0Chec...

Page 245: ...ENERATOR SET SPEC NO 5381A T ROUBLE SYMPTOM AND CONDITIONS PROBABLE CAUSE TEST CHECK AND OR REMEDY GENERATOR CON TIN UE D 4 Continued D Break or cut in output D Inspect Repair or replace as cable assembly required ED Unbalanced load E Check aircraft 400 Hz components _ act 30 73 Trouble Shooting Chart Sheet 19 of 19 Figure 6 3 2 Page 29 ...

Page 246: ...YOBART t f QD MOTOR GENERATOR DIVISION e HOBART BROTHERS COMPANY c 5 b s a OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 3 2 Page 30 Ott 30 73 ...

Page 247: ...sembly Removal and Installation Genera I Remova I Preparation for Removal Location Equipment required Remova I Procedures Instal iation Preparation for Installation Location Equipment required Installation Procedures Individual Components Removal and Installation Genera I Generator Control Box Trays Re mova I Installation Power Module Pane I Assembly Remova I Ott 30 73 CHAPTER SECTION 4 l 4 2 PAGE...

Page 248: ...ntrol Box Removal Installation CHAPIER SECTION FIGURE NUMBER 4 l 4 l 4 l 4 l 4 l 4 l 4 l 4 2 1 Control Tray Removal Typical 4 2 2 Power Module Panel Assembly 4 2 4 4 4 4 LIST OF ILLUSTRATIONS TITLE Self Propelled Generator Set Accelerator Control Cable Connection Steering Gear Clutch Shaft and Linkage Pedals and Master Cylinder Pedals Assembly Attachment Engine Generator Hoisting Arrangement Typic...

Page 249: ...placing the canopy assembly and also the engine generator assembly when removed 2 Equipment required Tools required for this job are the usual mechanics hand tools Time may be saved by the use of air or electric driven impact wrenches Other equipment required includes a Two chain hoists with lifting chains and hooks b Jack stands or blocks for supporting the unit at least 12 inches above normal po...

Page 250: ...sitive lead at the starter solenoid 7 Close the fuel tank shut off valve Ref l l Fig 3 item 14 located on the right side of the vehicle and disconnect both the fuel delivery and return hoses 8 Remove floorboard as follows a Remove gearshift lever knob b Remove four attaching screws and lift off gearshift lever boot Reinstall knob c Use a floor creeper to gain access to the underside of the floorbo...

Page 251: ...OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 1 Front canopy 5 Steering column 2 Top canopy 6 Access cover 3 Folding doors 7 Lower canopy pane I 4 Rear canopy and control box 8 Battery box doors Se If Prope I led Generator Set _ _ ___ _ Figure 1 Oct_3W73 4 l _ _ _ _ __ Page 3 ...

Page 252: ...on both sides 12 Remove turn signal control from steering column Disconnect horn wire 13 Note the position of steering whee I spokes when front whee Is are pointing straight ahead for future installation of steering column Support steering column and remove steering column clamps screw in lower steering column U Loosen spl ined joint clamping joint 2 and slide joint off steering gear box shaft Lif...

Page 253: ...required NOTE Identify and mark all leads disconnected so that they may be properly reconnected a Disconnect all stator leads at terminal board cn right side of unit b Disconnect all 12 V DC leads at protective devices low oil pressure temperature etc c Disconnect 12 V DC voltage regulator leads at regulator d Disconnect hydraulic actuator and governor control box leads as required e Disconnect al...

Page 254: ...FTING POWER SLOWLY AND LIFT GRADUALLY TO AVOID DAMAGE TO ANY PART NOTE it should not be necessary to cut any wires cables or leads 20 Remove two screws and nuts which attach clutch shaft pillow block bearing 6 Fig 4 to bracket 7 Remove cotter pin 1 and washer Slide clutch rod 2 out of clutch pedal arm If the rod cannot be completely disengaged from the pedal unhook spring 5 Fig 16 remove clutch pe...

Page 255: ...all coolant hoses at the radiator 26 Remove all radiator attaching hardware and use a hoist to carefully lift the radiator off 27 Remove front engine support screws and generator to frame attaching screws 28 Attach lifting hoists Figure 7 illustrates a typical hoisting arrangement Pro ceed as follows a Use a heavy chain with hooks to attach a hoist to the engine lifting eyes b Attach another hoist...

Page 256: ...ANCE AND OVERHAUL MANUAL TM 240A SELF PROPELlED GENERATOR SET SPEC NO 5381A 1 Stop lite switch lead 4 Retaining ring 2 Microswitch lead 5 Spring 3 Brake tube 6 Clutch pedal Pedals and Master Cylinder 1 Cap screws 2 Master cylinder and pedals assembly Pedals Assembly Attachment Figure 6 Page 8 ...

Page 257: ... CHECK ALL LIFTING CONNECTIONS CHAINS ETC TO BE CERTAIN THE ASSEMBLY CANNOT FALL Carefully lift the engine generator assembly with transmission attached out of the frame and move to a clear working area Lower the assembly to the floor and block in an upright position Disconnect hoists and remove chains Remove transmission as follows a Remove cap screws which attach transmission to exciter housing ...

Page 258: ...ed in Para 2 A 2 above B Installation Procedures 1 Install clutch and transmission It is much easier to install the clutch and transmission while the engine generator assembly is removed from the vehicle a Position clutch disc and clutch cover on the exciter flywheel Use a clutch alignment tool to align clutch disc splines with pilot bearing in the end of the exciter shaft b Align cover mounting h...

Page 259: ...y 2 Fig 6 and attach with two screws 1 Connect two brake tubes to master cylinder fitting Ref 3 Fig 5 Connect stoplight switch and Micro switch leads 1 and 2 Fig 5 Position bearing 6 Fig 4 on bracket 7 Attach with two screws nuts and washers 12 13 14 15 Ott 30 73 Connect clutch rod 2 Fig 4 to clutch pedal It may be necessary to slide the peda I partly off of the shaft to make this connection Ref P...

Page 260: ...ce light wires Install exhaust pipe elbows if used 22 Install floorboard as follows a Lift floorboard into position and align mounting holes Apply parking brake so floorboard will clear the lever Installattaching screws b Connect accelerator control cable see Fig 2 23 24 25 Check operation and adjustment of accelerator linkage Ref 2 3 Para 3 F Connect all fuel lines and hoses and open fuel valve a...

Page 261: ...cordance with 2 3 Para 4 D Adjust clutch pedal as required in accordance with 2 3 Para 4 A Check and inspect the complete unit in accordance with 1 2 Para 2 Lift the vehicle and remove blocks or jack stands Start the engine and allow it to idle Check coolant level and add coolant as required CAUTION BE SURE THAT TRAPPED AIR HAS BEEN EXPELLED AND THAT THE COOLING SYSTEM IS FULL Test and adjust the ...

Page 262: ...FOBART I a QD iMOTOR GENERATOR DIVISION c d HOBART BROTHERS COMPANY I 4 BL I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 4 l Page 14 act 30 73 ...

Page 263: ...s in Chapter 5 for complete wiring details 2 Generator Control Box Trays The three trays mounted in the generator control box are designed for quick and easy removal and installation All trays are removed in a similar manner A Removal 1 hscrew hex head captive fasteners 2 Fig 1 and pull tray outward 2 Unscrew serrated nut on Amphenol connector 3 and disconnect 3 Press both tray latches 1 down and ...

Page 264: ...ssemblv A Removal 1 Remove plastic cover 4 Figure 2 by removing two attaching screws 2 Remove attaching nuts and disconnect three output leads 5 from load con tactor 9 3 Disconnect the lower group of outgoing leads 6 from terminal board 7 4 Remove three terminal nuts 1 Remove two nuts and washers which attach cable clamps 3 These are also panel attaching nuts With generator cables 2 thus loosened ...

Page 265: ...0 0 s 9 ...

Page 266: ...s 10 Position cable clamps 3 on pane I mounting studs and secure with panel mounting nuts Install nuts 1 Connect leads 6 to terminal board 7 Refer to connection diagram in 5 l if necessary Connect output cables 5 to load contactor 9 Check all attaching parts for security Install cover 4 with two attaching screws 4 Control Box A Removal The control box and rear canopy are removable as an assembly I...

Page 267: ...r Engine Connection Diagrams Mechanical Repairs Engine Generator Canopy Assembly Sheet Metal Repair 5 2 Frame and Structural Repair 1 LIST OF ILLUSTRATIONS CHAPTER FIGURE SECTION N UMBER TITLE PAGE NO 5 l 5 l 5 l 5 l 5 l 5 l 1 Generator Circuit Connection Diagram 2 2 Engine Circuit Connection Diagram 3 3 Control Box Connection Diagram 4 4 Generator Control Tray Connection Diagram 5 5 Protective Mo...

Page 268: ...FOBART e QQ gMOTOR GENERATOR DIVISION 2 9 HOBART BROTHERS COMPANY c 2 8A d OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 5 o Page 2 pet 30 73 ...

Page 269: ...ox is generally repaired on the line by replacement of con trol trays or adjustment See 2 3 for adiustment procedures See 3 2 for trouble shooting and identification of defective components 3 Generator Generator repair is covered fully in the Overhaul Chapter 6 1 since major repairs to the generator require removal and disassembly with overhaul type facilities 4 Engine Many engine electrical syste...

Page 270: ...BART BROTHERS COMPANY 44 tR OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Replace with new 388971 with latest change date of 4 17 72 Generator Circuit Connection Diagram Figure 1 5 l Page 2 Oct 30 73 ...

Page 271: ...BART BROTHERS COMPANY 0 b I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET WC NO 5381A Replace with latest 480116 with latest change date of 7 25 73 Ott 30 73 Engine Circuit Connection Diagram Figure 2 5 l Page 3 ...

Page 272: ...z z HOBART BROTHERS COMPANY c b OPERATION MAINIENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Replace with latest 480117 latest change date 2 19 73 Control Box Connection Diagram Figure 3 5 l Page 4 Ott 30 73 ...

Page 273: ... DIVISION a 5 HOBART BROTHERS COMPANY 0 b B a OPERATION MAINlENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELlED GENERATOR SET SPEC NO 5381A Use diagram 389371 act 30 73 Generator Control Tray Connection Diagram Figure 4 5 l Page 5 ...

Page 274: ...t HOBART BROTHERS COMPANY c c b B e OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Replace with 480715 No change date Protective Monitor Tray Connection Diagram Figure 5 5 l Page 6 Ott 30 73 ...

Page 275: ...HOBART BROTHERS COMPANY 0 5 B B R OPERATION MAIN 7ENANCE AND OVERHAUL MAN UAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Replace with 388391 Latest change date of 7 24 73 Ott 30 73 Power Module Connection Diagram Figure 6 5 l Page 7 ...

