Page 1: ...3A 3 Model No 200F H62 Dual Output Specification No 5503A 4 Model No 200F H62P Dual Output Specification No 5503A 5 Model No 2OOF H61 Single Output 5031 MOTOR DRIVE Specification No 5507A 1 Model No 2...
Page 2: ......
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...
Page 4: ...nce When equipment is in operation use extreme care in doing necessary troubleshooting and adjustment MEDICAL AND FIRST AID TRFATMFNT First aid facilities and a qualified first aid person should be av...
Page 5: ...p6 l l 18 Feb 27n6 Feb 27 76 OPERATlON MAlNTENANCE AND OVERHAULMANUALTM 416 MOTOR DRIVEN GENERATORSET SERIES 5503AAND 5507A CHAPTER SECTION l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l...
Page 6: ...n6 3 l 8 Feb 27 76 OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A LIST OF EFFECTIVE PAGES CONT D List of Effective Pages Feb 27 76 Page 2 CHAPTER SE...
Page 7: ...7p6 7 kb27 7 6 8 Feb 27p6 9 Feb27 76 10 Feb27 76 11 Feb 27 7 12 Feb 27 76 13 Feb 27 76 14 Feb 27 76 15 Feb 27p6 16 Feb 27p6 1 oct30 75 2 o 30 75 1 Oct30 75 2 cct30 75 CHAPTER SECT ION 7 l 7 l 7 2 7 2...
Page 8: ...0 75 7 3 56 Ott 30 75 7 3 R Feb 24 76 7 3 58 Ott 30 75 7 3 59 Ott 30 75 7 3 60 Ott 30 75 7 3 61 Ott 30 75 7 3 62 Ott 30 75 7 3 63 Ott 30 75 7 3 64 Ott 30 75 7 4 1 Ott 30 75 7 4 2 act 30 75 7 4 3 act 3...
Page 9: ...the manual to guide and assist operators and maintenance people in the proper use and care of the equipment Use of the manual should not be put off until a trouble or need for help develops Read the...
Page 10: ...OPERATION MAINTENANCG OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A lntr oduc t ion Page 2 Feb 27p6...
Page 11: ...Inspection Lubrication lnsta Ilation Start Run Time Delay Relay Check Operation Genera I Preparation for Power De livery with Automatic Voltage Regulation Power Delivery with Automatic Voltage Regula...
Page 12: ...ing 2 o 1 Maintenance 2 l General Maintenance 1 Inspection 1 Lubrication 1 Parts Replacement 1 Inspection Check 2 2 1 General 1 Exterior Cables and Connections 1 Controls and Instruments 1 Motor Gener...
Page 13: ...ety Fault and Effect Chart Pmtective Monitor Chart Test Point Values Mechanical General Rotor Bearing Trouble Shooting I Removal and Installation RemovaI l nstaf lation Canopy and Sheet Meta General C...
Page 14: ...former Panel Assembly Contactor Pane I Motor Generator Repairs Mechanical Repair General Canopy Electrical Repair General Motor Switch Repair Wiring jhe Unit After Repair or Parts Replacement Overhaul...
Page 15: ...List Arrangement Symbols and Abbreviations Numerical Index Explanation of Numerical index Manufacturer s Literature CHAPTER FIGURE PAGE SECTION NUMBER TITLE NO l l l l l l 1 l l 1 1 l LIST OF ILLUSTRA...
Page 16: ...gle Output Motor Switch Schematic Diagram Dual Output Motor Switch Relay Pane I Transforrrer and Rectifier 18 19 20 22 24 26 27 29 29 31 32 33 34 35 37 l 2 1 Input Terminals 4 l 3 1 Operating Controls...
Page 17: ...2 2 5 2 3 5 2 4 5 2 5 Motor Switch Typical Run Motor Switch Connection Diagram Ail Generator Connection Diagram S ingie Output Control Box Connecticn Diagram Single Output Generator Control Tray Conne...
Page 18: ...bly Front Pane I Assembly Rear Panel Assembly Rear Pane I Assemb iy Front Pane I Asse mb iy Rear Pane I Assemb ly Rear Panel Assembly Generator Set Without Canopy Motor Switch Relay Panel Assembly Mot...
Page 19: ...I Features Detailed Description Motor Generator Control Box Generator control tray Generator output monitors Meter and line switches Automatic manual controls Test panel Protective re lay tray Sens i...
Page 20: ...ulator tray 16 Test pane I 16 Voltage regulator 16 Pushbutton Switch Pane I 16 instrument lights 16 Motor controls and instruments 20 Generator control switch 21 Convenience outlets 21 Resistor 21 Pus...
Page 21: ...or Switch Panel Assembly Motor over load safety system Motor switches Control relay Time de lay re lay 20 25 set onds Terminal boards Motor Switch Re lay Pane I Excitation deenergization relay Time de...
Page 22: ...t ion 1 Mount ing 1 Genera I 1 Mounting cautions 1 Ret ommended mounting instruct ions 2 Mounting surface 2 Pad mounting 2 Leveling pads 2 instructions for use of insulating pads 2 Vibration trouble s...
Page 23: ...egu iator tray Power Delivery with Automatic Voltage Regulation Preparation for Power Delivery with Manual Voltage Control Power Delivery with Manual Voltage Regulation Discontinue Power De livery Del...
Page 24: ...Diagram Voltage Reguiatcr Tray Pushbutton Switch Pane I Dual Output illustrated Load C ontactcr Pane I S ing ie Output Load Contactor Pane I Dual Output Current Transformer Pane I Output Termina I Pa...
Page 25: ...e machines as generator sets Generator output power is used principally for operation of an air craft seiectrica li equipment when the on board generators are not running Refer to Fig 1 for an illustr...
Page 26: ...of machines are identified by a six digit option number When such options are part of your purchase applicable instruction Manuak will be included in the Manu facturer s Data Chapter 8 60 Hz Series Sp...
Page 27: ...panel 7 Motor switch relay panel 8 Motor switch panel 9 Motor switch test panel 10 Motor 11 Lifting yoke 12 Transformer pane I 13 Load contactor panel 14 15 Frame Feb 27 7 6 Genercrtor Set 1 l l Page...
Page 28: ...epower Input cable size minimum Input fuse size maximum Rated speed RPM Excitation 500 MCM 1500 RPM 24 28 V DC GENERATOR Output power rating Volts Amperes rated load capacity Cycles per secand Kilowat...
Page 29: ...ontained unit Motor to generator coupling problems as well as alignment vibration etc are e Iiminated by th is design A feature which maintenance personnel will possibly appreciate most is the instaii...
Page 30: ...ing 6 Generator rotor winding 7 Exciter rectifier 8 Exciter rotor 9 Exciter field stator windings 10 Socket head screw 11 Bearing cap generator end 12 Bearing shim 13 Threaded hole 3 4 10 14 Bail bea...
Page 31: ...g 12 Bearing shim 3 Fan guard 13 Threaded hole 3 4 10 4 Fan 14 Bai I bearing 5 e Generator stator housing 15 Cap screw 6 Generator rotor winding 16 Bearing spacer 7 Exciter rectifier 17 Bearing cap mo...
Page 32: ...ad must be considered in a three phase system This lead is identified as N neutral or ground Later in the manual when we speak of line to neutral voltagei we mean the voltage value between one of the...
Page 33: ...OTOR DRIVEN GENERATOR SET SEtiiES 55Q3A AND 5507A 8 c I f 3 I I 1 Tray fastener 2 Light fixture 3 Fluoresced lamp 4 Generator controls tray 5 Protective relay tray 6 Regulator tray 7 Terminal board 8...
Page 34: ...termining which phase of voltage and current is indicated on the voltmeter and ammeter and whether the voltage is line to neutral or line to line The meter switch 5 is a four pas iticn rotary type A n...
Page 35: ...2 Resistor 20 ohm 100 watt 9 Am meter O 800 A 3 Test panel 1 0 Voltmeter 0300 V 4 Automatic manual switch 11 Frequency meter 380 420 5 Meter selectorsw itch 12 Variable transformer 3 75 amperes 6 Met...
Page 36: ...ual output michjnes is illustrated in Fig 7 1ter m 4 6 and 8 are not required for single output machines With the exception of the quantity of these parts Gesistor 4 interlock relay 6 and test bank sw...