Page 276: ...FOBART 8 f QQ MOTOR GENERATOR DIVISION 2 HOBART BROTHERS COMPANY a g e OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 5 l Page 8 ...

Page 277: ...echanical such as bearing replacement are covered fully in Chapter 6 Overhaul 3 Canopy Assembly A B Sheet Metal Repair If sheet metal dents bends etc are discovered they may be straightened and repaired by dollying and normal sheet metal practices When straightening has been completed sand the affected surfaces clean thoroughly and apply a good quality red oxide primer or equivalent When the prime...

Page 278: ...YOBART L QQ MOTOR GENERATOR DIVISION z z HOBART BROTHERS COMPANY c CT a t OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 5 2 Page 2 act 30 73 ...

Page 279: ...CTION Electrical 6 l Genera I Generator Control Box Assembly Cleaning Inspection Corrections Generator Preparation for Generator Overhaul Disconnect Generator from Engine Disassembly Cleaning Inspection Bearings Fan Exciter rectifier assembly Rotor assembly Generator and exciter stators Bearing Installation Reassembly Reassemble Generator to Engine PAGE 1 1 1 1 1 2 2 2 2 5 11 11 11 12 12 12 12 13 ...

Page 280: ...Rotation Typical 5 Flexible Coupling Removal or Installation Typical 6 Coupling Hub and Bushing 7 Generator Exploded View 8 Exciter Rotor Removal or Installation 9 Positioning Generator Rotor Removal or Installation Typical Preparation for Rotor lnstal lation Typica I Cleaning and Lubricating Hub and Bearing Typical Routing Exciter Leads Typical Installing Exciter Housing Typical Exciter Rotor Ins...

Page 281: ...for the sake of overhaul is not recommended In lieu of overhaul the control box assembly should be thoroughly cleaned and inspected at the time of generator overhaul when it will be easily accessible A Cleaning 1 Open doors and trays Remove access pane Is as required 2 Use clean dry compressed air to clean electrical components 3 If oil grease or other foreign material has accumulated clean with a...

Page 282: ...ic overhaul mainly for replacement of mechanical parts the bearings These annular type single row ball bearings have a life expectancy of approximately 5000 hours are performed in a continuous operation Since removal disassembly cleaning etc these overhau I procedures the complete sequence will be included in A Preparation for Generator Overhaul Remove the engine generator assembly in accordance w...

Page 283: ...Fig 2 3 Lower the generator until most of the weight is supported by the wooden blocks but continue to support the generator with the hoist CAUTION USE ADDITIONAL BLOCKING OR SHOP FACILITIES AS REQUIRED TO MAKE CERTAIN THE ENGINE CANNOT TIP ROLL OR FALL 4 Remove the fan cover 1 Figure 2 which is attached by screws 3 WOODEN BLOCK 1 Fan cover 3 Cover attaching screws 2 Fan housing to generator 4 Fly...

Page 284: ...crews To prevent engine rotation place the square end of a 3 4 drive extension 3 to 4 inches long in the square wrenching facility in the front pulley Attach a long flex handle to the extension and brace the handle against the floor or frame etc see Fig 4 This illustration shows wrench in position for TIGHTEN ING flexible coupling screws Position the wrench handle on the other side of the engine f...

Page 285: ...nected C Disassembly 1 Remove flexible coupling and fan shown in Figure 5 a Use a 5 16 inch Allen wrench to remove screws A Fig 6 b Oil the th rea ds and point of one of the screws and thread into partially threaded hole B Tighten screw to force tapered hub C off of split bushing D NOTE If hub C does not loosen at once strike it with a brass driving rod and heavy hammer When the hub is loose on th...

Page 286: ...m 4 g l 6 MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Flexible Coupling Removal or Installation Typical Figure 5 B A Setscrews B Threaded hole for removal C Hub D Split bushing E Generator shaft F Key Coupling Hub and Bushing Figure 6 ...

Page 287: ...event damage to centering seat and threads e Pull the exciter rotor assembly off of the rotor shaft E carefully and exercise the following cautions CAUTION PAY CLOSE ATTENTION TO THE FIELD LEADS A WHILE PULLING THE EXCITER FROM THE SHAFT ONE MECHANIC SHOULD WATCH THEM CONSTANTLY WHILE ANOTHER OPERATES THE PULLER MAKE CERTAIN THEY DO NOT CATCH AND BE SURE THEY SLIDE SMOOTHLY THROUGH THE EXCITER LEA...

Page 288: ...le coupling 5 Coupling hub 6 Machine key 7 Exciter armature 8 Diode 9 Pilot bearing 10 Pin 11 Machine key 12 Exciter housing Page 8_ __ _ 13 Exciter polepiece 14 lnsulaticn 15 Exciter coil 16 Front bearing bracket 17 Front bearing 18 Rear bearing 19 Retaining ring 20 Generator rotor 21 Generator stator housing 22 Engine flywheel adapter 23 Fan housing Generator Exploded View Figure 7 act 30 73 __I...

Page 289: ...LF PROPiiLED GENERATOR SET SPEC NO 5381A A Generator fie Id leads B Terminal lugs C Tape D Exciter flywheel E Armature shaft CH BA IF3 F Exciter lead tubes G Exciter locating ring H Rectifier I Diode J Exciter field Exciter Rotor Figure 8 _ _ _ _ ___ _ ___ _ _ _ Ott 30 73 _ _ _ _ _ _ _ _ _ _ _ 6 l ...

Page 290: ... E Inspection below After Cleaning and Inspection return to the next paragraph 8 bel ow if further disassembly instructions are required 8 If bearings require replacement after inspections under Para 3 E 1 below remove them with a suitable bearing puller after removing retaining ring 19 Fig 7 Pulling pressure should be exerted on the inner race of the bearing CAUTION USE A THICK FLAT WASHER OR OTH...

Page 291: ...ical damage such as cracks nicks damaged seals etc Inspect for evidence of overheating Overheated bear ings are generally darkened to a brownish blue or blue black color Re place the bearing if damaged in any way or if it shows evidence of over heating b Check the bearing for excessive looseness between the races and the bear ing balls c Turn the outer race slowly and check for any roughness or su...

Page 292: ...b Check security of all parts c Test each diode in accordance with 2 3 Para 2 C 4 Rotor assembly a Visually inspect the assembly for physical damage Inspect visible welds for breaks or fatigue cracks b Inspect insulation on leads and windings c Check windings in accordance with 2 3 Para 2 D 5 Generator and exciter stators a Visually inspect stators for physical damage and inspect welds for cracks ...

Page 293: ... Use HEAVY LEATHER GLOVES to remove bearings from oven and install them on rotor shaft When properly heated they will slide easily into place with little or no forcing G Reassembly 1 2 3 4 5 act 30 73 Allow bearings to cool to room temperature before installing housings Use a hoist and a strong V belt looped over each end of the shaft to position the rotor as shown in Figure 10 Lift the drive end ...

Page 294: ... position near generator Clean and lubricate the housing hub and lubricate the outer race of the bearing see Fig 11 7 Install retaining ring 19 Fig 7 8 Route generator rotor to rectifier leads through the housing hub Route the exciter stator field leads through the generator output lead opening in the generator stator see Fig 12 Preparation for Rotor lnsta I laticm Typica I Figure 10 ...

Page 295: ... sufficiently Tighten screws to 35 foot pounds NOTE a Tighten screws in a screw to opposite screw sequence tightening each screw only a little at a time Proceed with tightening around the bolt circuit several times until the housing is in place and all screws are tightly secured b Striking the ends of the rotor shaft with a rawhide or other soft hammer will relieve any stress or binding on the bea...

Page 296: ...ON HOBART BROTHERS COMPANV OPERATION MA IN TENANCE AND OVERHAUL MAN UAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Routing Exciter Leads Typical Figure 12 Installing Exciter Housing Typical _ _ _ _ _ Figure 13 ...

Page 297: ...I the field leads through the exciter rotortubes E Lubricate the shaft and exciter rotor bore Position the exciter armature so that the keyway lines up with the key and start it onto the generator shaft Install a threaded rod l 2 13 x 12 inches long into the end of the generator shaft NOTE More versatile equipment such as a longer l 2 13 rod which requires a 1 inch diameter pipe spacer may be used...

Page 298: ...his process until the armature is positioned firmly against the ring 19 Fig 7 Remove the threaded rod and installation equipment Insert the generator field leads through the holes in the rectifier plate H Fig 8 The leads should fit smoothly against the exciter shaft between the windings J and the rectifier H Remove the pull wires and solder new terminal lugs B to the ends of the generator field le...

Page 299: ...ing flange surface 4 of the fan housing 1 as illustrated in Fig 16 Use a steel ruler 5 to measure inward from the inner edge of the straight edge to the flywheel adapter 2 Make a note of this dimension for future reference This is the dimension used for locating the flexible coupling assembly cn the generator shaft see Fig 18 NOTE This dimension may vary a fraction of an inch between generator set...

Page 300: ... toward the end of the shaft when set screws are tightened h Remove the screwdriver from the bushing slot and tighten set screws A Figure 6 to pull hub onto bushing i Tighten the set screws alternately and evenly until tight Torque to 67 foot pounds see Fig 17 Strike against the outer end of the bushing Use a wood block to protect the bushing Screws can now be turned a little more using the specif...

Page 301: ...1A Torquing Hub Screws 67 ft lbs Figure 17 1 Generator 4 Generator to fan housing mounting surface 2 Coupling assembly 5 Steel ruler 3 Coupling to adapter mounting surface 6 Straight edge Measuring Flexible Coupling Location on Generator Shaft Figure 18 _ _ _ __ _ _ _ Ott 30 73 6 l ___kge 21 ...

Page 302: ...apter 2 Install six fan housing to generator screws 2 Fig 2 Torque to 35 foot pounds 3 Install six coupling to flywheel screws 6 Fig 3 Donot tighten until all screws are started Tighten and torque the coupling to flywheel screws to 85 foot pounds see Figure 20 To prevent engine rotation while tightening screws place a 3 4 inch drive extension in the front crankshaft pulley and attach a long flex h...

Page 303: ...xciter cover 2 Fig 7 6 Lift generator and remove wooden blocks as required to lower assembly to the floor 7 Lower the generator and remove hoist chain and lifting eye CAUTION BE SURE THE ASSEMBLY IS BLOCKED SUFFICIENTLY TO HOLD IT IN AN UPRIGHT POSITION I Reinstall Engine Generator Assembly Reinstall the engine generator assembly in the chassis and test in accordance with instructions in 4 1 Para ...