Page 37: ...dervoltage in the generator output An undervoltage condition which continues uninterrupted for a period of 4 to 12 seconds depend ing upon adjustment will cause the time delay circuit to open the load...
Page 38: ...he load contactor shoutd fail to close when the generator control ON switch is operated Another resistor 4 provides the same protection for relay 6 in the dual output unit 9 Fuse interlock relay The f...
Page 39: ...ock relay No 2 output used on dual output only 7 Plug interlock relay No 1 output 8 Test bank switch No 2 output used on dual output only 9 10 11 12 13 10 15 16 17 18 19 Test bank switch No I output F...
Page 40: ...in conjunction with Schematics Figs 8 and 9 and test values Ref 2 3 Fig 2 through 5 b Voltage regulator The regulator 2 is a solid state device designed to provide automatic voltage regulation of gen...
Page 41: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 389538 last change 6 8 72 Feb 27p6 Generator Schematic Diagram Single ptput Figure 8 l l Page 17...
Page 42: ...OPERATION MAINTENANGD OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 389541 last change 6 8 72 Generator Schematic Diqgram Dual OutIgut Figure 9 l l Page 18 Feb 27 76...
Page 43: ...GEND CS CAPACITOR 33YFD IOV DC CARICITOR I5OMFO 5OV DC CAPACITOR 6 8MFO 35V DC DIODE SILICON 400 PRV I SAMP POTEHTIOMETER 5OK l 2 WATT RESISTOR 660 OHM 1 2WATT RESISTOR 100 OHM l 2 ATT RESISTOR 6 5 K...
Page 44: ...urmeter 4 which will record up to 9999 hours The hourmeter also has a one tenth hour recording drum An indicating light 5 Iocated above the motor start stop switch glows amber when the motor start but...
Page 45: ...ducing power 5 Resistor This resistor 16 protects the load contactor operating circuit in the event of a blown diode in the rectifier 4 Fig 13 and 4 and 12 Fig 14 Ad justment is not critical Adjust sl...
Page 46: ...ating I ight amber No 1 output indicating light red No 2 output indicating light red used on duo l output No 1 output on off switch 10 11 12 13 14 15 16 No 2 output on off switch used on dual output M...
Page 47: ...es 12596 of normal rated value The closed relay sends a signal to the protective poni tor Ref paragraph 5 B 2 b This signal gates the overload SCR silicone controlled rectifier in the protective monit...
Page 48: ...A AND 5507A 1 Output load contactor 2 Overload module 3 Connector 4 Rectifier 5 Output bus bars l l Page 24 6 6 Output current transformer 7 Transformer resistor 25 ohm 7 l 2 watt 8 Resistor 250 ohm 1...
Page 49: ...ent Transformer Panel See Figure 15 This panel is located forward of the load contactor panel and mounts ammeter and I ine drop current transformers 1 Ammeter current transformers _ __ ___ The three a...
Page 50: ...load 4 No 1 rectifier 12 No 2 rectifier 5 No 1 output bus bars 13 No 2 transformer resistors 6 No 1 output current transformers overload 16 5 ohm 5 watt 7 No 1 transformer resistors 16 5 ohm 5 watt 1...
Page 51: ...5 which are connected to the generator output leads at the bus bar 1 terminals is to eliminate radio frequency inter ference before it is transmitted along the 400 Hz output cables 5 Terminal board Th...
Page 52: ...r operation oi the motor switches Any condition of overload in any phase causes the heater element to open the relay contacts and hus stop the motor by disconnecting the source of current for holding...
Page 53: ...A AND 5507A REMOTE CONTROL TERMINAL BOARDS OUTPUT TERMINALS START STOP W OFF I I i B I p i Output Terminal Panel Single Output Figure 16 REMOTE CONTROL TERMINAL BOARDS NO 1 START STOP 34 0 SUPEzRV fRY...
Page 54: ...ir purpose is to by pass the push button start switch and supply a holding current to the start switch or run switch coil when the stat t pushbutton is released Auxiliary contacts on the run switch as...
Page 55: ...3A AND 5507A i 3 4 1 Overload transformers 2 Overload relay 3 Main switch 4 Run switch 5 Start switch 6 Interlock rocker arm 7 Control transformer 8 Overload relay 9 Terminal boards 10 Time delay rela...
Page 56: ...hield 3 Stationary contact 4 Auxi I iaty contacts 5 Movable contacts 6 Contact attach ing screw 7 Shaft bearing 8 Movabie contact mounting shaft 9 Movable contact mounting bracket 10 Core adiusting sc...
Page 57: ...ATION MAINTENANCE AND OVERHAULMANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 388503 updated last change 8 5 75 Motor Switch Schematic Diagram Sing e Output Figure 20 Feb 27 76 l l Pag...
Page 58: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 388501 updated last change 3 7 75 Feb 27 76...
Page 59: ...t ion deenergizat ion re lay 3 Transformer and rectifier assembly 4 Filter 24 V 6 Mounting pane I 7 Motor shut down timer optional 8 Phase sequence re lay optional 5 Protective monitor time delay rela...
Page 60: ...rotective monitor system A range of 24 V DC to 28 V DC is acceptac le in this circuit A 3 MFD capacitor 2 is connected betmen the output terminals of the rectifier Its function is to prevent the low v...
Page 61: ...itch with a set of NO NC contacts which are connected in series with the motor starting circuit ISee PR Fig 20 and 21 I When input power is connected in the proper phase sequence the disc is rotated i...
Page 62: ...mounted directly to the generator frame by four semi Iliptic leaf springs Tires are pneumatic 8 75 x 16 5 inch Mechanical parking brakes mounted on the rear axle are operated by a hand lever located...
Page 63: ...Pro vide a working area around the unit at least two feet wide B Mounting 1 Genera I No hard and fast rules for mounting the generator set can be given because they may vary depending upon the users r...
Page 64: ...tween the skid and the floor may he p to compensate for slight unevenness in the mounting surface and also insulate the skid from the floor to reduce vibration Hobart pads No 389945 can be used with o...
Page 65: ...disconnect switch and fuses must be installed in the input circuit between the power source and the generator set Route the input leads cable or cm duit carefully so they will not be a hazard to perso...
Page 66: ...FULL OPERATING SPEED approximately 30 seconds then press the motor STOP button 19 and turn GFF the dis connect switch WARNING DO NCT PRESS THE STGP BUTTON OR INTERRUPT THE START CYCLE BEFORE THE MGTO...
Page 67: ...put panel cover Ref Section 4 1 Fig 1 item 14 b If cable horns are to be used install them over the two holes provided in the bottom of the terminal box after removing covers 15 c Insert the loose end...
Page 68: ...ith A B C and N conductors Each output terminal has hardware for attach ing more than one smaller cable if a single large cable is not desirable 4 Start Run Time Delay Relay Check It is important that...
Page 69: ...ign materials are in or on the unit B Position Switches and Controls Position or check the switches and controls as follows See Figure 1 which is a composite of all controls 1 Pushbutton switch panel...
Page 70: ...ECTIVE RELAY TRAY 1 Manual control transformer 6 Vo tmeter 2 Automatic manual switch 7 Frequency meter 3 Meter selector switch knob 8 Test bank switch 4 Line selector switch 9 Protective devices reset...
Page 71: ...7 Output indicating light OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SEri iES 5503A Al lD 5507A VGLTAGE REGULATOR TRAY 23 I6 17 I8 18 Output on off switch 19 Motor sta...
Page 72: ...V output Do not disturb this adjustment until the generator is running and a voltage value can be read on the voltmeter 3 Power Delivery with Automatic Voltage Regulation Operation with automatic volt...
Page 73: ...hree phases early in the power delivery run Use the meter switch 3 to select the phase Use the line switch 4 to select line to line or line to neutral voltage If the load is changing it is good operat...
Page 74: ...18 and hold until the indicating light 17 goes off This indicates that the load contactor has opened and power is no longer being delivered to the output cable B Disconnect the power delivery cable f...
Page 75: ...L MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A Pushbutton Switch Panel No 2 Output Test bank SWitch No 1 Output Test bank SWitch Protective Relay Tray Feb 27 76 Dual Gutput Operatin...
Page 76: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 1 3 Page 8 Feb 27 6...
Page 77: ...ment of Lamps and Fuses Replacement of Minor Electrical Components Replacement of Major Electrical Components Inspection Check General Exterior Cables and Connections Input and Output Cables Cable Con...
Page 78: ...ons 5 General Overall Inspection Motor Generator Rotor Bearings Motor Generator Temperature Check Electrical Components Ad j ujtmentflest General Test Pane Is 2 3 5 5 5 6 6 1 1 1 Motor switch Test Pan...
Page 79: ...me delay relay adjustment Undervoltage Time Delay Adjustment LIST OF ILLUSTRATIONS CHAPTER FIGURE PAGE SECT ION NUMBER TITLE NO 2 l 1 Lamp Chart 2 l 2 Fuse Chart 2 2 2 3 1 Test Panels Sheet 1 2 2 3 1...
Page 80: ...IES 5503A Ab1 D 5507A CHAPTER FIGURE SECTION NUMBER 2 3 6 2 3 7 2 3 a 2 3 9 2 o Page 4 LIST Cf ILLUSTRATIONS CONT D i ITLE PAGE NO Remote Ctitrol Terminal Boards Motor Generator and Exciter Stator Te...
Page 81: ...however it may be changed as required to meet varying operating conditions and environment See Section 2 In spection Check for inspection and check procedures to be used in conjunction with Section 2...
Page 82: ...quired for items such as relays instruments small switches and other controls Replacement of such items is a matter of disconnecting all wiring attached to the item removing attaching hardware taking...
Page 83: ...mp Industry Trade Number FS5 Motor GN indicating Pushbutton switch Lamp Industry NE51 H light pane I Trade Number Generator ON Pushbutton switch Lomp Industry NE51 H ind icating I ight pane I Trade Nu...
Page 84: ...OPERATION MAWENA ND OVERHAUL MANUAL TM 416 MOTOK DRIVEN GENERATOR SET SERES 5503A AND 5507A 2 l Page 4 Feb 27 f6...
Page 85: ...ONS 3 Controls and Instruments A Voltmeter Ammeter and Frequency Meter Observe these instruments af each generator start up to make certain they ore operoting If one of the instruments is suspected of...
Page 86: ...l tage r e lay Check underv l tage relay Check protective monitor system solid state Check all motor switch contacts Check motor switch interlock rocker arm Check voltmeter accuracy Check alI wiring a...
Page 87: ...ltage to normal 115 V output 6 Open the protective ielay tray and push the reset switch 9 to turn the indica ing light OFF and to reset the protective monitor relay D Undervoltage Sensing Relay Check...
Page 88: ...he same instant adjust in accordance with Section 2 3 Para 6 A 1 through 3 4 Check all contacts and lead terminals for secure mounting F Motor Switch Interlock Rocker Bar The motor switch interlock ro...
Page 89: ...iring 3 Check all connections and connectors for security Tighten all loose connections I General Overal I Inspection Inspect the entire generator set thoroughly while the canopy panels are removed fo...
Page 90: ...nerator discharge air at the duct outlet in the top of the canopy Use an accurate thermometer with Fahrenheit scale After one hour operation at full load in an ambient temperature of 90 deg F the disc...
Page 91: ...ng the motor control electrical equipment 8 Generator Controls Test Panel This panel is mounted in the generator control tray and is accessi bie by pulling the tray outward It contains 11 test jacks f...
Page 92: ...set are listed in Figures 2 3 4 and 5 Normai voitages for the most used test points are listed Motor Switch Test Panel 123 124 134 I 1 135 136 137 Em 140 141 142 Generator Controls Test Panel 1 118 1...
Page 93: ...I26 127 128 29 II t 4 I I30 131 I32 133 I I 1 I Voltage Regulator Test Panel Feb 27 76 0 G 0 II9 121 138 I39 I53 154 157 158 159 160 161 162 163 164 165 I66 168 169 170 173 1 I74 I75 I76 177 178 179...
Page 94: ...503A AND 5507A 0 0 I 147 148 149 I50 151 152 I55 J I56 160 I67 0 0 Protective Relays Test Panel Single Cutput Only Contact and Overload Test Panel Single Gutput Gnly 0 119 12 1 138 139 153 I54 157 I58...
Page 95: ...5 V AC 130 182 NA 110 115 115 V AC 134 135 0 V AC 110 116 0 VAC 136 137 0 V AC 110 l 17 115 V AC 141 142 115 200 V AC 111 112 0 VAC 143 144 0 VAC 113 l 14 0 v 149 160 0 VAC 118 l 19 24 28 V DC 153 154...
Page 96: ...115 VAC 115 V AC 115 V AC 0 V AC 115 VAC 0 V AC 0 V 24 28 V DC 24 28 V DC 24 28 V DC 24 28 V DC 0 V DC 0 V DC 24 28 V DC 0 V DC 28 V DC 36 V DC 0 V AC 0 V AC 0 V AC 115 V AC TEST VOLTAGE POINTS VALUE...
Page 97: ...135 0 V AC 110 116 0 VAC 136 137 0 VAC 110 117 115 VAC 141 142 115 200 V AC 111 12 ii V AC 143 144 0 04 V AC 113 l 14 24 28 VAC 149 160 0 V DC 118 119 V DC 153 154 0 v 119 120 24 28 V DC 155 156 0 v 1...
Page 98: ...28 24 28 0 0 24 28 0 0 44 73 25 25 25 115 VAC VAC VAC VAC V AC VAC V AC V DC V DC V DC V DC V DC V DC V DC V DC VAC V DC V DC VAC VAC V AC V DC TEST VOLTAGE POINTS VALUES 130 132 115 VAC 130 133 115 V...
Page 99: ...nput and generator output N neutral terminals are grounded 4 Check exciter field stator resistance in accordance with Para 4 C Resist ance should be 12 to 16 ohms at ambient temperature See Figure 7 5...
Page 100: ...light should glow amber Note the time required for the time de lay relay to actuate the excitatiocl deenergizaticn reiay Sect l l Fig 22 item 2 Operation of the EDR may be observed Elapsed time shoul...
Page 101: ...ting light should go OFF 20 Check the motor start stop terminal boards on the generator output terminal panel for correct wiring of remote control terminals see Figure 6 a Use a jumper wire to moke mo...
Page 102: ...ch in AUTOMATIC position and use the voltage regulator rheostat Ref 1 3 Fig 1 item 12 to check maximum and minimum generator voltage by turning the regulator rheostat fully CLOCKWISE for maxi mum volt...
Page 103: ...heck dual output machines in a manner similar to step 6 above Apply a load of 200 KVA Apply a load of 100 KVA to each put cable an dual output machines Check the following input values Voltage 460 V A...
Page 104: ...d relay should function to open the load contactots in less than 4 minutes To adjust the relay Ref 1 1 Fig 6 item 15 apply a load of 200KVA to the generator 100 KVA each cable Adjust slider band on re...
Page 105: ...es 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 chart belovJ for resistanc...
Page 106: ...ctions for testing diodes follows A Disconnect diode lead s 8 Use a good quality ohmmeter An instrument which indicates 50 ohms at the center of the scale is preferable NOTE Make certain the battery i...
Page 107: ...crew K NOTE Remember the contact will be moved in the direction of the bracket screw tightened 3 If a satisfactory adjustment cannot be attained by the above method it is per missible to bend the mova...
Page 108: ...w core adiusting G Screw bar adjusting B Locknut core adjusting screw l l C tearoncc C Bracket core J Front adjusting screw D Bracket adjustihg screw mounting K Rear adjusting screw E Core L Interlock...
Page 109: ...E CERTAlN THE REMOTELY LOCATED DtSCONNECT SWITCH IS OFF AND NO POWER CAN ENTER THE MOTOR SWITCH a Disccnnect stator leads IA 2A lB 2B and lC 2C from terminak on the rear of the motor switch panel so t...
Page 110: ...STOP switch buttar d If the time delay recorded above is not within the prescribed range turn the adjusting knob located in the top cover of the relay CLOCKWISE to increase time delay or COUNTERCLOCK...
Page 111: ...instant voltage reaches 90 V AC and the instant the undervoltage indicating light 10 comes ON NOTE An exact required delay time is not stated here because it may vary depending upon the customer s req...
Page 112: ...2 3 Ccl m I 1 OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A Time De lay Relay Figure 9 Feb 27 76 Page 22...