Page 304: ...FOBART I QD iMOTOR GENERATOR DIVISION e 0 2 Hosyn BROTHERS COMPANY B B OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 6 l Page 4 Ott 30 73 ...

Page 305: ...NICAL 1 General This section contains references only for finding mechanical overhaul information 2 Engine It is recommended that the local Cummins Engine representative be contacted for assistance regarding extensive engine repair or overhaul 3 Generator Mechanical overhaul of the generator is incorporated in the Electrical Overhaul 6 1 under main paragraph 3 Ott 30 73 6 2 Page 1 ...

Page 306: ...GENERATOR DIVISION HOBART BROTHERS COMPANY OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPECS NO 5381A 6 2 Page 2 Ott 30 73 ...

Page 307: ...F CONTENTS CHAPTER SECTION 7 l PAGE 1 1 1 1 1 1 Parts List Form Manufacturer s Codes Explanation of Manufacturer s Vendor Code List Parts List Explanation of Parts List Arrangement Symbols and Abbreviations Se If Prope I led Generator Set Canopy Assembly Generator Set Without Canopy Control Box Assembly Generator Control Tray Assembly Protective Relay Tray Assembly Voltage Regulator Tray Assembly ...

Page 308: ... and Brake Group Floorplates Pedals and Brake Group Hydraulic Brake Master Cylinder Steering Group Steering Gear Engine and Drive Train Group Governor and Accelerator Linkage Group Governor Oil Lines Fuel and Oil Lines Group Stator Terminal Panel Assembly Gearshift Safety Box and Back up Light Switch Group Transmission Assembly Clutch Group Generator Group 69 Seat and Transformer Rectifier Group O...

Page 309: ...ELLED GENERATOR SET SPEC NO 5381A TABLE OF CONTENTS CONTIN UD SUBJECT CHAPTER SECTION Vehicular Lights Group 7 3 PAGE 79 Body and Frame Group Battery Group Axle Group Addendum Sheet S 5381A Var 3 N umerica I Index Explanation of Numerical Index 7 4 81 85 87 91 1 1 Ott 30 73 June 25 74 Revised 7 o Page 3 ...

Page 310: ...7 o POeART e b QD EMOTOR GENERATOR DIVISION a z 2 HOBART BROTHERS COMPANY Q B I e OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A act 30 73 Page 4 ...

Page 311: ...pare parts Arrangement Chapter 7 is arranged as follows Table of Contents Section 1 Introduction Section 2 Manufacturer s Codes Section 3 Parts List Section 4 Numerical Index 4 Explanation of Ports List A Contents The parts list contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except 1 Standard har dware items attaching part...

Page 312: ...t does not have an identifying part number for a purchased part the HOBART PART NUMBER column will reflect No Number and the vendor s number will be shown in the NOMENCLATURE column Parts man ufactured by Hobart reflect no vendor code or part number in the NOMEN CLATURE column NOMENCLATURE Column The item identifying name appears in this column The indenture method is used to indicate item relatio...

Page 313: ...L TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 5 UNITS PER ASSEMBLY Column This column indicates the quantity of parts required for an assembly or sub assembly in which the part appears This column does not necessarily reflect the total used in the complete end item Ott 30 73 7 l Page 3 ...

Page 314: ...HOBART YOTOR GENERATOR DIVISION 2 Ow RT BROTHLRS COMPANY OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 l Page 4 act 30 73 ...

Page 315: ...name and description In case a manufacturer does not have a vendor code the full name of the manufacturer will be listed in the nomenclature column CODE VENDOR S NAME AND ADDRESS 0223 1 Anchor Rubber Company 840 S Patterson Boulevard Dayton Ohio 45402 02570 Crawford Fitting Company 29500 Solon Road Solon Ohio 44139 02660 Amphenol Corporation 2801 S 25th Avenue Broadview Illinois 60153 03924 Strato...

Page 316: ...ision Hoult Road P 0 Box 1312 Fairmont West Virginia 26555 Farr Company 2301 E Rosecrans E I Segundo California 90245 Gates Rubber Company 999 South Broadway Denver Colorado 80217 South Chester Corporation South Company Division 3rd Street Governor Printz Boulevard Lester Pennsylvania 19113 Hamilton Watch Company Columbia 8 West End Avenues Lancaster Pennsylvan ia 17604 Cutler Hammer Inc Power Dis...

Page 317: ...n Hamilton Avenue Stamford Connecticut 06904 Ohmite Manufacturing Company 3601 W Howard Street Skokie Illinois 60076 Protectosea I Company 1920 S Western Chicago Illinois 60608 The Sparton Corporation 2400 E Ganson Jackson Michigan 49202 Standard Pressed Stee I Company P 0 Box 796 Jenkintown Pennsylvania 19046 Stephens Adamson Manufacturing Company 275 Ridge way Avenue Aurora Illinois 60507 Stewar...

Page 318: ... Company 4309 W 24th Chicago Illinois 60623 Woodward Govern or Company 5001 N 2nd Street Rockford Illinois 61101 Borg Beck Long Division of Borg Warner Corporation 6558 S Menard Chicago Illinois 60638 Bussman Manufacturing Division of McGraw Edison Company 2536 W University Street St Louis Missouri 63017 Dodge Manufacturing Corporation 500 S Union Street Mishawaka Indiana 46544 Columbus Auto Parts...

Page 319: ... Industrial Corporation 1100 W Wright Street Cadillac Michigan 49601 75915 Litte lfuse Inc 800 E Northwest H ighway Des Plaines Illinois 60016 76534 North American Rockwell Corp Mechanical Spring Plant 500 E Ottawa Logansport Indiana 46947 77342 77640 77915 American Machine Foundry Company Potter Brumfield Division 1200 E Broadway P 0 Box 522 Prince ton Ind ian a 47570 Ross Gear Division TRW Inc L...

Page 320: ...versal Products Division 6455 Kingsley Avenue Dearborn Michigan Truarc Retaining Rings Division Wa Ides Kohinoor Inc 47 16 Austel Place Long Island City New York 11101 Warner Gear Division of Borg Warner Corp 1106 Seymour Street Muncie Indiana 47305 The Weatherhead Company 300 East 131st Street Cleveland Ohio 44108 Western Rubber Company 620 E Douglas Goshen Indiana 46526 Holub Industries Inc 413 ...

Page 321: ...s Nebraska 68601 91929 Honeywell Inc Buildings Controls Components Group Micro Switch Division Freeport Illinois 92850 Anchor Rubber Products Division Anchor Industries Inc 1725 London Road Cleveland Ohio 44122 95879 Alemite Instrument Division of Stewart Warner Corporation 1826 Diversey Parkway Chicago Illinois 60614 98410 E T C Inc 990 E 67th Street Cleveland Ohio 44103 The fo I lowing vendor s ...

Page 322: ...y Wilmington Delaware The Thomas Betts Company 36 Butler Street Elizabeth New Jersey 07207 Ark Les Switch Corp 51 Water Watertown Massachusetts 02172 North American Rockwell Corp Universal Joint Plant Allegan Michigan 49010 Chicago Miniature Lamp Works 4433 Ravenswood Avenue Chicago Illinois 60640 Minerallac Electric Company 25 N Peoria Street Chicago Illinois 60607 Genisco Technology Corp Illinoi...

Page 323: ...st of symbols and abbreviations used in the parts list A or AMP AC AR DC Fig hd hex Hz I D IN KVA MFD No NHA PRV PSI Re f TM T R V i Item not illustrated ampere alternating current as required direct current Figure head hexagon Hertz cycles per second inside diameter inch kilovolt ampere microfarad number next higher assembly peak reverse voltage pounds per square inch reference the item has been ...

Page 324: ...ERATOR DIVISION 2 1 z HOBART MOTHERS COMPAN 4P e 4 11 1 OPERATION MAINTENANCE t AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Se If Prop I led Generator Set _ _ 7 3 F age _ _ _ Figure 1 act 30 73 _ _ ...

Page 325: ...ET SE LF PROPE LLE D 90 KVA GENERATOR SET SELF PROPELLED 90 KVA WITH 28 5 V DC TRANS FORMER RECTIFIER GENERATOR SET SELF PROPELLED 90 KVA WITH 112 V DC TRAN S FORMER RECTIFIER CANOPY ASSEMBLY For details see Fig 2 TRANSFORMER RECTIFIER 28 5 V DC 1500 A For details see attached Manual No TM 197 TRAN SFORMER RECTIFIER 112 V DC 400 A For details see attached Manual No TM 237 A B C B C EXTINGUISHER FI...

Page 326: ...HOBAR 1 e Ta QQ MOTOR GENERATOR DIVISION 2 HOBART BROTHERS COMPANY 4 Q 8 11 6 OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A II Canopy Assembly ...

Page 327: ... For NHA See Fig 1 LATCH ASSEMBLY DOOR FASTENER ROLLER DOOR PIN STRAIGHT HEADED HANDLE DOOR AND CANOPY DOOR ASSEMBLY LEFT FRONT AND RIGHT REAR DOOR ASSEMBLY LEFT REAR AND RIGHT FRONT BUMPER DOOR STOP PANE L ASSEMBLY BOTTOM LE FT TRACK ROLLER PANEL BOTTOM LEFT PANEL ASSEMBLY BOTTOM RIGHT TRACK ROLLER PANEL BOTTOM RIGHT CANOPY TOP COVER ASSEMBLY RADIATOR CAP ACCESS STUD TURN LOCK FASTENER V24248 N o...

Page 328: ...ERATOR DIVISION s B QQ HOBART BROTHERS COMPANY 4 e 0 I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Generator Set Without Canopy Figure 3 _ 7 3 I Page 6 ___ Ott 30 73 __ _ ...

Page 329: ...T CANOPY For NHA See Fig 1 BOX ASSEMBLY CONTROL For details see Fig 4 RADIATOR AND COOLING SYSTEM For details see Fig 11 FLOORPLATE AND PEDALS GROUP For details see Fig 12 or 12A STEERING GROUP For details see Fig 14 ENGINE AND DRIVE TRAIN GROUP For details see Fig 16 SEAT AND TRANSFORMER RECTIFIER GROUP For details see Fig 25 AXLE GROUP For details see Fig 31 VEHICULAR LIGHTS GROUP For details se...

Page 330: ... L ...

Page 331: ...4567 BOX ASSEMBLY CONTROL For NHA See Fig 3 TRAY ASSEMBLY GENERATOR CONTROL For details see Fig 5 TRAY ASSEMBLY PROTECTIVE RELAY For details see Fig 6 TRAY ASSEMBLY VOLTAGE RE G ULATOR For details see Fig 7 PANE L ACCESS SIDE PANE L ASSEMBLY POWER MODULE For details see Fig 8 GROMMET RUBBER V92850 No AGW 9611 GROMMET RUBBER V92850 AGW 1501 PANEL REAR FRON T PANE L AN D IN STR UMEN TS GROUP For det...