Page 113: ...TING TABLE OF CONTENTS SUBJECT CHAPTER SECTION PAGE Electrical 3 l General Trouble Shooting Chart Description Use of Trouble S hooting Chart Equipment for Trouble Shooting Safety Fault and Effect Char...
Page 114: ...Output 3 l 2 Motor Switch Schematic Diagram Dual Output 3 l 3 Generator Schematic Diagram Single Output 3 l 4 Generator Schematic Diagram Dual Output 3 l 5 E iectricoi Trouble Shooting Chart Sheets 1...
Page 115: ...y the operator however major repairs must be undertoken by experienced mechanics and electricians only 2 Trouble Shooting See Figure 5 A Description The trouble shooting chart lists information under...
Page 116: ...ood quality multi scale voltohmmeter is the only instrument required for trouble shoot ing However for checking motor generator windings a double bridge or Kelvin bridge must be used and NOT a Wheatst...
Page 117: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 3 88503 last change 8 5 75 Motor Switch Schematic Diagram Single OpTput Figure 1 Feb 27 76 3 l Page 3...
Page 118: ...OPERATION MAlNTENkfAND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 388501 last change 3 7 75 Motor Switch Schematic Diagram Dual qytput Figure 2 3 l Page 4 Feb 27n6...
Page 119: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 389538 last change 6 8 72 Generator Schematic Diagram Sing e Output Figure 3 Feb 27 f6 3 l Page 5...
Page 120: ...I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 389541 last change 6 8 72 Generator Schematic Diagram Dual Qutput Figure 4 3 l Page 6 Feb 27 76...
Page 121: ...Turn switch ON 2 Replace fuse or reset cir cuit breaker Check input circuit for loose connecfioi or short circuit Repair before operating unit Check voltage between TP test point 107 and TP 108 If ind...
Page 122: ...tive A Defective control relay CR 3 1 Page 8 F Press and hold START 1 PB button Check voltage between TP 112 and TP 113 If indicatec voltage is 115 V AC replace START STOP switch assembly A Check as f...
Page 123: ...y con tacts in main motor switch 1MS not mak ing good con tact A Time delay relays 1TR or 3lR improperly ad justed A Defective time delay relay ITR B Check voltage between points 112 and 115 If no vol...
Page 124: ...connectors or wiring as required B Check motor windings in accordance with 2 3 para graph 4 A Open or shorted diode in exciter rectifier 3REC B Open shorted or grounded exciter field A Input power so...
Page 125: ...UTOMATIC voltage regulator blown NO load but will drop under position load Replace fuse 2 Excitation deenergiza 2 Place automatic manual switch tion relay EDR defec 1s in AUTOMATIC pcsition t ive With...
Page 126: ...cuit Proceed as follows 1 Automatic manual switch 1s defective in 1 Place switch is in MAN UAL position Check volt MANUAL position age between points 130 and 131 Then check between points 130 and 134...
Page 127: ...oduce voltage 1 Diodes in exciter rectifier 3REC defective 2 Defective winding in exciter field or generator stator field 3 Defective compon ent in automatic and manual voltage control circuit 1 Check...
Page 128: ...meter 6 Use voltmeter to check voltages between point 130 ground and points 131 138 and 139 If very low voltage is indicated check for trouble under GENERATOR EXCITATION CIRCUITS above A Check voltage...
Page 129: ...t D Check for cause of lamp failures Replace lamps Load contactor A Load contactor coil will NOT close A Check and repair as follows circuit open circuited when ON button is pushed 1 Defective protect...
Page 130: ...eck voltage between points resistor by pass con 158 and 159 If normal volt tocts in load contactor age 95 V is recorded re defective place the load contactor QA On dual output one A Contactor operatin...
Page 131: ...pplicable ON switch Check voltage betwee points 158 and 159 for no 1 output Check voltoge betwee points 174 and 175 for no 2 output If normal voltage 95 V is recorded replace the applicable load conta...
Page 132: ...Defective economizer resistor 13 ES 4 Resistor 14RES M l ES improperly adjusted D E F A Be sure cable is not connected to aircraft Press and hold generator ON button Check voltage between point 154 a...
Page 133: ...witch IS or 25 in ON position Press applicable generator ON pushbutton If the contoctor re mains closed when the pushbutton is released the PIR relay is defec tive Replace relay Turn test bank switch...
Page 134: ...tive monitor 8 Check in accordance with Fig defective 7 A One of the resistors 7RES 8RES 9RES across overload trans formers is open circuited A Check voltages in accordance with Figure 7 Replace defec...
Page 135: ...tors across A An open resistor will cause a con tactor opens overload transformers is higher than normal voltage and overload open circuited Resistors between test points 161 and 162 indicating light...
Page 136: ...cir cuited A Open diode in exciter A See Generator Trouble 1 rotor rectifier 3REC Remedy A above A Open or short circuit in generator stator windings A Check diodes in accordance with 2 3 paragraph 5...
Page 137: ...n accord once with 2 3 paragraph 4 Send complete unit to overhaul if defective 5 Unbalanced output A Loose connection in output circuit A Check all output connections Discolored connectors indicate a...
Page 138: ...en diode above Same as open diode above 4 Shorted rotor wind ing EXCITER FIELD Same as shorted diode above Same as shorted diode above 1 Open circuited 2 Short circuited MOTOR ROTOR Same as open diode...
Page 139: ...except low WILL HEAT Will probably current output trip overload relay GENERATOR ROTOR 1 Open circuited winding NONE NO VOLTAGE OUTPUT 2 Short circuited winding NONE except low power NO VOLTAGE OUTPUT...
Page 140: ...ter reset button is pushed and released NO FAULT EXISTS Indicating Light which lndica tes remains ON when reset Test Defective P M switch is pushed Points board card OV Light 119 150 UF Light 119 151...
Page 141: ...5503A AND 5507A SECTION 2 MECHANICAL 1 Ge r a I There are no strictly mechanical components which require trouble shooting with the possible exception of the motor generator rotor bearings 2 Rotor Bea...
Page 142: ...oseness and noisy Operates replacement defects in accordance with Sec with wh in ing tion 2 2 Para 4 A 1 gr inding OF through 3 pounding sound 2 Bearing housings A Insufficient rotor end play A lnsta...
Page 143: ...nopy Remova I Canopy Installation Major Electrical Components Removal and lnstal lat ion General Preparation for Removal of Components Motor Switch Fcmel Assembly Removal lnstal lat ion Motor Switch R...
Page 144: ...PTER SECT ION PAGE Current Transformer Panel Assembly 4 2 5 Removal 5 Installation 5 Contactor Pane I Removal Installation Motor Genertitor 6 Removal 6 Installarion 6 LIST OF ILLUSTRATIONS CHAPTER FIG...
Page 145: ...g screws and lift off air exhaust deflector 8 2 Remove the lifting eye 10 by inserting a bar through the eye and unscrew ing in a counterclockwise direction Remove the rain guard 9 at the same time 3...
Page 146: ......
Page 147: ...be given Remove or disconnect the box as required for removal of the input terminal panei 3 10 Remove twelve screwS which attach the input panelassembly 3 and lift off the pane I Identify and disconn...
Page 148: ...attach with four screws in the top of the panel Connect motor switch panel leads to terminal panel WARNING BE SURE INPUT PGWER IS OFF 6 Install terminal box 2 and attach cable conduit as required Reco...
Page 149: ...tify all motor switch leads and cables before disconnecting so they may be reconnected in their original positions 1 2 3 4 5 4 7 8 Disconnect three input leads at Ll L2 and L3 terminals Disconnect thr...
Page 150: ...Motor switch panel assembly 5 Motor switch support 6 Lifting yoke assembly Switch panel support Generator Set Without CCIMPY Figure 1 4 2 Page 2 Feb 27 Z 7 8 9 10 11 12 Current transformer panel asse...
Page 151: ...terminal studs on the rear of the switch panel 7 Reconnect input leads at terminals Ll L2 and L3 Check all wiring in accord ance with connection diagram Section 5 2 Fig 2 4 Motor Switch Relay Panel A...
Page 152: ...he quick disconnect recep tacle connector Remove the complete voltage regulator tray assembly from the control box to make the box attaching screws accessible Remove machine screw from brace at rear o...
Page 153: ...holes and install four attach ing screws and washers 2 Reconnect six stator leads and transformer panel to load contactor leads 3 Reconnect small leads at terminal panel See wiring diagrams Section 5...
Page 154: ...support 6 OS an assembly 4 Remove the generator air outlet box Ref Section 6 2 Fig 1 item 14 and air outlet cover 15 to prevent damage which may be caused in moving the motor generator 5 Remove four...
Page 155: ...DRIVEN GENERATOR SET SERIES 5503A AND 5507A Iristall the generator air outlet box and air outlet cover removed in paragraph 9 A 4 above NOTE It mqy be necessary to realign the air out let box later w...
Page 156: ...4 2 Page 8 OPERATION MAINlEG AND OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A Feb 27 f6...
Page 157: ...1 1 1 1 1 2 4 5 O Page 1 TABLE OF CON TENTS SUBJECT CHAPTER SECTION Mechanical Repair 5 1 General Canopy Sheet Metal Repair Frame and Structural Repair Electrical Repair 5 2 General Motor Switch Repai...
Page 158: ...on Diagram All Pushbutton Switch Panel Connection Diagram Sir g le Output 5 2 14 Contactor Panel Connection Diagrun Single Output Transformer Rectifier Connection Diagram All Generator Connection Diag...
Page 159: ...aph 3 they may be raightened 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 primer...
Page 160: ...I a I 1 OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 5 l Page 2 Feb 27 76...
Page 161: ...e arc shields Fig 1 item 2 by depressing lock springs and lifting upward to unhook then pull outward C lf switch contacts show signs of only moderate burning or pitting they may be re paired temporari...
Page 162: ...e and current as the larger contacts and therefore replacement is required less often If these contacts ore only darkened and slightly pitted they may be cleaned with carbon tetrachloride and o tint f...
Page 163: ...coil 2 Arc shield 3 Stationary contact 4 Auxiliary contacts 5 Movable contacts 6 Contact attaching screw 7 Shaft bearing 8 Movable contact mounting shaft 9 Movable contact mounting bracket 10 Core ad...
Page 164: ...3 Wiring the Unit After Repair or Parts Replacement When reconnecting w ires to an electrical component after repair or replacement make certain connections are made correctly Figures 2 through 15 ar...
Page 165: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A Fold out size Last change 8 1 75 Feb 27 6 Motw Switch Connection Diagram ili Figure 2 5 2 Page 5...
Page 166: ...ION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 389543 Fold out size Last change 3 7 75 Generator Connection Diagram Single C ytput Figure 3 5 2 Page 6 Feb...
Page 167: ...OERATfON MAiNTENANCE iND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A MOllX 30NVW 1 I I Feb 27 76 ze Control Box Connection Diagram Single d pu Figure 4 5 2 Poge 7...
Page 168: ...a I I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SEKES 5503A AND 5507A 3 86996 no change Generator Control Tray Coynection DiagratT All Figure 5 5 2 Page 8 Feb 27 76...
Page 169: ...RELAY 3R FlJSH6UTTCN R91 PROTECTIVE RELAYS 4R PLUG MERLCCK RLAY 6RES RECEPTACLE PROTECTIVE RELAYS 2s FlJJGq PROTECTIVE MONITOR BOILRD UF PROTECTIVE MCNITOR BOARD uv RED INDICATING LIGHT OV FAULT RED I...
Page 170: ...OPERATION MAINTENA ND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 3 87044 no change Current Transformer Pane Connection Dippram All Figure 7 5 2 Page 10 Feb 27n6...
Page 171: ...MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SE T SER ES 5503A AN D 5507A I 3 87070 last change 5 21 74 Feb 27 76 Pushbutton Switch Panel Connection Diagrym Single Output Figure 8 5...
Page 172: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 3 8707 1 no change Contactor Panel Connection Diagram Single C tput Figure 9 5 2 Page 12 Feb 27 76...
Page 173: ...MAINTENANCE A D OVERHAUL MANUAL Tiiil 4i C MOTOR DRIVEN GENERATOR SET SE lES 5503A AND 5507A SEE MOTOR SWITCH CONNECTION DIAGRAM END Feb 27 76 Transformer Rectifier Connect ion Diagram Al I Figure 10...
Page 174: ...ION MAINTENANCE AND OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A I 3 89545 Fold out size Last change 3 7 75 Generator Connection Diagram Dual Out yut Figure 11 5 2 Page 14 Fe...
Page 175: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 389547 OK No change Control Box Connection Dipgram Dual Oyfput Figure 12 Feb 27 76 5 2 Page 15...
Page 176: ...PERATION MAINTENANCE AND OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 388546 OK no change Protective Relay Tray Connection Diagram l JaI Output Figure 13 5 2 Page 16 Feb 27p...
Page 177: ...ION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERLS 5503A AND 5507A 387045 Last change 5 2 1 74 Pushbutton Switch Panel Connection Diagrpm Dual Output Figure 14 Feb 27 76 5 2 P...
Page 178: ...I OPERATION MAlNTENAmND OVERHAUL MANUAL TM 416 MOTOR DRlVEN GENERATOR SET SERIES 5503A AND 5507A 388558 OK no change Contactor Panel Connection Diagram Duql Output Figure 15 5 2 Page 18 Feb 27 76...
Page 179: ...6 l General Disassemble Repair Electrical Equipment and Motor Generator Electrical Equipment Motor Generator Cverhaul Removal Disassembly 6 2 Bearing Remova 1 Cleaning Inspection Bearings Fan Exciter...
Page 180: ...2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 LIST OF ILLUSTRATIONS TITLE Motor Generatar Bearing Removal and Installation Tools Motor Generator and Exe iter Fie Id Connections Motor Generator and Exciter Field Schem...
Page 181: ...Genera I Overhaul of the canopy assembly and frame is considered to be unnecessary 2 Disassemble DisassemblyAinstructions for the canopy assembly are included in Section 4 1 para 2 A 1 through 16 3 Re...
Page 182: ...r l OPERATION AWNTENA ND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A Feb 27 76...
Page 183: ...panels 2 Remove pushbutton switch panel Section 4 2 Figure 1 item 11 Remove in accordance with Section 4 2 para 5 A 1 through 2 3 Remove motor generator 12 in accordance with instructions in Section 4...
Page 184: ...op insulating pad Generator housing Bottom insulating pad Exciter field assembly Polebase support Exciter field windings 12 Motor generator rotor 13 Fan 14 Air outlet box 15 Exhaust air cover 16 Motor...
Page 185: ...bearing to slide out of the hub when the generator housing is removed Use pry bars to slide the generator housing away from the motor housing sufficiently to attach a lifting chain around the stator...
Page 186: ...ng has been removed the exciter stator 9 may be removed NOTE Allow the bearing spacer 17 to remain on the shaft motor end Tape it to the shaft if the fit is loose This precaution is to prevent assembl...
Page 187: ...2 SLEEVE NO 387213 3 CAP NO 387214 4 STUD 3 4 10X7 IN CUSTOMER FURNISH 5 b 1 r 1 I tn V I a 1 CUSTOMER FURNISH BEARING ItiSTALLATION TOOLS 6 Feb 27 f6 BEARING REMOVAL TOOLS 6 COLLAR NO 387393 7 SEAT...
Page 188: ...meter will contact the inner race of the bearing install two clamping screws and tighten to clamp the collar on the bearing Install seat 7 in the end of the rotor shaft 2 Pull th e bearing off the rot...
Page 189: ...ected the age and service of the beor ing should be considered before passing it for further service If the hour meter indicates the bearing has been in operational service approximately 5000 hours or...
Page 190: ...e plus and minus polarities are required Disconnect power source Disconnect generator field leads 3 and 6 at terminals 3 and 6 Check generator revolving field resistance by connecting ohmmeter to lead...
Page 191: ...D 5507A GENERATOR FIELD 3 MOlOU FIELD TERMINAL I EXCITER LEADSA 0 kC SENLRATOP FIELD TERMINAL 3 GENERATOR FlELD 6s MOTOR FIEbO 2 Motor Generator and Exciter Field Connections Figure 2 Feb 27 76 AC EXC...
Page 192: ...14 cap part The custcmer must supply a 3 4 IO nut and a 3 4 10 stud at least 7 inches long Both of these items should be readily available commercially The stud may be cut from a 3 4 I 10 threaded rod...