Page 332: ...IOTOR GENERATOR DIVISION HOBART BROTHERS COMPANY OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Generator Control Tray Assembly Figure 5 7 3 Page 10 act 30 73 ...

Page 333: ...A See Fig 4 METER FREQCRNCY 380 TO l 420 HZ VOLTMETER 0 TO 300 V AC AMMETER OTO 500A SWITCH ROTARY METER SELECTOR VO4009 No 81579 FT SWITCH TOGGLE V73559 No 2GL61 TABS PLATE INSTRUCTION SWITCH T a AUTOMATIC MANUAL CONTROL VO4009 No 80950 BRACKET SWITCH RESISTOR 50 OHM 100 WATT V44655 N o 0959 RESISTOR 25 OHM 100 WATT V44655 N o 0958 BRACKET RESISTOR V44655 No 12 KNOB RHEOSTAT V44655 No 5150 PLATE ...

Page 334: ...OPERATION I MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 3 Page 12 Ott 30 73 ...

Page 335: ...HAUL MANUAL TM 240A SELF PROPELLED GENERAT R SET SPEC NO 5381A NOMENCLATUXE UN ITS FIGURE HOBART IlEM NO PART NO 1234567 EFF A 5 25 382813 SCREW TRAY FASlENING 2 26 W l 1250 WASHER SCREW RETAIN IN G 2 I 28 27 404028 385785 TRAY NAME PLATE HOBART act 3op3 June x 74 Revked 7 3 Page 13 ...

Page 336: ...GENERATOR DIVISION HOwd T BROTHERS COMPANY OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPEiLED GENERATOR SET SPEC N 0 5381A I Protective Relay Tray Assembly _ Figure 6 ...

Page 337: ...L TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A NOMENCLATUiE 1234567 No tip 14DG RE LAY OVERVOLTAGE RE LAY UN DERVOLTAGE RE LAY UNDERFREQLENCY RElAY OVERFREQUENCY iNOT USED IN THIS APPLICATION SWITCH TOGGLE TEST BANK V73559 No 2GK71 73 RING LOCKING SWITCH BRACKET SWITCH MOUNTING TERMINAL CONNECTOR HOUSING CONNECTOR BOARD ASSEMBLY PROTECTIVE MON ITOR WASHER SHOULDER FIBER MOUNT SHOCK PROlECTlV...

Page 338: ......

Page 339: ...l 7 33 26 37 38 3GGii 122 3G l 723 30 41 42 33 44 45 46 333323 30 2 3777CA 370332A x4913 33912 332818 W l 1250 3 7771A 404028 402360 47 48 1570 ErF UN ITS per ASSY 2 1 5 1 1 I I I 1 I i I I 1 I 2 2 1 1 O ct 30 73 7 3 J r e 25 74 Reviced Pqs 17 ...

Page 340: ...GENERATOR DIVISION 0 z HOBART BROTHERS COMPANY b I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 538114 _ _ _ J 3 P_w 18 _ _ Voltage Regulator Tray Assembly Figure 7 act 30 73 _ _ _ ...

Page 341: ... ii ni rL I7 ...

Page 342: ...GENERATOR DIVISION HOBART BROTHERS C0MP m 7 3 Page 20 Power Mod vie Pane I Asse Figure 8 Revised June 25 74 ...

Page 343: ...FORMER CURRENT ASSY 3 j TRANSFORMER CURRENT V86151 3 3713A __ I _ 6 RESISTOR OVERLOAD BURDEN 7 5 i WATT 25 OHM V91637 Type RH 1 1 j 3 BRACKET MOUNTING RESlSTOI 3 SPACER TRANSFORMER CURRENT i V4302 1 24 PANEL TRANSFORMER 1 lNSUL 4TOR PANEL TRANSFORMER BRACKET MTG BOARD OVERLObb y I 1 MOUNT SHOCK RUBBER V89616 B 323 4 WASHER FIBER SHOULDER 4 BOARD OVERLOAD 12 V kS Su 1 CAPAC ITOR 0 1 MFD 500 V 3 REC...

Page 344: ...GENERATOR DIVISION HOBART BROTHERS COMPANY OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 3 Page 22 act 30 73 ...

Page 345: ...ABLE ASS Y POWER E LECTR ICAL No I _ 2 1 i 110 Neutral Output terminal panel I I to ground stud on control box support i l i 29 w 9407 197 CABLE ASSY POWER ELECTRICAL No 112 Phase A Stator termina1pane I to _ i i 1 transformer rectifier terminal block No I il 1 I 113 Phase lg Stator terminal panel to _ _ e I transformer rectifier terminal block I 1 I 30 W 9407 201 CABLE ASSY POWER ELECTRICAL No 11...

Page 346: ... BROTHERS COMPmY 4 1 1 B OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPE i iED GENERATOR SET SPEC NO 538lA 21 23 24 Control Box Front Pane I Instruments and Controls _ _ _ _ __ _ Figure 9 7 3 __ _ ___ _ _ _ _ Page 24 _ _ bet a 73 r a _ _r zz ...

Page 347: ...ER DC 60 AMP HOURMETER V26992 No 771 4150 FUSEHOLDER FUSE V71400 TYPE AGC 10 AMP GAGE PRESSURE ENGINE OIL GAGE TEMPERATURE ENGINE COOLANT VO4700 No 8585A LIGHT INDICATING GREEN LENS V72619 No 26 1192 300 BULB V71744 Type 120 MB BASE V72619 No 26 1310 l l 301 SW ITCH TOGGLE PERMISSIVE START AND CONTACTOR OPERATING VJ5434 No 102057 CAP DUST RECEPTACLE CONNECTOR VO2660 No 9760 28 CONNECTOR RECEPTACLE...

Page 348: ...BROTHERS COMPAN OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Control Box and Infernal Components Group Figure JO _ ___ __ 7 3 _ ____ _ _ __ _ _ Ott 30 73 _ _ Page 26 ___ _ __ _ __ ...

Page 349: ...589 5 402379 402382 402381 402377 16DA 5082 W 10051 6 w 10051 5 H F 2962 384910 384911 388917 ZATION V77342 No KAP 14DY SOCKET RELAY VO2660 No 77 MIP 11 BRACKET SOCKET MOUNTING CAPACITOR 6 8 MFD 35 V TERMINAL BOARD V88223 No 441 8 TERMINAL BOARD V88223 No 441 20 TERMINAL BOARD V98410 No 38012 3820 CONNECTOR PLUG VO2660 No MS 3106A 28 16s CLAMP CABLE VO2660 No AN 3057 16 CONNECTOR PLUG VO2660 No MS...

Page 350: ...a YTi w W11131WN 3 z HOBART EROTI ERS COMPANV b I OPERATION MAINTENANCE AND OlPERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 538JA THERMOSTAT EEkYAzJR HOUSING Radiator and Cooling System Group Figure 11 Ott 30 73 ...

Page 351: ...EMBLY SUPPLY CLAMP HOSE V66295 No C52P 1 1 HOSE RUBBER 1 IN I D PIPE STEE L 3 4 IN ELBOW PIPE 45 DEG N SPPLE PIPE CLOSE 3 4 NPT LINE ASSEMBLY VENT CLAMP HOSE V35738 No J340 2 AR 1 2 2 1 HOSE RUBBER J 4 IN I D ADAPTER STRAIGHT TUBE TO l HOSE V30327 No KA04 04NS ADAPTER STRAIGHT PIPE TO l TUBE V79470 No 48 X 4 ELBOW PIPE TO TUBE V79470 No 49 X4A 4X4 2 AR 2 1 CLAMP HOSE TOP V66295 No C32P 1 HOSE RUBB...

Page 352: ... iWOTOR GENERATOR DIVISION d HOBART BROTHERS COMPANV __ _ OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 538JA 7 3 act 30 73 Page 30 ...

Page 353: ...HS COMPANY OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 538JA NOMENClATUiE UN ITS FIGURE HOBART ITEM NO PART NO 1234567 EFF A Y JJ 28 387313 RAIL SIDE 2 29 402958 CORE RADIATOR 1 Ott 30 73 7 3 Page 31 ...

Page 354: ...ATOR DIVISION 2 0 z HOBART BROTHERS COMPANY d OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 538JA Floorplate Pedals and Brake Group Figure 12 __ __ _ _ _ _ 713 _ _ __ _ ___ _ oct wn Page 32 _ _ _ ...

Page 355: ... PULL SPEED CONTROL CABLE V41625 No 32 B 46 PLATE ASSEMBLY FLOOR SPRING EXlENSION ACCELERA TOR PE DAL RETURN CLEVIS CONTROL CABLE ROD CROSSOVER ARM CONTROL CABLE AND RE TURN SPR IN G PEDAL ACCELERATOR BRACKET CONTROL CABLE PLATE FLOOR PEDALS AND BRAKE MASTER CYLINDER ASSEMBLY PAD PEDAL PIN CLEVIS BRAKE PEDAL RING RETAINING PEDAL BRAKE PEDAL CLUTCH FITTING LUBRICATION 90 DEG V95879 No 16138 CLEVIS ...

Page 356: ...FOBAR e QD MOTOR GENERATOR DIVISION a I HOBART BROTHERS COMPANY c 2 4 Q B xta OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 538JA Page 34 ...

Page 357: ... CLUTCH ROD ADJUST ING Not threaded ROD CLUTCH ADJUSTING PIN CLUTCH ROD SWIVEL BEARING PILLOW BLOCK V71956 BRON ZOIL 3 4 INCH BRACKET BEARING MOUNTING LIN K CLUTCH ROD KEY WOODRUFF SHAFT CLUTCH THROWOUT BRAKE LINES ASSEMBLY TUBE ASSEMBLY COPPER l MASTER CYLINDER TO REAR AXLE TUBE ASSEMBLY COPPER MASTER CYLINDER TO TEE FRONT BRAKES TUBE ASSEMBLY COPPER TEE TO RIGHT FRONT BRAKE TUBE ASSEMBLY COPPER ...

Page 358: ...ERATOR DIVISION 3 HOFJARf BROTHERS COMPAN OPERATION MAINTENANCE AND OMRHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 538JA 23 Floorplate Pedals and Brake Group Figure J2A 7 3 Page 35A Revised June 25 74 ...

Page 359: ... A I _ 1234567 4 ARM CROSS OVER THROTTLE t ASSEMLY SPRING Vi6053 8136 l ROD CROSS R PLATE FLOOR ASSEMBLY PIATE INSPECTION MASTER l CYLINDER PLATE FLOOR REAR SECTION Not required this applic on CYLINDER BRAKE MASTER WITH PE D A tiLy m I BRACKET gDAL sCLUTCH I ASSEMBLY PEDAL BRAti CLUTCH l ASSEMBLY BRACKET PEDAL BRAKE ASSY RING RETAINING EXTERNAL BRACKET BRAKE CLUTCH l PEDALS ASSEMBLY YOKE V31007 J4...

Page 360: ...FOBART a QD UlOTOR GENERATOR DIVISION w HOBART BROTHERS COMPANY a if b B l e 0 PERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 3 Page 35C Revised June 25 74 ...

Page 361: ...SFEC NO 538JA _ a I 1 EY WOODRUFF 89 a i BEARING PILLOW BLOCK v71955 Br il 3 4 In BRACKETi MOUNTING p LLO BLCCI LlNES ASSEMBLY BRAKE i TUBE jSEMBLy COPPER MA R CYL1NqER TO REAR t j 3 J tt y R I 38 402454 39 J 366 40 401662 30FP 1113 June 25 74 Revised MASTER CYLlNQER TO TEE FRQNT BRAKES TUBE ASSEMBLY COPPER TEE TO LEFTFRONT BRAKE TUBE ASSEMBLY COPPER TEE 1 TO RiGHT FRONT BRAKE TEE UN ION V79470 70...

Page 362: ...z f E HcmlRT BROTHERS COMPANY b OPERATION MAINTENANCE AND OVERHAUL MAN UAL TM 240A SELF PROPELLED GENERATOR SET SEC NO 5381A Hydraulic Brake Master Cylinder Figure 13 _ _ _ __ __ __ _ 75 _ _ act 30 73 __ ____ __ _____ _ _ Page 34 _ _ _ _ ...

Page 363: ...mber 10 No Number act 30 73 NOMENCLATME 1234567 CYLINDER HYDRAULIC BRAKE MASlER V63477 No FE 42194 For NHA See Fig 12 CAP V63477 No FC 16500 GASKET CAP V63477 No l FC 6019 BOOT V63477 No FD 23090 RING RETAIN ING V 63477 No FC 11720 WASHER V63477 No FC 5133 PISTON V63477 No FC 1338 CUP V63477 No FD 962 SPRING V 63477 No FC 1318 BODY V63477 No FE 41208 PARTS KIT MASTER CYLINDER RE PAIR V63477 No FC ...

Page 364: ...7 3 Page 38 OPERATION MAiNTE NANCE AND QVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SAC NO 5381A Steering Group Figure 14 Revised June 25 74 ...

Page 365: ...AMP INCANDESCENT VO8108 No 53 FLASHER V77977 No 180 Located on rear of control box instrument panel WHEEL STEERING V77915 No 586 CLAMP STEERING COLUMN COLUMN ASSEMBLY UPPER V77640 No UC28 177 PARTS KIT HORN BUTTON AND SWITCH V77640 No 465530 COLLAR RUBBER STEERING COLUMN COVER RUBBER FLOOR PANEL HOLE e SUPPORT STEERING COLUMN UPPER SUPPORT STEERING COLUMN LOWER SUPPORT STEER IN G COLUMN LOWER UNIV...

Page 366: ...RT B ZMOTOR GENERATOR DIVISION 0 QD z HOBM7T BROTHERS COMPANY 43 4 lw OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 24OA SELF iR0PELLE D GENERATOR SET SPEC NO 5381A 16 Steering Gear Page 40 _ __ _ _ __ _ _ _ ...

Page 367: ... 3AEoo SHIM WORM COVER V77640 N o 253VM003 SHIM WORM COVER V77640 No 24DC03 SHIM WORM COVER V77640 No 24DC04 SHIM WORM COVER 07640 No 24DC05 CUP BEARING UPPER V77640 l No 400078 BEARING BALL THRUST V77640 No 400081 Al SHAFT WORM V77640 No 253 JAOO4 CUP BEARING LOWER V77640 No 400056 N UT ADJUSTING SCREW V77640 No 3100 COVER SHAFT V77640 No 253TMOOO GASKET COVER V77640 No 24DF04 RING RETAINING V776...

Page 368: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 538iA 7 3 Page 42 Engine and Drive Train Group Figure 16 Ott 30 73 ...

Page 369: ...34 No 191818 BRACKET REGULATOR MOUNTING CAPACITOR 0 5 MFD V90201 No B 206020 SWITCH TEMPERATURE SENSING l V75418 No 33080 205 SW iTCH LOW OIL PRESSURE SHUT DOWN V75418 No C 25900 10 DIODE FLY BACK SlLiCON 400 PRV 1 5 AMP FUEL AND OIL LINES GROUP For details see Fig 19 FILlER ASSEMBLY FNL V15434 N o 156164 BRACKET FtiL FILTER MOUNTING KIT QUICK START V61112 No CS 3267 207 BRACKET QUICK START MOUNTI...

Page 370: ...7 3 Page 44 OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A act 30 73 ...

Page 371: ...CATOR SERVICE V2 1585 No L 14440 20 KIT IN D ICATOR INSTALLATION V21585 No L 14439 HOUSING AIR CLEANER PIPE AIR CLEANER SUPPORT AIR CLEANER CLAMP EXHAUST PIPE BRACKET EXHAUST PIPE CLAMP EXHAUST PIPE PIPE EXHAUST LEFT PIPE EXHAUST RIGHT MUFFLER AND EXHAUST MAN IFOLD LEFT MUFFLER AND EXHAUST MAN IFOLD RIGHT DRIVE SHAFT V78992 No 7260 116 SAFETY DEVICES GEAR SHIFT l For details see Fig 21 TRANSMISSIO...

Page 372: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Governor and Accelerator Linkage Grpup Eig ure 17 Page W _ ...

Page 373: ...Fig 16 GOVERNOR KIT ELECTRIC HYDRAULIC BOX ASSEMBLY CONTROL LEAD ELECTRICAL JUMPER POTENTIOMETER ASSEMBLY BOX CONTROL MOUNT RUBBER V61463 No B 323 CABIE ASSEMBLY COAXIAL CABLE COAXIAL CLAMP CABLE V66503 No 203908 CONNECTOR PLUG V66503 No 203771 PLUG MAGNETIC PICKUP BALL JOINT V57448 No FR 4Y ROD THREADED GOVERNOR LINKAGE ARM ACTUATOR ARM FUEL PUMP LINES OIL GOVERNOR For details see Fig 18 ACTUATOR...

Page 374: ...SION 2 HOBART BROTHERS COMPANY d OPERATION MAlNlENAN CE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A To RETURN LINE AT REAR OF LEFT BANK Govervor Oil Lines ___ _ Figure 18 7 3 _ _ _ __ _ _ _ _ _ _ _ Page 48 _ __ ...

Page 375: ... LINES OIL GOVERNOR For NHA see Fig 17 CLAMP HOSE V35738 No J340 HOSE RUBBER LOW PRESSURE HIGH TEMP 3 8 IN I D V24161 No 3319 1 6 ADAPTER HOSE TO TUBE V30327 N o KA06 06N S ELBOW MALE V79470 No 49 X 6 ADAPTER PIPE TO TUBE V79470 l No 48 X 6 TEE PIPE V79470 No 3750 X 4 TUBE ASSEMBLY FUEL PUMP TO ACTUATOR ADAPTER PIPE TO TUBE VO2570 No 300 l 2 ADAPTER PIPE TO TUBE VO2570 No 300 l 2 RESTRICTED TUBE C...

Page 376: ...L MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A TO FUEL RETURN ON ENGINE LT SIDE TO LOW OIL PRESSURE 5 SHUT DOWti SWITCH LINE LUB OIL ENGINE TO LOW OIL td URE SWITCH8 OIL PRESSURE TO FUEL STRAINER Fuel and Oi I Lines Group _ _ Figure 19 773 ___ __ __ ___ _ __ _ _ _ __ 3P ____ _ _ kge zL _ _ _ _ _ _ ...

Page 377: ...SE V35738 No J340 HOSE RUBBER LOW PRESSURE HIGH TEMP l 4 IN I D V24161 No 3319 1 4 ADAPTER HOSE TO TUBE l V30327 No KA04 04N S ELBOW MALE V79470 No 49 X 4 N IPPLE PIPE CLOSE l 8 IN NPT TEE PIPE V79470 No 3750 X 2 BUSHING PIPE 3 8 TO l 8 IN E LBOW V79470 No 50 X 4 FUEL LINES GROUP HOSE RUBBER WIRE INSERTED V03924 No 312 8 ADAPTER HOSE TO TUBE V03924 No 7115 8s ELBOW MALE V79470 No 49X8X8 COUPLING P...

Page 378: ...pPERATlON MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Stator Termina l Pane I Assembly Figure 20 7 3 Page 52 Ott 30 73 ...

Page 379: ...INAL For NHA see Fig 16 NUT PLAIN HEX 3 8 16 TERMINAL OUTPUT BUSH ING INSULATOR SCREW CAP HEX HD 3 8 16 X2 IN WASHER LOCK 3 8 IN WASHER FLAT 3 8 IN WASHER INSULATOR BUSH IN G IN SULATOR PANEL STATOR TERMINAL UN ITS AS REF 3 3 3 7 3 Page 53 MOTOR GENERATOR DIVISION d HOEUR BROTHERS C0MPP N OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 1 2 3 4 ...

Page 380: ...TOR DIVISION E HOBART BROTHERS COMPANY OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 3 Page 54 Gearshift Safety Box and Back up Light Switch Group Figure 21 Ott 30 73 ...

Page 381: ...ENCLATURE UN ITS 1234567 EFF AGY GEARSH IFT SAFETY BOX AND BACK UP LIGHT SWITCH GROUP For NHA see Fig 16 SWITCH AND ACTUATOR ASSEMBLY BACK UP LIGHTS REF 1 ACTUATOR SWITCH V91929 No MB273lA SWITCH MICRO V91929 No BZ 2R BRACKET BACK UP SWITCH MOUNTING BOX ASSEMBLY GEARSH IFT SAFETY SWITCH MICRO V91929 l No BZ 2RD IN SULATOR M lCR0 SW ITCH ARM SWITCH ACTUATOR SPACER ARM BOX SWITCH MOUNTING PLATE BOX ...

Page 382: ...TOR DIVISION z 0 z HOBART BROTHERS COMPANY b c 11 1 OPERATION MAINTENANCE AND OVERHAUL MAN UAL TM 240A SELF PROPE LLED GENERATOR SET SPEC NO 5381A Transmission Assembly _ _ __ __ _ ____ Figure 22 7 3 _ _ _ ____ _ _ _ Page 56 _ ...