Page 193: ...the housing until the open end is resting on the block See Fig 5 3 Install a 3 4 10 eyebolt in each end of the rotor shaft 4 Place a chain around the rotor shaft between the generotor windings and the...
Page 194: ...oN INTEW KE AND OVERHAUL MANUAL TM46 MOTOR DRIVEN GENERATOR SET SERiES SS03A 41 rD 5507A Stator Housing Blocking Arrangement Typical Figure 5 6 2 Page 12 ii Rotor Lifting Arrangement Typical Figure 6...
Page 195: ...NCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SEXIES 5503A AiuD 5507A Pulling Rotor Bearing Into Stator Housing Typical Figure 7 Pushing Housing Onto Rotor Shaft Bearing Feb 27 76 Figure 8...
Page 196: ...2 and 18 and attach with cap screws Tighten screws securely 11 The next step is to measure the rotor shaft end play There are several ways to do this The two most accurate methods will be described he...
Page 197: ...lncl 50 that the jc c point will touch the generator slip ring when the screw is threaded further into the cross bar Tighten clamp securely and thread screw into cross bar until the screL d point just...
Page 198: ...ANuAL 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 1 Testing and Adiusting The motor generator may be tested after overhaul by following procedures outlined in Section 2 3 under paragraphs 3...
Page 199: ...nation of Parts List 1 Manufacturer s Codes 7 2 1 Explanation of Manufacturer s Vendor s Code List Parts List 1 7 3 1 Explanation of Parts List Arrangement 1 Symbols and Abbreviations 1 Generator 3 1...
Page 200: ...el Assembly Contactor Overload Panel Assembly Control Box Assembly Generator Control Tray Assembly Generator Control Tray Swb4sembly Protective Relays Tray Assembly Protective Relays Tray Sub Assembly...
Page 201: ...e parts 3 Arranaemen t 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 Parts Li...
Page 202: ...urchased part the HOBART PART N UMBER 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...
Page 203: ...are usable on Specs 5507A 2 only Parts coded H are usable on Specs 5507A 3 only Parts coded J are usable on Specs 5507A 4 only 5 UN ITS PER ASSEMBLY Column This column indicates the quantity of parts...
Page 204: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL iM 416 MOTOR DRIVEN GENERATOR SET SERIES 550314 AND 5507A 7 1 Page 4 oct 30 75...
Page 205: ...se 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 00779 hp Inc k 0 Box 3608 Harrisburg Pennsylvan...
Page 206: ...sumer Industrial Plastics Products Masland Duraleather Company Amber Willard Streets Philadelphia Pennsylvania 19134 South Chester Corporation South Co Division 3rd Street Governor Printz Blvd Lester...
Page 207: ...sion of MC Graw 8 Ed ison Corn pany 2536 W University Street St Lou Missouri 63107 72619 Dialight Corporation 60 Stewart Avenue Brooklyn New York 11237 72765 Drake Manufacturing Company I 4626 N Olcot...
Page 208: ...isco Technology Corporation Illinois Division 9367 William Street Rosemont Illinois 60018 Jaymar Terminal Boards Inc 25 27 Brutus Street Weedsport New York 13166 Westinghouse Electric Corporation Tran...
Page 209: ...Switch Division Chicago Spring Streets Freeport Illinois 61032 Harry Davies Company 700 N 27th Camden New Jersey Agastat Division Elastic Stop Nut Corporation of America 1027 Newark Avenue E l abeth...
Page 210: ...OPERATION MAINTENANCE AND OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 7 2 Page 6...
Page 211: ...eviations used in the parts list Item not illustrated A or AMP ampere AC alternating current AR as required DC direct current Fig Figure hd head hex hexagon Hz Hertz cycles per second I D inside diame...
Page 212: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A SEE SUPPLEMENTARY MANUAL FOR DETAILS OF TRAILER PARTS 7 3 Page 2 Generator Set Figure 1 hi Ott 30 75...
Page 213: ...L 200F H61 SINGLE OUTPUT WITH 95V 201 A MOTOR IN PUT GE NE RATOR SET MODE L 200F H 51 SINGLE OUTPUT GENERATOR SET MODEL 200F H51P SINGLE OUTPUT FOR TRAILER MOUNTING GENERATOR SET MODEL 200F H52 DUAL...
Page 214: ...OPERATION MAINTENANCE AND OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A Q i 7 Canopy Assembly Figure 2 7 3 Page 4 Ott 30 75...
Page 215: ...AL ACEFH 1 ACEFH 1 PANEL ASSEMBLY FRONT For Details See Fig 4 ACEFH 1 PANEL ASSEMBLY RIGHT FRONT DUCT ASSEMBLY AIR EXHAUST 1 1 DEFLECTOR ASSEMBLY AIR EXHAUST PANEL ASSEMBLY LEFT FRONT 1 RIGHT REAR 2 T...
Page 216: ...OPERATION MAlNTENANCE OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 7 3 Page 6 Canopy Asse mbl y Figure 3 Ii act 30 75...
Page 217: ...XHAUST DEFLECTOR ASSEMBLY AIR EXHAUST PANELASSEMBLY LEFT FRONT l RIGHT REAR TOP ASSE MB LY CANOPY TOP ASSEMBLY CAN OPY BD GJ PANEL ASSEMBLY REAR For Details See Fig 8 DJ PANE L ASSE MB LY REAR For Det...
Page 218: ...I j_ __ OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 7 3 Page 8...
Page 219: ...RONT For NHA See Fig 2 ACE FH COVE R TEST PANE L ACCE SS ACE FH COVE R MOT0 R SWITCH ACCESS ACE FH COVE R RELAY PANE L ACCESS ACE FH SCREW CAP HEX HEAD ACE FH WASHER LOCK ACE FH WASHER FLAT ACE FH LUG...
Page 220: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERlES 5503A AND 5507A Rear Panel Assembly Figure 5 7 3 Page 10 Ott 30 75...
Page 221: ...AGW 8301 AEF NUT l 4 20 HEX ST AEF WASHER LOCK l 4 ST AEF WASHER FLAT l 4 ST AEF WASHER INSULATOR V89873 AEF STUD TERMINAL AEF BUSHING AEF NAME PLATE N AEF NAME PLATE A AEF NAME PLATE F AEF NAMEPLATE...
Page 222: ...L pm _ OPERATION MAINTENANCE AND OVERHAUL MANUAL l M 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A Rear Panel Assembly Figure 6 7 3 Page 12 Ott 30 75...
Page 223: ...0 CH GROMMET RUBBER 02231 No AGW 8301 CH STRIP TERMINAL V88223 No 441 20 CH NAME PLATE REMOTE START STOP CH NAMEPLATE REMOTE ON OFF CH N AMk PLATE l OUTPUT CH NAME PLATE N CH NAMEPLATE F CH NAME PLATE...
Page 224: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 73 Page 14 Front Pane I Asse mb ly Figure 7 Ott 30 75...
Page 225: ...NC LATURE 1234567 EFF PANELASSEMBLY FRONT For NHA See Fig 3 DOOR PANEL ASSEMBLY LEFT NAMEPLATE DANGER HIGH VOLTAGE SCREW FASTEN ING DOOR WASHER TA IN IN G V24248 No 10014 12 BLOCK CONTACT V14280 No l...
Page 226: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 23 7 3 Page 16 Rear Panel Assembly Figure 8 Ii Ott 30 75...
Page 227: ...WASHER INSULATOR STUD NAMEPLATE A NAMEPLATE l OUTPUT NAMEPLATE N NAMEPLATE REMOTE START STOP STRIP TE RMINAL V88223 No 441 5 GROMMET RUBBER V02231 No AGW 8301 BUSHING DOOR INSPECTION HOLE CON TACTOR P...
Page 228: ...1 a 1 OPERATION MAINTENANCE AND MOTOR DRIVEN GENERATOR SET 7 3 Page 18 OVERHAUL MANUAL TM 416 SE RlES 5503A AND 5507A Rear Panel Assembly Figure 9 Ott 30 75...
Page 229: ...UBBERV02231 No AGW BG 8301 NAMEPIATE N NAMEPLATE A NAMEPLATE F NAMEPLATE B NAMEPLATE C NAME PLATE REMOTE START STOP NAME PLATE REMOTE ON OFF STRIP TERMINAL V88223 No DOOR INSPECTION HOLE 441 5 BUSH IN...