Page 383: ...SHER SPRING RETAINING V79410 4497 SPRING CONTROL LEVER V79410 4498B LEVER GEARSH IFT HOUSING CONTROL V79410 T87D 148 RAIL LOW REVERSE SHIFT V79410 T87D 2 1 PLUG EXPANSION V79410 103892 RAIL SECOND HIGH SHIFT V79410 T87D 20 BALL DETENT V79410 453593 SPRING BALL V79410 T8B 42 FORK SECOND HIGH SHIFT V79410 T87D 23B PLUNGER INTERLOCK V79410 T87 86 PLUG PLUNGER ACCESS V79410 4572 D SCREW SHIFT FORK LOC...

Page 384: ...7 3 Page58 OPERATION MAINIENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A OCP30 73 ...

Page 385: ...9410 114605 RETAINER MAIN DRIVE BEARING V79410 T87D 6B GASKET BEARING RETAINER V79410 l T87D 145B RING SNAP MAIN DRIVE GEAR v794 10 4745 RING SNAP BEARING V79410 l T97 6 l 2 BEARING BALLMAIN DRIVE V79410 X3206MG WASHER OIL RETAINER V79410 T81 137H GEAR MAIN DRIVE V79410 T87E 16C PLUG OIL DRAIN 3 4 PIPE V79410 103881 CASE TRANSMISSION V79410 l T87D 1 BEARING ROLLER V79410 T97 26 PLUG OIL LEVER V794...

Page 386: ...OXRATION MAI NTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 3 Page60 Ott 30 73 ...

Page 387: ...V79410 T87D 28 WASHER THRUST COUN TERSHAFT INNER REAR V79410 T87D 32 WASHER THRUST COUNTERSHAFT l OUTER REAR V79410 T87D 33 GEAR REVERSE IDLER ASSEMBLY V794 10 AT870 10 GEAR REVERSE IDLER V79410 l l T87D 10 BUSHING GEAR V79410 T74 85 SHAFT ASSEMBLY MAIN lAT870 2C SHAFT MAIN V79410 T87D 2C WASHER OIL RETAINING V79410 l T90A 136 BEARING BALL MAIN SHAFT V794 10 X3320G RING SNAP BEARING V79410 l 79OA ...

Page 388: ...w s P CID mUtUn uLl at nn WN OIVISION f Y 0 c HOBAR BHOII4IRSCOMPAW 46 I Q OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 3 Page 62 Ott 30 73 ...

Page 389: ...14606 BOLT HEX HD 3 8 16 X 1 V79410 179839 BOLT HEX HD 3 8 16 X 2 v794 10 179847 SPRING ANCHOR CLIP V79410 A21 11 BOLT BRAKE DRUM V79410 l 452OY F IAN GE V79410 4547M DRUM AND FLANGE ASSEMBLY V794 10 2A4547M DRUM BRAKE V79410 4508RR y io R LOCK 7 l 6 V79410 NUT HEX 7 16 20 V79410 103027 PIN COTTER l 8 X l 3 4 V79410 103388 NUT HEX CASTELLATED l 20 V79410 Jl 50 BAND BRAKE V79410 4AA24 12 BOLT HEX H...

Page 390: ...OPERATION MAIN XNANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 3 Page 64 Ott 30 73 ...

Page 391: ...DJUSTiNG BOLT V79410 A22 2 1G SPACER SPR iN G V794 10 A22 22 G SPRiNG ERAKE RELEASE V79410 A26 9 t30LT SAKE ADJUSTiNe V79410 A22 7H STUD LiNK V79410 4302C LiN K SRACE A24 2OE S ACER V79410 PiN CAM LELZR V794JO Xl290 PiN i 3D END V79410 X1283 LEE GRAKE CAM V7 410 A22 20 END tZAKE ROD ADJUS i MErNT A22 1 1 2C PiN CCIrIER l 8 X 7 8 V79410 108630 LEVER HAND ERAKE i i D CaNNEChNS HAND G IAE E SHAFT LQN...

Page 392: ...DlVlSlON f HOBART BROTHERS COMPANY 0 c s Q OPERATlON MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Clutch Group _ __ _ Figure 23 7 3 _ ___ ____ ___ act 30 73 _ ___ _ _ _ _ ___ _ Page 66 _ ____ ...

Page 393: ... see Fig 16 SPRING HE LICAL RE LEASE SLEEVE SLEEVE ASSEMBLY CLUTCH RELEASE BEARING BALL V71000 No A2256 14 SLEEVE RELEASE V71000 No CL 2394 CLUTCH ASSEMBLY FRICTION ATTACH IN G PARTS SCREW CAP HEX HD 3 8 16 X 3 4 IN WASHER LOCK 3 8 IN mm m m COVER CLUTCH ATTACH IN G PARTS NUT HEX V71000 No 4905 m w Mm SPRING HELICAL COMPRESSION V71000 42 14 PIN RELEASE LEVER V71000 No 3696 EYE BOLT V71000 6287 SPR...

Page 394: ... _ K9 3 wrrrw w L we I aw CI z HOBART BROTHI RSCOMPAN c I OPERATION MAIN IENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET WC NO 5381A Generator Group Figure 24 7 3 Page 68 Ott 30 73 ...

Page 395: ...N G ASSEMBLY UN ITS EFF ACY REF FAN RADIAL SIX DUAL BLADE TYPE COUPLING FLEXIBLE GENERA TOR TO ENGINE HUB FLEXIBLE COUPLING kEY MACHINE HUB ARMATURE EXCITER DIODE NEGATIVE 35 AMP V84970 No ST46ON DIODE POSITIVE 35 AMP V84790 No ST46OP BEARING SLEEVE CLUTCH PILOT PIN SPRING V56878 No 21 S 187 0500 KEY MACHINE EXCITER HOUSING EXCITER POLEPIECE INSULATION POLEPIECE WINDINGS EXCITER FIE LD BRACKET FRO...

Page 396: ...SION HOESRT BROTHERS COMPANY OPERATION MAINIENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Seat and Transformer Rectifier Group Figure 25 7 3 _ _ _ _ Ott 30 73 _ _____ _ age 7_0 _ _ ___ ...

Page 397: ...SHION SEAT BOTTOM PANE L ASSEMBLY OUTPUT TERMINAL For details see Fig 26 SEAT SINGLE COVER TRANSFORMER RECTIFIER SUPPORT COVER TRANSFORMER RECTIFIER SUPPORT LEFT COVER TRANSFORMER RECTIFIER l SUPPORT RIGHT A B C B C SUPPORT STATOR LEADS CLAMP CABLE BRACKET CABLE CLAMP WIRING HARNESS T R LINE DROP AND CURREN T LIM ITIN G CONNECTOR PLUG WIRING HARNESS PANEL ASSEMBLY TRANSFORMER RECTIFIER TERMINAL Fo...

Page 398: ...FOBART a QD EMOTOR GENERATOR DIVISION a 2 HOBART BROTHERS COMPANY c 2 B 8 OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 3 Page 72 Ott 30 73 ...

Page 399: ...0 34 W 9407 198 35 w 9407 199 NOMENCLATURE BOX CABLE PLUG AANGER 112 v T R CABLE PLATE CANOPY REINFORCEMENT FOR HANGER SUPPORT 112 V CABLE HANGER TRANSFORMER RECTIFIER 112 V DC For details see Manual No TM 237 0 CONDUIT CABLE 112 V T R SUPPORT 112 V T R SPACER TRANSFORMER RECTIFIER 28 5 V DC For details see Manual No TM 197 SUPPORT SEAT AND T Rs PANE L SIDE B C C C C C C C C B CABLE ASSEMBLY TERMI...

Page 400: ...DIVISION m 0 QQ 2 HOBART BROTHERS COMPANY 4f I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Output Terminal Panel Assembly _ _ 7 x _ Page74 _ _ __ Figure 26 _ _____ _ _ Ott 30 73 ...

Page 401: ...D OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A NOMENCLATUIE 1234567 EFF PANEL ASSEMBLY OUTPUT IERMINAL For NHA See Fig 25 NUT PLAIN HEX 3 8 16 TERMINAL OUTPUT BUSH IN G INSULATING SCREW CAP HEX HD 3 8 16 X2 IN WASHER LOCK 3 8 IN WASHER FLAT 3 8 IN WASHER FIBER BUSHING INSULATING NUT PLAIN HEX l 4 20 WASHER LOCK l 4 IN WASHER FLAT l 4 IN WASHER INSULATING ROD THREADED l 4 20 X...

Page 402: ...WOTOR GENERATOR DIVISION a E HOBART BRCITHERS COMPAN b 8 c OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC N 0 5381A Transformer Rectifier Terminal Panel Assembly P age76 _ _ _ _ ...

Page 403: ...240A SELF PROPELLED GENERATOR SET SPEC NO 5381A W 11242 5 WASHER FLAT l 4 IN lODH 244 BOARD TERMINAL lODH 239 STRIP INSULATING 389830 BRACKET TERMINAL BLOCK NOMENCLATURE 1234567 PANEL ASSEMBLY TRANSFORMER RECTIFIER TERMINAL For NHA See Fig 25 NUT PLAIN HEX 3 8 16 WASHER FLAT 3 8 IN WASHER LOCK 3 8 IN WASHER LOCK 3 8 IN SCREW CAP HEX HD 3 8 16 X 2 NUT PLAIN HEX l 4 20 WASHER LOCK l 4 IN SCREW CAP H...

Page 404: ...MOTOR GENERATOR DIVISION 9 c c HOBART BROTHERS COMPANV 4 4 I 6 OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Vehicular Lights Group I Figvre 28 _ act 30 73 Page 78 __ _ ...

Page 405: ...ICULAR LIGHTS GROUP For NHA See Fig 3 HEADLIGHT V73331 No 898305 LAMP SEALED BEAM V73331 No 5947212 DIRECTIONAL LIGHT VEHICULAR V75175 No KD766A 12 LAMP INCANDESCENT VO8108 NO 1073 STOPLIGHT TAIL LIGHT VEHICULAR V75175 No KD766ST 12 LAMP INCANDESCENT VO8108 No 1034 LIGHT BACK UP V75175 No KD766 2338 12 LAMP INCANDESCENT VO8108 No 1073 LIGHT MARKER CLEARANCE V75175 No KD541 1640 12 LAMP INCANDESCEN...

Page 406: ...GENERATOR DIVISION HOBART BROTHERS COMPAN OFERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Bodyand Frcme Figure 29 7 3 Page80 Revised June 25 74 _ _ ...