Page 230: ...I m I O PERATiON MAINTENANCE AND OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 7 3 Page 20 Generator Set Without Canopy t i Figure 10 Ott 30 75...
Page 231: ...SSE MB LY MOTOR SW ITCH For Details See Fig 12 FGHJ PANE LASSEMBLY MOTOR SWITCH For Details See Fig 12 E PANE L ASSEMBLY CURRENT TRANS REF 1 1 1 1 1 FORMER For Details See Fig 13 PANE L ASSEMBLY LOAD...
Page 232: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND s j A _ 1 I 7 3 Page 22 Motor Switch Relay Panel Assemibly Figure 11 Ott 30 75...
Page 233: ...R RELAY SPRING V77342 No 2OC206 RELAY ENCLOSED PLUG IN V77342 No KA 4244 1 SOCKET RELAY 77 M IP 7s VO2660 No MOUNT SOCKET RELAY TRANSFORMER RECTIFIER ASSY CAPACITOR MFD 50 V V90201 No MTA3D50 RECT IF...
Page 234: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 28 Motor Switch Assembly Figure 12 7 3 Page 24 Ott 30 75...
Page 235: ...ATE Ll NAMEPLATE L2 NAMEPLATE L3 CABLE Ll CABLE L2 CABLE L3 INSU IAT ION C LAMP H OSE CLAMP HOSE TRANSFORMER CT V83774 l No 6CT 15 RELAY OVERLOAD VO1121 Type UN ITS EFF A trY ABCD FGHJ E BOVl6 HEATER...
Page 236: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 7 3 Page 26 Ott 30 75...
Page 237: ...E MAGNETIC YOKE YOKEASSY MAGNETIC MOVABLE HOLDDOWN COIL COIL NVR YdKE ASSY STATIONARY STRAP CONNECT IN G BAR CONNECTING CLAMP ARMATURE SHAFT CONTACT SWITCH INSULATOR SHAFT SHAFT ASSE MB LY ARMATURE MO...
Page 238: ...OPERATION MAINTENANCEmAN OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 7 3 Page 28...
Page 239: ...FG CABLE hO9 C CONTACTOR TO C OUTPUT ABE FG CABLE lOl 104 A PANEL TO A CONTACTOR CDHJ CABLE lo2 105 B PANELTO l B C ONTAkTOi CDHJ CABLE 103 106 C PANELTO C CONTACTOR CDHJ CABLE 107 116 A CONTACTOR TO...
Page 240: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A Current Transformer Panel Assembly i Figure 13 7 3 Page 30 Ott 30 75...
Page 241: ...PANEL T RANSFORMER CURRENT ASSEMBLY For NHA See Fig 10 NUT 6 32 HEX ST INSULATOR EPOXY MICA 012 RESISTOR 50 OHM 25 WATT SCREW 6 32x 3 RD HD ST STRIP TERMINAL V98410 No 38012 3820 NUT 3 8 16 HEX ST WAS...
Page 242: ...I __ ___ OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 7 3 Page 32 Contactor and Overload Panel Assembly Figure 14 Ott 30 z...
Page 243: ...o 105 802 ABEFG CONTACTOR WARD LEONARD V74063 No A 874C ABEFG GROMMET RUBBER VO2231 No 79 ABEFG MOUNT SHOCK V21678 No 8323 ABEFG HOUSING SOCKET CONNECTOR V89110 No l 480287 0 ABEFG TERMINAL SOCKET VO0...
Page 244: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 7 3 Page34 Contactor and Overload Panel Assembljl Figure 15 i Ott 3op5...
Page 245: ...OAD ASSEMBLY CDHJ JACK INSULATED TIP V74970 No 105 802 CDHJ BOARD OVERLOAD ASSEMBLY CDHJ MT SHOCK V21678 Na B 323 BRACKET MOUNTING BOARD CDHJ OVERLOAD CDHJ GROMMET RUBBER 02231 No 79 CDHJ HOUSING SOCK...
Page 246: ...7 3 Page36 m LIzI _ ____ OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR D RIVE N GE NE RATOR SET SE RIES 5503A AN D 5507A Control Box Assembly Figure 16 Ott 30 75...
Page 247: ...NTROL ASSEMBLY For NHA See Fig 10 REF 388330 3 TRAY ASSEMBLY GENERATOR CONTROLS For Details See Fig 17 1 387895 2 TRAY ASSE MBLY PROTECT IVE 1 RELAYS For Details See Fig 19 ABEFG 1 387895 l TRAY ASSE...
Page 248: ...I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 7 3 Page38 Generator Controls Tray Figure 17 Ott 30 75...
Page 249: ...300 AC 60741 e i f r L No 331 LH i 1 AMMETE R O 500 AC V6074 1 No 331 Lij SWITCH METER SELECTOR VO4009 No 8157 FT li y SWITCH LINE VO4009 No 81029K 1 NAME PLATE METE R SELECTOR i SWITCH 1 BRACKET MOU...
Page 250: ...m 8 I __ _ _ _ ___ OPE ATlON MAINTENANCE AND OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERIES 550314AND 5507A 7 3 Page40 Generator Controls Tray Sub assembly Figure 18 I Ott 30 75...
Page 251: ...NOMENCLATURE UN ITS 1234567 EFF AK 18 5 6 386832 l 1 TRAY SUB ASSEMBLY GENERATOR CONTROL For NHA See Fig 17 REF 370382A HANDLE TRAY 1 384912 SLIDE DRAWER RIGHT 1 384913 W 11250 I SLIDE DRAWER LEFT 1 W...
Page 252: ...r ___ OPERATION MAINTENANCE AND OVERHAULMANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A Protective Relays Tt ay Assembly 11 Figure 19 7 3 Ott 30 75 Page42...
Page 253: ...No VM91 l 6A BUTTON PLUG HOLE V90763 No SS 48152 N AIviEPLATE OVE RVO LT AGE NAMEPLATE UNDERVOLTAGE NAMEPLATE UNDERFREQUENCY NAMEPLATE OVERLOAD NAMEPLATE PRESS TO RESET SW ITCH PUSHBUTTON SPST VO4009...
Page 254: ...7 3 Page44 r I I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A Ott 30 75...
Page 255: ...CH TOGGLE V15605 No 732OK3 ABEFG 1 CDHJ 2 ESISTOR 100 OHM 25 WATT V44655 No 0368 RESISTOR 100 OHM 25 WATT V44655 No 0368 RELAY UNDERFREQUENCY ASSEMBLY ABEFG 1 CDHJ 2 RELAY UNDERVOLTAGE ASSY RELAY OVE...
Page 256: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 7 3 Page46 Protective Relays Tray Sub assemblyI figure 0 Ott 30 75...
Page 257: ...EM NO PART NO 1234567 EFF 20 386846 l TRAY SUB ASSEMBLY PROTECTIVE RELAY For NHA See Fig 19 1 384912 SLIDE DRAWER RIGHT 2 W 11250 WASHER RETAINING V24248 lo 10014 12 3 382818 SCREW FASTENING TRAY 4 37...
Page 258: ...kiid e J OPERATION MAINTENANCE AND OVERHAULMANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A Regulator Tray Assembly Figure 21 I 7 3 Page48 Ott 30 75...
Page 259: ...NEL ASSEMBLY TEST REGU LATOR 1 402946 JACK INSULATED TIP V74970 No 105 802 2 401563 3 HOUSING PIN CONNECTOR V89110 No 1 480286 0 3 401565 l TERMINAL PIN V89110 No 61118 1 No Number 43039 1A 386884 UN...
Page 260: ...I I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERB 5503A AND 5507A Regulator Tray Sub assembly Figure 22 1i...
Page 261: ...ART NO NOMENCLATURE UN ITS 1234567 EFF AGrY 22 1 2 3 4 5 6 7 386884 370382A 384913 384912 W 11250 382818 SCREW FASTENING TRAY 386890 TRAY REGULATOR 404028 NAMEPLATE HOBART TRAY SUBlASSEMBLY REGULATOR...
Page 262: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 15 14 I i 7 3 Page52 Contmi Box Group Figure 23 Ii Ott 3op5...
Page 263: ...No 38012 3820 GROMMET VO2231 No AGW 8301 MOUNT CONTROL BOX V89373 No 314C CLAMP PLASTIC V81074 No EC 7 CLAMP CABLE VO2660 No AN 3057 12 CONNECTOR PLUG ELECTRI CAL VO2660 No MS 3106A 22 145 CONNECTOR P...
Page 264: ...I I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5 07A 7 3 Page 54 Pushbutton Panel Assembly ii Figure 24 Ott 30 75...
Page 265: ...h 20 RECEPTACLE DUPLEX V11419 No 1410X BRACKET MTG CIRCUIT BREAKER CIRCU IT BREAKER 120 V 20 A 1 POLE V90211 No QOB 120 SWITCH LIGHT PANEL V15605 No 732OK3 SWITC H ASSEMBLY START ST0 P BUSHING FIBER A...
Page 266: ...7 3 Page56 OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND5507A...
Page 267: ...ME l V26992 No SG 771 40 130 j 1 t NbMEPLATE LIGHT ON OFF 1 1 I PLACARD OPERATING INSTRUC I T ION l 1 NAME PLATE 400 CYCLE 2 NAME PLATE 120 RECEPTACLE 2 LABEL ROTATl ON 7 1 NAMEPLATE IDENTIFICATION l...
Page 268: ...OPERATION MAINTENANCE AND OVERHAUL MANuALTM MOTOR DRIVEN GENERATOR SET SERIES 5503A AN j50 A 7 3 Page58 Generator Group Figure 25 Ott 30 75...
Page 269: ...UP j For NH A See Fig 10 REF I STRAP GROUND 1 COVE R MOT0 R E ND l j I CAk BEARING MOTOR END l Jyi 1 SHIM BEARING 2 5 BEARING V43991 No S 3620 2 i I COLLAR f EARING SPACER I MOTOR END I 1 HOU SING STA...
Page 270: ...7 3 Page60 OPERATION MAINTENANCE OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A...
Page 271: ...ITEM NO PART NO 1234567 EFF AK 25 21 386003 SUPPORT POLE BASE ASSEMBLY ABCDE 1 387642 SUPPORT POLEBASE ASSEMBLY i0 sl G STATOR GENERATOR FGHJ 1 22 38053l 5 END ABCDE 1 380529 6 I iOUSlNG STATOR GENERA...
Page 272: ...OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A 7 3 Frame Group Figure 26 Ott 30 75 Page62...
Page 273: ...386790 3 386819 4 386811 5 W 9554 3 6 481801 7 387205 8 480075 Ott 30 75 N OMENC LdTURE 1234567 EFF MOUNTING FRAME GROUP For NHA See Fig 10 SUPPORT ASSEMBLY CONTROL PA NEL SUPPORT ASSEMBLY CONTROL BOX...
Page 274: ...I I OPERATION MAINTENANCE AND OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A 7 3 Page64 Ott 30 75 I...
Page 275: ...far below a part number 1000 The figure numberand item number loca tion of the part is listed directly oppositethe part If the part is used in morethan one place each location is listed commencing wi...
Page 276: ...AME GROUP TRE 170 W 10051 2 W 10051 6 W 10051 8 W l 0072 4 w 10079 7 w 10833 W 10854 4 W l 0874 l W 10875 1 W l 1097 2 W l 1097 28 W l 1097 8 w 11110 13 W l 1166 l W l 1242 10 Numerical Index 7 4 Page...
Page 277: ...9 15 12 40 4 5 5 18 6 25 8 22 9 24 10 13 13 8 lo 16 4 8 5 22 6 28 9 18 10 12 13 6 5 3 6 13 8 l 9 16 21 41 8 26 13 l l4 l9 i 17 14 W l 1263 6 W l 1278 5 W l 1280 2 W l 1280 6 W l 1287 2 W 2974 F W 297...
Page 278: ...142 lOOMS 122 o lOOMS 122 1 lOOMS 132 lOOMS 14 1OOMS 36 1OOMS 383 1OON M 369A 1OON M 92 1OON M 94 Numerical Index 7 4 Page4 OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET...
Page 279: ...2OOMS 138 2OOMS 140 2ooMS 143 2OOMS 145 200MS 146 200N M 97 30GH 1201 30GH 417 30GH 719 30GH 720 30GH 72 1 30GH 722 30GH 723 360800 363769 2 363770 l 363771 5 370382A 380525 6 380528 11 380528 6 38052...
Page 280: ...4 386775A 386781 386787 Numerical Index 7 4 Page6 OPERATION MAINTENANCE AND OVERHAUL MANUALTM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A NUMERICAL INDEX CONT D FIGURE AND ITEM NUMBER 22 5 1...
Page 281: ...86837 l 386841 386844 l 386844 10 __ 386844 5 386846 l 386849 386850 386858 386859 l 386867 386871 386883 386884 386890 386898 386902 386903 386904 386905 386906 386907 386908 Ott 30 75 15 11 26 2 26...
Page 282: ...3 386924 386928 386 933 386934 386935 386943 386944 386947 386949 o 386950 386953 386966 386967 386971 386976 386978 386979 l 386983 387005 387020 15 1 14 15 15 5 15 13 15 14 15 15 2 22 3 19 2 17 3 14...
Page 283: ...66 387168 387179 387181 387189 387197 387203 387205 387206 387336 387513 1 387529 387640 1 387642 387725 387737 387895 1 387895 2 387927 387928 387958 387959 387960 387966 387967 Ott 30 75 14 1 14 10...
Page 284: ...388443 3 388443 4 388443 5 Numerical Index 7 4 Page 10 OPERATION MAINTENANCE AND OVERHAULMANUALTM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A NUMERICAL INDEX CONT D FIGURE AND ITEM NUMBER 2...
Page 285: ...022 389536 1 389537 389990 1 400MS 17 4OOMS 18 4ooMS 19 400MS 63 400MS 72 400075 1 400078 400092 400097 400098 400262 400325 400533 400589 5 400847 2 400847 3 401556 Ott 30 75 1 o 3 o 1 o 3 o 11 O 3 o...
Page 286: ...3 401564 4 401564 5 401565 l 401566 l 1 40191 l 20 40191 l 5 401911 8 4020373 402037 8 402119 7 402 125 402 127 402344 402377 402378 Numerical Index 7 4 Page 12 14 5 15 4 19 28 21 2 23 17 14 6 15 7 19...
Page 287: ...0333 1 I I OPERATION MAINTENANCE AND OVERHAUL MANUAL TM 416 MOTOR DRIVEN GENERATOR SET SERIES 5503A AND 5507A NUMERICAL INDEX CONT D Ott 30 75 FIGURE AND ITEM NUMBER 23 9 1931 23 12 23 10 11 6 7 7 8 3...
Page 288: ...404060 3 404065 1 404395 430374 6 430374 7 430391A 480075 480639 481571 481572 481596 481801 481802 481803 481807 481916 481917 481922 481939 481941 481942 481952 NumericaI Index 7 4 Page 14 19 17 12...
Page 289: ...50GH P 1167 50MS 209 50MS 28 50MS 696 50NH 435 482018 3 o 9 o 5CW 2127 4 13 5 26 6 29 8 19 9 2 1 5cw 975 4 12 5 2 1 6 22 8 24 9 20 5Cw 976A 4 11 5 27 6 21 8 20 9 22 8 25 9 19 243 12 22 12 47 5 14 6 4...
Page 290: ...47 75GH 48 75GH 50 75GH 51 75GH 566 75N H 306 75N H 307 75N H 35 1 5 12 6 15 8 16 9 6 5 13 6 16 8 17 9 7 5 l 1 6 8 8 15 9 5 5 9 6 7 8 8 9 3 15 9 6 6 8 7 6 18 8 18 193 The following numberswere added t...
Page 291: ...ANUAL TM 416 MOTOR DR IVEN GENERATOR SET SERIES 5503A AN D 5507A CHAPTER 8 MANUFACTURER S LITERATURE Compone nt Manufacturer Voltage Regulator 115 v AC Hobart Brothers Company Opercltionand Maintenanc...
Page 292: ...8 O Page2 OPERATION MAINTEN AND OVERHAULMAE IUALTM 416 MOTOR DRIVEN GENERATOR SET SERES 5503A AND 5507A __ Feb 27 f6...