Page 407: ...Details See Fig 30 SUPPORT BATTERY CLAMP WIRE HARNESS V76369 No MIN E30 l 2 TW BODY AND FRAME ASSEMBLY FENDER REAR LEFT ASSEMBLY TREAD SAFETY STOP SIDE LEFT ASSEMBLY SIDE LEFT BODY ASSEMBLY DOOR ACCESS BATTERY FRONT ASSEMBLY DOOR ACCESS BATTERY REAR ASSEMBLY WASHER SOUTH CHESTER CORP V24248 Style 7PT 10014 l 1 KNOB FASTENING PANEL SIDE LEFT BODY ASSEMBLY FENDER FRONT LEFT ASSEMBLY BUMPER FRONT ASS...

Page 408: ...GENERATOR DIVISION HOBART BROTHERS COMPANY OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 3 Page82 Revised June 25 74 ...

Page 409: ...554 3 NOMENCLATURE 1234567 EFF VALVE DRAIN FUEL V79470 No 145 GAUGE FUEL GASKET FUEL GAUGE Furnished with gauge CAP FUEL TANK V49234 No 1273A BOX CABLE ASSEMBLY Mountedon Right Side CLAMP CABLE BRACKET CLAMP CABLE BOX CABL E ASSEMBLY BOX PLUG ASSEMBLY PANEL SIDE BOX PANEL REAR BOX BOX MICRO SWITCH OUTPUT CABLE SUB ASSEMBLY SWITCH MICRO V91929 No BZ 2R AND ACTUATOR No MB2731A PANEL HINGED SUB ASSEM...

Page 410: ...ZMOTOR GENERATOR DIVISION 2 HOBART BROTHLRS COMPAN OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A i GROUND Battery Group Figure 30 act 30 73 7 3 Page84 ...

Page 411: ...78 l 5CW 2048 388635 403492 1 NOMENCLATUZE 1234567 EFF BATTERY GROUP For NHA See Fig 29 CABLE ASSEMBLY BATTERY CONNECTOR CABLE ASSEMBLY BATTERY CONNECTOR CABLE ASSEMBLY BATTERY TO STARTER POSITIVE CABLE ASSEMBLY BATTERY TO GROUND NEGATIVE CABLE ASSEMBLY BATTERY TO GROUND NEGATIVE ROD BATTERY CLAMP CLAMP BATTERY HOLD DOWN BATTERY STORAGE 6 VOLT AABM Group 7D Type HDD 70 CABLE ASSEMBLY GROUND ENGINE...

Page 412: ...ERATOR DIVISION a 2 HOBART BROTHERS COMPANY c b L1 J OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Axle Group _ _ _ _ _ _ Figure 31 7 3 __ act 30 73 _ _ _ __ _ ___ _ __ qage86 ...

Page 413: ...L REAR SPACER REAR WHEEL AXLE ASSEMBLY FRONT WITH SPRINGS HOSE ASSEMBLY FRONT BRAKE V12204 No 1119402 ADAPTER BRAKE HOSE V63477 No FC 3963 FITTING LUBRICATION V95879 No 1610 B BOLT SPRING SHACKLE BOLT U SPRING MOUNTING HANGER SPRING OUTER HANGER SPRING INNER SPRING FRONT TWO LEAF l 06534 No 6MC 08 AXLE FRONT Modified Rockwell StandardAxle No 32552 F 6 DRIVE SHAFT ASSEMBLY l No 7200 116 V78992 AXLE...

Page 414: ...FOBART I s QQ MOTOR GENERATOR DIVISION z c 2 HOBART BROTHERS COMPANY 42 Q BL13 OPERATION MAINTENAN CE AND OVERHAUL MAN UAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 3 Page 88 Ott 30 73 ...

Page 415: ...VERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A NOMENCLATURE UN ITS FIGURE HOBART Per ITEM NO PART NO 1234567 EFF ASSY 31 28 4022 10 SPRIN G REAR TWO LEAF V76534 No 6MC 08 2 29 384847 PLATE SPRING MOUNTING 2 30 402209 AXLE AND TRANSFER CASE V78500 No 35 3105 1 Ott 30 73 7 3 Page89 ...

Page 416: ...FOBART I z 0 QQ MOTOR GENERATOR DIVISION 2 HOBART BROTHERS COMPAN d OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A 7 3 Page90 Ogt 3y73 ...

Page 417: ...don Right Side PLUG BOX ASSEMBLY PANEL BOX THIN PANEL BOX THICK BOX ASSEMBLY CABLE PLUG PANEL HINGED SWITCH ASSEMBLY MICRO SWITCH MICRO V91929 No BZ 2R ACTUATOR SWITCH V91929 No MB2731A PARTITION BOX cABlES TERMINAL BLOCK TO T R PLATE COVER T R SUPPORT Not Req d PLATE FLOOR BetweenSeat T R PLATE FLOOR Between T R Fenders SUPPORT CABLE OUTPUT TRANSFORMER RECTIFIER ASSEMBLY 112 V For Details See Man...

Page 418: ...FOBART 0 s 0 QQ EMOTOR GENERATOR DIVISION c 2 HOBART BROTHERS COMPANY 9 c BIG OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SFEC NO 5381A 7 3 Page92 Revised June 25 74 ...

Page 419: ...st andfar Below a part number 1000 The figure numberand item number location of the part is directly oppositethe part If the part is used in morethan one place each location is listed commencing with the first location the part is listed NUMERICAL INDEX FIGURE PART NUMBER ITEM N UMBER A 25 ACTUATOR SWITCH AXLES AND DRIVE SHAFT GROUP AXLE GROUP B 93 BATTERY GROUP BEARING BALL THRUST BEARIN G BALL B...

Page 420: ... DW 1704 DW 4437 DW 6080 DWP 1186 O DWP 1804 l DWP 560 DWP 982 ENGINE AND DRIVE TRAIN GROUP EYEBOLT FILTER ASSEMBLY FUE L FLANGE SENDER FLASHER FLOORPLATE AND PEDALS GROUP FLOORPLATE PEDALS AND BRAKE GROUP FRONT PANELAND INSTRUMENTS GROUP FE L LINES GROUP FUSE FW 1312 GASKET CAP I GASKET COVER I GASKET FUEL GAUGE N umericaI Index 7 4 Page2 FIGURE ITEM NUMBER 22 57 13 l 25 9 16 38 23 O 23 4 23 5 4 ...

Page 421: ... REVERSE IDLER 22 56 GEAR SECOND 22 46 GEARSHIFT SAFETY BOX AND BACK UP LIGHT SWITCH GROUP 21 o GENERATOR GROUP 24 O GENERATOR SET WITHOUT CANOPY l 5 3 o GOVERNOR AND ACCELERATOR LINKAGE GROUP 17 O 11 22 5 4 24 16 9 7 9 7 9 o lo 16 29 l 1 15 17 22 43 LAMP LAMP IN CAN DESCEN T LAMP SEALED BEAM LEVER RE LEASE NUT N UT AD JUSTIN G SCREW NUT HEX NUT HEX CAS IELLATED NUT HEX STEEL OIL LINE ENGINE TO OI...

Page 422: ...EW ADJUSTING SCREW FIL HD SCREW RD HD SEAL PlAlN ENCASED SEAT AND TRANSFORMER RECTIFIER GROUP SENDER FUEL GAGE SHAFT ASSEMBLY MAIN SHAFT WORM SHIM WORM COVER SIDE BODY LEFT SLEEVE RELEASE SPACER SPRIN G SPRING SPRIN G AD JUSTIN G BOLT SPRING ANCHOR CLIP SPRIN G AN TI RATTLE SPRIN G HE LICAL COMPRESSION STEERING GEAR GROUP STEER IN G GROUP STRUT RELEASE LEVER STUD LINK SWITCH MICRO N umericaI Index...

Page 423: ...GHTS GROUP 25 20 29 4 9 21 9 13 1 o l 2 25 3 1 l 3 25 27 29 39 18 O 3 7 w 10051 5 W 10051 6 W 10072 1 W 10072 3 w 101 19 4 w 10750 1 W 10760 10 W 10761 1 10842 5 W l 0853 4 W 10863 6 W 10869 2 W 10869 3 W l 0869 7 W 10874 1 W 10875 1 W 10886 1 W 10886 3 W 10886 10 W 10891 1 W 10891 2 W 10891 7 W 10891 9 W 10892 4 W 10893 0 W l 0893 2 Ott 30 73 June 25 74 Revised 28 O 29 l 10 15 10 14 24 18 24 17 1...

Page 424: ... 1242 l 8 1 250 I W l 1254 4 W l 1254 6 W l 1262 6 W l 1278 5 W l 1280 2 I W l 1282 W l 1330 W l 1439 1 W l 1477 1 W l 1563 W 2974 K W 2974 L W 7814 1 W 7814 5 W 799F 136 W 799G 165 N umericaI Index 7 4 Page6 NUMERICAL INDEX CONT D FIGURE ITEM NUMBER 19 3 19 6 18 6 20 4 26 4 27 5 27 3 6 28 9 8 9 19 16 15 26 l 1 27 9 20 6 27 2 26 6 5 26 6 43 7 5 29 10 26 10 27 7 20 5 26 5 27 4 20 l 26 l 27 l 27 6 2...

Page 425: ...v Y 680 l CZ 129 lCZ 48 1cz 74 lCZ 93B 1ODH 239 1ODH 244 1ODH 845 O lODH 846 3 1ODH 847 2 lOJ 178 lOOGH 112 lOOGH 142 lOOGH 386 1OOGH 829 4 1OOGH 832 act 30 73 June 25 74 Revised SELF PROPELLED GENERATOR SET SPEC NO 5381A NUMERICAL INDEX CONT D FIGmE ITEM NUMBER 12 42 5 3 5 2 30 9 25 34 25 35 17 l 1 26 13 29 48 8 3 6 20 5 l 9 6 13 5 15 l 1 22 20 22 24 22 68 22 72 22 80 22 87 22 91 9 5 8 2 1 8 6 6 ...

Page 426: ... 16DA 4052 0 16DA 4117 16DA 4133 16DA 4210 16DA 4249 16DA 4i53 1 11 1 16DA 5082 16DA 954 4 3AY 84 3OFP 1113 3OFP 874 3OFP 877A 3OFP 975 2 2 14 2 13 5 16 8 O 24 19 6 l 10 l 10 13 24 10 21 8 12 40 22 106 23 O 12 33 3OFP 975 5 12 35 3OFP 975 10 12 36 3OFP 975 12 12 34 30GH 1262 9 3 30GH 718 6 35 30GH 719 6 36 N umericaI Index 7 4 Page8 NUMERICAL INDEX CONT D FIGURE ITEM NUMBER 24 13 24 14 8 16 22 l 1...

Page 427: ...35033 1 2 352278 O 352281 352289 355140 363771 5 370382A 380471 380520 6 381439 382743 382813 382818 383297 1 383766 384178 2 384183 l 384204 384225 I 384380 384233 384563 I 384575 384815 384817 act 30 73 June 25 74 Revised NUMERICAL INDEX CONT D FIGURE ITEM NUMBER 6 33 6 34 6 37 6 38 9 10 28 12 23 6 28 l 2 l 16 13 18 9 8 7 8 8 2 15 2 o 2 16 16 12 5 20 5 23 6 40 7 2 22 105 24 2 1 5 15 21 4 5 25 6 ...

Page 428: ...84935 o 384950 384960 384968 384974 384977 385105 385151 385171 385265A 385275 385785 385812 385813 385814 385992 386000 386030 N umericaI Index 7 4 Page 10 NUMERICAL INDEX CONT D FIGURE 8 ITEM NUMBER 12 26 12 32 22 107 31 3 31 10 31 l 1 31 26 31 12 31 27 31 25 31 29 10 17 1o o 5 o 6 O 7 o 5 24 6 41 7 3 5 19 6 27 2 4 12 29 12 13 12 23 12 14 12 10 31 22 22 5 12 17 17 3 11 4 5 o 5 27 8 3 8 2 8 l 2 2...

Page 429: ...63 386164 386269 386277 386368 386374 386375 386612 386655 386693 386718 386772 386787 386829A 1 386884 386890 38692 1 387055 387095 387129 1 387249 l 387256 3873 13 387537 1 387544 act 30 73 June 25 74 Revised FIGURE ITEM NUMBER 2 18 2 o 2 9 2 8 2 10 2 o 2 l 1 2 12 29 29 29 18 29 5 29 20 29 14 2 6 2 5 21 10 14 9 14 10 24 22 14 16 17 12 12 7 24 20 8 8 4 3 7 o 7 2 7 6 8 12 21 11 31 5 12 o 24 23 24 ...

Page 430: ...387736A 387738A 3877698 l 387770A 387771A 387836 388327A 5 388328 30 388480 o 388635 388771 388777 388779 388794 388808 388813 388823 388827 5 388829 388830 388831 388840 5 38884 1 388843 388848 388855 388856 FIGURE ITEMNUMBER 17 13 17 14 18 O 8 11 8 10 8 4 17 o 4 5 8 O 6 4 6 16 8 15 4 2 6 O 6 O 6 44 8 25 4 l 5 o 6 39 11 O 30 7 29 3 16 27 16 28 29 30 29 26 29 28 29 29 30 3 30 2 30 l 14 13 29 14 30...

Page 431: ...16 I 388917 388932A 388953 388954 388955 388956 388957 388958 388959 388960 388961 388963 388964 388965 388968 388975 388977 388978 388979 388980 388982 388984 389040 I 389130 389227 Ott 30 73 June 25 74 Revised FIGURE ITEM NUMBER 29 25 29 8 29 9 11 O 11 24 11 23 1l 27 3 l 4 o 4 8 4 4 lo 18 29 31 16 10 17 o 17 17 17 19 17 18 17 20 17 21 12 o 12 9 12 5 12 8 12 6 16 8 19 o 16 18 20 O 25 3 26 O 25 4 ...

Page 432: ...389825 389826 389827 I 389830 389834 389868 389869 389870 38992 1 400017 l 400030 1 400078 40008 1 400127 400155 400176 l 400197 400309 400333 1 400400 400575 400589 5 N umericaI Index 7 4 Page 14 NUMERICAL INDEX CONT D FIGURE ITEM NUMBER 25 29 2 23 11 16 25 7 11 18 11 19 25 6 16 31 31 o 30 5 25 5 25 16 16 17 25 13 27 O 25 l 1 25 15 25 28 25 26 27 12 29 39 11 17 16 l 17 o 17 l 17 2 12 12 6 19 1o 5...

Page 433: ...41 40 1472 22 44 40 1473 22 42 401476 22 39 401477 22 40 40 1478 22 48 401479 22 50 401480 22 51 401481 22 52 401482 22 49 401483 22 53 401484 22 54 401485 22 65 401486 22 66 401489 22 28 401490 22 29 401491 22 31 401492 22 33 401493 22 37 401494 22 6 401495 22 8 401497 22 9 401498 22 7 401499 22 12 401500 22 16 401501 22 15 401502 22 14 401503 22 13 401504 22 l 1 401505 22 10 401507 22 l 09 40150...

Page 434: ...0 1570 40 1572 401573 40 1576 401577 401578 40 1579 401580 401584 401585 401586 401587 401588 401589 401590 401591 40 1592 40 1593 401646 401660 401662 401911 3 40191 l 8 40191 l 20 Numerical Index 7 4 Page 16 FIGUIE ITEM NUMBER 22 3 22 4 22 l 22 45 22 55 31 l 21 l 25 O 29 43 6 18 8 13 17 5 8 11 6 15 6 14 8 12 22 17 22 60 22 63 22 2 1 22 62 22 71 22 59 22 64 22 67 22 99 22 102 22 34 22 70 22 77 22...

Page 435: ...2037 12 402037 15 402037 24 4020376 402077 4 402096 402098 402119 8 402208 402209 402210 4022 18 402222 402279 402298 402350 402368 402377 402378 402379 402380 402381 402382 402394 402396 402397 402410 FIGURE ITEM NUMBER 1o 7 22 36 22 35 28 5 28 3 8 14 29 43 2 19 4 6 29 23 4 7 9 l 11 5 16 l 1 l 4 27 8 31 14 31 30 31 13 31 28 5 14 16 35 31 15 31 9 31 24 22 96 28 7 31 4 10 12 5 18 1o 9 6 26 10 l 1 1...

Page 436: ...402809 402826 402834 402835 402836 402837 402907 402908 402935 2 402958 403034 403042 403062 403064 403065 403336 403345 l 403345 2 403379 403380 403477 403478 403492 l 403590 4 403590 5 403708 l FIGURE ITEMNUMBER 17 15 17 9 12 37 22 111 j 11 7 18 l 19 1 17 8 17 7 6 29 6 11 16 40 6 30 2 17 5 7 14 7 14 17 15 o 14 14 14 5 14 15 17 10 8 7 11 29 11 l 2 7 16 23 16 19 16 20 6 12 18 7 18 8 9 15 9 14 16 O...

Page 437: ... 42548 430278 43039 1A 430476 4499A 480069 1 480069 2 480229 480235 1 480289 480354 48043 1 480639 480646 481007 5CW 1932 5CW 1932 O 5CW 2048 5CW 2 127 5cw 975 5CW 976A I 50GH 548 50GHP 19 50GH P 206 Ott 30 73 June 25 74 Revised FIGURE ITEM NUMBER 12 4 6 17 16 22 16 21 16 5 17 4 16 6 31 7 21 5 12 41 31 16 5 2 1 29 24 7 l 6 25 22 108 16 33 16 O 24 3 24 O 24 4 25 12 16 39 24 O 5 8 24 6 25 30 29 38 1...

Page 438: ...2 56531 56532 56534 56535 56551 56552 56553 6FW 2114 8 6FW 343OA 2 6FW 3632 13 6FW 401 3A 6FW 6364 6FW 6368 I 60GH P 1030 60GHP 412 60GHP 413 60GH P 416 I 60GH P 424 60GH P 649 60GH P 936 I 60GH P 945 60GH P 946 I 60GHP 950 N umericaI Index 7 4 Page20 FIGURE ITEM NUMBER 28 13 16 30 12 30 12 l 23 O 22 22 16 37 22 o 22 l 12 1l 25 11 26 21 6 25 25 1l 15 1l 13 11 8 19 2 18 2 19 9 19 14 11 3 16 32 28 9...

Page 439: ...DW P 560 12A 27 FLOORPLATES PEDALS BRAKE GROUP 12A 0 J 366 12A 39 S 5482 32 16 SWITCH MICRO 32 8 w 10863 6 W 7814 4 W 799F 136 W 7995 204 W 9407 198 16DA 1997 4 3OFP 1113 30F P 975 2 30F P 975 5 30F P 975 7 3OFP 975 10 384817 384818 384819 384851 384950 384960 384968 384974 384977 385171 386235 386236 386718 387092 387129 1 act 30 73 June 25 74 Revised 12A 29 16 41 12A 5 12A 24 32 l 1 9 25 12A 41 ...

Page 440: ... 1 400954 401467 401539 401662 401937 2 401937 3 402394 402396 402397 402410 402454 402900 403066 403714 403763 1 404028 404065 1 404172 3 404173 404174 Numerical Index 7 4 Page22 NUMERICAL INDEX CONT D FIGURE ITEM NUMBER 12A 6 12A 2 12A 4 32 14 32 13 32 12 29 36 32 1 32 15 12A 14 12A 31 12A 23 29 22 9 17A 9 l 1A 8 24 12A 16 12A 32 32 7 12A 40 8 23 8 22 12A 18 12A 20 12A 22 12A 21 12A 38 6 46 16 2...

Page 441: ...481607 l 481607 2 481690 481765 481767 481776 481777 481778 5CW 1932 O 50G H 548 50GHP 341 50GHP 379 6FW 5072 60GHP 1030 60GHP 416 60GH P 649 60GHP 936 60G HP 945 60GHP 950 60GHP 951 June 25 74 Revised NUMERICAL INDEX CONT D FIGURE ITEM NUMBER 31 21 14 6 14 12 9 22 12A 7 12A 9 12A 0 9 24 9 23 14 l 1 6 47 31 20 31 19 29 33 29 16 29 17 29 O 29 12 29 7 29 32 32 6 12A 30 12A 8 29 35 32 10 29 38 12A 26...

Page 442: ...R 8 f QQ MOTOR GENERATOR DIVISION c i HOBART BROTHERS COMPANY 0 B l OFERATlON MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A Numerical Index 7 4 Page24 Revised June 25 74 ...

Page 443: ...OE 2 72 Parts Catalog Bulletin No 967144 WoodwardGovernor Company 2301 Proportional Actuator Bulletin 82506B 2301 Twelve volt Control Bulletin 82556A Magnetic Pickups for Electric Governors Bulletin 82510B Regulator Voltage 115 V AC Hobart Brothers Company Operation and Maintenance Manual TM 232 f c r Transformer Rectifier For 5381A Vl only 28 5 V DC Hobart Brothers Company Operation and Maintenan...

Page 444: ...FOBART 4 QQ MOTOR GENERATOR DIVISION HOBART BROTHERS COMPI NI 2 I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 240A SELF PROPELLED GENERATOR SET SPEC NO 5381A J3 9 Ott 30 73 Page 2 _ __ ___I ...

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